DriSteem Vapor-logic 4 Installation And Operation Manual
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DriSteem Vapor-logic 4 Installation And Operation Manual

DriSteem Vapor-logic 4 Installation And Operation Manual

Humidifier control system
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4
®
Vap o r- lo gic
H umi di f i e r C o nt r ol S ys te m
Ins tallatio n a n d
Operation Man u al

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Summary of Contents for DriSteem Vapor-logic 4

  • Page 1 Important: Read and save these instructions. ® Vap o r- lo gic H umi di f i e r C o nt r ol S ys te m Ins tallatio n a n d Operation Man u al...

  • Page 3: Table Of Contents

    C o n t e n t s Overview ....... . . 1–11 Appendices .

  • Page 5: Overview

    Overview Va p o r- l o g i c 4 c a p a b i l i t i e s Accurate, responsive control Vapor-logic® , DRI-STEEM’s humidification system controller, has been setting the standard for exceptional functionality and accurate RH control since 1992.
  • Page 6 Overview Va p o r- l o g i c 4 c a p a b i l i t i e s Enhanced diagnostics include: Test outputs function, using the keypad/display or Web interface Insert a USB to verify component operation flash drive into Test humidifier function, by simulating demand to validate the Vapor-logic4...

  • Page 7: Humidification System Overview

    Overview H u m i d i f i c a t i o n s y s t e m o v e r v i e w Figure 3-1: Typical humidification system layout (GTS humidifier shown) Dispersion assembly Humidifier Connect a computer directly to the Vapor-logic4 board, or through a...

  • Page 8: Vapor-Logic4 Control Board

    Overview Va p o r- l o g i c 4 c o n t r o l b o a r d Figure 4-1: Vapor-logic4 control board Power to board connection USB connection Factory connection points for drain, steam valve, etc. Field connection points for transmitters, power vent, etc.

  • Page 9: Connection Points

    Overview Va p o r- l o g i c 4 b o a r d c o n n e c t i o n s Figure 5-1: Vapor-logic4 control board connections LED-1 (power indicator) LED-2 P19: Steam = Steam or hot water valve = Power to board =Ground for blower and P16 triac = Ground for power return...

  • Page 10: Using The Keypad/Display

    Overview U s i n g t h e k e y p a d / d i s p l a y Figure 6-1: Using the Vapor-logic4 keypad/display Typical Home screen Change set point from the Home screen by pressing the Up or Down arrow keys until set point is highlighted (as shown here), press Enter, press Up or Down arrow...

  • Page 11: Using The Web Interface

    Overview U s i n g t h e W e b i n t e r f a c e Figure 7-1: Using the Vapor-logic4 Web interface (Setup screen shown) Click on a tab label to move to another screen Click on CHANGE to change value To change value:...

  • Page 12: Pre-Installation Checklist And Instructions

    Installation ☐ See Figure 8-1 for field terminal block locations. Note that Figure 8-1: field wiring connection locations on the Vapor-logic4 board are Vapor-logic4 control board detail surrounded with a white border. Full board ☐ See the figure on the next page for instructions on how to make wiring connections.
  • Page 13 Installation ☐ If you have a remote-mounted control cabinet, the water level control device, thermal trip, safety interlock, fill valve, and drain valve wiring must be minimum 18-gauge (1 mm stranded wire run in a conduit separate from power wires. Do not use shielded (screened) cable for water level control devices.
  • Page 14 Installation I n s t a l l a t i o n p r o c e s s The Vapor-logic4 board is designed to make installation very easy: white. inserting wires and tightening screws. board fully configured, with drain, fill, and other humidifier components factory-wired to the board, and the keypad/display attached to the humidifier and connected to the Vapor-logic4 board.
  • Page 15 Installation I n s t a l l a t i o n p r o c e s s – Vapor-logic4 keypad – Ethernet – Modbus – BACnet – LonTalk – Multiple-tank communication 2. Complete the Setup process. See instructions beginning on Page 24. 3.

  • Page 16: Step 1: Field Wiring

    Installation F i e l d w i r i n g : C o n t r o l i n p u t Connect control input signal wiring by inserting wires into Figure 12-1: Terminal P11 (labeled 24vdc, RH, and ground) per the wiring Terminal P11 diagram on the next page.
  • Page 17 Installation F i e l d w i r i n g : C o n t r o l i n p u t Figure 13-1: Vapor-logic4 control input wiring connections Signal by others Transmitter On-off RH humidistat...
  • Page 18 Installation F i e l d w i r i n g : L i m i t c o n t r o l s Duct or SDU airflow proving switch Figure 14-1: Connect wiring for a duct or Space Distribution Unit (SDU) Terminal P13 airflow proving switch by inserting wires into the terminal block plug at P13 (labeled AFsw and 24vac) per the wiring diagram on...
  • Page 19 Installation F i e l d w i r i n g : L i m i t c o n t r o l s Figure 15-1: Vapor-logic4 limit controls wiring connections Airflow switch In a duct When using an SDU Duct high limit (not used on SDU or Area-type) Temperature compensation transmitter or auxiliary temperature sensor...
  • Page 20 Installation F i e l d w i r i n g : L i m i t c o n t r o l s Temperature compensation transmitter Figure 16-1: or auxiliary temperature sensor Terminal P14 Connect wiring for a temperature compensation transmitter or an auxiliary temperature sensor by inserting wires into the terminal block plug at P14 (labeled 24vdc and TS) per the wiring diagram on the previous page.
  • Page 21 Installation F i e l d w i r i n g : C o m m u n i c a t i o n c o n n e c t i o n s Vapor-logic4 keypad/display Figure 17-1: If your keypad/display is factory-mounted and connected to the Terminal P10 Vapor-logic4 board, proceed to installing the next device required...
  • Page 22 Installation F i e l d w i r i n g : C o m m u n i c a t i o n c o n n e c t i o n s Figure 18-1: Vapor-logic4 communication wiring connections Communication...
  • Page 23 Installation F i e l d w i r i n g : C o m m u n i c a t i o n c o n n e c t i o n s Web interface communication Figure 19-1: Terminal P9 Utilizing the Vapor-logic4 Web interface is optional.
  • Page 24 Installation F i e l d w i r i n g : C o m m u n i c a t i o n c o n n e c t i o n s After a system prompt appears, type in ipconfig and then hit Enter.
  • Page 25 Installation F i e l d w i r i n g : C o m m u n i c a t i o n c o n n e c t i o n s 4. Connect to the humidifier. Figure 21-1: a.
  • Page 26 Installation F i e l d w i r i n g : Programmable triac Figure 22-1: Connect wiring to the output by inserting wires into the terminal Terminal P16 block plug at P16 (labeled Triac) and into the terminal block plug at P19 (labeled ground), per the wiring diagram below.
  • Page 27 Installation F i e l d w i r i n g : A r e a - t y p e , S D U , c o m b u s t i o n a i r, p o w e r v e n t Area-type and SDU dispersion fans Figure 23-1:...

  • Page 28: Step 2: Setup

    Installation To simplify the field-installation process, humidifiers are sent from Figure 24-1: the factory configured as ordered. However, some settings are Keypad/display screens unknown at the factory and need to be defined during the setup “A” indicates that these process using the Setup menu. The Setup menu is also where you settings apply to Tank A.
  • Page 29 Installation Using the Web interface Although not required for humidifier operation, the Web interface allows convenient and remote access to Vapor-logic4. See Page 19 for Web interface connection and IP address instructions. Follow the instructions below to complete the setup process.
  • Page 30 Installation I n s t a l l a t i o n : S e t u p Table 26-1: Setup menu Minimum Maximum Menu item Default value Units Notes value value Input signal RH transmitter Transmitter enabled RH set point RH offset PID tuning RH PID band...
  • Page 31 Installation I n s t a l l a t i o n : S e t u p Table 27-1: Setup menu (continued) Default Minimum Maximum Menu item Units Notes value value value Limit control Airflow switch Switch in system HL switch Switch in system HL transmitter...
  • Page 32 Installation I n s t a l l a t i o n : S e t u p Table 28-1: Setup menu (continued) Minimum Maximum Menu item Default value Units Notes value value Water management Drain valve Type Model-specific* Damper Motorized CAUTION! Changing drain valve settings requires...
  • Page 33 Installation I n s t a l l a t i o n : S e t u p Table 29-1: Setup menu (continued) Minimum Maximum Menu item Default value Units Notes value value Water management (continued) Skim Skim enabled Enabled as default except on DI water systems.
  • Page 34 Installation I n s t a l l a t i o n : S e t u p Table 30-1: Setup menu (continued) Default Minimum Maximum Menu item Units Notes value value value CAUTION! Changing temperature sensor settings Remote temp sensor can require component changes for system to operate correctly.
  • Page 35 Installation I n s t a l l a t i o n : S e t u p Table 31-1: Setup menu (continued) Default Minimum Maximum Menu item Units Notes value value value Programmable outputs CAUTION! Programmable dry contact (P12) is rated for 10 Amp maximum.Exceeding this maximum rating Dry contact can cause the dry contact (relay) component on the...
  • Page 36 Installation I n s t a l l a t i o n : S e t u p Table 32-1: Setup menu (continued) Default Minimum Maximum Menu item Units Notes value value value Units Display inch-pound Display SI Security Require password Set password None...

  • Page 37: Step 3: Startup

    Installation Start-up To start up your humidifier, go to the Start-up Checklist in your humidifier tank’s installation, operation, and maintenance manual.

  • Page 38: Operation

    Operation O p e r a t i o n : U s i n g m e n u s a n d s c r e e n s Vapor-logic4 keypad/display has the following menus and screens: Figure 34-1: Using the keypad/display –...

  • Page 39: Home Screen

    Operation Vapor-logic4 returns to the Home screen on the keypad/display Figure 35-1: after a user-defined period of idleness. The Home screen displays Keypad/display Home screen the items most frequently viewed: Actual space RH or dew point, SPACE RH SET PT 212˚...

  • Page 40: Status Screen

    Operation T h e S t a t u s s c r e e n Using either the keypad/display or the Web interface, the Status Figure 36-1: screen is where all humidifier parameters can be viewed. Keypad/display screens See the tables on the following pages for Status screen item “A”...
  • Page 41 Operation T h e S t a t u s s c r e e n Table 37-1: Status menu Default Minimum Maximum Menu item Units Notes value value value Master standby, Drain tank, Test I/O, or Test heat. Auto mode, the humidifier operates normally. All humidifier components are monitored and controlled.
  • Page 42 Operation T h e S t a t u s s c r e e n Table 38-1: Status menu (continued) Minimum Maximum Menu item Default value Units Notes value value High probe Systems using potable or softened water control water levels 1000 counts signal...

  • Page 43: Diagnostics Screen

    Operation T h e D i a g n o s t i c s s c r e e n The Diagnostics screen provides access to system messages, system Figure 39-1: data, humidifier information, and test functions. Keypad/display screens See the following pages for more information about the Diagnostics screen.
  • Page 44 Operation T h e D i a g n o s t i c s s c r e e n Figure 40-1: Vapor-logic4 Web interface Diagnostics screen Click on buttons to activate functions. View messages by clicking on “View Messages” on any screen or by opening Clear messages the Diagnostics screen.
  • Page 45 Operation T h e D i a g n o s t i c s s c r e e n Table 41-1: Diagnostics menu Minimum Maximum Menu item Notes value value Download data Alarm history RH history Temperature history RH and temp history Download system data here.
  • Page 46 Operation T h e D i a g n o s t i c s s c r e e n Table 42-1: Diagnostics menu (continued) Default Minimum Maximum Menu item Units Description value value value Test outputs (continued) Contactor 1, 2, 3, or 4 SSR control Ignition module 1, 2, 3, or 4 Cycles output to verify operation.
  • Page 47 Operation T h e D i a g n o s t i c s s c r e e n Table 43-1: Diagnostics menu (continued) Message Description Does message auto-clear? Messages Replace contactors Contactors have reached normal life span. Replace contactors. Service unit Regularly scheduled unit servicing is due.

  • Page 48: Alarms Screen

    Operation T h e A l a r m s s c r e e n The Alarms menu displays system alarms. Using the keypad/ Figure 44-1: display, go to the Alarms menu by pressing the Alarms softkey Keypad/display screens (which will be flashing if there is an Alarm), or by pressing the Home softkey and then the Alarms softkey.
  • Page 49 Operation T h e A l a r m s s c r e e n Table 45-1: Alarms menu Does alarm Alarm label Description auto-clear? Tank temp sensor failed Tank temp sensor has failed. RH signal out of range RH signal is out of range.
  • Page 50 Operation T h e S e t u p s c r e e n The Setup menu is where system parameters can be changed. This menu is used primarily during initial installation, but can also be used for making changes or adjustments as needed during operation.

  • Page 51: Pid Tuning

    Operation Improve humidifier response time with PID tuning Kp = Proportional gain factor Ki = Integral gain factor When your system has a humidity or dew point transmitter, you can adjust and control the set point through the keypad/display or Kd = Derivative gain factor Web interface using a proportional, integral, and derivative (PID) control loop.
  • Page 52 Operation The integral term The integral term is an accumulation of RH error over time multiplied by the integral gain. Every 1/10 second when the demand is updated, the instantaneous RH error (RH set point – actual RH) is added to a temporary variable that accumulates the error.
  • Page 53 Operation The derivative term The derivative term is the measured change in error over time multiplied by the derivative gain (differentiating error with respect to time). If the actual measured RH is below set point and is rising, the derivative term subtracts from the demand in anticipation of the approaching set point.
  • Page 54 Operation PID setup tips A large PID band (10% to 20%) yields tighter and more stable control with longer response times. A small PID band produces quicker response times, but control may become unstable if the RH regularly goes outside the band. As a rule, start with a PID band of 10%.

  • Page 55: Water Level Control

    Operation W a t e r l e v e l c o n t r o l Probe system Figure 51-1: Water level control for standard Standard or softened water systems use conductivity probes to water systems measure and control water level for optimum operating efficiency. Water conductivity must be at least 100 μS/cm for the probe system to operate.
  • Page 56 Operation W a t e r l e v e l c o n t r o l Float valve system Figure 52-1: Water level control for DI/RO DI/RO water systems (except for steam injection) use a float valve water systems system to control water levels for optimum operating efficiency.

  • Page 57: Duct High Limit Options

    Operation D u c t h i g h l i m i t o p t i o n s Duct high limit options When a duct high limit option is ordered, DRI-STEEM provides either a duct high limit switch or a duct high limit humidity transmitter (4 to 20 mA output, 0 to 100% RH range) for duct mounting.

  • Page 58: Temperature Sensor/Transmitter

    Operation Te m p e r a t u r e c o m p e n s a t i o n c o n t r o l o p t i o n , a u x i l i a r y t e m p . s e n s o r Temperature compensation control option When selected as an option, DRI-STEEM provides a temperature...

  • Page 59: Tank Preheating

    Operation Ta n k p r e h e a t i n g a n d a q u a s t a t Tank preheat feature The tank preheat feature heats the water in the tank to near boiling to allow a rapid response to a demand signal.

  • Page 60: Freeze Protection

    Operation F r e e z e p r o t e c t i o n , f a n o p e r a t i o n , s e n s o r o f f s e t s Freeze protection Freeze protection is similar to aquastat operation with some exceptions.

  • Page 61: Automatic Drain Sequence

    Operation A u t o m a t i c d r a i n s e q u e n c e o p e r a t i o n Automatic drain sequence for potable water (not softened) When configured to run a potable water humidifier with an automatic drain valve, Vapor-logic4 uses an automatic drain sequence (ADS) to reduce mineral accumulation in the tank and...

  • Page 62: Skimming

    Operation D r a i n i n g , s k i m m i n g Draining when using softened water When using softened water draining occurs for a one-minute duration after a period of time based on 1000 hours of 100% operation to remove residue from the drain valve mechanism.

  • Page 63: Service Interval

    Operation S e r v i c e i n t e r v a l , d a t e / t i m e , b a t t e r y b a c k u p Service interval The Vapor-logic4 controller tracks the amount of water converted to steam by the humidifier.

  • Page 64: Security/Password

    Operation S e c u r i t y, d o w n l o a d i n g d a t a , a n d d a t a b a c k u p a n d r e s t o r e Security/password To control who can change Vapor-logic4 settings, enable the security function and define a password in the Setup menu.

  • Page 65: Firmware Updates

    Operation F i r m w a r e u p d a t e s Uncompressing firmware updates Figure 61-1: Copying the vl4_update folder 1. Obtain the firmware update file from your DRI-STEEM representative or distributor. The update file will be titled DRI-STEEM_vl4_update_ver_x.x.x.zip.
  • Page 66 Operation F i r m w a r e u p d a t e s Installing firmware updates Figure 62-1: LED-2 location on Vapor-logic4 board Note: For mission-critical applications, DRI-STEEM recommends that you have a spare Vapor-logic4 board on hand before updating. LED-1 (power indicator) LED-2 1.

  • Page 67: Test Outputs, Test Run

    Operation Te s t o u t p u t s , t e s t r u n Test outputs When completing an installation or repair, cycle all outputs, such as fill valve, drain valve, etc., to verify operation. Go to the test outputs section of the Diagnostics menu and scroll through each connected output to verify operation.

  • Page 68: Modbus, Bacnet, Lontalk Interoperability

    4. Set up communication with Vapor-logic4 using your Modbus, BACnet, or LonTalk network manager, referencing the tables on NOTE: Orient the LON ProtoCessor module as the following pages. shown, with wire connectors end at the side of the Vapor-logic 4 board.
  • Page 69 Operation M o d b u s , B A C n e t , L o n Ta l k i n t e r o p e r a b i l i t y Table 65-1: Interoperability variable and object names Variable name and Read Only Modbus...
  • Page 70 Operation M o d b u s , B A C n e t , L o n Ta l k i n t e r o p e r a b i l i t y Table 66-1: Interoperability variable and object names (continued) Variable name and Read Only Modbus...
  • Page 71 Operation M o d b u s , B A C n e t , L o n Ta l k i n t e r o p e r a b i l i t y Table 67-1: Interoperability variable and object names (continued) Variable name and Read Only Modbus...
  • Page 72 Operation M o d b u s , B A C n e t , L o n Ta l k i n t e r o p e r a b i l i t y Table 68-1: Interoperability variable and object names (continued) Variable name and Read Only Modbus...
  • Page 73 Operation M o d b u s , B A C n e t , L o n Ta l k i n t e r o p e r a b i l i t y Table 69-1: Interoperability variable and object names (continued) Variable name and Read Only Modbus...

  • Page 74: Multi-Tank Operation

    Operation M u l t i p l e - t a n k o p e r a t i o n Important: All multi-tank communication Introduction: One master controller, multiple slave tanks must go through the master controller Vapor-logic4 has the capability to operate multiple DRI-STEEM to reach slave tanks.
  • Page 75 Operation M u l t i p l e - t a n k o p e r a t i o n Trim tanks Priority groups A tank functioning as a trim tank is assigned to priority group 0 Vapor-logic4 assigns humidifiers a priority and always operates before tanks in priority groups 1, 2, or 3.
  • Page 76 Operation M u l t i p l e - t a n k o p e r a t i o n Configuring multi-tank systems Humidifier tanks ordered as a multi-tank group are configured at the factory. The configuration process includes: Wiring a multi-tank group of humidifiers This section describes making wiring connections for multi-tank systems.
  • Page 77 Operation M u l t i p l e - t a n k o p e r a t i o n Using the keypad/display with a multi-tank group The keypad/display communicates with every humidifier tank’s controller in the multi-tank group. When a multi-tank group is operating normally, the keypad/display shows the Multi-tank System Home screen.

  • Page 78: Troubleshooting

    Operation Tr o u b l e s h o o t i n g i n t r o d u c t i o n 1. Review issues, possible causes and recommended actions. The troubleshooting guide on the following pages presents issues, possible causes and recommended actions for typical issues.
  • Page 79 Operation Tr o u b l e s h o o t i n g g u i d e Table 75-1: Troubleshooting guide Issue Possible causes Actions Green power indicator light is off. transformer. Setup menu to program dry contact and/or 24 from Setup menu VAC triac.
  • Page 80 Operation Tr o u b l e s h o o t i n g g u i d e Table 76-1: Troubleshooting guide (continued) Issue Possible causes Actions When transmitter or humidistat alarms appear, Alarm: possible causes are: At terminal P11 RH signal out of range -- RH signal: 2-10 VDC.
  • Page 81 Operation Tr o u b l e s h o o t i n g g u i d e Table 77-1: Troubleshooting guide (continued) Issue Possible causes Actions Alarm: Do not use shielded Water probe miswired (screened) wiring. Alarm: Faulty water probe exceed the recommended 50' (15 m) limit.
  • Page 82 Operation Tr o u b l e s h o o t i n g g u i d e Table 78-1: Troubleshooting guide (continued) Possible causes Actions Issue Alarm: Tank is not full. Excessive fill time Alarm: Excessive refill time wired menu.
  • Page 83 Operation Tr o u b l e s h o o t i n g g u i d e Table 79-1: Troubleshooting guide (continued) Issue Possible causes Actions Unit does not fill with water. open, verify proper 24 VAC to fill valve. If voltage is present and valve does not open, replace valve or valve coil.
  • Page 84 Operation Tr o u b l e s h o o t i n g g u i d e Table 80-1: Troubleshooting guide (continued) Issue Possible causes Actions control board. Alarm: Tank not draining valve. and pitch requirements. system, or automatic drain is disabled drain pipe Unit does not perform automatic drain sequence...
  • Page 85 Operation Tr o u b l e s h o o t i n g g u i d e Table 81-1: Troubleshooting guide (continued) Issue Possible causes Actions Alarm: Tank temperature sensor failed 1000 Ohms = 68 °F (20 °C); 1702 Ohms = 212 °F (100 °C). temperature thermostat Alarm: Tank overtemp...
  • Page 86 Operation Tr o u b l e s h o o t i n g g u i d e Table 82-1: Troubleshooting guide (continued) Issue Possible causes Actions Heater burnout replace with larger humidifier. Consult DRI-STEEM. Increase skim duration, frequency of drain cycle, and/or frequency of cleaning.
  • Page 87 Operation Tr o u b l e s h o o t i n g g u i d e Table 83-1: Troubleshooting guide (continued) Issue Possible causes Actions Humidity is below desired level. humidity level humidifier. repair, or replace as needed. fill P-trap with water or repair as needed.
  • Page 88 Operation Tr o u b l e s h o o t i n g g u i d e Table 84-1: Troubleshooting guide (continued) Issue Possible causes Actions Humidity above set point. transmitters malfunctioning, repair or recalibrate. Hunting (humidity swings above and below desired set repair or replace.
  • Page 89 Operation Tr o u b l e s h o o t i n g g u i d e Table 85-1: Troubleshooting guide (continued) Issue Possible causes Actions Alarm: Blocked flue high wind vent cap or isolate as recommended by local codes. Alarm: fault Alarm:...

  • Page 90: Replacement Parts

    Operation R e p l a c e m e n t p a r t s Table 86-1: Vapor-logic4 replacement parts Description Quantity Part number Main board 408495-001 Keypad/display (includes printed circuit board, LCD display screen, membrane switch, front and back of plastic cover) 408495-010 27"...
  • Page 91 Appendix A p p e n d i x : C o n t r o l i n p u t s i g n a l s DRI-STEEM offers three control options for all its humidification systems controlled by Vapor-logic4: On-off control, demand signal control, and transmitter control.
  • Page 92 Appendix A p p e n d i x : C o n t r o l i n p u t s i g n a l s Transmitter control Calculation of transmitter % RH With transmitter control, the Vapor-logic4 board receives a signal that corresponds to the actual humidity level measured in the space (mA reading) –...
  • Page 93 Appendix A p p e n d i x : S e n s o r p l a c e m e n t Recommended sensor locations Other factors that affect humidity control Sensor or transmitter location has a significant impact on Unsatisfactory humidity control may involve humidifier performance.
  • Page 94 Appendix A p p e n d i x : G T S m o d e l - s p e c i f i c d e f a u l t s e t u p v a l u e s Table A-4-1: GTS model-specific default setup values Water usage before auto drain/flush...
  • Page 95 N o t e s :...

  • Page 96: Warranty

    For the most current product information, DRI-STEEM’s Limited Warranty shall not be effective or actionable unless visit our Web site: www.dristeem.com there is compliance with all installation and operating instructions furnished by DRI-STEEM, or if the products have been modified or altered without the written consent of DRI-STEEM, or if such products have been subject to accident, misuse, mishandling, tampering, negligence or improper maintenance.

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