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Summary of Contents for Munters MCD100G
- Page 1 Original instructions Users manual MCD100G, MCD120G, MCD140G, MCD155G Desiccant dehumidifier with gas heater for reactivation Applies to all units manufactured from week 22, 2013 190TEN–1081–J1408 © Munters Europe AB 2014...
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Page 2: Important User Information
Important user information Intended use Safety Munters dehumidifiers are intended to be used for the Information about dangers are in this manual indicated dehumidification of air. Any other use of the unit, or by the common hazard symbol: use which is contrary to the instructions given in this... -
Page 3: Table Of Contents
Table of contents Important user information ....Safety ........Intended use ......General . - Page 4 Fault tracing, gas heater unit ....10 Contact Munters ......Fault tracing list ......
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Page 5: Introduction
1.1 General Munters manufactures a wide range of efficient dehumidifiers designed for different uses and applications. Contact your nearest Munters office if you have any questions regarding the installation or the use of your dehumidifier. For product data, see section Technical specification. - Page 6 OFF position before carrying out any service work. - Use only approved lifting equipment to prevent personal injury and damage to the equipment. - Always contact Munters for service or repair. WARNING! Never lift an assembled unit using lifting eye bolts attached to the top box. Lifting eye bolts must only be used for lifting the top box during installation of a split unit.
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Page 7: Operation Monitoring
1.5 Operation monitoring The dehumidifier is controlled and monitored from the control panel on the front of the unit, see section 5.1, Control panel. The HMI (Human Machine Interface) is used to display values and parameters, and to input settings and commands to the control system. The HMI is described in the separate supplement. 1.6 Application limitations The dehumidifier conforms to the emission limits of residential, commercial and light-industrial environments except for the emission limits for harmonics emission (EN 61000–3–12). -
Page 8: Marking
3 ~ 400V 50 Hz 15 kW 15,7 kW IP33 Made in Sweden Munters Europe AB Isafjordsgatan 1 164 26 Kista, Sweden Figure 1.4 Position of identification plate Figure 1.5 Identification plate, example Explanation of "Fabr. no" on the identification plate:... -
Page 9: Dehumidifier Design
Dehumidifier design 2.1 Product description The desiccant dehumidifier has been designed to effectively dehumidify the air in environments requiring low air humidity. ® All functional components are enclosed in a corrosion resistant Aluzink casing (standard) or stainless steel casing (option) which makes installation and maintenance easy. The unit is constructed on a steel base frame which allows the use of a fork-lift truck during transportation and installation. - Page 10 1. Process air 2. Dry air 3. Reactivation air 4. Wet air Figure 2.2 Airflow overview Dehumidifier design 190TEN–1081–J1408...
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Page 11: System Overview
2.3 System overview 2.3.1 Front view Figure 2.3 Front view, main components 1. Filter box, process air 6. Pressure switch for reactivation air 2. Reactivation fan motor 7. High temperature cut-out switch (HTCO) 3. Temperature sensor, PT1000 8. Process fan motor 4. -
Page 12: Rear View
2.3.2 Rear view Figure 2.4 Rear view, main components 1. Control panel 5. Inspection glass 2. Main power switch 6. GasMultiBloc control unit 3. Gas shut-off valve 7. Gas control valve with actuator 4. Gas burner Dehumidifier design 190TEN–1081–J1408... -
Page 13: Main Components, Exploded View
2.4 Main components, exploded view Figure 2.5 Main components 1. Reactivation fan 8. Rotor drive motor 2. Filter, reactivation air 9. Drive belt 3. Gas train with GasMultiBloc control unit 10. Rotor 4. Process fan 11. Rotor seal 5. Electrical panel 12. -
Page 14: Gas Burner Unit
2.5 Gas burner unit Direct fired gas burners are used on all MCD-series dehumidifiers. The burner operates on natural gas or propane (option) and uses the reactivation air to supply the oxygen necessary for combustion. A correct reactivation airflow is therefore essential to ensure that the burner operates efficiently. For optimal performance, the reactivation air must contain minimum 20 % oxygen. -
Page 15: Gasmultibloc ® Control Unit
1. Burner head port 2. Flame detection probe 3. Mixing plates 4. Spark ignitor 5. Spark ignitor connection plug 6. Gas pipe 7. Flame detection connection plug 8. Silicone cable Figure 2.7 Side view of the burner ® 2.6 GasMultiBloc control unit 2.6.1 Principle of operation A GasMultiBloc control unit in the gas train controls and monitors the gas pressure and flow. -
Page 16: Overview
2.6.2 Overview Figure 2.9 Overview, GasMultiBloc A. Flow from gas supply B. Flow to gas burner 1. Gas shut-off valve 6. Cover plate for gas filter 2. Low pressure switch 7. Screw for cover plate 3. Pressure test point for gas supply (P 8. -
Page 17: Gas Control Valve Unit
2.7 Gas control valve unit In this modulating gas reactivation heater system, there is a control valve fitted in the gas line between the GasMultiBloc and the gas burner. This makes it possible to vary the gas flow and burner capacity during operation. -
Page 18: Burner Safety Control Unit
2.8 Burner safety control unit The burner safety control unit is located in the electrical panel, see Figure 2.3 . The control unit ensures safe ignition, start-up and shut-down during both normal operation and if a fault occurs. It is equipped with a self-checking flame monitoring circuit that controls the combustion process. The flame monitoring circuit applies the necessary safety measures if the flame signal occurs to soon or not at all, and if any type of fault in the flame detector, detector cables or flame signal amplifier occurs. -
Page 19: Programme Indicator
2.8.2 Programme indicator The programme indicator shows the status of the burner. Since the programme indicator remains in the position where shutdown occurs, it gives valuable information that facilitates fault tracing. The different situations causing shutdown are indicated by the following symbols: Figure 2.12 Programme indicator Symbol Description... -
Page 20: Flame Detection
2.8.3 Flame detection A flame detection probe is used to verify that a flame is present. The detection probe consists of a metal electrode which is positioned in the flame. The burner's control unit senses the existence, or not, and condition of the flame during start-up and normal operation. - Page 21 Variable speed The frequency converter for the process fan is controlled either by flow or pressure. At flow control, a pressure sensor measures the pressure difference over the inlet cone on the process fan. At pressure control, a pressure sensor measures the air pressure in the dry air duct. The actual value from the pressure sensor is calculated, together with the fan coefficient, by the PLC in the control system.
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Page 22: 3Energy Recovery Purge
2.10.3 Energy Recovery Purge 1. Reactivation air 2. Heated reactivation air 3. Wet air 4. Process air 5. Dry air 6. Purge air 7. Warm purge air Figure 2.13 Principle for Energy Recovery Purge Energy Recovery Purge (ERP) is an energy saving solution that recycles heat from the rotor, after the reactivation section in the rotational direction of the rotor. -
Page 23: Installation
Installation 3.1 Safety WARNING! All electrical equipment connections must be carried out in accordance with local regulations and by qualified personnel. Risk of electrical shock. WARNING! The unit must never be connected to a voltage or frequency other than that for which it was designed. Refer to the unit identification plate. -
Page 24: Inspection Of Delivery
4. Remove all packaging material from the unit, and make sure that no damage has occurred during transportation. 5. Any visible damage must be reported in writing to Munters within 5 days and prior to installation of the unit. 6. Dispose of the packaging material according to local regulations. -
Page 25: Storing The Dehumidifier
Refer to Munters for advice if in doubt. NOTE! If there is a need for reduction of vibrations from the dehumidifier, contact Munters for instructions. Refer to standard EN1299+A1:2008. See section 8.3, Dimensions and service space for unit and service dimensions. - Page 26 Figure 3.3 Rotor box Figure 3.4 Top box Figure 3.5 Fans Figure 3.6 Filter box Figure 3.7 1. Reactivation fan 2. Process fan 3. Filter boxes Installation 190TEN–1081–J1408...
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Page 27: Assembly
3.7.1 Assembly 1. Pull off the protection tape from the rotor box seals. 2. Make sure that the four lifting eye bolts for the top box are tightened. Figure 3.8 Lifting eye bolts for top box 3. Lift the top box onto the rotor box and make sure that the guide lips and M8 screws align in each corner, see Figure 3.9 . - Page 28 Figure 3.10 A: M8 screw seen from underneath. Figure 3.11 D: Cover plates 4. Tighten the four M8 screws (A) to compress the seals. 5. Fasten the two cover plates (D) with pop rivets (4 x 10 mm) . 6. Unscrew the lifting eye bolts from the top box to prevent lifting of the assembled unit. 7.
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Page 29: Electrical Connections
3.7.2 Electrical connections 1. Install the infeed box and the cable for power supply. Figure 3.14 Power supply infeed box (E) 2. Connect the cables for the reactivation fan and process fan, see Figure 3.15 , Figure 3.16 and Figure 3.17 . Figure 3.15 Fan motor wiring Figure 3.16 Process fan Figure 3.17 Reactivation fan... - Page 30 Terminal block (drive motor) Drive motor cable Brown cable Brown cable 6 (yellow) 4 (blue) 2 (green) Table 3.1 Connections for rotor drive motor 4. Connect the HTCO and PT1000, see Figure 3.19 , Figure 3.20 and Figure 3.21 . Run the cables through the rubber grommet (F).
- Page 31 6. Connect the DPT (Differential Pressure Transmitter) for the reactivation fan. The bottom side of the DPT is marked with plus (+) and minus (-) at the two connections. – Connect the tube from the fan duct (before impeller) to plus (+). –...
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Page 32: Duct Installation
3.8 Duct installation 3.8.1 General recommendations The connections for process and reactivation air are designed in accordance with the recommendations in ISO 13351. The rectangular duct connections contain tapped inserts for M8 screws. NOTE! The dehumidifier has been designed to operate at specific process airflows (corresponding to the fan sizes installed) and must not be directly connected to air-conditioning systems. -
Page 33: Duct For Outdoor Air Inlet
3.8.2 Duct for outdoor air inlet When bringing ambient air from outdoors into the dehumidifier, the inlet duct opening must be located sufficiently high above ground level to prevent dust and debris from entering. The ducting must be designed to prevent rain and snow from being drawn into the dehumidifier. The air inlet must be located away from possible contaminants such as engine exhaust gases, steam and harmful vapours. -
Page 34: Duct Connection Dimensions For Inlets
3.8.4 Duct connection dimensions for inlets MCD100-155G Figure 3.26 Reactivation air inlet 250 (5x) M8 (12x) 1250 1358 1358 1418 1408 Figure 3.27 Process air inlet Figure 3.28 Process air inlet (for installation with filter box) (for installation without filter box) C: Use hexagon head bolts (M8 x 25). -
Page 35: Duct Connection Dimensions For Fans
3.8.5 Duct connection dimensions for fans MCD100-155G (2x) M8 (12x) Figure 3.29 Process air outlet (dry air outlet) C: Use hexagon head bolts (M8 x 25). Installation 190TEN–1081–J1408... - Page 36 MCD100-155G 140 (2x) 134 (2x) M8 (10x) M8 (8x) MCD120 MCD100 MCD140 MCD155 Figure 3.30 Reactivation air outlet (wet air outlet) C: Use hexagon head bolts (M8 x 25). Installation 190TEN–1081–J1408...
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Page 37: Gas And Air Supply
3.9 Gas and air supply WARNING! All connections of gas to the unit must be carried out in accordance with local regulations and by qualified personnel. WARNING! The reactivation air must not be contaminated with combustible substances in the state of gas, steam, fog or dust that mixed with air will create hazardous situations. -
Page 38: External Humidity Transmitter
3.11 External humidity transmitter The dehumidifier is delivered with one of the humidity transmitters described below. The transmitter has an output signal of 4–20 mA for temperature and humidity respectively. Humidity transmitter for relative humidity in wall mounted version (standard): ■... -
Page 39: Commissioning
Commissioning WARNING! Commissioning and initial start-up of the unit should be carried out by Munters personnel only. WARNING! The mains power supply is permanently connected to the main power switch of the unit. Risk of electric shock. 4.1 Pre-start checks 1. - Page 40 NOTE! If the gas supply pressure exceeds 30 mbar, a pressure reduction valve must be fitted in the gas supply inlet pipe. 6. Close the pressure test point outlet (P 7. Unscrew the hood covering the dial and make sure that the low pressure switch is set at 18 mbar. If necessary, set the pressure using the dial, see Figure 4.2 and Figure 4.3 .
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Page 41: Airflow Adjustment
Failure to correctly adjust the airflows can cause malfunction of the unit. Any damage to the unit resulting from incorrect adjustment of the airflows can invalidate the warranty of the unit. The airflows must never be set above the rated airflows. If higher airflows are requested, consult Munters for verification. -
Page 42: Base Configuration Settings
5. Adjust the set point for the process airflow in the control system so the measured differential pressure value corresponds to the calculated value. 6. Connect the manometer to the pressure nipple on the reactivation fan. Repeat the procedure in step 3–5 to set the actual reactivation airflow. -
Page 43: Setting The Gas Burner Effect
4.4 Setting the gas burner effect 4.4.1 Setting maximum effect NOTE! The procedure in section 4.3, Airflow adjustment must be done before setting the gas burner effect. 1. Start the unit by setting the mode switch to MAN. 2. Wait until the control valve is completely opened, i.e. the actuating rod indicator is in position E as shown in Figure 4.7 . -
Page 44: Setting Minimum Effect
5. Examine the flame through the inspection glass. The flame should be evenly spaced over the full length of the burner, and have a blue colour. 6. If the unit is running normally, wait 5–10 minutes to let the normal operational temperature to be reached before continuing with the next step. -
Page 45: Operation
Operation 5.1 Control panel ALARM SERVICE SIEMENS Figure 5.2 Main power switch Figure 5.1 Control panel Item Switch/Indicator Function Figure 5.2 Main power switch (see When the main power switch is in position 0, the unit is not powered beyond the switch. When the main power switch is in position 1, the dehumidifier can be started. -
Page 46: General
5.2 General The mode switch on the control panel has two operating positions: AUTO (Automatic position): The dehumidifier’s fans, rotor and reactivation heater are activated ■ only when the humidity exceeds the desired value (the set-point). If continual process air operation is selected in the control system display, the process air fan continues to run even after the unit has stopped dehumidifying. -
Page 47: Operating The Unit
5.4 Operating the unit 5.4.1 Initial start-up, Manual mode (MAN) 1. Set the main power switch to position 1 and check that the display lights up. 2. Set the mode switch to MAN position. Check that: The white lamp which indicates that the dehumidifier is in operational mode lights. A few seconds ■... -
Page 48: Service And Maintenance
This value is programmed by Munters personnel at initial start-up of the unit. Service and maintenance... -
Page 49: Service Options
Munters products. All test equipment used by our personnel to ensure proper system balancing is certified for accuracy. Munters Service can offer a service plan adapted to suit the conditions of a specific installation. See contact addresses on the back page of this manual. -
Page 50: (0-24000 Hours)
6.6 Service and maintenance schedule (0–24000 hours) Service level Start Service work Operating time in hours 4000 8000 12000 16000 20000 24000 Calendar time in months Filter inspection, replace filter if necessary, function controls Preventive inspection including safety check Capacity check, rotor inspection Replacement of high-temperature protection Inspection of heater coils Replacement of drive belt and belt fastener... -
Page 51: Service And Maintenance Schedule (28000-48000 Hours)
6.7 Service and maintenance schedule (28000–48000 hours) Service level Service work Operating time in hours 28000 32000 36000 40000 44000 48000 Calendar time in months Filter inspection, replace filter if necessary, function controls Preventive inspection including safety check Capacity check, rotor inspection Replacement of high-temperature protection Inspection of heater coils Replacement of drive belt and belt fastener... -
Page 52: Maintenance Schedule For Gas Heater Unit
6.9 Maintenance schedule for gas heater unit Inspection and maintenance procedures are described in the following table. WARNING! Adjustment, maintenance and repairs must only be carried out by qualified personnel who are fully aware of the hazards of operating and maintaining equipment containing high voltages, temperatures and flammable gases. WARNING! Leaking gas can cause fire or explosion. -
Page 53: Air Filter Replacement
6.10 Air filter replacement 6.10.1 Preparation 1. Set the mode switch to position 0. 2. Wait 60 seconds for the heater to cool down. 3. Set the main power switch to position 0 and lock the switch. 6.10.2 Reactivation air filter 1. -
Page 54: 3Process Air Filter
6.10.3 Process air filter 1. Unscrew the screws holding one of the covers (see Figure 6.5 ). Carefully remove the cover from the filter box without damaging the gasket. 2. Pull the channel spacers straight out from the filter box to release the filters, see Figure 6.6 . 3. -
Page 55: Fault Tracing, Gas Heater Unit
For more information, refer to section 2.8.2, Programme indicator. Before contacting Munters service, go through the list below and rectify the fault if possible. WARNING! Adjustment, maintenance and repairs must only be carried out by qualified personnel who are fully aware of the hazards of operating and maintaining equipment containing high voltages, temperatures and flammable gases. - Page 56 Fault symptom Possible cause Corrective action The burner will not start. The burner control unit indicator has stopped. Check the programme indicator to establish the reason for the failure. Check that when both solenoid valves (V1, V2) in the GasMultiBloc are open, the change in the flame characteristics does not cause the flame to “lift-off”...
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Page 57: Measuring Flame Signal And Differential Gas Pressure
7.2 Measuring flame signal and differential gas pressure (> 12 μA DC) Figure 7.1 Measuring flame signal and differential gas pressure. Flame detection probe GasMultiBloc control unit DC meter (0–100 µA)* Differential pressure indicator or U-pipe Combustion chamber Airflow through burner * The flame signal must be higher than 12 µA. -
Page 58: Technical Specification
Technical specification 8.1 Capacity diagrams Approximate capacity in kg/h. Contact your nearest Munter´s office for further information. NOTE! The figures in the diagrams are based on a rated airflow (1/1). MCD100 MCD120 kg/h kg/h 80 % RH 60 % RH 40 % RH 80 % RH 60 % RH... -
Page 59: Noise Data
8.2 Noise data 8.2.1 MCD100E Setup A: All ducts connected 1. Ductwork for dry air Setup B: Process inlet not connected to duct 2. Ductwork for process air Setup C: Reactivation inlet not connected to duct 3. Ductwork for reactivation air Setup D: Reactivation and process inlet not connected to duct 4. -
Page 60: Mcd120E
8.2.2 MCD120E Setup A: All ducts connected 1. Ductwork for dry air Setup B: Process inlet not connected to duct 2. Ductwork for process air Setup C: Reactivation inlet not connected to duct 3. Ductwork for reactivation air Setup D: Reactivation and process inlet not connected to duct 4. -
Page 61: Mcd140E
8.2.3 MCD140E Setup A: All ducts connected 1. Ductwork for dry air Setup B: Process inlet not connected to duct 2. Ductwork for process air Setup C: Reactivation inlet not connected to duct 3. Ductwork for reactivation air Setup D: Reactivation and process inlet not connected to duct 4. -
Page 62: Mcd155E
8.2.4 MCD155E Setup A: All ducts connected 1. Ductwork for dry air Setup B: Process inlet not connected to duct 2. Ductwork for process air Setup C: Reactivation inlet not connected to duct 3. Ductwork for reactivation air Setup D: Reactivation and process inlet not connected to duct 4. -
Page 63: Dimensions And Service Space
8.3 Dimensions and service space 8.3.1 Dimensions " 4 Figure 8.1 Dimensions, MCD100–140G D. Option " 4 Figure 8.2 Dimensions, MCD155G D. Option Technical specification 190TEN–1081–J1408... -
Page 64: Dimensions For Units Without Process Fan
8.3.2 Dimensions for units without process fan Dim D 1514 1514 1514 1509 Figure 8.3 Dimensions for units without process fan 8.3.3 Service space Figure 8.4 Required service space Technical specification 190TEN–1081–J1408... -
Page 65: Technical Data
8.4 Technical data MCD100G MCD120G MCD140G MCD155G Process air Figures quoted are rated, based on a fan inlet temperature of 20 °C and an air density of 1,2 kg/m Rated airflow (m 2, 78 3,33 3,89 4,25 Rated airflow (m... - Page 66 MCD100G MCD120G MCD140G MCD155G Weight, total (kg) 1132 1153 1153 1062 Weight, total, without process fan (kg) Miscellaneous data Drive motor power, 50/60 Hz (W) 10/12 10/12 10/12 10/12 Filter class (standard) IEC protection class, unit IP33 IP33 IP33 IP33...
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Page 67: Scrapping
Scrapping The unit must be scrapped in accordance with applicable legal requirements and regulations. Contact your local authorities. The rotor material is not combustible, and should be deposited like glass fibre materials. If the rotor has been exposed to chemicals that are dangerous to the environment the risk must be assessed. The chemicals can accumulate in the rotor material. -
Page 68: Contact Munters
Munters Belgium nv Blarenberglaan 21c Tel: +3215285611 Air Treatment B-2800 Mechelen service@muntersbelgium.be www.muntersbelgium.be CZECH REPUBLIC Tel: +420 775 569 657 Munters CZ, organizacni slozka Slevacská 2368/68 info@munters-odvlhcovani.cz Air Treatment CZ-615 00 BRNO www.munters-odvlhcovani.cz DENMARK Munters A/S Ryttermarken 4 Tel: +4544953355... - Page 72 www.munters.com...
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