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DriSteem Vapor-Logic, Installation And Operation Manual

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DriSteem Vapor-Logic Installation And Operation Manual Download Page 15

11

VAPOR-LOGIC

®

 VERSION 6 INSTALLATION AND OPERATION MANUAL

•  Communication connections

– Vapor-logic keypad
–  Ethernet
–  Modbus
–  BACnet
–  LonTalk
–  Multiple-tank communication

•  Programmable triac and relay
•  Area-type, SDU dispersion fans, or steam blowers
•  Combustion air switch and power vent (GTS systems only)

2 .   Complete the Setup process .

  See instructions beginning on Page 28 .

3 .   Start up humidifier(s) .

  See instructions on Page 37 . 

Refer to the Pre-installation Checklist and drawings on the previous pages, and 
then make the field wiring connections as described on the following pages .

Installation process

INSTALLATION

Summary of Contents for Vapor-Logic

Page 1: ...VAPOR LOGIC VERSION 6 Humidifier Control System Installation and Operation Manual READ AND SAVE THESE INSTRUCTIONS...

Page 2: ...keypad display 19 Communication connections 19 Field wiring 24 Sensor placement 26 Step 2 Setup 28 Using the keypad display 28 Using the Web interface 29 Setup screen 29 Step 3 Startup 37 OPERATION 3...

Page 3: ...historical data 68 Backing up and restoring data 68 Firmware updates 69 Downloading firmware updates 69 Installing firmware updates 72 Test outputs and test run 73 Modbus BACnet LonTalk interoperabil...

Page 4: ...d here and in the IOM resulting in property damage personal injury or death If the IOM is missing go to www dristeem com to download a replacement mc_071608_0910 Hot surfaces and hot water Steam humid...

Page 5: ...s USB port allows easy firmware updates and data backup and restore capability Real time clock allows time stamped alarm and message tracking and accurate drain and flush scheduling Auxiliary temperat...

Page 6: ...tem Insert a USB flash drive into the Vapor logic board s USB port to perform software updates download data logs and back up and restore data Vapor logic capabilities Enhanced diagnostics include Tes...

Page 7: ...d remotely Connect a computer directly to the Vapor logic board or through a network to use the Web interface OPERATING CONDITIONS The Vapor logic main board and keypad display must be operated and st...

Page 8: ...key components of the Vapor logic control board See the illustration on the next page for more detail Power connection Factory connection points for drain steam valve etc Field connection points for...

Page 9: ...r 3 Ignition module 3 XT dual drain 2 HPS pump 2 Z3 supply CT2 Contactor 2 Ignition module 2 XT dual fill 2 HPS pump 1 Z2 drain P17 all are 24VAC outputs CT1 Contactor 1 Ignition module 1 HPS single z...

Page 10: ...oes not include fill icon see Page 61 Typical Home screen Tank temperature Tank status Change set point from the Home screen by pressing the Up or Down arrow keys until set point is highlighted as sho...

Page 11: ...move to another screen Click here to view alarms Click here to view messages To change value Highlight value type in new value click on APPLY Click on CHANGE to change value Click on label to contract...

Page 12: ...n the electric subpanel Do not ground the shield screen wire on the humidistat or transmitter end If you have a remote mounted control cabinet the water level control device thermal trip safety interl...

Page 13: ...end of wire and insert wire here P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 SSR BL Steam Fill Drain SDU NO 2 PV CA 24VAC CAsw 24VAC PVsw TS 24VDC DHL 21VDC 24VAC AFsw NO 1 C 1...

Page 14: ...d to the humidifier and connected to the Vapor logic board INSTALLING VAPOR LOGIC IS A THREE STEP PROCESS 1 Connect field wiring from device to Vapor logic board See instructions beginning on Page 12...

Page 15: ...e SDU dispersion fans or steam blowers Combustion air switch and power vent GTS systems only 2 Complete the Setup process See instructions beginning on Page 28 3 Start up humidifier s See instructions...

Page 16: ...ing measured All transmitters provided by DriSteem are two wire devices using a 4 to 20 mA signal Demand signal by others Demand signals are sent to the Vapor logic board from another control system s...

Page 17: ...GND lug 2 wire 18GA Shield cable Control panel shield GND lug RH Dew point Vapor logic Vapor logic P11 P11 Room or duct RH Y 21VDC RH 21VDC RH 21VDC 4 20 mA humidity sensor COM Note Input resistance 5...

Page 18: ...revent output short cycling In other words the humidity level has to fall below set point before the humidistat closes and energizes the humidifier Once the humidifier is energized the humidistat stay...

Page 19: ...ucing this signal the humidity set point is set at the humidistat The keypad display then is used for maintaining and troubleshooting the humidification system with humidifier control stemming from th...

Page 20: ...assembly See also Sensor placement on Page 26 DUCT HIGH LIMIT SWITCH OR TRANSMITTER Connect wiring for a duct high limit switch or transmitter by inserting wires into the terminal block plug at P13 l...

Page 21: ...et terminal strip for SDU blower and air flow switch 21 VDC Transmitter On off Vapor logic Vapor logic 4 20 mA High limit sensor Duct mount Modulating high limit NC C GN 2 wire 18GA shield cable TYP C...

Page 22: ...onitors duct or space air temperature Mount the auxiliary temperature sensor wherever you want to monitor temperature Auxiliary temperature readings are logged to the data log TEMPERATURE COMPENSATION...

Page 23: ...pad display This connection provides DC power and communication to the keypad display See Caution at right before routing cable If a longer keypad display cable is needed order a replacement cable fro...

Page 24: ...onTalk terminals Next multitank humidifier PC or BACnet IP Ethernet connection J1001 Install jumper if multi tank system and controller is at end of communications link Step 1 Field wiring Communicati...

Page 25: ...WEB INTERFACE DIRECTLY TO A COMPUTER NOT ON A NETWORK 1 Connect the Ethernet cable Insert the male end of an RJ45 Ethernet cable into the Vapor logic board at P9 labeled Ethernet see Figure 21 1 until...

Page 26: ...way to change the IP address of the humidifier using Vapor logic is to use the keypad display Go to Setup Communications Network IP address on the keypad display and change the IP address such that t...

Page 27: ...er address bar see Figure 23 1 delete all existing text in the browser address bar type the Vapor logic IP address into the browser s address bar and press Enter Note The Vapor logic default IP addres...

Page 28: ...onnect wiring for remote signaling using a programmable relay dry contact by inserting wires into the terminal block plug at P12 or P16 per the wiring diagram in Figure 25 1 Tighten screws This connec...

Page 29: ...ustion air switch and or GTS power vent by inserting wires into the terminal block plugs at P15 and P16 Tighten screws Remove shunt on J403 combustion air or J404 power vent if it is installed The com...

Page 30: ...nd sampling time D Acceptable behind wall or partition for sampling entire room if sensor is near an air exhaust return outlet Typical placement for sampling a critical area E Not acceptable These loc...

Page 31: ...corner of the inside surface of double pane window glass on north or northeast facing window Window Doorway Window Point of vapor absorption Vapor absorption has taken place Airflow switch or differe...

Page 32: ...After entering the Setup menu press the Up and Down arrows to scroll through all setup parameters or to change values Use the Enter key to select parameters A indicates that these settings apply to T...

Page 33: ...ection and IP address instructions Follow the instructions below to complete the setup process INSTALLATION Click on a tab label to move to another screen Click here to view alarms Click here to view...

Page 34: ...o Yes RH set point 35 0 100 RH offset 0 20 20 DriSteem recommends using default values for offsets and PID settings when first setting up your humidifier PID tuning RH PID band 10 0 50 Proportional ga...

Page 35: ...BACnet BACnet controlled No No Yes Control via LonTalk LonTalk controlled No No Yes Humidistat Humidistat enabled No No Yes Limit control HL switch Switch in system Yes No Yes HL transmitter Transmitt...

Page 36: ...humidifier automatically drains and then flushes the tank at user defined intervals Usage Model specific 0 2 200 000 lbs Select amount of water to be converted to steam before auto drain flush starts...

Page 37: ...not an XT menu item The minimum aquastat setting prevents tank water freezing Higher settings keep tank water warm reducing time required to bring water to boiling after a call for humidity Aquastat e...

Page 38: ...ylinder No No Yes Disables specific cylinder Disable right cylinder No No Yes Disables specific cylinder Clear foaming fault Yes No Yes Auto clearing of foaming fault Pulse fill mode No No Yes Fan bas...

Page 39: ...eway 192 168 1 1 0 0 0 0 255 255 255 255 Enable DHCP No No Yes Use keypad display to access this menu item This item is not available when using the Web interface Programmable outputs Dry contact 1 or...

Page 40: ...Minutes The number of inactivity minutes Vapor logic remains in read write mode before returning to read only mode Capacity adjust Capacity calibration GTS systems 100 0 0 0 245 0 Changing the capaci...

Page 41: ...100 steam output scaled across 6 8 VDC range H 4 staged 8 10 VDC 0 to 100 steam output scaled across 8 10 VDC range User selectable 0 10 VDC in 0 1V increments Table 37 2 Control input example for two...

Page 42: ...owing screens Status Diagnostics Alarms Setup Help Press the Main softkey to go to Status Diagnostics Alarms or Setup screens Press the Up or Down arrow keys to choose a submenu or change a value Pres...

Page 43: ...n See the table below for a description of tank level indicators Above the tank level indicator is a tank temperature display showing actual tank temperature CHANGING MODE AND SET POINT Mode and Set p...

Page 44: ...us MAIN BACK 2 24 A TANK STATUS HOME Auto Space RH 34 RH Mode MAIN BACK 3 24 A TANK STATUS HOME 34 RH RH set point 35 RH Space RH A indicates these settings apply to Tank A All humidifier tanks are la...

Page 45: ...rain valve if so equipped opens and the tank drains All humidifier operation is suspended and the drain valve remains open until the unit is taken out of Drain tank mode See the Diagnostics section fo...

Page 46: ...14000 counts Mid water probe Water No water Low probe signal 0 14000 counts Low water probe Water No water DI low water switch Water No water Airflow switch Flow No flow Interlock switch Open Closed...

Page 47: ...ch Open Closed GTS 04 systems only Flue pressure switch Open Closed GTS systems only Low water sensor No water Water GTS 04 systems only Current 0 Model dependent Amps XT systems only High water probe...

Page 48: ...heir own For example a No airflow message appears when there is no airflow in the duct If airflow returns the No airflow message auto clears but stays in the Messages Log per the rules described above...

Page 49: ...UAL Diagnostics screen View messages by clicking on View Messages on any screen or by opening the Diagnostics screen Clear messages by clicking here Click on buttons to activate functions OPERATION FI...

Page 50: ...XT systems only Phase XT systems only Test outputs Fill valve Cycles output to verify operation Pulse fill valve Universal water systems Note Humidifiers with the universal water system use the same...

Page 51: ...witch or safety interlock switch are not operating correctly Diagnostics screen OPERATION Table 46 1 Diagnostics menu Message Description Does message auto clear Messages Replace contactors Contactors...

Page 52: ...S set point The system will continue to operate but the membranes may need to be replaced Not available in Europe Yes RO flush active The unit is performing an RO flush or has done so and remains inac...

Page 53: ...by cleared alarms The Alarms Log holds 30 alarms As alarms are cleared they move down the list below active alarms When the Alarms list reaches 30 alarms new alarms add to the top of the list and the...

Page 54: ...r is put into a keep cool state where fill and drain cycles operate to keep tank water from boiling First resolve any safety issues then resolve whatever is causing the problem Restart the controller...

Page 55: ...times indicating that foaming is a persistent problem If not corrected humidifier shuts down Cylinder may need to be completely drained twice to prevent foaming See Start up procedure in XT Electrode...

Page 56: ...production exceeds the TDS set point The system will continue to operate but the membranes may need to be replaced No Incoming air temperature sensor WMS systems only Air temperature upstream of wett...

Page 57: ...open P20 input on control board A red Status LED blink indicates there is an active fault preventing the unit from operating These conditions can be viewed as alarms through the Vapor logic display I...

Page 58: ...tatus Demand call for humidification Green Auto mode no faults Keypad display is attached and working Humidification demand is present Yellow Auto mode active message preventing unit from running Red...

Page 59: ...multiplied by its corresponding gain factor These gain factors are the setup variables you have access to from the Setup menu By making a gain factor larger you increase its overall influence on syst...

Page 60: ...t point the demand decreases slightly The amount it increases or decreases depends on the magnitude of the RH error and the integral gain value The closer you are to the set point the smaller the addi...

Page 61: ...erm in the PID equation is the PID band The PID band defines the range of measured RH values F C for dew point control where the PID loop is in operation The PID loop is in operation when the measured...

Page 62: ...large integral gain Ki quickens the system response but may cause it to oscillate and become unstable A small integral gain yields tighter more stable control at the expense of a long response time T...

Page 63: ...mum usable life the humidifier shuts down and the Faulty water probe alarm appears An adjustable skim time allows for an extended skim period 0 to 120 seconds to reduce mineral accumulation When skimm...

Page 64: ...loses when a ready water condition is reached This float switch provides low water protection for the heating outputs If the water falls below the float the heating outputs are disabled See Chloride c...

Page 65: ...employ an algorithm that monitors conductivity and manages drain and fill events to optimize humidifier performance and provide proper steam output As the water in the cylinder boils into steam the c...

Page 66: ...t HL span message appears in the Messages Log and the Message label lights on the keypad display If necessary the reduction of the humidifier output continues until maximum high limit set point is rea...

Page 67: ...logic is calibrated for 20 F to 160 F 29 C to 71 C with output from 4 to 20 mA For example a temperature reading of 70 F 21 C should produce a measurement of 12 mA You can calibrate the sensor by adj...

Page 68: ...ns FREEZE PROTECTION Freeze protection is similar to aquastat operation with some exceptions The freeze protect set point is fixed at 40 F 4 C Its purpose is to prevent the tank from freezing in cold...

Page 69: ...ection of the Setup menu First automatic draining and flushing must be enabled Second the amount of water converted to steam before an automatic drain sequence begins must be defined Usage Defaults fo...

Page 70: ...umidifier receives a call for humidity after the ten hour end of season drain down period has begun the controller stops the end of season draining the tank refills and the humidifier resumes normal o...

Page 71: ...BATTERY BACKUP NONVOLATILE MEMORY If there is a power outage date and time settings will be saved Alarms unit configuration and usage timers will remain in nonvolatile memory indefinitely SECURITY PAS...

Page 72: ...10 567028344 421073 23 1 26 10 9 41 AM 23 0 211 567030677 421075 23 1 26 10 9 42 AM 23 0 212 567033008 421077 23 1 26 10 9 43 AM 23 0 212 567035339 421079 23 1 26 10 9 44 AM Unit Start Auto cleared me...

Page 73: ...WARE UPDATES The Vapor logic controller can be field upgraded to the latest firmware version via the USB port on the Vapor logic board Firmware updates are available at no charge on the DriSteem websi...

Page 74: ...Note The screenshots in this table depict typical Internet Explorer screens in Windows XP While your browser and operating system might be set up differently the screenshots are provided as a general...

Page 75: ...Unzip button in the WinZip Self Extractor window A WinZip window opens to confirm that the firmware update has been unzipped 8 Click the OK button 9 Click the Close button to close the WinZip Self Ext...

Page 76: ...4 and 5 do not remove the USB flash drive or cycle the power until the signal occurs as explained in Step 5 4 The update process begins immediately and takes up to 1 minute Wait for the relay on the V...

Page 77: ...or logic has a test run capability to confirm system functionality This capability allows a technician to simulate a demand for steam production when there isn t one such as when performing routine ma...

Page 78: ...by the edge Avoid touching the components or circuit board 4 Plug LON ProtoCessor module into mounting pins as shown in Figure 74 1 with LonTalk connector at the edge of the board Make sure all pins...

Page 79: ...P Steam demand as a percentage of the humidifier s total capacity 0 to 100 0 to 100 Aux_temp RO IR 6 30006 AI 06 nvoAuxTemp Temperature of auxiliary temperature sensor F C 20 to 160 29 to 170 Water_te...

Page 80: ...Supply_water_conductivity_ s RO IR 31 30031 AI 15 nvoSupply_ S Supply water conductivity in S S S 0 to 1000 0 to 1000 Stage_1_temperature RO IR 32 30032 AI 16 nvoStage1Temp Stage 1 temperature F C 0...

Page 81: ...ons are 1 Auto 2 Local standby 3 System standby 4 Manual drain 1 to 4 1 to 4 Read HR 1 40001 MSV 01 nvoRunMode Mode of the unit or system The defined options are 1 Auto 2 Local standby 3 System standb...

Page 82: ...00 PID Ki RW HR 9 40009 AV 12 nciPIDki PID Ki integral gain factor 0 to 1000 0 to 1000 PID Kd RW HR 10 40010 AV 13 nciPIDkd PID Kp derivative gain factor 0 to 1000 0 to 1000 MT_runmode Write HR 14 400...

Page 83: ...I 6 10006 BI 06 nvoPowerVentSwch 0 Not ready 1 Ready Stage_3_ High Pressure System RO DI 6 10006 BI 06 nvoPowerVentSwch 0 Closed 1 Open Low_water_sensor_ GTS RO DI 7 10007 BI 07 nvoLowWaterSensr 0 No...

Page 84: ...overtemp Unit reboot required RW DV 6 6 BV 06 nvoAlrmOvertemp Signal at RH input out of range RW DV 7 7 BV 07 nvoAlrmRHsignal nvoAlrmDewPtSgnl nvoAlrmDemndSgnl Duct RH sig out of range RW DV 8 8 BV 0...

Page 85: ...4 GTS Blower 1 fault WM Temp sensor stage 1 fault RW DV 28 28 BV 28 nvoAlrmBlower1 GTS Blower 2 fault WM Temp sensor stage 2 fault RW DV 29 29 BV 29 nvoAlrmBlower2 GTS Blower 3 fault WM Temp sensor st...

Page 86: ...S High pump pressure RW DV 55 55 BV 55 nvoAlrmFoaming1 XT Overcurrent 2 HPS High inlet water temp RW DV 57 57 BV 57 nvoAlrmOverCur2 XT Supply water 2 failure HPS Low pump pressure RW DV 58 58 BV 58 nv...

Page 87: ...mp on RW DV 45 45 BV 45 nvoMsgTempCompOn Clean probes RW DV 46 46 BV 46 nvoMsgCleanProbe Duct HL trip RW DV 47 47 BV 47 nvoMsgDuctHLtrip Duct HL span RW DV 48 48 BV 48 nvoMsgDuctHLspan Insufficient wa...

Page 88: ...500 152 m Note Multi tank groups can also be operated using the Web interface See Multi tank operation with Web interface on Page 88 OPERATION START UP ORDER AND TRIM TANKS All humidifier tanks in a...

Page 89: ...For best performance multiple electric humidifiers in a given priority group must all have the same heater controls That is they should all be 100 SSR control or all be sequenced SSR control or all be...

Page 90: ...any unit can be used 3 Redundant Provides the capability to offset a tank that is offline for any reason This tank will only run when a trim load or peak unit is shut down for service or alarm conditi...

Page 91: ...s On the last board in the series of connected boards jumper the pins at J1001 located on the Vapor logic board next to the RJ11 phone socket see Page 5 On all other boards J1001 should not be shunted...

Page 92: ...Multi tank setup menu The controller will automatically calculate the new system capacity Important Each tank in a multi tank system must have a unique tank designator A B C P Duplicate tank designati...

Page 93: ...t is not yet at boiling temperature MODE SysAuto SET PT SPACE RH OUTPUT 0 35 20 MASTER MESSAGE MAIN ALARM Master screen Multitank Status screen HOME BACK MT Master B No comm A Cold D No comm C No comm...

Page 94: ...ow appear when operating in multi tank mode Each connected tank automatically shows up as a link Click on a tank link to view its status Important All system tanks must be network connected via Ethern...

Page 95: ...or Messages Log items if applicable Example Tank temp probe wiring etc Time issue began Example Always after remodel after a change in weather etc System changes Example Pressure new boiler new servi...

Page 96: ...ct closure No readable information on keypad display No power or incorrect voltage to Vapor logic board Check main power supply Reset control transformer circuit breaker if tripped Reset thermal cutou...

Page 97: ...P13 Duct high limit signal 0 21 VDC 2 10 VDC At terminal P14 Auxiliary temp sensor or temperature compensation sensor 2 10 VDC Check output on transmitter If there is no output replace transmitter Ver...

Page 98: ...piping is not too long See instructions in the humidifier s manual Verify there is a P trap installed on the tank and or that the P trap is not plugged Verify that there is a machine ground between co...

Page 99: ...in the Auto position and is closed Missing probe rod Replace missing probe rod if possible otherwise replace probe rod assembly Tank is full Probe malfunctioning Clean or replace probe Low water cond...

Page 100: ...to automatic Replace valve if there is a broken return spring on the drain valve Clean or replace drain valve if an obstruction in the valve does not allow complete closure Close manual drain valve if...

Page 101: ...iping size and pitch requirements Unit does not perform automatic drain sequence Humidifier may not have automatic drain system or automatic drain is disabled Inspect unit to verify that an automatic...

Page 102: ...sensor Reduced or no output even though water level is correct Electric humidifiers Heater malfunctioning Verify that proper voltage is being applied to heaters Verify heater amperage matches wiring d...

Page 103: ...ly Check venting system and combustion dampers Verify wiring and connections on switches are properly connected Incorrect or nonexistent control voltage Check for proper supply voltage on electrical d...

Page 104: ...t or vapor hose Recalibrate if controls are out of calibration If fill valve is stuck open repair or replace If zone valve will not open repair or replace Interconnecting steam piping to the dispersio...

Page 105: ...ove and below desired set point Malfunctioning control system If there is a faulty or inaccurate humidity controller or transmitter repair or replace Check for proper Vapor logic control settings RH s...

Page 106: ...lame sensor is cracked Replace Polarity reversed at power block Check polarity Alarm Ignition module number fault Ignition sequence engaged without power to gas valve Verify ignition sequence Replace...

Page 107: ...x plugs Vapormist Humidi tech only 1 183504 005 Keypad display includes printed circuit board LCD display screen membrane switch front and back of plastic cover 1 408495 011 Keypad display communicati...

Page 108: ...VAPOR LOGIC VERSION 6 INSTALLATION AND OPERATION MANUAL OPERATION Main board Keypad display Molex connector plug 2 position shown Replacement parts FIGURE 104 1 VAPOR LOGIC REPLACEMENT PARTS LonTalk c...

Page 109: ...105 VAPOR LOGIC VERSION 6 INSTALLATION AND OPERATION MANUAL...

Page 110: ...106 VAPOR LOGIC VERSION 6 INSTALLATION AND OPERATION MANUAL...

Page 111: ...107 VAPOR LOGIC VERSION 6 INSTALLATION AND OPERATION MANUAL...

Page 112: ...eem s Limited Warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by DriSteem or if the products have been modified or a...

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