Vapac VapaNet Series Operation Manual Download Page 1

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These instructions contain operating information and should be left with the unit.

Resistance Heater Units

Installation & Operation Manual

Edition 6

(For use with Software version 8.0 and subsequent issues)

Installation in countries covered by EC Directives:

This product meets the requirements of the RoHS Directive 2002/95/EEC

This product will meet the requirements of the Low Voltage Safety Directive 2006/95/EEC and the

EMC Directive 2004/108/EEC when installed in accordance with the instructions contained in this

manual.

Failure to comply with these instructions may invalidate the manufacturer's warranty or any

certificate/declaration of conformance requested to be supplied with the unit.

Summary of Contents for VapaNet Series

Page 1: ...ectives This product meets the requirements of the RoHS Directive 2002 95 EEC This product will meet the requirements of the Low Voltage Safety Directive 2006 95 EEC and the EMC Directive 2004 108 EEC when installed in accordance with the instructions contained in this manual Failure to comply with these instructions may invalidate the manufacturer s warranty or any certificate declaration of conf...

Page 2: ... Off Control 13 1 5 6 Security Circuit E P O Shutdown 14 1 5 7 Load Shed Option 14 1 5 8 Master Slave System 15 2 0 Start Up Operation 16 2 0 1 Start up check list 16 2 0 2 Start Up Instructions 17 2 0 3 Commissioning Start Up 17 2 0 4 Features of VAPANET Resistance Heater Unit 17 2 1 Service Advice 18 2 1 1 Cylinder Inspection 18 2 2 1 Feed Valve with Strainer 19 2 2 2 Drain Pump 19 3 0 Location ...

Page 3: ...ore commissioning the unit check that all electrical power connections including those at the terminals and contactor are tight Check that the transformer primary winding connection is correct for the supply voltage at Vapac terminals A1 A2 The Vapac transformer must not be used to power other equipment To comply with EMC aspects see recommendations on page 9 Use a high limit humidistat to ensure ...

Page 4: ...se to sources of strong electro magnetic emissions e g variable speed lift motor drives kVa transformers etc Don t mount the unit in an unventilated enclosure Don t mount in a position requiring ladder access to the unit Don t mount the unit behind a false ceiling or other situation where an unusual malfunction e g water leak would cause damage Don t mount the unit in an area which will be hosed d...

Page 5: ...500 250 LR20 LR20P 435 205 80 1000 500 500 LR30 LR30P 602 205 80 1000 500 750 Within the area of H1 or H2 above the unit nothing must protrude out from the wall as this will effect the natural ventilation path of the Unit Fig 3 Clearances around LR units Fig 2 LR5 LR5P to LR 30 LR30P RDU ...

Page 6: ...343 70 850 62 237 190 610 810 322 346 190 610 73 555 F F D 55 990 360 20 5 520 468 31 1 790 55 505 Wall mounting fixing centres Steam outlet pipes position Gland Plate 120 x 120 NB Entry hole for Gland Plates approx 105 x 90 Gland Plate 120 x 120 NB Entry hole for Gland Plates approx 105 x 90 D Drain discharge 35mm pipe F Two water feed BSP male connection Note RDU units cannot be fitted to LR40 L...

Page 7: ...t of 300mm Do use the full height available between the unit and steam pipe to provide maximum slope min 12 20 for condensate to drain back to the steam cylinder or down to a condensate separator Always provide a continuous slope Do provide adequate support to prevent sagging a fit pipe clips every 30 50cm or b support straight lengths on cable trays or in heat resistant plastic pipe Do ensure rad...

Page 8: ...ts Don t use a wrench or other tool to tighten the water supply connection the nylon nut and rubber washer provided should only require tightening by hand to effect a seal If water seepage occurs undo the nut to wipe the washer clean and re seat it 1 3 2 Drain connection General Do s Do ensure metal drain and supply water pipework is grounded electrically close to the unit a ground earth stud is p...

Page 9: ...ion marked with the supply Voltage that is to be connected between VAPANET power terminals A1 and A2 The transformer primary circuit terminal positions are clearly marked 200V 230V 380 415 440V If the actual measured site voltage is 400v the preferred tapping is 380V The transformer is fitted below the Drain tray and is accessible by removing two screws and the cover which should be slid it toward...

Page 10: ...ing 547 Normally open when unit is in standby or fault not running If the unit is part of a master slave system or network the run fault outputs can be selected via keypad display as either network system or unit only This is selectable at Service Engineers Level in the Engineering Menu in the window Fault Run Scope The default is network It is possible to get both alarm Run indication in all unit...

Page 11: ... The transformer also has a 9V secondary tapping which provides power to the VAPANET 1150630 PCB Important The Vapac transformer must NOT be used to power other equipment or the warranty will be invalidated 1 4 6 RDU Connection Vapac terminals 25 26 are included to provide a 230Vac electrical supply for the fan motor in the RDU Room Distribution Unit Note The 230Vac at terminals is derived from th...

Page 12: ...nt A 14 6 16 8 18 2 28 7 33 0 16 6 19 1 10 5 11 5 12 2 Power rating Kw 2 92 3 861 4 562 5 742 7 593 5 742 7 593 6 909 8 240 9 263 Max Output Kg hr 3 96 5 24 6 19 7 79 10 3 7 79 10 3 9 37 11 17 12 56 Fuse Rating phase A 20 20 20 32 40 20 25 20 20 20 Supply cable terminals mm 2 4 4 4 16 16 16 16 10 10 10 Voltage V 200 230 380 415 440 200 230 380 415 440 Nominal cylinder size Kg hr 20 20 20 20 20 30 ...

Page 13: ...emand generated by Master Response 8 100 1 5 3 Control Signal Selection Selection of the control signals is done a part of the initial set up procedure using the keypad display For confirmation that the signal has been selected view the information window If the unit has not got a keypad then this is done on the configuration board 1150634 mounted on the main control board 1150630 using the jumper...

Page 14: ...oked via a display either hard wired or hand held When this option is selected making the connection between terminals 11 12 will activate the load shed software routine which will inhibit the operation of either the unit or in the case of twin cylinder units unit or just the 2 nd cylinder This will limit the power used during peak supply periods If this option is selected the fan interlock airflo...

Page 15: ...essary if all nine slave cylinders are configured Ö xxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx Õ Esc Ø Vapac J2 Vapac part no 1150631 CR1 Net J1 Vapac PART No 1150630 16 CR6 1 Net CR7 J6 J5 CR5 1 6 6 10 CR3 16 J1 J2 J3 1 F2 CR1 1 F1 CR2 J4 1 8 CR4 1 16 Vapac PART No 1150630 16 CR6 1 Net CR7 J6 CR5 1 6 6 10 CR3 16 J1 J2 J3 1 F2 CR1 1 F1 CR2 J4 1 8 CR...

Page 16: ...de rate the unit g Unit Configuration Plug U C P Provides the Vapanet control PCB with information regarding the system hardware i e the size of the cylinder and whether the unit is an On Off LR or Proportional LRP model It is fitted directly onto the control P C B If a display is fitted only one resistor is fitted to the UCP but if no display is present additional resistors need to be present to ...

Page 17: ...ssing the small button between the electrical connections THIS SHOULD ONLY BE DONE ONCE THE CYLINDER HAS BEEN INSPECTED AND THE FAULT S RECTIFIED Foaming protection In particular the VAPANET is designed to prevent the onset of foaming and to introduce corrective drainage to keep the unit working Not applicable to units fed with de ionised de mineralised water Automatic switch off The VAPANET PCB w...

Page 18: ...ng 5 Empty any loose scale from the lower casing and clean as necessary 6 Inspect the elements for excessive scale build up or damage and clean replace as required Should it be necessary to replace elements ensure that they are replaced with the same type and power Please also ensure that the integral cables are re connected exactly as the original When disconnecting an element please note the poi...

Page 19: ...follows Turn off the water supply to the Unit Undo the nylon nut connecting the flexible connection to the valve inlet The strainer can be removed using long nosed pliers to grip the centre flange provided on the strainer for this purpose Withdraw the strainer Wash and replace it Reconnect and turn on water supply Reconnect electrical supply to allow unit to operate Note Always replace the straine...

Page 20: ...apac Reset Button Cylinder 1 On Off Drain Switch Cylinder 2 On Off Drain Switch Network LED Red Network Button Service Pin User LED s Power Available Neon Cylinder 2 On Off Drain Switch Cylinder 1 On Off Drain Switch Alpha Numeric Display Network LED Red Network Button Service Pin Power Available Neon User LED s Vapac 1 2 0 I ...

Page 21: ...tialisation process the LEDs will flash Green Red Amber repeatedly for 10 seconds to check that the LEDs are operation correctly Remedy 1 Check that UCP1 is fitted to plug fitted to CR4 pins 7 8 for units with Alpha numeric display or fitted to configuration PCB part number 1150634 which is fitted to CR4 if no display is fitted see section 1 5 3 of manual for more details Ensure that good electric...

Page 22: ...nder 2 if fitted in standby 3 RED Flashing Variable Period or ON OFF Cylinder 1 Online Cylinder 2 if fitted in standby The variable period is determined by the demand signal for cylinder 1 as follows Cylinder 1 demand LED ON RED LED OFF 12 5 0 5 seconds 3 5 seconds 25 1 0 seconds 3 0 seconds 37 5 1 5 seconds 2 5 seconds 50 2 0 seconds 2 0 seconds 62 5 2 5 seconds 1 5 seconds 75 3 0 seconds 1 0 sec...

Page 23: ...the Installation Operation Maintenance manual When complete reset the high temperature cut out on top of the cylinder and re start the unit 4 Float Switch Fault Will be seen if the top float switch is made but the lower switch is open If seen the float switch and associated wiring should be inspected cleaned and or replaced as required 5 Service Interval Expired Will be seen if the unit has run fo...

Page 24: ...ned and will quickly return 5 Event in Progress This is a transitional state while the unit is actually performing a particular routine The LED indication is for information only and requires no user intervention 6 Event Completed If one of the above conditions have been implemented when it has been completed the unit by default will continue to run however it is possible to change this to stop vi...

Page 25: ... demand is fully adjustable between 0 50 Timed Drain down Used to drain all the water from the cylinder if the unit remains on standby for longer than a preset but adjustable time period For information on setting these options please see the display manual 3 6 Use with LRO unit For information on setting up a system with a Vapanet Reverse Osmosis unit please see the doccumentation supplied with t...

Page 26: ...l of water in the cylinder Switch unit on and check that the display indicates Vapac on line Apply the voltmeter set to the ful line Voltage across the output terminals of the SSR being tested i e the two terminals carrying the cabling to the elements Correct Voltmeter Response oscillating between full and near zero Voltage If Voltmeter reads a constant near zero Volts Check a That the unit is not...

Page 27: ...GHT SUPPLY CONNECTION FROM ONE 0v AC or DC Supply 9v to 12v AC or DC Supply Blue Grey or N BLUE BLUE RED NETWORK CABLE DISPLAY PCB BOARD NETWORK CABLE 0v AC Fused Supply 9v AC Fused Supply Part Number 1150631 1 Blue 1 Brown 2 Brown 2 Blue 70 VA Auto wind see note 1 BLUE RED 230 VOLTS TAPPING IS A Red 9v AC 0v AC 24v AC J1 CLOSED CIRCUIT HUMIDITY SIGNAL 4 20 mA J1 OPEN CIRCUIT HUMIDITY SIGNAL 0 10 ...

Page 28: ...and POT 5v dc Demand POT 0v dc Black Red AI 1 V or mA INPUT AI 1 Ref Violet White DI 5 CYL 1 SSR 9v dc feed DO 5 Pink Black DI 6 NOT USED 9v dc feed DO 6 Red DO 7 Com DO 7 NC DO 7 NO DO 8 Com DO 8 NC DO 8 NO DO 10 NO DO 10 NC DO 10 Com DO 9 NO DO 9 NC DO 9 Com ANALOGUE INPUT 5 0v COM AI 5 0v COM AI 6 ANALOGUE INPUT 6 0v COM AI 7 ANALOGUE INPUT 7 0v COM AI 8 ANALOGUE INPUT 8 4 1 M1 CYLINDER 1 DRAIN...

Page 29: ...et Pink Pink Pink Pink Pink Pink Pink Pink Violet Pink Violet Pink Violet Violet Black Red Violet White Red Black Red DO 7 Com DO 7 NC DO 7 NO DO 8 Com DO 8 NC DO 8 NO DO 10 NO DO 10 NC DO 10 Com DO 9 NO DO 9 NC DO 9 Com ANALOGUE INPUT 5 0v COM AI 5 0v COM AI 6 ANALOGUE INPUT 6 0v COM AI 7 ANALOGUE INPUT 7 0v COM AI 8 ANALOGUE INPUT 8 51 36 34 33 35 52 53 54 57 61 6 5 8 7 67 68 4 12 11 Valve Feed ...

Page 30: ...TH VOLT FREE CONTACTS OR ON OFF CONTROL SIGNAL VOLT FREE CONTACTS 8 7 5 6 4 2 1 CONTROL INPUT 0 20 VOLTS J1 OPEN CIRCUIT 0 20 mA J1 CLOSED CIRCUIT HUMIDITY SIGNAL 0 10 volts J1 OPEN CIRCUIT HUMIDITY SIGNAL 4 20 mA J1 CLOSED CIRCUIT J1 OPEN CIRCUIT J1 OPEN CIRCUIT 8 7 4 6 5 2 1 TEMPERATURE THERMISTOR INPUT PREFURED TYPE 10K3A1 Grey 20 BLUE 22 20 Grey Blue 22 25 26 RDU SUPPLY OR REMOTE FAN START 14 ...

Page 31: ... dc feed DO 5 Pink Black DO 6 NOT USED 9v dc feed DO 6 Red DO 7 Com DO 7 NC DO 7 NO DO 8 Com DO 8 NC DO 8 NO DO 10 NO DO 10 NC DO 10 Com DO 9 NO DO 9 NC DO 9 Com ANALOGUE INPUT 5 0v COM AI 5 0v COM AI 6 ANALOGUE INPUT 6 0v COM AI 7 ANALOGUE INPUT 7 0v COM AI 8 ANALOGUE INPUT 8 4 1 CUSTOMER CONNECTION TERMINALS RUN UNIT FAULT ALARM COMMON UNIT CYLINDER 2 DRAIN PUMP 240 V M1 M1 CYLINDER 1 DRAIN PUMP...

Page 32: ...rd DO 7 NO DO 7 NO DO 8 NC DO 8 Com DO 8 NC DO 8 Com DO 7 Com DO 7 NC DO 7 NC DO 7 Com Red Red Red Red Red Red Black Black Black Black Violet White White Violet Pink Violet Sol Violet Violet Control Fuse Pink Pink White Violet White Violet Violet Pink Violet Pink Pink Violet Violet Pink Violet Pink Pink Violet CYL 1 Violet Violet Valve slow fill Water Feed Pink Pink Pink Pink Control Fuse Pink Pin...

Page 33: ...ATER 1 Phase Neutral plus Earth OR 2 Phase plus Earth ELEMENT EMC Filter MASTER Earth RATED 20A Fuse 1 RATED SSR 1 68 RED 67 BLACK 75A SHEET 2 of 3 LZD 548 SUPPLY FROM LR05P UNIT LZD 547 SHEET 1of3 SUPPLY TO RATED AC1 25A CONTACTOR BLUE BLUE RED VAPAC 5 KG HR CYLINDER LR05P AND LR05 HEATER ELEMENTS POWER CONNECTIONS FOR CYLINDER 1 OR 2 Phase plus Earth 1 Phase Neutral plus Earth 200 250 VOLT 50 OR...

Page 34: ...TALLATION OPERATION MANUAL EDITION 2 OR LATER 1 Phase Neutral pluss Earth OR 2 Phase plus Earth ELEMENTS 10 WAY 16 AMP PLUG LR10SP UNIT EMC Filter MASTER Earth SSR 2 75A RATED 10 WAY 16 AMP SOCKET AT 16A RATED MCB S RATED SSR 1 75A 68 RED SUPPLY FROM LZD 548 67 BLACK LZD 547 SHEET 1of3 SUPPLY TO AC1 40A CONTACTOR RATED BLUE BLUE RED ELEMENTS 3 X 2 5 KW HEATING VAPAC 10 KG HR CYLINDER PARALLEL FOR ...

Page 35: ...KW HEATING 6 WAY 35 AMP SOCKET 200 250 VOLT 50 or 60 Hz FOR ELECTRICAL LOADS AND POWER SUPPLY DETAILS PLEASE REFER TO THE VAPANET LR LHP INSTALLATION OPERATION MANUAL EDITION 2 OR LATER 3 Phase Neutral plus Earth Front ELEMENTS EMC Filter MASTER Earth IF IN DOUBT ASK 75A SSR 2 RATED AT 20A RATED Fuses 6 WAY 35 AMP PLUG SSR 1 RATED 75A 68 RED LZD 548 SUPPLY FROM 67 BLACK LR10DP UNIT BLUE LZD 547 SH...

Page 36: ...RP INSTALLATION OPERATION MANUAL EDITION 2 OR LATER 3 Phase Neutral plus Earth ELEMENTS 10 WAY 16 AMP PLUG EMC Filter CYLINDER 1 Earth 10 WAY 16 AMP SOCKET 75A SSR 2 RATED RATED Fuses 16A RATED SSR 1 75A 68 RED 67 BLACK SUPPLY FROM LZD 548 SHEET 2 of 3 LR10P UNIT SUPPLY TO LZD 547 SHEET 1of3 AC1 25A CONTACTOR RATED BLUE BLUE RED VAPAC 10 KG HR CYLINDER POWER CONNECTIONS FOR CYLINDER 1 REQUIRED IF ...

Page 37: ... OPERATION MANUAL EDITION 2 OR LATER plus Earth 3 Phase Neutral Front 6 X 2 5 KW LH40P CYLINDER 1 LH20P UNIT AND EMC Filter CYLINDER 1 Earth IF IN DOUBT ASK Fuses RATED 16A 75A SSR 1 RATED PLUG 16A RATED SSR 1 75A 68 RED SUPPLY FROM LZD 548 67 BLACK or LZD 548 SHEET 1of3 LZD 547 SHEET 1of3 SUPPLY TO AC1 40A CONTACTOR RATED BLUE BLUE RED VAPAC 20 KG HR CYLINDER POWER CONNECTION HEATER ELEMENTS IN S...

Page 38: ...LINDER 1 LR20DP UNIT AND EMC Filter CYLINDER 1 Earth IF IN DOUBT ASK 75A SSR 2 RATED AT 20A RATED Fuses 6 WAY 35AMP PLUG 6 WAY 35AMP SOCKET 75A RATED SSR 1 68 RED SHEET 2 of 3 SUPPLY FROM LZD 548 67 BLACK BLUE or LZD 548 SHEET 1of3 LZD 547 SHEET 1of3 SUPPLY TO AC1 40A CONTACTOR RATED BLUE RED VAPAC 20 KG HR CYLINDER POWER CONNECTION B3 CYLINDER 2 200 250 VOLT 50 or 60 Hz HEATER ELEMENTS IN DELTA F...

Page 39: ...20A RATED Fuses 6 WAY 35AMP PLUG 6 WAY 35AMP SOCKET RATED SSR 1 75A 68 RED SHEET 2of3 LZD 548 SUPPLY FROM 67 BLACK LZD 457 SHEET 1of3 SUPPLY TO AC1 40A CONTACTOR RATED BLUE BLUE RED VAPAC 30 KG HR CYLINDER POWER CONNECTION LR60 FOR CYLINDER 2 LRP 60 AND LR60 HEATER FOR CYLINDER 1 LR30P LR50P LR60P LR30 LR50 ELEMENTS IN STAR 380 440 V 3 PHASE ONLY REQUIRED IF RDU IS FITTED 3 Phase plus Earth Neutra...

Page 40: ...TED Fuses 6 WAY 35AMP PLUG 6 WAY 35AMP SOCKET RATED SSR 1 75A SHEET 2 of 3 68 RED LZD 548 SUPPLY FROM 67 BLACK BLUE SUPPLY TO LZD 547 SHEET 1of3 or LZD 548 SHEET 1of3 AC1 90A CONTACTOR RATED BLUE RED VAPAC 30 KG HR CYLINDER POWER CONNECTION HEATER ELEMENTS IN DELTA 200 250 V 3 PHASE AND LR60D FOR CYLINDER 2 LR60DP AND LR60D FOR CYLINDER 1 LR30DP LR50DP LR60DP LR30D LR50D 200 250 VOLT 50 60 Hz 3 Ph...

Page 41: ... constricted leading to excessive pressure in the steam lines N B Standard steam distribution pipes are manufactured such that any condensate is drained back towards the Vapac steam cylinder Reverse slope pipes are available and are fitted with a drain connector to enable condensate to be taken away to a suitable drain min 300mm R B L H min 20mm L B H min 20mm B L R min 20mm X Y Y X min 20mm AIR F...

Page 42: ... indicates that a reverse slope steam pipe is required This is fitted with a drain point to allow condensate to be taken away to a convenient drain Figure 2 shows recommendations on how to space one or more steam pipes in a horizontal duct Figure 3 shows recommendations on how steam pipes should be spaced in a vertical duct Figure 4 shows mounting details for 35 and 54 Ø steam pipes NB The duct sh...

Page 43: ...m escaping via the condensate drain connection 3 Care should be taken to support steam hose sufficiently such that no kinks are formed which would flood with condensate causing the bore of the tube to become constricted leading to excessive pressure in the steam lines 4 The duct should be clear of obstructions transformations and bends until the steam has been absorbed into the airflow Vapac Humid...

Page 44: ...Vapac Humidity Control Ltd reserve the right to change the design or specification of the equipment described in this manual without prior notice Made in England by Vapac Humidity Control Ltd Nov 2005 ...

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