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Stulz DesicAir 1000 Series, Installation, Operation And Maintenance Manual

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Stulz DesicAir 1000 Series Installation, Operation And Maintenance Manual Download Page 33

DEZ

 

S

ERIES 

1000

 

I

NSTALLATION

,

 

O

PERATION AND 

M

AINTENANCE 

M

ANUAL

 

 

A-2

 

 

STULZ Air Technology Systems, Inc. 

1572 Tilco Drive 

Frederick, Maryland USA 21704 

DESICAiR PRODUCT DIVISION 

Telephone: (301) 620-2033 

Facsimile: (301) 620-1396 

Periodic General Maintenance Checks and Services Checklist 

Date:  

 

Prepared By:  

 

Model Number:   

Serial Number:    

Item Number: 

 

 

Monthly 

Filters 

 

 

 Cleanliness 

  

  

 No 

Obstructions 

  

  

 

Rotor

 

   

   

  Check Condition of Rotor Face 

   

   

  Check Condition of Seals 

   

   

Miscellaneous 

  Check and Tighten Loose Fasteners 

  Check Condition of Belts 

  Check Pressure Drop Readings on Gauges 

  Status Indicator Lights “Press to Test” Feature Operates Properly (Should Illuminate When Pressed) 

Quarter-Annually 

  Tighten Electrical Connections and Check for Corrosion 

   

  Check Contacts on Contactors for Pitting  

   

  Clean Unit as Necessary  

   

  Check Motor Amps Per Unit Name Plate 

   

  Check Motors, Lubricate Per Maintenance Schedule 

   

Annually 

  Conduct a Complete Check of All Services Listed Above and Clean Unit’s Interior 

  Inspect Wiring For Fraying, Discoloration 

Summary of Contents for DesicAir 1000 Series

Page 1: ...STULZ Desicair DEZ Series 1000 Desiccant Dehumidification System Installation Operation and Maintenance Manual ...

Page 2: ...than the owner of the equipment for which this manual is written without the prior written consent of Stulz Air Technology Systems Inc STULZ This document contains STULZ confidential and proprietary information Distributing or photocopying this document for external distribution is in direct violation of U S copyright laws and is strictly prohibited without the express written consent of STULZ Unp...

Page 3: ...nitoring Unit Performance 13 4 0 UNIT FEATURES 14 4 1 Control Sensor Terminals 14 4 2 Remote Start Stop Contact 14 4 3 Optional Customer Contacts 14 4 4 Sensor Retransmit Terminals 14 4 5 Electrical Disconnect 14 4 6 Emergency Stop 15 4 7 Dampers 15 4 8 Filter Status 15 4 9 Voltage Sensor Phase Monitor 15 4 10 Process Air Proving 15 4 11 E2 Controller and Display 15 5 0 PREVENTIVE MAINTENANCE 16 5...

Page 4: ...ram 11 Figure 5 Sample Non E2 Control Panel Layout 12 Figure 6 Sample E2 Control Panel Layout 12 Figure 7 Differential Pressure Gauges 13 Figure 8 E2 Controller and Display 15 Figure 9 Overheat Safety Switch 19 Figure 10 Rotor Assembly Parts 22 Figure 11 Rotor Scratch Repair 24 Tables Table 1 Blower Motor Lubrication Intervals 17 Table 2 Service Conditions 17 Table 3 Lubrication Interval Multiplie...

Page 5: ...ollowed to avoid difficulties Spare parts are available from STULZ to ensure continuous operation Using substitute parts or bypassing electrical or other components in order to continue operation is not recommended and will void the warranty 1 2 1 Technical Data Package This manual is part of the Technical Data Package provided with your unit The Technical Data Package typically includes drawings ...

Page 6: ...ion rotor type and process and reactivation accessories or options Process CFM Rotor Diameter in Centimeters DEZ XXX XX AA B C D E F G H I J K L M N Model Reactivation Cabinet Construction Process Reactivation Number Type and Rotor Accessories Accessories The last 17 digits represented by the lowercase letters a n below pertain to the electrical system unit controls control scheme and control pane...

Page 7: ... operate the unit with any cover screen guard panel etc removed unless the instructions specifically state to do so and then do so with extreme caution to avoid personal injury Never attempt to lift any component in excess of 35 pounds without additional help Placards and or stickers have been placed in various locations on or in the unit These placards stickers are intended to call attention to p...

Page 8: ...ake and discharge openings must be completely free of obstructions Ensure panels are on and properly secured into position CAUTION Do not operate the unit without filters It is better to operate the unit with dirty filters than no filters Operating the unit without filters may void the warranty 1 4 Theory of Operation The DEZ Series 1000 dehumidification system is designed to dehumidify a space to...

Page 9: ...esiccant Non toxic Non corrosive Desiccant Capable of Withstanding 100 RH Without Adverse Effect Counterflow Process and Reactivation Air Patterns Overheat Safety Protection Electric Reactivation Heat Easy Access to Internal Components Low Operating Cost Energy Efficient Dehumidification Optional Process and Reactivation Inlet Air Filters For a comprehensive list of the features included refer to ...

Page 10: ...utdoor use the process and reactivation inlets and outlets may be equipped with louvers or hoods to prevent rain and snow from entering the unit Screens may be provided to prevent birds and other small animals from nesting in the inlets and outlets For a comprehensive list of the features refer to the DIN sheet provided specifically for this unit see section 1 2 2 The DIN sheet is a listing of all...

Page 11: ...blower assemblies while somewhat smaller also require sufficient clearance for removal The leaving reactivation air can be very warm and humid Keep items that may be damaged by excessive heat and humidity away from the reactivation air outlet Position the unit in the desired location Make sure the mounting surface is able to support the weight of the equipment and keep it level Secure the unit to ...

Page 12: ...A and maximum fuse size MFS 2 6 Installing a Humidistat or Relative Humidity Transmitter A terminal block is provided for the connection of a humidistat or temperature RH sensor Interconnecting field wiring must be installed in accordance with NFPA 70 of the National Electrical Code N E C Refer to the electrical drawing for the electrical connections Wall mounted control sensors should typically b...

Page 13: ...ls 2 Set airflows to the required rotor pressure drop versus the airflow required for this application Airflow is indicated by rotor pressure drop values as viewed on the differential pressure gauges The Unit Nameplate shows the optimum Reactivation Side and Process Side pressure drops labeled as Rotor Pressure Drop Gauge Values with values shown as in w g Process airflow is set using an airflow d...

Page 14: ... which cycles the unit on and off to maintain the relative humidity setting See section 3 5 1 Mode Selector Switch for the correct mode setting to enable humidistat control 3 4 1 1 D Stat II This control method function is similar to D Stat except the process blower runs continually The reactivation heater and blower cycle on and off in response to a humidistat provided as an option or a customer ...

Page 15: ...dity PI loop output exceeds 0 the reactivation heater and reactivation blower turn on The controller calculates PI loop outputs for humidity reactivation discharge air temperature and reactivation heater temperature see Figure 4 As each of these PI loop outputs modulate the controller selects the lower PI loop output and uses that output to control the reactivation heater Note This methodology pre...

Page 16: ... indicator lights to notify the operator of the current status of the unit The green Unit On and red fault indicator lights are equipped with press to test capability This can be used to verify lights are working If a light does not illuminate when pressed it may be burned out or the electrical connections may be faulty For specific information regarding troubleshooting indicator lights refer to t...

Page 17: ...ivation airflows are set using the rotor pressure drops Refer to the Unit Nameplate for the appropriate settings for the Rotor Pressure Drops inches w c The Unit Nameplate indicates the pressure drops across the rotor as set by the factory After all ductwork is installed during initial installation the airflows may need to be adjusted to re establish rotor pressure drops to the values indicated on...

Page 18: ...OCK DRY CONTACT This contact closes when the process blower is operating It can be used to indicate unit operating status or to start and stop auxiliary equipment such as a circulating fan or condensing unit SUMMARY FAULT CONTACT This contact notifies the operator of such problems as a heater fault rotor motor fault or a fault with the process and or reactivation blower motors REACTIVATION AIR PRO...

Page 19: ...ty filters than no filters Operating the unit without filters may void the warranty 4 9 Voltage Sensor Phase Monitor The unit may be equipped with either a voltage sensor or a phase monitor device A voltage sensor used on single phase units causes the control power to be interrupted in the event of low line voltage A phase monitor used on 3 phase units causes the control power to be interrupted in...

Page 20: ...hat the rotor seals for wear and ensure the seals are touching the rotor face and rotor flange Check the rotor drive belt for signs of abnormal wear Check each blower mounting and inspect the blower wheel for loose fasteners Tighten if necessary Ensure that the wheel is free of debris Lubricate motor bearings if necessary Check that shaft key pulley and bearing lockdowns are tight 5 2 Yearly Thoro...

Page 21: ...ow These intervals are based on average use See nameplate on motor for frame size and rated speed Table 1 Blower Motor Lubrication Intervals NEMA IEC Frame Size Rated Speed RPM 3600 1800 1200 900 Up to 210 incl 132 5500 Hrs 12000 Hrs 18000 Hrs 22000 Hrs Over 210 to 280 incl 180 3600 Hrs 9500 Hrs 15000 Hrs 18000 Hrs Over 280 2200 Hrs 1 7400 Hrs 12000 Hrs 15000 Hrs Table 2 Service Conditions Severit...

Page 22: ...e as Severe 3 Table 3 lists a multiplier of 0 5 for severe conditions 4 Table 4 shows 1 2 in or 3 9 teaspoons of grease to be added 5 4 3 Lubrication Procedure Be sure that the grease you are adding is compatible with the grease already in the motor Consult the factory or the motor manufacturer if you are using grease other than the recommended type CAUTION To avoid damage to motor bearings keep g...

Page 23: ...perature Light is Illuminated Check the reactivation thermal overheat safety switches S4 1 S4 2 and S4 3 if provided The switches are located in the reactivation outlet duct and in the duct connection box under the desiccant rotor If one of the safety switches is tripped turn the unit selector switch to Off and disconnect main power then press the Reset button on the Overheat Safety Switch shown i...

Page 24: ...at the power supply voltage and phase are correct and that the airflows are adjusted to the correct values 1 To check the dehumidifier performance take dry bulb and wet bulb temperature measurements upstream and downstream of the dehumidifier rotor in the process airstream Convert the readings to dry bulb temperature and grains per pound see Appendix B Compare the results to those indicated by the...

Page 25: ...information 3 Do not allow the rotor to come into contact with paint oil acids etc 4 Do not allow dirt dust or debris to settle into the rotor element Follow rotor washing instructions if the rotor has been subjected to long periods of storage in extreme conditions 5 Do not subject the rotor to vibration 7 2 Replacing the Rotor Drive Belt The following instructions for removing and replacing a dri...

Page 26: ...belt tensioner and remove belt 12 NOTE The rotor does not need to be removed if just changing the belt 13 Inspect Teflon coated rubber seal in top rotor cover for any signs of wear damage and replace if necessary See Replacing Seals 14 If top rotor seal is removed and replaced remove the rotor and replace bottom seal also See section 7 4 Replacing Seals 7 2 2 Installing the New Belt 1 Replace belt...

Page 27: ...ce it is outside of the cassette This may cause damage to the rotor flutes Allow the rotor to achieve equilibrium by leaving it in an area where humidity is not controlled for a minimum of eight hours 2 Using an industrial dry vacuum with a clean soft and smooth applicator draw air through the rotor flutes into the vacuum Vacuum the entire surface of the rotor 3 With the water solution in the spra...

Page 28: ...board over the bead to press the silicone into the crack and make the surface of the silicone smooth and flush with the face of the rotor This will further enhance the penetration of the silicone and will ensure that the silicone does not protrude above the surface of the rotor 6 Immediately after pressing the silicone into the crack with the cardboard remove the masking tape This must be done bef...

Page 29: ...ou must provide a freight carrier account number A written or faxed purchase order is required on warranty parts and must be received prior to 12 00 p m for same day shipment The purchase order must contain the following items Purchase Order Number Date of Order STULZ Stated Part Price Customer Billing Address Shipping Address Customer s Telephone and Fax Numbers Contact Name Unit Model No Serial ...

Page 30: ...DEZ SERIES 1000 INSTALLATION OPERATION AND MAINTENANCE MANUAL 26 ...

Page 31: ...DEZ SERIES 1000 INSTALLATION OPERATION AND MAINTENANCE MANUAL A Appendix A Forms ...

Page 32: ...thout unusual noise 5 Filter s installed if required 6 Duct work installed and sealed against leaks 7 Air dampers installed in ductwork if re quired 8 Incoming line voltage matches equip ment nominal nameplate rating toler ance 9 Main power wiring connections to the equipment including earth ground have been properly installed according to ap plicable codes 10 Customer supplied main power branch c...

Page 33: ... of Rotor Face Check Condition of Seals Miscellaneous Check and Tighten Loose Fasteners Check Condition of Belts Check Pressure Drop Readings on Gauges Status Indicator Lights Press to Test Feature Operates Properly Should Illuminate When Pressed Quarter Annually Tighten Electrical Connections and Check for Corrosion Check Contacts on Contactors for Pitting Clean Unit as Necessary Check Motor Amps...

Page 34: ...L B Appendix B Unit Performance Curves Note Unit Performance Curves are provided for reference only Data is based on reactivation entering air conditions at 95ºF 130 GPP Refer to the Technical Data Sheet provided with the unit for specific unit performance data ...

Page 35: ...Leaving Temperature 1 Find the correct Process Entering Moisture humidity value in grains per pound GPP on the x axis of the Process Leaving Air Temperature graph 2 Move vertically in a straight line to intersect the curve closest to the entering air temperature Interpolate as required 4 Move horizontally to the left and intersect the scale marked Process leaving Air Temperature The value at this ...

Page 36: ...ally in a straight line to intersect the curve closest to the entering air temperature Interpolate as required 3 Move horizontally to the left and intersect the scale marked Process Leaving Air Moisture The value at this point represents the process air moisture humidity leaving the dehumidifier in GPP Leaving Temperature 1 Find the correct Process Entering Moisture humidity value in grains per po...

Page 37: ...Leaving Temperature 1 Find the correct Process Entering Moisture humidity value in grains per pound GPP on the x axis of the Process Leaving Air Temperature graph 2 Move vertically in a straight line to intersect the curve closest to the entering air temperature Interpolate as required 3 Move horizontally to the left and intersect the scale marked Process leaving Air Temperature The value at this ...

Page 38: ...ally in a straight line to intersect the curve closest to the entering air temperature Interpolate as required 3 Move horizontally to the left and intersect the scale marked Process Leaving Air Moisture The value at this point represents the process air moisture humidity leaving the dehumidifier in GPP Leaving Temperature 1 Find the correct Process Entering Moisture humidity value in grains per po...

Page 39: ...Humidity MFS Maximum Fuse Size Desorb Removal of Absorbed or Adsorbed Vapor Molecules MCA Minimum Circuit Ampacity Dew Point Temperature At Which Humid Air Becomes 100 Saturated NEC National Electric Code DEW TRAC Modulates Reactivation Heat To Maintain Dew Point Temperature PH Phase Dry Bulb Temperature of Air As Measured By a Thermometer PSG Product Support Group F Degrees Fahrenheit PSI Pounds ...

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