Nortec GS Series Installation & User Manual
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Nortec GS Series Installation & User Manual

Gas steam humidifier
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User & Maintenance
IMPORTANT: Read and save this guide for future reference. This
guide to be left with equipment owner.
GS Series
Gas Steam Humidifier
Installation,
Guide
1506222-D

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  • Page 1 Installation, User & Maintenance IMPORTANT: Read and save this guide for future reference. This guide to be left with equipment owner. GS Series Gas Steam Humidifier Guide 1506222-D...
  • Page 2 FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS: Do not try to light any appliance. Do not touch any electrical switch; do not use any telephone in your building.

  • Page 3: Table Of Contents

    GENERAL - WARNING ..........1 - DELIVERY .
  • Page 4 - STARTING THE HUMIDIFIER ........

  • Page 5: General

    GENERAL This installation guide has been designed to provide assistance when installing, mounting, and commissioning a GS Series humidifier. Actual on site application may vary. Consult Technical Services or your local NORTEC representative. WARNING · Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon...

  • Page 6: Model Specification

    MODEL SPECIFICATION FUEL BLOWER SPEED NATURAL GAS PROPANE FUEL BLOWER SPEED NATURAL GAS PROPANE FUEL BLOWER SPEED NATURAL GAS PROPANE FUEL BLOWER SPEED NATURAL GAS PROPANE FUEL BLOWER SPEED NATURAL GAS PROPANE FUEL BLOWER SPEED NATURAL GAS PROPANE MODEL GS 100 SPECIFICATIONS INPUT (BTUH)* STEAM CAPACITY (LBS/HR) 140,000...

  • Page 7: Gs Indoor Installation

    HIGH ALTITUDE - A derate in input exists for installations at higher altitudes. For Canadian models, an automatic 10% derate applies to installations from 2000-4500 feet. For U.S. Models, refer to the chart below for high altitude derate information. Feet 0-2000 2001-3000 3001-4000...

  • Page 8: Locating And Mounting

    B149 Installation Codes. Refer to the Gas Piping section of this manual. LOCATING AND MOUNTING GS Series humidifiers are designed for floor mounting or on a GS Stand (optional). The clearance dimensions shown in this manual are for reference only and are the minimum required for maintenance of the humidifier.

  • Page 9: Gas Piping

    · DO NOT mount humidifiers on vibrating surface. Consult factory. · The humidifier shall not be installed directly on carpeting, tile or other combustible material other than wood flooring. · Some insulating materials may be combustible.

  • Page 10: Combustion Air Requirements

    Attach the air supply line to the manifold using a hose clamp or hose coupling if required. See Figure WARNING: Air supply line should not obstruct any services going to the humidifier front and right side cabinet panels. WARNING: BH Type venting must be used in a direct vent application.

  • Page 11: Exhaust Venting

    6 elbows in the system. · Maintain an upward slope of ¼” per ft on all horizontal vent pipe runs. · This gas humidifier may not be used in conjunction with a power venter or draft inducer. Figure #6...
  • Page 12 Vertical Venting Application Using B or BH Venting B or BH type vent using double wall vent with double wall connectors is required. Reference local and/or national codes before installation of the vent. Horizontal run 1/4"rise per ft Exhaust venting outlet Steam Outlet Side Wall Venting Application Using BH Type Only...
  • Page 13 B type double wall vent with double wall connectors is required for category I, serving two or more gas appliances. Exhaust venting outlet Condensate Steam Outlet Note: These are guidelines only. Follow local and/ or national codes in your respective area. ·...
  • Page 14 · All horizontal runs must be adequately supported with hangers or straps to prevent sagging. Installation as a Category I Appliance · The GS series humidifiers have a fan-assisted combustion which operates with a non-positive vent static pressure when installed with the appropriate vent diameter.

  • Page 15: Additional Requirements When Venting Through A Sidewall

    · All joints must be sealed using high temperature RTV silicone. BH Vent Manufacturers 1. Flex-L International 2. Fas-N Seal 3. Heat-Fab Inc. 4. Z Flex · The gas humidifier is supplied with the following exhaust outlets. GS 100 3” GS 200 4” GS 300/400 5”...

  • Page 16: Electrical

    The vent terminal must be installed in the same atmospheric pressure zone as the combustion air inlet of the humidifier. If this is not possible (as in cases of positive or negative room pressures) the humidifier should be installed with the direct vent option.

  • Page 17: Primary Wiring

    PRIMARY 208-240V 1 phase line voltage wiring to unit VOLTAGE (ACTUAL) 600V/3ph Neutral 460V/3ph Neutral 380V/3ph Neutral 208V/3ph Neutral 120V/1ph 120V/1ph Neutral 120V/1ph Neutral NOTE: VoltageAt Terminal Block Must Be InAccordance With Spec. Label. All Wiring To Be InAccordance With Existing NationalAnd Local Electrical Codes. (BY OTHERS) Ground Wire Ground...

  • Page 18: Low Voltage Control Wiring

    8: When 24 Vac input received, the unit will initialize a full tank blowdown. 9: Safety interrupt (24 Vac). 10 & 11: Remote indication connection for humidifier “on” status indication. 12 & 13: Remote indication connection for humidifier “active” status.

  • Page 19: Control Installation

    · It is recommended to have a faucet installed close to the humidifier to allow quick filling of the system on initial start up. This can also be very useful for mandatory cleaning of the unit.

  • Page 20: Aux Drain Port

    Steam Distributor Installation Manual - Form #XX-231 and SAM-e Short Absorption Manifold - Form #XX-249. · The GS series of Gas-Steam humidifiers can develop steam pressures up to 12”w.c. to overcome duct and steam line pressures. An enclosed trap on the drain line prevents steam from going to drain.

  • Page 21: Typical Gstc Outdoor Installation

    GSTC Outdoor Typical Installation Rooftop BH Vent (By Nortec) Electrical Disconnect (By others) Roof Curb (By others) Drain Lines Funnel With Air Gap GS Outdoor Typical Installation Rooftop BH Vent (By Nortec) Electrical Disconnect (By others) Roof Curb (By others) Figure # 13 Insulated Steam Line...

  • Page 22: Roof Curb Dimensions

    Mode l GSTC Outdoor 100 GSTC Outdoor 200 GSTC Outdoor 300 GSTC Outdoor 400 GSTC Outdoor 500 GSTC Outdoor 600 Left FRONT Mode l Dim e nsion A GSTC Outdoor 100 8.63" (27.91cm) GSTC Outdoor 200 15.06" (38.25cm) GSTC Outdoor 300 30.63"...

  • Page 23: Gas Piping

    · Do not store or use gasoline or other flammable vapors and liquids in the vicinity of the humidifier. · The humidifier may be installed directly on combustible flooring or, in the U.S., on wood flooring or Class A, Class B or Class C roof covering materials.

  • Page 24: Exhaust Venting

    Nortec. ELECTRICAL INSTALLATION · Power and control wiring is to be routed into the humidifier through the pipe chase in the base pan of the outdoor models located in the burner area. · Installation details for primary and low voltage control wiring are the same as for indoor units.

  • Page 25: Fill Water Supply Line

    FILL WATER SUPPLY LINE · Each unit is supplied with a ½” NPT male connection to the fill valve. Refer to Figure #21 for connection details. A minimum fill rate of 10 l/min (2.6 gal/min) is required for all unit sizes. Allowable pressure range is 30-80 psig.

  • Page 26: Steam Lines

    The GS Series of humidifiers is equipped with a unique float chamber water level monitoring device. Two magnetic floats (one is a backup) measure 5 different water levels in the humidifier for proper operation.

  • Page 27: Start Up Procedure

    Test the ignition system safety shut-off in the following method. · Close the shut-off valve in the gas supply line · Set the demand signal to the humidifier to 100% · Ensure all external controls connected to the security loop are closed ·...

  • Page 28: Starting The Humidifier

    %) at which time the unit will again begin the combustion sequence TAKING OUT OF OPERATION If it is required that the humidifier be taken out of operation (e.g. for service or end of season shut-down), proceed as follows: ·...

  • Page 29: Installation Checklist

    HUMIDIFIER MOUNTING £ Verify proper clearances around the unit £ Humidifier mounted level £ Humidifier properly secured to stand and stand bolted to floor £ All service doors accessible £ Roof curb sized correctly (Outdoor Model Only) GAS PIPING £...
  • Page 30 ELECTRICAL INSTALLATION £ Comply with local regulations £ Proper supply voltage (must match rating plate) and breaker size £ Electrical disconnect switch close to humidifier £ Cables properly affixed £ Low voltage wiring & control signal(s) wired to correct terminals £...

  • Page 31: Scale Management

    The feature can be programmed in the software to occur after a specific amount of operating time and can also be triggered by a signal sent to the humidifier from a building management system. WATER QUALITY...

  • Page 32: Fault Conditions

    Since the amount and type of maintenance required is generally as a result of how much the humidifier operates, all GS humidifiers monitor the amount of steam produced over time and will indicate when service is required.

  • Page 34: Cleaning The Tank

    CLEANING THE STEEL TANK CAUTION: Water and scale may be hot enough to cause burns. Turn off humidifier and allow it to cool before cleaning. It is recommended that the tank be cleaned at least once every season to maintain optimum operation.

  • Page 35: Servicing The Unit

    Gas Valve Setting The gas valves used in the GS series humidifier are negative-pressure-regulated valves. The valve setting listed on the product rating plate is shown relative to atmosphere –...

  • Page 36: Components Replacement

    Hot Surface Igniter and Flame Sensor Replacement 1. Shut off electrical power and gas supply to the humidifier. 2. Remove the right side service access door. 3. Disconnect all wiring to the igniter and flame sensor. 4. Unscrew the fixing nuts for the igniter and flame sensor.

  • Page 37: Removal And Installation Of The Combustion Blower

    Tighten the 4 brass nuts of burner mounting plate to a torque of 95 in-lb. 8. Leak test the gas train before re-commissioning the humidifier. Removal and Installation of the Combustion Blower 1. Shut off electrical power and gas supply to the humidifier.

  • Page 38: Air Switch Replacement

    Figure #30 Gas Valve Replacement 11. Leak test the gas train before re-commissioning the humidifier. Air Switch Replacement 1. Shut off electrical power to the appliance. 2. Remove right side service panel. 3. Remove wiring connections to switch. 4. Remove pressure hose(s) from switch noting proper location.

  • Page 39: Transformer Replacement

    Ignition Module Replacement 1. Shut off electrical power to the humidifier. 2. Remove the front electrical access door. 3. Disconnect all wiring connections to the ignition module, labeling as required. 4. Remove the 2 screws securing the ignition module and remove.

  • Page 40: Drain Pump Replacement

    NOTE: To avoid water spillage (some water will be left on the tank bottom after manual draining) use shop vac to remove left over water. Figure #36 Drain Pump Assembly Fill Box Replacement Leak test all water connections before re-commissioning the humidifier. - 36 -...

  • Page 41: Removal Of The Heat Exchanger

    Removal of Heat Exchanger 1. 1. Take the humidifier out of operation. 2. 2. Disconnect the gas supply pipe from the connection on the humidifier and close off the pipe. 3. 3. Unlock and remove the right side panel(s). 4. 4. On Direct Vent units only: Remove hoses from air intake manifold and air inlet elbows.

  • Page 42: Dip Switch Settings

    - 38 -...

  • Page 43: Software Flow Chart

    3 DAY DRAIN 3 DAY DRAIN FUNCTION Function Disabled Function Enabled (Factory set) KEEP WARM 3 DAY DRAIN FUNCTION Function Enabled Function Disabled (Factory set) - 3 day drain MAINTENANCE (GSP) MAINTENANCE INTERVAL (GSP) 500 hour (Factory set) 1000 hour ANALOG CHANNEL 1 Input Range 0-10V input...
  • Page 44 INPUT CHANNEL DUAL CHANNEL FUNCTION One Channel Input Dual Channel Inputs TIME PROPORTIONING TIME PROPORTIONING Disabled (Factory set) Enabled BLOWDOWN (GSP) BLOWDOWN 25% (Factory set) MAINTENANCE SHUTDOWN MAINTENANCE SHUTDOWN FUNCTION Unit will shutdown 72 hours after service time expired, by gen- erating an error.

  • Page 45: Menu Structure

    NORTEC TC CONTROLLER INTRODUCTORY SCREEN NORTEC GSTC-400 VERSION X.XX SYSTEM LOCKOUT 09.05.02 9:30 NOTES: Go To: System Status - page 22 Menu Structure MAIN MENU SYSTEM STATUS MENU SERVICE LEVEL MENU USER SETTINGS Service Level - page 24 User Setting - page 26 Keypad Display Menu Structure GENERAL...
  • Page 46 SYSTEM STATUS 1 of 2 MAIN MENU SYSTEM STATUS MENU USER SETTINGS ENTER MENU MENU 1. DISPLAY TOGGLES BETWEEN STATUS: LOCKOUT LOCKOUT, ACTIVE, AND STANDBY, DEPENDING ON SYSTEM DEMAND DEMAND CHANNEL 1 0% DEMAND CHANNEL 2 0% 2. ONLY VIEWED IF UNIT IS CONFIGURED FOR CAPACITY LIMIT DUAL CHANNEL.
  • Page 47 SYSTEM STATUS 2 of 2 MAIN MENU SYSTEM STATUS SERVICE LEVEL MENU USER SETTINGS ENTER MENU SYSTEM STATUS 1. DISPLAYS THE USER SELECTABLE MAINTENANCE INTERVAL SERVICE INTERVAL HOURS 2. DISPLAYS THE TIME LEFT BEFORE MAINTENANCE REMAINING XXX HOURS IS DUE START DATE: MM:DD:YY 3.
  • Page 48 MAIN MENU SYSTEM STATUS SERVICE INTERVAL SERVICE HISTORY SERVICE LEVEL MENU FAULT HISTORY USER SETTINGS ENTER TANK DRAIN TANK PRE-CLEAN BURNERS SHORT CYCLE DELAY SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY MENU TANK DRAIN TANK PRE-CLEAN BURNERS SHORT CYCLE DELAY SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY MENU...
  • Page 49 SERVICE LEVEL 2 of 2 SERVICE LEVEL MAIN MENU SYSTEM STATUS SERVICE INTERVAL SERVICE HISTORY SERVICE LEVEL MENU FAULT HISTORY USER SETTINGS ENTER TANK DRAIN TANK PRE-CLEAN BURNERS SHORT CYCLE DELAY SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY MENU TANK DRAIN TANK PRE-CLEAN BURNERS SHORT CYCLE DELAY...
  • Page 50 MAIN MENU SYSTEM STATUS DATE/TIME/UNITS LANGUAGE CONTROLS SERVICE LEVEL MENU WATER MANAGEMENT USER SETTINGS ENTER CONTROL TYPE CAPACITY LIMIT CALIBRATE 1. VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING. DATE/TIME/UNITS LANGUAGE CONTROLS WATER MANAGEMENT MENU CONTROL TYPE CAPACITY LIMIT CALIBRATE USER SETTINGS 1 of 3 TIME HH:MM...
  • Page 51 MAIN MENU SYSTEM STATUS DATE/TIME/UNITS LANGUAGE CONTROLS SERVICE LEVEL MENU WATER MANAGEMENT USER SETTINGS ENTER CONTROL TYPE CAPACITY LIMIT CALIBRATE USER SETTINGS 2 of 3 USER SETTINGS PAGE 1 FTBD HOURS FTBD HOUR BLOWDOWN RATE FLOAT CHECK FILL CORRCTN DRAIN CORRCTN DRAIN COOL: 1.
  • Page 52 MAIN MENU SYSTEM STATUS DATE/TIME/UNITS LANGUAGE CONTROLS SERVICE LEVEL MENU WATER MANAGEMENT USER SETTINGS ENTER CONTROL TYPE CAPACITY LIMIT CALIBRATE DATE/TIME/UNITS LANGUAGE CONTROLS WATER MANAGEMENT MENU CONTROL TYPE CAPACITY LIMIT CALIBRATE DATE/TIME/UNITS LANGUAGE CONTROLS WATER MANAGEMENT MENU CONTROL TYPE CAPACITY LIMIT CALIBRATE USER SETTINGS 3 of 3 USER SETTINGS...

  • Page 53: Main Menu

    NORTEC TC CONTROLLER INTRODUCTORY SCREEN NORTEC GSTC-400 VERSION X.XX SYSTEM LOCKOUT 06.07.03 9:30 Product name NORTEC GSTC (100-600) Version The display will indicate the revision level of the control software System Depending on system activity, the display will toggle between LOCKOUT, ACTIVE or STANDBY. Date/Time The actual date and time will be displayed.
  • Page 54 Field only visible if the unit is configured for dual modulation. This field will display the modulation demand input on that channel. Capacity limit: This field displays the user adjusted capacity limit set for the humidifier. SCREEN 2: SYSTEM DEMAND XXX% BURNERS ACTIVE X/X OUTPUT/BURNER...
  • Page 55 SCREEN 4: SERVICE INTERVAL XXX HOURS REMAINING XXX HOURS START DATE: MM:DD:YY Service interval: This field displays the user (or factory default) setting for the humidifiers service reminder in steam hours. Remaining: This field displays the amount of time (steam hours) remaining before the next service is to be performed.

  • Page 56: Service Level

    BURNERS SHORT CYCLE DELAY Service history In this area the customer can view the history of service maintenance performed on the humidifier. SERVICE HISTORY X/Y The service history stores the last 10 service periods. X = service occurrence, where 1 is the most recent.
  • Page 57 BURNERS SHORT CYCLE DELAY Fault history In this area the customer can view the history of recorded faults for the humidifier. FAULT HISTORY X/Y The fault history stores the last 54 system faults. X = fault occurrence, where 1 is the most recent.
  • Page 58 Tank Pre-Clean The tank pre-clean feature when activated will activate the drain valve for a fixed period of time (depending on unit size). The fill valve will then activate, filling the tank partially with cold water. At the completion of the fill cycle the tank will once again drain.
  • Page 59 User Settings When a parameter requires a change, press the two arrow keys and enter the password (0335). As long as you remain in this section, you will not need to enter the password more than once. Date / Time Units This field is used for modifying the Date, time and the units of measurement.
  • Page 60 This section allows the user to set the frequency of full tank blowdowns (FTBD). FTBD’s drains and re-fills the entire contents of the humidifier after a preset accumulated operating time. Run time is measured in steam hours (weighted run time hours), and can be adjusted from 0 hours (feature off) to 400 hours in 25 hour increments.
  • Page 61 FTBD Hour Works in conjunction with FTBD hours. DATE/TIME/UNITS LANGUAGE CONTROLS WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT CALIBRATE Here the user sets the time of day (24 hour format) when they want the FTBD to execute. The time can be set to trigger the cycle during off hours, when the humidity requirements are minimal.
  • Page 62 SMART – The humidifier has a tank sensor that communicates the water temperature to the controller. If the water is hot during drain cycles the fill valve will be activated. This is the most “water smart” of the settings.
  • Page 63 PID constants for optimal performance. Capacity Limit In this section the customer can adjust the maximum output of the humidifier between 25-100%. To adjust the maximum capacity, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN arrows to adjust the output between 25 and 100%.

  • Page 64: Fault And Warning List

    If the blower RPM is above the RPM tolerance for more than 10 seconds, this fault is generated and the humidifier stops. If the blower RPM is below the RPM tolerance for more than 10 seconds, this fault is...
  • Page 65 FAULT GIF-X GAS RE-IGNITION BURNER X FAULT DRAIN NOT WORKING DRAIN IS BLOCKED FAULT FLOAT CHECK FAULT ILLEGAL FLOAT COMBINATION FAULT FILL VAVLE ON DETECTION INCONSISTENT FAULT KEEP WARM TIME TOO LONG TO HEAT FAULT STACK OVER TEMP. SWITCH TRIPPED FAULT MAINTENANCE TIME...
  • Page 66 GSTC Warning GSP warning displayed displayed WARNING IMW-X IGNITION MODULE X FAIL WARNING APW-X AIR PROVING SWITCH X OPEN WITH BLOWERS ACTIVE WARNING AOW-X AIR PROVING SWITCH X OPEN WITH BLOWERS ACTIVE WARNING BHW-X BLOWER X RPM HIGH WARNING BLW-X BLOWER X RPM LOW WARNING...

  • Page 67: Exploded View Internal Components Spare Parts

    - 63 -...
  • Page 68 GS Series Internal Components Spare Parts Number Description Cover Plate, Clean-Out Port Gasket, Tank Cover Plate Secondary Safety Switch Fill Box Vacuum Break Valve ½” npt P-Trap Dual Fill Valve 10.0 l/min & 0.35 l/min Heat Exchanger Gasket Direct Vent Air Manifold...
  • Page 69 GS Series Internal Components Spare Parts - continued Number Description Igniter / flame sensor gasket Hot Surface Igniter Replacement kit 110-120V Models 208-240V Models Flame Sensor Replacement Kit Igniter / flame Sensor Replacement Kit 110-120V Models 208-240V Models Combustion Blower...

  • Page 70: Exploded View Indoor Cabinetry Spare Parts

    - 66 -...
  • Page 71 GS Series Indoor Cabinetry Spare Parts Number Description Service Door Assembly Fron t Door Assembly Recessed Handle Transformer 24/16V 15VA 50/60 hz Logic Control Board I/O Board Primary Transformer 110-120 V Models 208-240V Models Fuse for Primary transformer, 6.25 AMP...

  • Page 72: Exploded View Outdoor Cabinetry Spare Parts

    - 68 -...
  • Page 73 Description 1 Transformer 24/16V 15VA 2 Transformer 208-24Vac 250VA Fuse 6.25 Amp for 208V transformer 3a LCD Display Assembly 3b LCD Mounting Bracket 3c On-Off-Drain Switch 4 Logic Control Board 5 I/O Board 6 Ignition Control Module 7 Slotted wire duct 8 Relay Mount Socket 9 Blower Relay 10 Thermostat, On/Off, 80F...
  • Page 74 25 Fan Hood 26 Cover Plate Top Panel 27 Gasket, Steamline 400/500/600 1507871 28 Cover Plate Steam Line 400/500/600 1507810 Step-up transformer (120/240V option) 1508167 Mounting bracket, step-up transformer 1507759 31 Mid Cross Member 32 Gas Line Bracket 33 Rear Frame Element 34 Rear Panel 35 Cross Member Mounting bracket, float chamber 1508114...
  • Page 75 -71 -...

  • Page 76: Gs Quick Reference

    Item GS 100 Gas Pressure Natural Gas min "wc/mbar Natural Gas max "wc/mbar Propane min Propane max Min free air opening in/cm 13/33 Input BTU's 140,000 Min GSTC Direct vent min Gas Piping Size in/cm 1/2/1.3 "BH" Vent "B" Vent "BH"...

  • Page 77: Limited Warranty

    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.
  • Page 78 Walter Meier (Climate USA) Inc. 826 Proctor Avenue, Ogdensburg, New York 13669 Walter Meier (Climate Canada) Ltd. 2740 Fenton Road, Ottawa, Ontario K1T3T7 Tel: 866 NORTEC 1 Fax: 613 822 7964 northamerica.climate@waltermeier.com www.humidity.com...

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