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31

 

 

| HP Series Installation Manual 

 

Installing 1 inch Screws/Studs 

In the final step of this instruction Media Clamping Strips are used to secure the media to the 
frame. In this step the screws used to fasten the Media Clamping Strip to the finished assembly 
must be installed.  Each Media Clamping Strip requires 3 screws evenly spaced.  Clamping 
strips are 46 inches in length upon arrival from the factory however if the Clamping Strip is cut 

to fit the duct size it will still require 3 screws evenly spaced to properly secure it.  After each 
screw is installed use the factory supplied nuts to lock them in place. 

 

 

Figure 26: 1 Inch Screw / Stud Installation 

 
 

Installation of Wire Mesh 

The 4ft wide Wire Mesh can now be cut to length (duct height or top mounting stud to bottom 
mounting studs.)  To fasten the Wire Mesh to the assembly use the factory supplied self-
threading ½ inch screws starting from the top angle and middle channels working out and 
down.  Be sure to install the wire mesh square when first fastened otherwise it will not align 
properly at the opposing end.  Notch around screws previously installed for best results.

 

 

 

Figure 27: Mesh Installation 

Summary of Contents for HP Series

Page 1: ...peration Manual Includes installation operation maintenance and troubleshooting information for your HP Series humidifier 1507183 B 25 OCT 2010 Important Read and save these instructions This guide to be left with equipment owner ...

Page 2: ...red for installation or maintenance of recipient s equipment All references to the Nortec name should be taken as referring to WALTER MEIER LTD Liability Notice Nortec does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts components equipment that are not authorized or approved by Nortec Copyright Notice Copyright 2010 WALTER M...

Page 3: ...ion of the Valve Block 22 High Pressure Piping 22 Low Pressure Piping 22 Valve Controller Installation 23 Wiring of the System 25 Pump Controller Wiring Notes 27 Mist Eliminator Installation 34 Startup Operation and Maintenance 35 Commissioning and Startup 37 HP HVAC Start up Checklist 38 Operation 39 Maintenance 42 Danfoss Stainless Steel Axial Piston Pump 42 Electrical Motor Service 43 Inlet Wat...

Page 4: ...ding to local and national electrical code Electrical connection to be performed by a licensed electrician CAUTION Plumbing Plumbing to be performed by a licensed plumber Drain water from humidifier can be very hot Do not drain to public sink All plumbing work should be done according to local plumbing code CAUTION Installation Do not mount on hot surfaces Do not mount in area where freezing can o...

Page 5: ...ets into an air stream During this process the air absorbs moisture increasing its relative humidity levels As the water droplets evaporate they absorb some energy in the form of heat from the air This loss of heat causes the air temperature to drop resulting in a phenomenon known as adiabatic cooling The HP HVAC adiabatic system has 2 effects The relative humidity of the air increases humidificat...

Page 6: ... is limited such as in an air handler precautions should be taken to prevent the wetting of sensitive components downstream Components Nortec Supplied Nortec will supply the following components 1 High pressure pump skid 2 Valve controller 3 Valve block assembly 4 Nozzle manifolds 5 In duct plumbing 6 Mist eliminator optional 7 Air proving switch optional 8 High limit humidistat optional 9 Humidis...

Page 7: ...HP Series Installation Manual 4 Figure 1 Typical Installation with Medium Pump ...

Page 8: ...5 HP Series Installation Manual Figure 2 Typical Installation with Large Pump ...

Page 9: ...cting and drains must be constructed from stainless steel To ensure that the HP HVAC nozzles do not become blocked or damaged over time the following conditions should also be met Conductivity 20 micromhos or less Ph 6 2 7 5 Multiple Zones Oftentimes a single pump package will be used to serve different ducts or zones In this case each duct will have its own set of manifolds valve controller and v...

Page 10: ...7 HP Series Installation Manual Installation ...

Page 11: ...o be located outdoors NEMA rated disconnect switches should be used per national and local codes Sizing High Pressure Stainless Steel Tubing Stainless steel piping must be supplied for distances between the HP pump module and the HP manifolds These distances should be kept to a minimum to minimize pressure losses and maximize system performance however it is important to avoid over sizing the line...

Page 12: ... bends Avoid twisting and kinking the lines while un spooling and installing When supporting the hose keep in mind that thermoplastic hose has a tendency to return to position it was supplied in Pipe Supports and Fasteners The installer must also supply support for feed piping When selecting brackets pipe strapping and various other supports ensure that local and national plumbing codes are follow...

Page 13: ... airflow from the HP manifolds to end of the wet section The drain pan should terminate with a drain connected to a P trap The P trap should be at least 2 inches taller center to center that the duct static pressure and should drain to an open funnel drain For systems up to 750 lb s per hour a 1 diameter drain should be used For larger systems a 2 diameter drain or multiple 1 diameter drains shoul...

Page 14: ...t of airflow Avoid installing other equipment on top of or in front of the pump module Occupants The pump will generate some noise and vibration during operation The pump should be located somewhere in a place noise and vibrations will not disturb occupants of the building Installing the pump module on vibration isolators is recommended to minimize vibrations Optional pump covers are available for...

Page 15: ...HP Series Installation Manual 12 Figure 3 Medium Pump Module Installation Drawing ...

Page 16: ...13 HP Series Installation Manual Figure 4 Large Pump Module Installation Drawing ...

Page 17: ...ry to properly install the rails If a wet section has not yet been constructed in the duct or air handler it should be constructed before the humidifier installation has started If the duct is greater than 8 feet in width install mounting rail extensions P N 1510135 onto the mounting rails Assemble all vibration clamps on the mounting rails as detailed in the following figure There should be an eq...

Page 18: ...ting Rail Installation Install the manifolds onto the mounting rails using the previously installed mounting rail clamps The manifolds should be equally spaced in the duct There should be at least 6 from the top of the duct to the mounting rails Mounting rails should be installed on the upstream side of the manifolds Figure 8 Rail and Clamp ...

Page 19: ...tion Manual 16 Install the air break end caps onto the one end of the HP manifolds Figure 9 Endcap Install the manifold fittings to the bottom end of the HP manifolds Figure 10 HP HVAC Manifold and Plumbing Installation ...

Page 20: ...17 HP Series Installation Manual ZONEVAL VE ASS EMBLY 4 Min 6 Min 4 Min 4 Min 4 Min 6 Min Figure 11 Manifold Minimum Spacing Figure 12 Nozzle Aiming ...

Page 21: ...ld have a slight decline towards the valve blocks This allows for water to drain from the manifolds and lines when the system is not in use In installations where water hammer is of concern it is recommended to install some flexible piping between the valve block and the manifold feed lines Using flexible feed lines between the valve block and the manifold supply piping can also simplify the insta...

Page 22: ...ble Ensure that arrow matches direction of flow Tighten compression fittings 3 1 in 78 mm 0 9 in 23 mm O 0 5 in 13 mm 1 0 in 24 mm Figure 14 P N 2546701 Check Valve Installation of the Needle Valve Connection Type compression fittings on the inlet and outlet Install near inlet to valve block ...

Page 23: ...s the transmission of vibrations through piping If the pump is only a short distance away it is recommended to use high pressure flexible hose for the entire run Vibrations can be transmitted from air handlers the HP pump modules or other mechanical room equipment it is strongly recommended to use a 2 ft 0 6 m length of flexible piping at the valve blocks and HP pump module to protect the equipmen...

Page 24: ...21 HP Series Installation Manual Figure 15 Typical Valve Block Assembly ...

Page 25: ... If stainless lines are used it is recommended to install a length of flexible hose between the metal piping and the pump inlet to minimize vibration transmission Flush low pressure piping with water prior to installation to clear any debris A drain line for the pump must also be connected this line should connect flow to an open air funnel or floor drain to prevent backpressure on the pump Water ...

Page 26: ...ese may include air proving switches A duct high limit switches B disable switches C other on off type devices Install these devices in accordance with their respective installation instructions All on off style devices should be wired in series and connected between terminals 1 and 2 on the valve controller terminal strip The circuit between terminals 1 and 2 is a 24VDC circuit 16 or 18 AWG stand...

Page 27: ...nections not used for single stage systems Flush valve is always connected to valve controller terminals 13 and 14 Pump controller terminal 9 GND is an available accessory ground Single Stage Control Options Time proportioning control Connect a 0 10 humidistat to valve terminals 3 and 4 On Off Control Connect a humidistat between valve controller terminals 1 and 2 Also connect a jumper between ter...

Page 28: ...ller The valve controller need only close the loop and does not need to provide a voltage or current If the valve controller does provide a signal it should be wired to a relay which will then close the pump controller loop Remote Monitoring The pump controller terminal strip features several sets of dry contacts to allow for connections to a building management system status lights or other types...

Page 29: ...HP Series Installation Manual 26 Figure 17 Valve Coils Figure 18 Valve Wiring ...

Page 30: ...t Eliminator Overview The Mist Eliminator is available in standard sizes ranging from 4ft high x 4ft wide to 12ft high x 20ft wide with 4ft increments between If a duct size does not fall under one of our standard sizes simply order the next larger size then cut to fit The drain pan is to be installed at the bottom of the plenum to remove the water collected by the Mist Eliminator The height of th...

Page 31: ...ey must be cut to fit Over lapping joints slightly is recommended for the floor angles only as they should be sealed along the entire length of angle with appropriate caulking to prevent free air flow through the drain pan Angles may have to be cut in half to make up two 4ft lengths When securing the mounting angles to the duct place the side with circular holes against the duct and the bent edge ...

Page 32: ...alled vertically at the center point of the duct In Figure 23 Large Duct Mounting Channel Locations a 6ft high x 10ft wide mist eliminator frame is shown Notice how the mounting channel placement is offset from the center Installations between 8ft x 12ft to 16ft x 20ft may involve the removal of excess material Excess material is removed equally from both sides of the frame not from the middle To ...

Page 33: ...HP Series Installation Manual 30 Figure 22 Mounting Channel Location Figure 23 Large Duct Mounting Channel Locations Figure 24 Mounting Channel Installation Figure 25 Mounting Channel Extension Kit ...

Page 34: ...l require 3 screws evenly spaced to properly secure it After each screw is installed use the factory supplied nuts to lock them in place Figure 26 1 Inch Screw Stud Installation Installation of Wire Mesh The 4ft wide Wire Mesh can now be cut to length duct height or top mounting stud to bottom mounting studs To fasten the Wire Mesh to the assembly use the factory supplied self threading inch screw...

Page 35: ...t of the screws through the media If the recommended method cannot be followed use a flat clean surface to pre cut the media Be sure to cut the media with precision so not to be short on the final section of the assembly Figure 28 Mesh Installation Media Clamping Strip Installation The final step is to secure all components of the assembly using the media clamping strip Place the strips so the 1 i...

Page 36: ...33 HP Series Installation Manual ...

Page 37: ...HP Series Installation Manual 34 Startup Operation Maintenance ...

Page 38: ...he valve blocks Connect a hose and route to drain In the case where 1 pump feeds multiple zones work with only 1 zone at a time 6 Turn on the pump for several minutes and check for leaks Again the pump can be activated temporarily using a jumper on terminals 1 and 5 7 Reconnect the manifold supply line at the valve inlet 8 Disconnect the manifolds from their individual feed lines ensuring that the...

Page 39: ...ccur when the valves open and close For it to work correctly it must be calibrated 1 Install the needle valve and adjust the valve to the fully open position by turning the handle counterclockwise 2 Run the humidifier full output so that all valves are open and all nozzles are spraying water 3 Observe the nozzle spray near the top of the manifolds Increase the flow restriction by turning the needl...

Page 40: ...connected 0 10V control signal connected to terminals 3 and 4 On Off safety devices or jumper connected to 1 and 2 Valve Block Inspection Valve coils wired to valve controller High pressure supply connected and tight Drain line connected High pressure supply lines flushed Manifold supply lines connected Manifold Inspection Air handler drains are connected and open Nozzle manifolds are securely mou...

Page 41: ...bly will open valves as needed to provided water flow to the manifolds The manifolds will then spray water into the air stream humidifying the air 6 When the humidity targets have been met the valve controller will close the valves and shut off the pump stopping the spray of water 7 Water will drain from the manifolds to reduce the microbial growth that may occur in standing water An air break cap...

Page 42: ...hat accompanies the humidifier for further information Maintenance Triplex Ceramic Plunger Pump Maintenance 1 The triplex ceramic plunger pumps pump skids with Giant pumps are oil lubricated and require maintenance The pump has a break in period of 50 hours After this time has elapsed the crankcase oil must be changed The service indicator light will not illuminate to indicate that the break in pe...

Page 43: ...s the reset rocker switch inside the pump controller to reset the counter and shutoff the service indicator Table 3 Crankcase Oil Capacity Pump Model Oil Capacity Do Not Overfill Giant P205REIB 9 fl oz Giant P208REIB 9 fl oz Giant P217REIB 9 fl oz Giant P218REIB 9 fl oz Giant P219REIB 9 fl oz Giant P220REIB 9 fl oz Giant P56W 14 fl oz Giant P420A 30 fl oz Synthetic 75w 90 grade oil is recommended ...

Page 44: ...41 HP Series Installation Manual Figure 30 P200 Series Pumps Figure 32 P420A Pumps Figure 31 P56W Pump ...

Page 45: ...mmends against this and cannot offer warranty on downstream components damaged by pump debris resulting from pumps run past 8000 hours Electrical Motor Service 1 Two types of electrical motors are used to drive the pumps those with sealed rotor bearings and those with external greased bearings The sealed rotor bearing types are maintenance free while the external bearing types require periodic lub...

Page 46: ...s 5 Reinstall the filter housings tighten hand tight with the filter wrench 6 Turn the supply water back on 7 Turn the power back on High and Low Pressure Lines and Hoses The hoses and lines should be periodically inspected for damage cracking leaking Ensure that the pipes are rubbing on any vibrating equipment Atomization Nozzles The Nortec HP HVAC system is designed to operate only on reverse os...

Page 47: ...eliminator media Odors produced could be harmful to occupants downstream As well chemicals and solvents could degrade the fire and antibacterial coatings on the media 3 For optimum performance Nortec recommends replacing mist eliminator media annually End of Season Shutdown 1 At the end of a humidification season the system can either be left in standby or shutdown for the off season 2 A properly ...

Page 48: ...s to be decommissioned shut down for an extended period of time or stored in a cold area the following procedure is applicable 1 Disconnect the low pressure line at the inlet of the pump 2 Connect the pump inlet to a canister containing a mixture of 35 glycol and water 3 Disconnect the high pressure supply line at the inlet to the valve block 4 Run the pump briefly to circulate the glycol mixture ...

Page 49: ...Troubleshooting 46 Troubleshooting ...

Page 50: ...p Inspect and replace if necessary The motor may have shorted or have been single phased or overloaded without protection Pump head mechanism may have been damaged Brass pump crank bearings connecting rods may have become damaged frozen causing the motor to lock up Disassemble pump head and repair replace as required Pump module has stopped running and red lamp is on Thermal overload circuit has b...

Page 51: ... or missing atomization nozzles A reusable hose fitting or manifold connection has come loose or has not been made correctly The drain solenoid on the pump module is stuck open allowing all the pumped water to leave the system An auto drain valve on manifolds isn t closing verify that the sealing ball is seating properly Pump module runs but there is no fog coming out of the nozzles The water pres...

Page 52: ...49 Troubleshooting ...

Page 53: ...Spare Parts 50 Spare Parts ...

Page 54: ...e is equipped with a variable frequenc y drive whic h is an option 2 T his pump c an either be a stainless steel pum p as shown or a triplex c eram ic plunger pum p 8 9 10 11 15 1 Medium Pump Module Spare Parts Figure 35 Medium Pump Module Spare Parts ...

Page 55: ...is equipped with a variable frequency drive which is an option 2 Detail View T his pump can either be a stainless steel pump as shown or a triplex ceramic plunger pump 1 8 9 10 11 17 7 Large Pump Module Spare Parts Figure 36 Large Pump Module Spare Parts ...

Page 56: ...1 x 1502839 1507311 1601109 x x 1504311 1507171 G1100 PM 230V 1ph 1504259 1504211 x 1502839 1507311 1601109 x x 1504311 1507156 G1100 PM 460V 3ph 1504259 1504579 x 1502839 1507311 1601109 x x 1504311 1507161 G1100 PM 575V 3ph 1504259 1506563 x 1502839 1507311 1601109 x x 1504311 1507172 G1550 PM 230V 1ph 1504265 1504212 x 1502839 1507311 1601109 x x 1504311 1507152 G1550 PM 230V 3ph 1504265 150421...

Page 57: ...9 1506494 1506479 1502839 1504307 1601109 1505622 1505621 x 1506936 GVFD2100 PM 230V 3ph 1504259 1505119 1506491 1502839 1504307 1601109 1505622 1505621 x 1506931 GVFD2100 PM 460V 3ph 1504259 1505119 1506481 1502839 1504307 1601109 1505622 1505621 x 1506941 GVFD2100 PM 575V 3ph 1504259 1503891 1506478 1502839 1504307 1601109 1505622 1505621 x 1506937 GVFD3500 PM 230V 3ph 1505608 1505120 1506490 15...

Page 58: ...506729 1506377 x x 1507033 1506544 D1100 PM 460V 3ph 1506429 1504216 x 1503900 1506729 1506377 x x 1507033 1506559 D1100 PM 575V 3ph 1506429 1506563 x 1503900 1506729 1506377 x x 1507033 1507179 D1800 PM 230V 1ph 1503899 1504212 x 1503900 1506729 1506377 x x 1507033 1506553 D1800 PM 230V 3ph 1503899 1504216 x 1503900 1506729 1506377 x x 1507033 1506543 D1800 PM 460V 3ph 1503899 1504216 x 1503900 1...

Page 59: ...h 1506430 1506494 1506479 1503900 1505279 1506377 1505622 1507034 x 1506403 DVFD1100 PM 230V 3ph 1506429 1506495 1506492 1503900 1505279 1506377 1505622 1507034 x 1506389 DVFD1100 PM 460V 3ph 1506429 1506408 1503900 1506729 1506377 x x 1507033 1506393 DVFD1100 PM 575V 3ph 1506429 1506494 1506479 1503900 1505279 1506377 1505622 1507034 x 1506402 DVFD1800 PM 230V 3ph 1503899 1505119 1506491 1503900 ...

Page 60: ... 1506359 17 Large Pump Module Cover 1506870 18 Pressure Relief Val 1503900 19 3 Amp Fuse for Transformer 1323056 Table 9 Valve Assembly Number Description Part Number 1 24 Vdc Coil Clip on 1507293 2 Valve HP 3 2 SS 1507292 3 Valve HP 2 2 NC SS 1507294 Table 10 Mist Eliminator Spare Parts Part Number Description 2529853 Media Mist Eliminator 48 w X 12 h X 1 d 2529849 Mesh Welded Wire 4x4 304 Stainl...

Page 61: ...Spare Parts 58 Figure 37 3 and 6 Stage Valve Assembly Spare Parts ...

Page 62: ...59 Spare Parts ...

Page 63: ...Wiring Diagrams 60 Wiring Installation Diagrams ...

Page 64: ...61 Wiring Diagrams Figure 38 Pump Control ...

Page 65: ...tic Sensor Warm Water Relief Valve Pump Controller with Danfoss VLT 2800 or VLT Aqua FC 200 Wiring Diagram number 1506682 Rev F 12 22 09 R Humid Fault Indicator Lamp VDC 10 VDC Supply 3 1 5 6 4 2 Push to reset hour counter 55 13 20 50 Analog input 0 20mA 24 vdc Supply 24 VAC Cooling Fan for Totally Enclose Model only Manifold Control Connection H u m i d S e r v i c e H u m i d F a u l t H u m i d...

Page 66: ...63 Wiring Diagrams Figure 40 Pump Controller with Danfoss Integrated VFD ...

Page 67: ...Wiring Diagrams 64 Figure 41 1 Stage Valve Controller ...

Page 68: ...65 Wiring Diagrams Figure 42 3 Stage Valve Controller ...

Page 69: ...Wiring Diagrams 66 Figure 43 6 Stage Valve Controller ...

Page 70: ... 8 4 in 214 mm 6 0 in 152 mm 3 6 in 92 mm 1 5 in 39 mm 3 0 in 75 mm 6 8 in 171 mm O 0 4 in 10 mm Voltage 24VDC Power 18 W per coil 3 coils total Inlet Connection compression fitting Drain Connection compression fitting Manifold Connection 3 8 compression fitting Max Pressure 2000 psig 138 bar Min Flow 0 3 gpm 1 Lpm Max Flow 7 9 gpm 30 Lpm Pressure Loss 36 psig max flow 2 5 bar Weight 16 lbs 7 kg M...

Page 71: ...4 mm O 0 4 in 10 mm 2 3 in 57 mm 1 5 in 39 mm 3 6 in 92 mm 1 5 in 39 mm 3 0 in 75 mm 6 8 in 171 mm Voltage 24VDC Power 18 W per coil 5 coils total Inlet Connection compression fitting Drain Connection compression fitting Manifold Connection 3 8 compression fitting Max Pressure 2000 psig 138 bar Min Flow 0 3 gpm 1 Lpm Max Flow 7 9 gpm 30 Lpm Pressure Loss 36 psig max flow 2 5 bar Weight 28 lbs 13 k...

Page 72: ... in 203 mm 8 0 in 202 mm 2 3 in 57 mm 1 4 in 34 mm 3 2 in 80 mm 4 0 in 100 mm 6 0 in 152 mm 8 4 in 214 mm Voltage 24VDC Power 18 W per coil 7 coils total Inlet Connection compression fitting Drain Connection compression fitting Manifold Connection 3 8 compression fitting Max Pressure 2000 psig 138 bar Min Flow 0 3 gpm 1 Lpm Max Flow 7 9 gpm 30 Lpm Pressure Loss 36 psig max flow 2 5 bar Weight 38 l...

Page 73: ...Wiring Diagrams 70 Figure 47 HP Valve Controller April 9 2010 ...

Page 74: ...71 Wiring Diagrams ...

Page 75: ...all 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 Any further warranty must be in writing signed by an officer of THE COMPANY THE COMPANY s limited warranty on accessories not of the companies manufacture such as controls humidistats pumps etc is limited to the warranty of the origin...

Page 76: ...Inc 826 Proctor Avenue Ogdensburg NY 13669 CANADA Walter Meier Climate Canada Ltd 2740 Fenton Road Ottawa Ontario K1T 3T7 TEL 1 866 NORTEC1 FAX 613 822 7964 EMAIL nortec waltermeier com WEBSITE www humidity com Certificate No 002419 ...

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