Nortec Airfog Series Installation Manual Download

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2008-04-11

1502247-C

AIRFOG

Series

Atomizing
Humidifier

Installation Manual

Summary of Contents for Airfog Series

Page 1: ...2008 04 11 1502247 C AIRFOG Series Atomizing Humidifier Installation Manual TM ...

Page 2: ... 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 2008 WALTER MEIER LTD All rights reserved RECORD OF REVISIONS For each revision put the revised pages in your manual and discard the superseded pages Wr...

Page 3: ...UT 8 2 ZONES A INTRODUCTION 11 B SUPPLY FEED LINES 11 C CLEANING 11 D MOUNTING OF NOZZLES 11 E CONNECTING NOZZLES 13 F SADDLE CLAMP INSTALLATION 13 G VACUUM VALVE 14 H PILOT OPERATED AIR REGULATOR 14 I PRIMARY AIR PRESSURE CONTROL 17 J PRIMARY WATER PRESSURE CONTROL 17 K CONTROL PANEL 17 L ELECTRICAL WIRING 17 M PILOT LINES 19 10 20 MINI OCTO INSTALLATION 1 AFE SELF CONTAINED AIRFOG SYSTEMS 22 A A...

Page 4: ...PROCEDURES 36 10 50 MAINTENANCE 1 MAINTENANCE 38 2 SEASONAL MAINTENANCE 38 3 SEASONAL STARTUP 38 4 UNSCHEDULED MAINTENANCE 39 5 VACUUM VALVE TESTING 39 6 CHECKING FOR VACUUM LEAKS 39 10 60 TROUBLESHOOTING 1 TROUBLESHOOTING 42 10 70 SPARE PARTS 1 SPARE PARTS 46 WARRANTY ...

Page 5: ... Pressure Control Section 18 Figure 14 Control Panel 18 Figure 15 Control Panel terminal Strip Interfaces 18 Figure 16 Schematic Plumbing Layout 19 10 20 MINI OCTO INSTALLATION Figure 1 Mini Installations 23 Figure 2 Plumbing End Connections 23 Figure 3 Octo Layout with Interfaces 25 Figure 4 Octo Spray Pattern 25 Figure 5 Ceiling Mounting of Octo 27 Figure 6 Octo Air and Water Interfaces 27 Figur...

Page 6: ... 60 TROUBLESHOOTING Table 1 Troubleshooting 42 10 70 SPARE PARTS Table 1 Rebuild Kits and General Parts 46 Table 2 Octo Spare Parts 48 Table 3 AFE Nozzle Spare Parts 50 Table 4 Vacuum Valve Spare Parts 52 Table 5 Control Panel Spare Parts 54 ...

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Page 8: ...10 00 Page 1 2008 04 11 10 00 INTRODUCTION ...

Page 9: ... systems that are tailored specifically for each application Two products fall under this category a HP HVAC uses high pressure water to create a very fine mist for spray into ducts and air handlers b AFE Nozzle systems use compressed subsonic air flows and water to create a fine mist that is sprayed directly into a space 3 The packaged products group describes systems that are ready to operate ou...

Page 10: ...e B HUMIDIFICATION ZONES IN SPACE APPLICATIONS 1 The movement of humidity through a space is very rapid In applications where accurate humidity control is essential it is important that the structure be reasonably air tight to prevent humidity from escaping to the outside If a large amount of infiltration or exfiltration is encountered it may be necessary to oversize the system to compensate for t...

Page 11: ...EQUIPMENT 1 The designer should have already provided drawings of the proposed AIRFOG humidification system physical layout These drawings and parts list should clearly identify the system components by name and part number physical spacing zone identification and comments on nozzle location and pointing directions 2 During installation there will be a requirement to a Attach mounting brackets to ...

Page 12: ...aterial used in the mounting surface d Insulation for the cold water pipe feeding the system is required to prevent water vapor from condensing and dripping on other structures machines personnel or materials e The NORTEC supplied parts should be checked against the designer s drawings and parts list to ensure the correct quantity of the correct part numbers are available ...

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Page 14: ...10 10 Page 7 2008 04 11 10 10 INSTALLATION ...

Page 15: ...location of the nozzles is very dependent upon these obstructions Figure 1 Typical Nozzle Layout can be used as a guide for identifying the various components used with a system 2 The supply and feed lines for the system should be kept in straight unobstructed lines where possible Air and water distribution network pipes are to be installed level along walls pillars or hung from the ceiling Avoid ...

Page 16: ...10 10 Page 9 2008 04 11 Figure 1 Typical Nozzle Layout for Wall Mounted System ...

Page 17: ...10 10 Page 10 2008 04 11 Figure 2 Multi Zone Layout ...

Page 18: ...hen using Nortec supplied saddle clamps the maximum line size for supplying to nozzles is 11 16 O D If saddle clamps by others are used please size fittings to match the pipe C CLEANING 1 Manual valves must be installed at the ends of all lines to facilitate cleaning and drainage of lines Cleaning is done by temporarily connecting the pipes to a compressed air source at one end of the pipe The oth...

Page 19: ...10 10 Page 12 2008 04 11 Figure 3 Water and Air Line Pressure Control Figure 4 Nozzle to Bracket Interface Figure 5 AFE Nozzle Ceiling Mounting ...

Page 20: ... it reaches the bottom Gentle pulling of the tube without movement is a good indication that a proper seal has been made 3 Allow enough free tubing to permit the nozzle to swivel horizontally or vertically for future pointing alignment F SADDLE CLAMP INSTALLATION 1 The type of clamp used by NORTEC as shown in Figure 7 Saddle Clamp requires that the pipe be drilled first Drill a 1 4 hole squarely i...

Page 21: ... valve is the water regulator The water regulator is used as the first stage of water pressure reduction The water regulator reduces the supply water pressure to a range between 5 and 10 psig This is set manually at time of installation Please note that system performance is not sensitive to the exact setting as long as the pressure is within this range 4 The second stage of water pressure reducti...

Page 22: ...rol panel the primary air supply input feed the output air feed to the nozzles and to gauge port used to feed pilot signal to the water regulator There are no manual adjustments required 3 Install the pilot air regulator on the feed line before the nozzles by splicing into the air feed line to the nozzles See Figure 11 Pilot Air Regulator Installation Ensure the proper flow direction when installi...

Page 23: ...10 10 Page 16 2008 04 11 Figure 8 Vacuum Valve Operation Figure 9 Vacuum Valve Interfaces Figure 10 Pilot Air Regulator Figure 11 Pilot Air Regulator Installation ...

Page 24: ...h is provided by the NORTEC supplied step down transformer 120 VAC to 24 VAC The transformer plugs into any standard 120 VAC outlet that must be located within 6 six feet of the control panel Power is connected to the low voltage terminal trip located inside the panel as illustrated in Figure 16 Control Panel Terminal Strip Interfaces Control panels are supplied by NORTEC in two configurations The...

Page 25: ...10 10 Page 18 2008 04 11 Figure 12 Primary Air Pressure Control Section Figure 13 Primary Water Pressure Control Section Figure 14 Control Panel Figure 15 Control Panel Terminal Strip Interfaces ...

Page 26: ...ulator The control panel requires an input pneumatic air control supply which is usually tapped off the main air supply line upstream of the pilot air regulator The control panel has two pneumatic fittings located on its top plate one marked pilot in and the other marked pilot out The pilot in is connected to the control supply with the 1 4 plastic tubing A second 1 4 line connects the pilot out t...

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Page 28: ...10 20 Page 21 2008 04 11 10 20 MINI OCTO INSTALLATION ...

Page 29: ...tations directly beneath the Mini systems 4 The Mini nozzles must be a minimum of 6 feet above the floor and 36 below the ceiling in order to prevent condensation on these surfaces See Figure 1 Mini Installation 5 Four accessible internal mounting holes are located in each corner of the rear panel The mounting procedure is a Either attach the supplied mounting bracket hardware or bolt panel direct...

Page 30: ...10 20 Page 23 2008 04 11 Figure 1 Mini Installations Figure 2 Plumbing End Connections ...

Page 31: ...ned to be suspended from the ceiling by either a threaded rod or chains Octos with nozzles on only one side may also be mounted on a wall or pillar single sided configurations Prior to mounting ensure there are no obstacles such as duct work lighting large equipment etc Please refer to Figure 4 Octo Spray Pattern for further information The Octo unit should be installed as high as possible above t...

Page 32: ...sleeve in the fitting with the supplied brass sleeve 6 For a standard Octo unit a separate control panel and 1 4 O D plastic tubing for pilot line is required To install this line the fitting on the unit is a push in style located above the main air connection Simply cut the tubing square and push one end into the fitting Route the line back to control panel location 7 If multiple Octo units are t...

Page 33: ...direction that will not have the plume strike a solid object or another plume for at least 16 feet Figure 9 AFE Octo Nozzle Spray Pattern helps in visualization of these AIRFOG plumes 11 The center vertical rail is to be mounted in the center of the duct and attached to the manifold rails using the supplied hardware It is important that the center vertical rail is sized correctly and securely fast...

Page 34: ...10 20 Page 27 2008 04 11 Figure 5 Ceiling Mounting of Octo Figure 6 Octo Air and Water Interfaces ...

Page 35: ...10 20 Page 28 2008 04 11 Figure 7 Four Octo Units with a Single Control Panel Figure 8 AFE Octo Nozzle Spray Pattern ...

Page 36: ...10 30 Page 29 2008 04 11 10 30 START UP PROCEDURE ...

Page 37: ... ON position 4 Adjust the air pressure regulator in the control panel to about 70 psig to obtain maximum water throughput for each nozzle for this startup test 5 There should an audible hissing sound as the compressed air works its way through the piping to the nozzles If this is not detected and air can not be felt by hand directly in front of the nozzle orifice then air is not being provided to ...

Page 38: ...ity try turning the thumb wheel counter clockwise Some experimentation may be necessary to obtain the best results Please refer to Figure 1 Capacity Output vs Vacuum Valve Adjustment for more information D SELF CLEANING CYCLE ADJUSTMENT 1 The AFE Mini and Octo Systems all feature an automatic self cleaning mechanism that prevents mineral build up or dirt from affecting nozzle performance This mech...

Page 39: ... cleaning time after every 8 hours of operation Using settings that result in an off time of less than 10 seconds are not recommended As well using settings that result in an on time of less than 15 minutes are not recommended E SETTING THE SYSTEM FOR NORMAL OPERATION 1 Once the start up and adjustment and configuration procedures have been completed the unit is ready to operate normally The follo...

Page 40: ...10 30 Page 33 2008 04 11 Figure 1 Capacity Output vs Vacuum Valve Adjustment Figure 2 AFE Capacity Chart ...

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Page 42: ...10 40 Page 35 2008 04 11 10 40 SHUT DOWN PROCEDURE ...

Page 43: ...upply 5 Turn off the air supply valve on the primary air pressure control system 6 Turn the system off at the control panel 7 Turn the air compressor off C For long periods weeks or longer of system down time it is recommended that high pressure air is used to blow all water out of the system D It is important to NOT undertake disconnection and removal of components when they are connected to or a...

Page 44: ...10 50 Page 37 2008 04 11 10 50 MAINTENANCE ...

Page 45: ... 2 SEASONAL MAINTENANCE A In most cases there is a humidification season but if this is not the case it is recommended that the following actions be conducted once a year 1 A detailed visual leak inspection using soapy water and low pressure less that 10 psig of all air and water transport pipes and system components is to be recorded on a sketch to indicate leak locations and severity 2 Compariso...

Page 46: ... is applied 4 Adjust vacuum valve thumb wheel to zero force spring backed off B While system in operating visually watch the spray pattern from the nozzles C If the system is completely sealed no vacuum leaks in the water line then once the system is turned on for the first time all nozzles should start spraying starting with the nozzles closest to the vacuum valve The negative pressure created in...

Page 47: ... the nozzles by changing the required amount of vacuum needed to operate the vacuum valve Since the nozzles can only generate a fixed amount of vacuum negative pressure the flow rate of water is reduced which causes a finer spray and less output If there was a vacuum leak in the water line it may not be noticeable with the vacuum valve spring tension set to zero but it should become noticeable wit...

Page 48: ...10 60 Page 41 2008 04 11 10 60 TROUBLESHOOTING ...

Page 49: ...e main diaphragm No control of output Replace o ring rebuilt vacuum valve Other O rings Vacuum leak low output no output Water leaks out Replace Cracked Housing Vacuum leak or water dripping from valve Replace damaged component Blockage Reduced output No output Clean Pilot Air Regulator Damaged Diaphragm Loss in air pressure No air pressure Uncontrolled air pressure Repair Stuck Closed Or Open Una...

Page 50: ...n System only stays on for a few seconds Reduce the off cycle Increase the on cycle Burnt Timer The timer lights are not on Burnt smell from inside the control panel Replace Panel Regulators Damaged Diaphragm Loss in air pressure No air pressure Uncontrolled air pressure Repair AFE Nozzle Stuck Cleaning Needle Nozzle does not clean itself Lubricate seal and shaft of needle Nozzle Drips Water on th...

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Page 52: ...10 70 Page 45 2008 04 11 10 70 SPARE PARTS ...

Page 53: ... water and air delivery nozzle tubes The lead time to obtain replacement parts or repair kits is considered an acceptable risk Other owners decide that this risk is too high and choose to maintain spare parts and repair kits in house so that rapid repairs can be made Table 1 Rebuild Kits and General Parts Part Description 1603115 Repair kit for Watts pilot water regulator 1603114 1603004 1603117 R...

Page 54: ...10 70 Page 47 2008 04 11 Figure 1 Octo Exploded View ...

Page 55: ...sembly 0 0 0 1 1 1 1 1 1 5 1603021 Pilot Lamp Assembly 0 0 0 1 1 1 1 1 1 6 1603001 Air Regulator Panel Mount 0 0 0 1 1 1 1 1 1 1603118 Repair Kit for 1603001 Air Regulator 0 0 0 1 1 1 1 1 1 7 1603050 Repeat Cycle Timer 0 0 0 1 1 1 1 1 1 8 1603112 Watts Pilot Air Regulator 0 0 0 1 1 1 1 1 1 1603117 Repair Kit for Watts Pilot Air Regulator 1603112 0 0 0 1 1 1 1 1 1 Not Shown 1506260 E P Converter 0 ...

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Page 57: ...d View Table 3 AFE Nozzle Spare Parts ITEM PART DESCRIPTION QTY 1 1603120 AFE Nozzle Repair Kit 1a O Ring Seal 2 1b Flat Washer 2 1c Retaining Clip SST 2 1d O Ring Valve Seat 1 1e Piston Seal 1 1f Rod Seal 4 2 1604040 Cleaning Needle 1 3 1604039 Piston 1 ...

Page 58: ...10 70 Page 51 2008 04 11 Figure 3 Vacuum Valve Exploded View ...

Page 59: ...ing 1 1 1 2 1603002 Panel Mount Water Reg 1 4 P 1 1 1 1603119 Repair Kit for 1603002 Water Regulator 1 1 1 1603114 Panel Mount Water Reg 1 4 P SST for DI 1 1 1 3 1603008 Pressure Gauge 1 1 2 1 8 CB 0 30 1 1 1 4 1603004 Pilot Water Regulator 1 1 1 1603110 Pilot Water Regulator SST for DI used in 1603114 1 1 1 1603116 Repair Kit for 1603004 1603114 and 1603110 Pilot Water Regulator 1 1 1 Italics den...

Page 60: ...10 70 Page 53 2008 04 11 Figure 4 Control Panel Exploded View ...

Page 61: ... Control Panel Only 0 1 4 1603050 Repeat Cycle Timer 1 1 5 1603200 Pressure Gauge Panel MTG Bars 1 1 6 1493096 Lamp Green Indicator 1 1 7 1453001 Switch On Off 1 1 8 1603023 Lamp Amber Indicator 1 1 9 1603064 Valve 3 way 24 Vac Solenoid Replacement Kit 0 1 10 1603001 Air Regulator Panel Mount 1 1 1603118 Repair Kit for 1603001 Air Regulator 11 1853104 Lock c w 2 keys 1 1 Italics denote replacement...

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Page 63: ...u of all other warranties expressed or implied by law No liability whatsoever shall 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 4 THE COMPANY s limited warranty on accessories not of the companies manufactu...

Page 64: ...tor Avenue Ogdensburg NY 13669 TEL 1 866 NORTEC 1 EMAIL northamerica climate waltermeier com WEBSITE www humidity com CANADA Walter Meier Climate Canada Ltd 2740 Fenton Road Ottawa ON K1T 3T7 TEL 1 866 NORTEC 1 FAX 613 822 7964 Authorized Agent ...

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