INSTALLATION AND OPERATING INSTRUCTIONS

Resistive Humidifiers

1115

661

EN

141

2

Defensor Mk5

2

3

Contents

1 Introduction 41.1 To the very beginning 41.2 Notes on the installation and operating instructions 42 For your safety 53 Product overview 73.1 Unit types 73.2 Identificationoftheunit 83.3 Standarddelivery 83.4 Humidificationsystemoverview 93.5 Steamhumidifierconstruction 93.6 Functional description 104 Basic planning 114.1 Selecting the unit 114.2 Selecting the control system 144.3 Options 164.4 Accessories 174.4.1 Accessoriesoverview 174.4.2 Accessorydetails 184.5 Additional planning instructions 205 Mounting and installation works 215.1 Safetyinstructionsformountingandinstallationworks 215.2 Unitfitting 215.2.1 Humidifierlocation 215.2.2 Mountingthehumidifier 235.2.3 Inspecting the installed unit 235.3 Steam installation 245.3.1 Positioningandmountingofthesteamdistributionpipes 245.3.2 Positioningandmountingofthefanunit 275.3.3 Installingthesteamandcondensatelines 285.3.4 Inspecting the steam installation 305.4 Water installation 315.4.1 Performingthewaterinstallation 315.4.2 Inspectingthewaterinstallation 335.5 Electric installation 345.5.1 Electricinstallationoverview 345.5.2 Wiring diagram 355.5.3 Notes on component installation 375.5.4 Inspecting the electrical installation 406 Operation 416.1 Unitconfiguration 416.2 Putting into operation 436.3 Takingoutofoperation 456.4 Interrogationoftheoperatingstatus 466.5 Setting the operating parameters 506.6 Maintenance 556.6.1 Notes on maintenance 556.6.2 Dismantlingandre-assemblywork 566.6.3 Notesoncleaning 596.6.4 Toresetthemaintenanceindication 596.7 Fault elimination 606.7.1 Fault indication 606.7.2 What,if..? 616.7.3 Replacingunitfuses 636.7.4 Resettingfaultindication“Error” 637 Technical data 64

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Limitation

ThesubjectoftheseinstallationandoperatinginstructionsarethesteamhumidifierDefensor Mk5 in theversions:“Visual”and“Process”.Thevariousaccessories(humidistats,waterfilter,etc.)areonlydescribedinsofarasthisisnecessaryforproperoperationoftheequipment.Furtherinformationonaccessories can be obtained in the respective instructions.

These installation and operating instructions are restricted to:

– the planningofahumidifyingsystemthatistobeequippedwithasteamhumidifierDefensorMk5

– the installation, commissioning, operation and servicing ofthesteamhumidifierDefensorMk5

Theseinstallationandoperatinginstructionsaresupplementedbyvariousseparateitemsofdocumenta-tion(sparepartslist,installationinstructionsforelectricalinstallation,etc.).Wherenecessary,appropri-atecross-referencesaremadetothesepublicationsintheseinstallationandoperatinginstructions.

Conventions

Thissymboldrawsattentiontosafety instructions and warningsofpotentialdangerwhich,ifunheeded,couldresultininjurytopersonsand/ordamagetoproperty.

Safekeeping

Pleasesafeguardtheseinstallationandoperatinginstructionsinasafeplace,whereitcanbeimmedi-atelyaccessed.Iftheequipmentchangeshands,thedocumentationshouldbepassedontothenewoperator.Ifthedocumentationgetsmislaid,pleasecontactyoursupplier.

Language versions

These installation and operating instructions are available in various languages. Please contact your supplierforinformation.

1 Introduction

1.1 To the very beginning

Wethankyouforhavingpurchasedthesteam humidifier Defensor Mk5.

ThesteamhumidifierDefensorMk5incorporatesthelatesttechnicaladvancesandmeetsallrecognizedsafetystandards.Nevertheless,improperusemayresultindangertotheuserorthirdpartiesand/orimpairmentofmaterialassets.

Toensureasafe,proper,andeconomicaloperationof thesteamhumidifierDefensorMk5,pleaseobserveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallationand operating instructions.

Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyoursupplier.Theywillbegladtoassistyou.

1.2 Notes on the installation and operating instructions

5

2 For your safety

Intended use

SteamhumidifiersDefensorMk5are intendedexclusively fordirect or indirect room humidification or for humidification in laboratory and process applications withinthespecifiedoperatingconditions.Anyothertypeofapplication,withoutthewrittenconsentofyoursupplier,isconsideredasnotconformingwiththeintendedpurpose.Themanu-facturer/suppliercannotbemadeliableforanydamagesresultingfromimproperuse.Theuserbearsfullresponsibility.Operationoftheequipmentintheintendedmannerrequiresthat all the information in these instructions is observed (in particular the safety instructions).

General safety instructions

– ThesteamhumidifierDefensorMk5mustonlybeinstalled,operatedservicedandinall cases repaired only by persons who are adequately qualifiedtoundertakesuchworkandarewellacquaintedwiththeproduct.Ascertainingthequalificationsisthecustomer‘s responsibility.Thisunitmaynotbeusedbypersons(includingchildren)withreducedphysical,sensoryormentalabilitiesorpersonswithlackingexperienceand/orknowledge,unlesstheyaresupervisedbyapersonresponsiblefortheirsafetyortheyreceivedinstructionsonhowtooperatetheunit.Childrenmustbesupervisedtomakesurethattheydonotplaywithunit.

– Caution Hot water vapour - Danger of scalding! The Defensor Mk5 produces hot water vapour. There is danger of scalding when getting in touch with hot water vapour or the hot water inside the steam cylinder and the lime collector tank. Prevention:Donotcarryoutanyworkonthesteamsystemduringoperation(steamlines,steamdistributor,fanunit,etc.).IfthesteamsystemisleakysettheDefensorMk5immediatelyoutofoperationasdescribedinchapter6.3.Correctlysealthesteamsystembeforeputtingtheunitintooperationagain.

– Caution Danger of burning! During operation the components of the steam sys-tem (steam cylinder, steam distributor, etc.) get very hot (up to 100 °C). There is danger of burning when touching the hot components. Prevention: BeforecarryingoutanyworkonthesteamsystemsettheDefensorMk5outofoperationasdescribedinchapter6.3,thenwaituntilthecomponentshavecooleddownsufficientlythuspreventingdangerofburning.

– Caution, danger of electric shock! The Defensor Mk5 is operated with mains voltage. Before commencing workontheDefensorMk5,theunitistoberendered inoperative inaccordancewithsection6.3andprevented from further inadvertentoperation(isolateunitfromtheelectricalpowersupply,isolatewatersupply).

– Observe all local safety regulations.– relatingtotheoperationofmains-operatedelectrical and electronic equipment– and the provision of water, steam and electrical installations

– Poorlymaintainedhumidificationsystemscanendangerhealth.The servicing inter-vals should therefore be adhered to without reservation and the servicing work carried out correctly.

– Ifitissuspectedthatsafe operation is no longer possible,thentheDefensorMk5should immediately be shut down and secured against accidental power-up. This canbethecaseunderthefollowingcircumstances:– iftheDefensorMk5isdamaged– iftheDefensorMk5isnolongeroperatingcorrectly– ifconnectionsand/orpipingarenotsealedorcablesareloose

– TheDefensorMk5mustonly be operated under the specified operating conditions (seesection7).

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– Thecustomer is responsible for theregular inspection,cleaninganddisinfectionoftheductsectioninwhichthesteamdistributorisinstalled.Thismustbeperformedinaccordancewiththehygieneregulationsinforceforoperatingair handling units.

– TheDefensorMk5isprotectedaccordingtoIP21.Makesuretheunitsareinstalledinadrip-prooflocation.

– Caution! IftheDefensorMk5isinstalledinanareawithoutawaterdrain,watersen-sorsmustbefittedinthearea,suchthatintheeventofleakageinthewatersystem,thewaterfeedissafelyshutoff.

– Caution, danger of corrosion! In order to avoid damage, no corrosion-sensitive componentsshouldbelocatedintheareaoftheaerosolstreams.

– No work/repairshouldbecarriedoutontheDefensorMk5otherthanthatdescribedinthese instructions.

– Useexclusivelyoriginal accessories and spare partsavailablefromyoursupplier.

– No modifications must be undertakenon theDefensorMk5without theexpresswrittenconsentofthemanufacturer.

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3 Product overview

3.1 Unit types

ThesteamhumidifiersDefensor Mk5 are available in 2 different type series:

– Visual Fordirectorindirectroomairhumidificationwithstandard requirements for control precision.

– ProcessFordirectorindirectroomairhumidificationinlaboratory and process appli cationswherethereare increased requirements for control precision.

Basically,thedevicesofbothtypeseriesareofthesameconstructionexceptforthelevelcontrolandelectronics.TheVisualunits>10kg/hareequippedwithacombinedcontactor/electroniccontrolandalevelunitwithasinglefloat.ToachieveahigherlevelofaccuracytheProcessunitsincludeadedicatedelectroniccontrolwithspecialcontrolsoftwareandareequippedwithalevelunitcomprisingtwofloats.

Theyareavailableinversionssuitableforoperationwithuntreated drinking water(with lime collec-tor tank)orwithfully demineralized water(without lime collector tank).Allversionsareequipped,asstandard,withanoperating and display unit,bymeansofwhichthecurrentoperatingparameterscanbereadandtheequipmentconfiguredforoperation,andanintegrated PI controller.Theequip-mentcanbesuppliedwithvariousotheroptions.

Type overview and type designation

Theunitsofbothtypeseriesareavailableinvariousversionswithdifferent steam capacities and layout of the power section(heatingvoltage).Thefollowingtableprovidesanoverviewofthevariousmodels and their capacity ranges.

Defensor Mk5 Visual ..-../Process..-.. Heating voltage

small large double unit large5 8 10 16 20 24 30 40 50 1) 60 1) 80 1)

max. steam capacity in kg/h5.0 8.0 10.0 16.0 20.0 24.0 30.0 40.0 50.0 60.0 80.0 400V/3~/50...60Hz4.6 7.3 9.0 14.6 18.0 21.9 27.0 36.2 45.0 54.0 72.4 220V/3~/50...60Hz5.1 8.4 10.3 16.7 20.6 25.1 30.6 41.5 51.2 61.2 83.0 415V/3~/50...60Hz5.1 8.7 10.3 ––– ––– ––– ––– ––– ––– ––– ––– 240V/1N~/50...60Hz5.1 8.0 10.0 ––– ––– ––– ––– ––– ––– ––– ––– 230V/1N~/50...60Hz3.9 5.8 7.1 11.6 14.3 17.4 21.5 28.8 35.6 43.0 57.6 200V/3~/50...60Hz

1) Mk5 ... 50 ... Mk5 ... 60 ... Mk5 ... 80 ... Unit A: 20 kg/h 30 kg/h 40 kg/h Unit B: 30 kg/h 30 kg/h 40 kg/h

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Thetypedesignationisstructuredasfollow:

Designation CodeBrand name CondairProduct line Defensor Mk5

Type series –Directorindirectroomhumidification –Humidificationforlaboratoryandprocessapplications

VisualProcess

Operating mode – Operation with untreated drinking water (with lime collector tank) –Operationwithfullydemineralizedwater(withoutlimecollectortank)

–VE

Steam capacity in kg/h – 5, 8, 10, 16, 20, 24, 30, 40, 50, 60 or 80 ..Heating voltage – 400V/3~/50...60Hz – 220V/3~/50...60Hz – 415V/3~/50...60Hz – 240V/1N~/50...60Hz – 230V/1N~/50...60Hz – 200V/3~/50...60Hz

400V/3~220V/3~415V/3~

240V/1N~230V/1N~200V/3~

3.3 Standard delivery

The standard delivery includes:

– SteamhumidifierDefensorMk5compl.(accordingtotypedesignation)equippedwiththedesiredoptions(remoteoperatingandfaultindication,pressurecompensationkit,etc.)accordingtochap-ter 4.3

– Fixingsetincludingdowelsandfixingscrews(forsingleunitsupto40kg/h),mountingprofilewithdowelsandfixingscrews(fordoubleunits50...80kg/h)

– Installation and operating instructions

– Sparepartslist(red)

– Orderedaccessories(steamdistributionpipe,steamhose,etc.)accordingtochapter4.4

CondairAG/CH-8808PfäffikonMk5 Visual 30 XXXXXXX 02.13400V 3~ / 50...60Hz 22.3 kWDampf/Steam/Vapeur=30.0kg/hWasser/Water/Eau=1...10bar

MadeinSwitzerland

3.2 Identification of the unit

Theidentificationoftheunitisfoundonthetypeplate:

Type designation Serialnumber(7digits) Month/Year

Heating voltage

Maximumsteamcapacity

Admissiblewatersupplypressure

Powerconsumption

Fieldwithcertificationsymbols

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3.4 Humidification system overview

1 Steamhumidifier 2 Electrical connections 3 Water drainage 4 Limecollectortank(onlyonunitsforoperation

with untreated drinking water) 5 Filter valve (accessory “Z261”) 6 Water supply (building side) 7 Fanunit(accessory“FAN3S..”) 8 Condensatehose(accessory“KS10”) 9 Steamhose(accessory“Z10”)10 Steamdistributionpipe(accessory“81–...”)

3.5 Steam humidifier construction 1 Housing (500 or 600) 2 Power board 3 Heating contactor (Visual >10 kg/h only) 4 Mains contactor 5 Supplymodule 6 Control board 7 Cable openings 8 LC-Display 9 Control keys 10 Unit switch 11 Drain switch12 Statusindicator(LED)13 Limecollectortank(onlyonunitsforoperation

with untreated drinking water) 14 Drain 15 Water connection16 Steamcylinder 17 Drain pump 18 Resistance heating element19 Inletvalvewithfilter 20 Water supply 21 Filling pipe22 Overflowpipe23 Steamoutletconnector 24 Water cup 25 Pressure equalizing pipe 26 Level unit 27 Type plate

5

6

4

3

7

1

2

10

8

9

23

1

26

2

3

4

5

6

27

7

8

9

10 11 12 13

15 14

17

16

18

19 20

21 22

24 25

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3.6 Functional description

TheDefensorMk5steamhumidifierisanunpressurizedsteamgenerator.Itoperatesontheresistanceheatingprincipleandisdesignedfordirect(withfanunit)andindirect(withsteamdistributionpipe)roomair humidification in ventilatingandair-conditioning systems. In conjunctionwitha “Process”steamdistributionpipetheunitmaybeusedforhumidificationinlaboratoryandprocessapplications.

Water supply

Thewateristakenviaafiltervalve(accessory“Z261”)tothesteamhumidifier.Itreachesthesteamcylinderviatheinletvalve(levelcontrolled)andtheopenwatercup.

Level regulation

Thewaterlevelinthesteamcylinderiscontinuouslymonitoredwiththelevelunit.Ifthewaterlevelreachesapresetlevel(owingtotheevaporationprocess)thelevelunitsuppliesasignaltothecon-troller.Thisopenstheinletvalveandthesteamcylinderisfilledup.Whenthepresetoperatinglevelisreached, the level unit supplies another signal to the controller to close the inlet valve.Thepressureequalizingpipebetweenthesteamconnectionandthelevelunitensuresthatthewaterlevels are the same in the steam cylinder and the level unit.

Steam generation regulation

Thesteamisproducedinthesteamcylinderbyseveralresistanceheatingelements.Anexternalortheinternalregulatorforconnectionasrequiredcontrolthesteamproductionfullyvariablyfrom0to100%.

Flushing

Theevaporationprocessincreasestheconcentrationofmineralsinthewaterofthesteamcylinder.Asuitablevolumeofwatermustbeflushedthroughthesteamcylinderfromtimetotimeandreplacedbyfreshwatertoensurethatthisconcentrationdoesnotexceedaspecificvalueunsuitableforoperation.TheMk5steamhumidifierperformsanauto-adaptiveflushing.Thisconsistsofthefollowingtwoformsofflushing:

– Automatic flushing takesplaceassoonasthewater inthesteamcylinderexceedstheupperoperatinglevel(e.g.byfoamingofthewater).

– Flushing dependent on time performstheflushingprocessatpreselectedtimeintervals(seesec-tion6.1“Adjustments”).

Automaticortime-dependentflushingtakesplacedependingonthewaterqualityandtheoperatingdata.Ifthelowestoperatinglevelisreachedduringtheflushingprocess,theinletvalveremainsopenuntilthewaterlevelinthesteamcylinderhasreachedthenormalworkinglevelagain.Ifthelowestoperating level is not reached, the inlet valve is closed.

Lime collector tank

Themineralsprecipitatedbytheevaporationprocessaccumulateatthebottomofthesteamcylinder.Unitsdesignedforoperationwithuntreateddrinkingwaterareequippedwithanadditionallimecol-lectortanklocateddirectlyunderneaththesteamcylinder.Thiswaythemineralsdonotaccumulateinthesteamcylinderbutmainlyinthecollectortankthusextendingtheserviceintervalsandreducingthe maintenance costs.

Unitsdesignedforoperationwithfullydemineralizedwaterdonothavealimecollectortankasfullydemineralizedwatercontainsonlysmallamountsofminerals.

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4 Basic planning

AllthedatanecessaryfortheselectionandlayoutofaDefensorMk5humidifiersystemareprovidedinthefollowingchapters.

4.1 Selecting the unit

Theselectionoftheunitisreflectedinthetypedescription:

1. Application

2. Supplywaterquality

3. Requiredmaximumsteamcapacity

4. Requiredheatingvoltage

1. Application

Thetypeseriescanbeselectedonthebasisofthefollowingtable:

Scopeofuse Type series

For direct or indirect room air humidification with standard requirements for control precision.

Visual

For direct or indirect room air humidification in labora-tory and process applications where there are increased requirements for control precision.

Process

Achievable control precisionNote:Thecontrolprecisionmaydependonthelocationofthehumiditysensor.– Visual: ±5 %rh(PI-controlanduseofuntreateddrinkingwater)

±2 %rh(PI-controlanduseoffully demineralized water) Note:Duringthedraincycle(operationwithdrinkingwater)orduringtherefillcycle(operationwithfullydemineralizedwater)thecontrolprecisioncandeviatefromtheabovestatedvalues.

– Process: ±2 %rh(PI-controlanduseofuntreateddrinkingwater) ±1 %rh(PI-controlanduseoffully demineralized water)

Note:WhenoperatingtheMk5Processwithdrinkingwaterthecontrolprecisioncandeviatefromtheabovestatedvaluesduringthedraincycle.ForprocessairhumidificationwithconstantcontrolprecisiontheMk5ProcessmustbeoperatedwithfullydemineralizedwaterandthedraincyclemustbesettoPos.0(seechapter6.1).

2. Supply water quality Description Version

Unit withalimecollectortankforoperationwithuntreated drinking water and partially softened water (see also notes on water quality in chapter 5.4.1).

–

Unit withoutalimecollectortankforoperationwithfullydemineralizedwaterwithaconductivityvalue<15µS.Caution! Unit without lime collector tanks should not be operated with untreated drinking water or partially softened water.

VE

Defensor Mk5 Visual VE 24-400V/3~

Defensor Mk5 Visual VE 24-400V/3~

Defensor Mk5 Visual VE 24-400V/3~

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3. Calculating the maximum required steam capacity

Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:

V • ρmD = • (x2 - x1) 1000

V mD = • (x2 - x1) 1000 • ε

mD: maximumsteamdemandinkg/hV: volumeofsupplyairportionperhourinm3/h(forindirectroomhumidification)orroomvolumeto

behumidifiedperhourinm3/h(fordirectroomhumidification)ρ: specificgravityofairinkg/m3

ε: specificvolumeofairinm3/kgx2: desired absolute room air humidity in g/kgx1: minimum absolute supply air humidity in g/kg

Thevaluesforρ, ε, x2 and x1canbegatheredfromtheh,x-diagram or the Carrier-Diagramformoistair respectively.

Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalueslistedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroomairhumidityof45%rh.

Max.portionofsupplyairinm3/hr or roomvolumetobehumidifiedperhourinm3/hr

max. steamcapacity in kg/hTemperature/rel.humidityofsupplyair

-15 °C/90 %rh -5 °C/80 %rh 5 °C/60 %rh6501000200025003000375050006250750010000

8501350265033004000500066008250990013200

1000160032004000480060008000100001200016000

5816202430

40

50

60

80

Example: Max.portionofsupplyair3000m3/h, temperature/rel. humidityofsupplyair-15°C/90%rh

or

Important notes:

– Therequiredmaximumsteamcapacitydependson thespecificapplicationand the installation.Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionoftheairtobehumidifieddoesnotconsideranysteamloss(e.g.duetocondensationinthesteamhosesandthesteamdistributors),anyheatlossoftheunitaswellasanyabsorptionorreleaseofhumidityofmaterialslocatedintheroombeinghumidified.In addition, the calculated steam capacity does not consider any losses caused by the draining rate dependingonthewaterquality.

Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsiderationwhencalculatingtherequiredsteamcapacity.Ifyouhaveanyquestionsregardingthecalculationofthesteam capacity please contact your supplier.

– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesorforsystemswithvariableairvolumeflow,etc.),pleasecontactyoursupplier.

Defensor Mk5 Visual VE 24-400V/3~

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4. Heating voltage/control voltage Heating voltage

TheDefensorMk5steamhumidifiersareavailablewithvariousheatingvoltages.Themaximumachievable steamcapacity and the power consumption are directly dependent on the selectedheatingvoltage(seetable).

400 V/3~ 220 V/3~ 415 V/3~ 240 V/1N~ 230 V/1N~ 200 V/3~

50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz

DefensorMk5Visual.../Process...

kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A

...5-.. 5.0 3.8 5.5 4.6 3.4 9.0 5.1 4.0 6.0 5.1 4.0 17.0 5.1 4.0 16.5 3.9 3.0 8.2

...8-.. 8.0 6.0 8.7 7.3 5.5 14.4 8.4 6.5 9.0 8.7 6.5 27.2 8.0 6.0 26.0 5.8 4.5 13.1

...10-.. 10.0 7.5 11.0 9.0 6.7 17.7 10.3 8.0 11.5 10.3 8.0 33.0 10.0 7.4 32.0 7.1 5.5 16.1

...16-.. 16.0 12.0 17.4 14.6 10.9 28.7 16.7 13.0 18.1 –– –– –– –– –– –– 11.6 9.0 26.1

...20-.. 20.0 14.9 21.5 18.0 13.5 35.4 20.6 16.0 22.3 –– –– –– –– –– –– 14.3 11.1 32.2

...24-.. 24.0 18.1 26.2 21.9 16.4 43.1 25.1 19.5 27.2 –– –– –– –– –– –– 17.4 13.5 39.2

...30-.. 30.0 22.3 32.3 27.0 20.2 53.1 30.6 24.0 33.5 –– –– –– –– –– –– 21.5 16.7 48.3

...40-.. 40.0 30.0 43.3 36.2 27.2 71.4 41.5 32.3 45.0 –– –– –– –– –– –– 28.8 22.4 64.9

...50-..A 20.0

+30.0

14.9+

22.3

21.5+

32.3

18.0+

27.0

13.5+

20.2

35.4+

53.1

20.6+

30.6

16.0+

24.0

22.3+

33.5–– –– –– –– –– ––

14.3+

21.5

11.1+

16.7

32.2+

48.3B

...60-..A 30.0

+30.0

22.3+

22.3

32.3+

32.3

27.0+

27.0

20.2+

20.2

53.1+

53.1

30.6+

30.6

24.0+

24.0

33.5+

33.5–– –– –– –– –– ––

21.5+

21.5

16.7+

16.7

48.3+

48.3B

...80-..A 40.0

+40.0

30.0+

30.0

43.3+

43.3

36.2+

36.2

27.2+

27.2

71.4+

71.4

41.5+

41.5

32.3+

32.3

45.0+

45.0–– –– –– –– –– ––

28.8+

28.8

22.4+

22.4

64.9+

64.9B

Shouldyourequireaunitwithadifferentheatingvoltage,pleasecontactyoursupplier.

Control voltage

DefensorMk5steamhumidifiersaredesignedforastandardcontrolvoltageof220...240V/50...60Hz.

Ifusedinsystemswithoutseparatecontrolvoltagesupply,theDefensorMk5maybeequippedwithanoptionaltransformer400-500V/230V(seechapter4.4).

Defensor Mk5 Visual VE 24-400V/3~

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4.2 Selecting the control system

The various control systems

– System 1: Room humidity control

System1issuitedfordirect room humidification and air conditioning systems with mainly recirculated air.Thehumiditysensororhumidistatrespectivelyispreferablylocatedintheroomitselforintheexhaustairduct.

A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatB4 humidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1

– System 2: Room humidity control with continuous limitation of the supply air humidity

System2issuitedforairconditioningsystemswithalarge portion of supply air, low supply air temperature, post-humidification, or variable airflow volume.Ifthesupplyairhumidityexceedsthepresetvalue,thecontinuouslimitationiseffectedpriortotheroomhumiditycontrol.Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.Thehu-miditysensor(A2)forthelimitationofthesupplyairhumidityislocatedinthesupplyairductafterthesteamdistributionpipe.Thiscontrolsystemrequiresaexternal continuous controllerwiththeoption to connect a second humidity sensor.Attention!Thecontinuouslimitationofthesupplyairhumidityisnosubstituteforthesafetyhumidistat.

A1/2 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1Z inputsignalfromA2

DefensorMk5

DefensorMk5

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– System 3: Supply air humidity control

Supply air humidity control (humidity sensor installed in supply air duct) should be used only where room humidity control is impracticable for technical reasons.SuchsystemsalwaysrequireaPI-controller.Thehumiditysensor(A1)islocatedinthesupplyairductafterthesteamdistribution pipe.

A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller) Y inputsignalfromA1

Which humidity control system for which application?

Application Location of the humidity sensor

Room or exhaust air duct supply air ductAir conditioning systems with: supply air portion up to 33% System1 System1 supply air portion up to 66% System1or2 System2or3 supply air portion up to 100% System2 System3 supply air humidity control — System3Directroomhumidification System1 —

Pleasecontactyoursupplier,ifyourapplicationmeetsthefollowingconditions:

– Humidificationofsmallroomsupto200m3

– Airconditioningsystemswithahighnumberofairexchanges

– Systemswithvariableairvolumeflow

– Testfacilitieswithextremecontrolaccuracyrequirements

– Roomswithahighvariationinmax.steamcapacity

– Systemswithtemperaturefluctuations

– Coldroomsandsystemswithdehumidification

DefensorMk5

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4.3 Options

ThefollowingtablepresentsanoverviewofalloptionswhichareavailableforthesteamhumidifierDefensorMk5.

Defensor Mk5 Visual Process

Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80

Interface RS232/RS485(InterfacePCBRS232/RS485fordataex-changewithabuildingcontrolsystem)

RS

number 1 1 1 1 1 1

Remote operating and fault indication(PCBwithrelaycontactsfortheconnectionofremotedisplaysfor“Operation”,“Steam”,“Fault”and“Service”)

RFS

number 1 1 1 1 1 1

Pressure compensation kit up to 10’000 Pa(Assemblykitfortheinstallationofthefillingbowlontheequipmentcover,fortheopera-tionofthesteamhumidifierininstallationswithductairpressuresupto10’000Pa)

OVP

number 1 1 2 1 1 2

Transformer 400-500V/230V(Transformerforsystemswithoutaseparatecontrolvoltagesupply)

TRAF 1)

number 1 1 1 1

Connection terminal 400-415 V/3~(Separate terminals for systems wheredirectconnectionofheatingvoltagetomaincontactor(standardversion)isnotpermittedbylocalregulations)

KLK KLG KLK KLG

number 1 1 2 1 1 2

Unit housing stainless steel S-Inox L-Inox S-Inox L-Inox

number 1 1 2 1 1 2

1) Whenorderingindicatethetypeofunit

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4.4 Accessories

4.4.1 Accessories overview

Thefollowingtablepresentsanoverviewofallaccessorieswhichareavailableforthesteamhumidi-fierDefensorMk5.

Defensor Mk5 Visual Process

Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80

Steam distribution pipe(seeaccessorydetailsinchapter4.4.2)

81-...

number 1 2 1 2

Steam distribution pipe Process(seeaccessorydetailsinchapter4.4.2)

Z..

number 1 2 1 2

OptiSorp steam distribution system(seeaccessorydetailsinchapter4.4.2)

System 1 System 2 System 1 System 2

number 1 1 1 1

Fan unit(seeaccessorydetailsinchapter4.4.2)

FAN3S Mk M

orFAN3S

Mk M FC

FAN3S Mk L FAN3S Mk M

orFAN3S

Mk M FC

FAN3S Mk L

number 1 1 2 1 1 2

Steam hose / meter Z10 (ø54/42)

number 1 2 1 2

Condensate hose / meter KS10

number 1 2 1 2

Filter valve Z261

number 1(persystem)

Mounting profile BS4 BS5 BS6 1) BS4 BS5 BS6 1)

number 2 2 2 2 2 2

Humidity sensor, room CRC

number 1(persystem)

Humidity sensor, duct CDC

number 1(persystem)

1) FordoubleunitsthemountingprofilesBS6areincludedinthestandarddelivery

18

Steam distribution pipes 81-... for indirect room humidification

Thesteamdistributionpipesareselectedonthebasisoftheduct width(forhorizontalinstallation)orthe duct height(forverticalinstallation)andthecapacityofthesteamhumidifier.Important!Alwaysselectthelongestpossiblesteamdistributionpipe(optimumhumidificationdistance).

4.4.2 Accessory details

Steam distribution pipes 81-... for Defensor Mk5 (CrNi steel)

Duct width (B) Steam output

Type Length in mm (L) 3) in mm max. in kg/h81-200 1) 200 210...400 1081-350 2) 350 400...600 3081-500 2) 500 600...750 3081-650 650 750...900 5081-800 800 900...1100 5081-1000 1000 1100...1300 5081-1200 1200 1300...1600 5081-1500 1500 1600...2000 5081-1800 1800 2000...2400 5081-2000 2000 2200...2600 5081-2300 2300 2500...2900 5081-2500 2500 2700...3100 50

1) Onlyforunitswithamax.steamcapacityof10kg/h2) Onlyforunitswithamax.steamcapacityof30kg/h3) Speciallengthavailableonrequest

Note:Ifthehumidificationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,theamountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesorthe OptiSorp steam distribution system mustbeused.Ifthisisthecase,contactyoursupplier.

Steam distribution pipe “Process” (accessory “Z...”)

Thesteamdistributionpipe“Process”isusedfordirect humidification of materialinmanufacturingprocesses (processhumidification),or inventilationductswithacritical saturation distance (thesteamdistributionpipe“Process”reducesthesaturationdistancebyapproximately30%).Thedesiredlengthmustbespecifiedwhenordering.

Pleasecontactyouryoursupplier,theywillassistyouincustomizingthesteamdistributionhead“Pro-cess”.Pleasehavethefollowinginformationreadilyavailable:

– steamquantityinkg/h

– dimensionsofventilationduct(widthxheight)

Important! Thetableforthedeterminationofthehumidificationdistanceprovidedinchapter5.3.1doesnot apply to the Process steam distribution pipe.

19

OptiSorp steam distribution system

TheOptiSorpsteamdistributionsystemisusedinventilationductswhereonlyashorthumidificationdistance isavailable(seechapter5.3.1forcalculationofhumidificationdistance).Ductdimensionsshouldbegivenwhenordering.Pleasenotethefollowingdataforthis:

OptiSorp Number of steam connections

max. steam capacity in kg/h 1)

Duct dimension

Width in mm Height in mm

System 1 1 45 (30) 450...2700 450...1650

System 2 2 90 (60) 450...2700 450...2200

1) For duct width <600 mm the values in parenthesis are valid

Note:FurtherinformationontheOptiSorpsteamdistributionsystemcanbefoundintheseparatein-stallationandoperatinginstructionssuppliedwiththeproduct.

Fan unit

Thefanunits–incombinationwiththesteamhumidifiersDefensorMk5–areusedforthedirectroomhumidification.Theycanbemountedseparately above the unittothewall.

Thetypeoffanunitandtheamountrequiredisdependentonthesteamcapacityofthebasicunit(s)andcanbegatheredfromthetableinchapter4.4.1.

Note:Furtherinformationonthefanunitcanbefoundintheseparateinstallationandoperatinginstruc-tionssuppliedwiththeproduct.

Thefanunitsaredeliveredwith:

– Installation accessories including steam hose

– Installation and operating instructions Fan unit

20

4.5 Additional planning instructions

Inadditiontotheselectionofthesteamhumidifier,theaccessoriesandtheoptions,otherpointsshouldbeconsideredduringplanning.Pleasenotetheinformationinthefollowingchapters:– Unitfitting(seechapter5.2)– Steaminstallation(seechapter5.3)– Waterinstallation(seechapter5.4)– Electricinstallation(seechapter5.5)

Ifyouhaveotherquestionsrelatingtoplanningthatarenotadequatelycoveredbytheseinstallationandoperatinginstructions,pleasecontactyoursupplier.Hewillbehappytoprovidefurtherassistance.

21

5 Mounting and installation works

5.1 Safety instructions for mounting and installation works

– Allmountingandinstallationworkmustbeperformedonly by adequately qualified personnel.Ascertainingthequalificationsisthecustomer‘sresponsibility.

– Alllocalregulationsrelatingtotheexecutionoftherespectiveinstallationwork(Water,steamandelectricalinstallation)mustbenotedandcompliedwith.

– Alltheinformationcontainedintheseinstallationandoperatinginstructionsrelatingtoequipmentassemblyandtowater,steamandelectricalinstallationmustbeuncondi-tionallyobservedandcompliedwith.

– Caution - Danger from electric shock! The connection of the steam humidifier to the mains electrical supply must not be made until all installation work has been completed.

– Electronic components are very sensitive to electrostatic discharges. In order to protect thesecomponents,duringallinstallationworkwiththeequipmentopened,precautionsmustbetakenagainstdamageduetoelectricaldischarge(ESDprotection).

5.2 Unit fitting

5.2.1 Humidifier location

Theinstallationsiteofthesteamhumidifierdependslargelyonthelocationofthesteamdistributionpipeorfanunit(seechapter5.3.1and5.3.2),respectively.Toensureproperfunctioningofthesteamhumidifierandtoobtainanoptimalefficiency,thefollowingpointsmustbeconsideredandobservedwhenchoosingthelocationforthesteamhumidifier:

– Installthesteamhumidifiersothatthelength of the steam hose is kept as short as possible (max. 4 m) and that the minimum bend radius (R= 300 mm) and up-slope (20 %) or down-slope (5 %)ofthesteamhoseisobserved(seechapter5.3.3).

– ThesteamhumidifiersDefensorMk5aredesignedforwall-mounting.Makesurethattheconstruc-tion(wall,pillar,floor-mountedconsole,etc.)towhichthehumidifiersaretobemounted,offersasufficientlyhighload-bearingcapacity(takenoticeoftheweightinformationfoundinthischapter),andissuitablefortheinstallation.

Warning!Donotmountthesteamhumidifierdirectlytotheventilationduct(insufficientstability).

– ThebackpaneloftheDefensorMk5isretainingheatduringoperation(max.surfacetemperatureofthemetalhousingapprox.60-70°C).Makesure,therefore,thattheconstruction(wall,pillar,etc.)towhichtheunitsaretobemounted,doesnotconsistofheat-sensitivematerial.

– Foroperationinvolvingafanunit,thesteamhumidifiermustalwaysbeinstalledlowerthanthefanunit.

– Installthesteamhumidifierinsuchamannerthatitisfreelyaccessiblewithsufficientspaceavail-ableformaintenancepurposes(refertothefollowingillustrationforminimumdistances).

22

Dimensions and Weights

Minimum distances to observe

437 mm 500 mm

1087

mm

1087

mm

392 mm 594 mm

160 mm257 mm 194 mm212 mm30

0 mm

300 m

m

69 mm 132 mm 103 mm45 mm

min.

400 m

m

min. 600 mm min. 50 mm min. 400 mm

min.

600 m

m

50 mm

min.

600 m

m

Mk5 ...50.. Mk5 ...60.. Mk5 ...80..Unit A: 20 kg/h 30 kg/h 40 kg/hUnit B: 30 kg/h 40 kg/h 40 kg/h

Unit AUnit B

Housing size small large double unit largeSteamcapacity in kg/h 5 8 10 16 20 24 30 40 50 60 80

Netweightin kg 36 36 37 38 41 43 43 44 1x41

1x43 2x43 2x44

Grossweight in kg 51 51 52 53 71 73 73 74 1x71

1x73 2x73 2x74

23

5.2.2 Mounting the humidifier

• Usethedrillingtemplate(printedonthepacking)tomarkattachmentpoint“A”onthewall.Important! Observe location notes.

• Drillholeø10mm,insertthesuppliedplasticplug,andtightenthescrewuntilthedistancebetweenthewallandthescrewheadis5mm.

• Unlockleftfrontpanelandremovebothfrontpanels.Hanguptheunitonthescrew,andusethespiritleveltoadjustithorizontallyandvertically.

• Markattachmentpoints“B”.Whenfinished,removetheunitagain.

• Drillholesø10mmandinsertthesuppliedplasticplugs.

• Hangtheunituponthescrewagainbeforeattachingitwiththeremainingtwoscrews.Beforetight-eningthescrews,readjusttheunitwiththespiritlevel.

• Reattachthefrontpanelsandlockthem.

5.2.3 Inspecting the installed unit

Usethefollowingchecklisttoascertainthattheinstallationwasperformedcorrectly:

Is/aretheunit(s)inthecorrectplace?(seechapter5.2.1)

Is/aretheunit(s)correctlyalignedverticallyandhorizontally?

Issteamhumidifierproperlysecured?(stabilityofthecarryingstructure)

Caution!WhenfixingtheDefensorMk5,useonly the fixing materials supplied with the unit.Iffixingwiththematerialssuppliedisnotpossibleinyourparticularcase,selectamethodoffixingthatisofsimilarstability.Incaseofdoubt,pleasecontactyoursupplier.

Note:Thefollowingexplainshowtofixtheunitwithoutoptionalmountingprofiles.Toinstalltheunitwithmountingprofiles,pleasenotethespecialinstructionsprintedonthepackaging.

View from the front

Measure Housing sizesmall large

a 232,0 mm 237,0 mmb 175,0 mm 181,0 mmc 166,5 mm 166,5 mmd 460,0 mm 460,0 mm

24

5.3 Steam installation

5.3.1 Positioning and mounting of the steam distribution pipes

Thelocationforthesteamdistributionpipesshouldbedeterminedatthetimeofdimensioningtheairconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidificationoftheductair.

Calculating the humidification distance

Thewatervapor,emittingfromthesteamdistributionpipes,requiresacertaindistancetobeabsorbedbytheambientairsothatitisnolongervisibleassteam.Thisdistanceisreferredtoashumidifica-tion distance “BN”andservesasabasisforthedeterminationoftheminimumdistancesfromtheupstream components in the system.

Humidificationdistance BN Expansionandmixingzone

φ1: Incoming air humidity beforehumidificationφ2: Air humidity afterhumidification

Thecalculationofthehumidificationdistance“BN”isdependentonseveralfactors.Foraroughestima-tionofthehumidificationdistance“BN”,thefollowingtableisuseful.Recommendedstandardvalueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevaluesgiveninbold type only apply to steam distribution pipes 81-..., the values in brackets apply to the OptiSorp steam distribution system.

Humidity at inlet φ1 in %rh

Humidification distance BN in mHumidity at outlet φ2 in %rh

40 50 60 70 80 905 0,9 (0,22) 1,1 (0,28) 1,4 (0,36) 1,8 (0,48) 2,3 (0,66) 3,5 (1,08)

10 0,8 (0,20) 1,0 (0,26) 1,3 (0,34) 1,7 (0,45) 2,2 (0,64) 3,4 (1,04)20 0,7 (0,16) 0,9 (0,22) 1,2 (0,30) 1,5 (0,41) 2,1 (0,58) 3,2 (0,96)30 0,5 (0,10) 0,8 (0,17) 1,0 (0,25) 1,4 (0,36) 1,9 (0,52) 2,9 (0,88)40 − 0,5 (0,11) 0,8 (0,20) 1,2 (0,30) 1,7 (0,45) 2,7 (0,79)50 − − 0,5 (0,13) 1,0 (0,24) 1,5 (0,38) 2,4 (0,69)60 − − − 0,7 (0,16) 1,2 (0,30) 2,1 (0,58)70 − − − − 0,8 (0,20) 1,7 (0,45)

Forductwidths<600mmthehumidificationdistancefortheOptiSorpsystemincreasesbyapprox.50%

φ1in%rh: Relativesupplyairhumiditypriortohumidificationatthelowestsupplyairtemperatureφ2in%rh: Relativesupplyairhumidityafterthesteamdistributionpipeatmaximumcapacity

Example

given: φ1=30%rh,φ2=70%rh

humidificationdistanceBN: 1,4 m (0.36mforOptiSorpsteamdistributionsystem)

Note:Ifthehumidificationdistancehastobereducedfortechnicalreasons,theamountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesortheOptiSorp steam distribution system mustbeused.Ifthisisthecase,contactyoursupplier.

25

Minimum distances to be observed

To prevent thewater vapor, that is emitting from the steam distributionpipe, from condensing ondownstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeobserved(dependsonthehumidificationdistance“BN”).

before/after filter/register before/after fan, zone exit

Caution!Thehumidificationdistanceandderivedfromittheminimumdistancebetweenthesteamdistributorandsystemcomponents locateddownstreamintheductaredeterminedonthebasisoftheexpectedoperatingparameters(e.g.airspeed,supplyairtemperature,etc.)whenplanningthesystem.Analterationoftheseoperatingparametersatalatertimemayinducethatthedeterminedhumidificationdistanceisnotcorrectanylongerandsteamiscondensatingduringoperationonsys-temcomponentslocateddownstreamintheduct.Thismayleadtodamageofthesystemand/oranexcessivegrowingofgerms.

Installation notes and dimensions

Thesteamdistributionpipesaredesignedforeitherhorizontalinstallation(ontheductwall)or,withaccessories,forverticalinstallation(intheductfloor).Theoutlet orifices should always point up-wards and at right angles to the airflow.

Ifpossible,thesteamdistributionpipesshouldbeinstalledonthepressure sideoftheduct(max. duct pressure 1500 Pa).Ifthesteamdistributionpipesareinstalledonthesuctionsideoftheduct,the maximum vacuum must not exceed 1000 Pa.

Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)andpositionthesteamdistributionpipesintheductsothatauniformdistributionofsteamisachieved.

before/after constriction after expansion before bend

before branch before diffuser before control sensor

2,5xBNbeforesubmicronparticlefilter

0.5 x BN BN0.5 x BN

BN BN 5 x BN

1.5 x BN * 5 cm BN BN

26

Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved.

Note:PleasenotetheinstructionsintheseparatedocumentationforthisproductwhenlocatingtheOptiSorp steam distribution system.

Guidelines for dimensioning the ventilation ducts

– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufficientlysizedcontrolopeningshouldbeplanned.

– Withintherangeofthehumidificationdistance,theventilationductshouldbewater-proofed.

– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidifiedairfromcon-densingalongtheductwall.

– Poorairflowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canleadtocondensationofthehumidifiedair.

– Steam distribution pipes must not be mounted to round ducts.

Ifyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithsteamhu-midifiers,contactyoursupplier.

Installing the steam pipes/the OptiSorp steam distribution system

Detailedinformationontheinstallationofsteamdistributionpipes/OptiSorpsteamdistributionsystemcanbefoundintheseparate“MountingInstructions”forthisproducts.

gmin= 150mmhmin= 85mm

min.H=250mm H≥400mm min.H=200mm

min.H=400mm min.H=350mm min.H=300mm

min.H=600mm min.H=500mm min.H=400mm

min.H=720mm min.H=600mm min.H=500mm

27

Thefanunitismountedon the wall separately above the unit.Toallowthesteamcomingfromthefanunittospreadoutevenly,withoutcondensingonobstacles(ceilings,joists,pillars,etc.),thefollow-ingminimumdimensionsmustbeobservedwhenselectingthelocationforthefanunit.

FAN3SMkM/FAN3SMkMFC FAN3SMkL

mDmax. 8kg/h 16kg/h 30kg/h 40kg/h

A min. 4.0 m 6.0 m 8.0 m 10.0 m

B min. 1.0 m 1.0 m 1.0 m 1.5 m

C ca. 2.2 m 2.2 m 2.2 m 2.2 m

D ca. 0.5 m 0.7 m 1.0 m 1.5 m

E min. 0.15 m

E max. (max.lengthofsteamhose) 4.0 m (recommended: 2.0 m)

Note:Theminimumspacesinthetableapplyforaroomatmosphereof15°Candmax.60%rh.Forlowertemperaturesand/orhigherhumiditythevaluesmustbeincreasedaccordingly

Note:Inordertoachieveauniformdistributionofthehumiditywithintheroom,additionalfactorssuchastheroomsize,theroomheight,etc.,mustbetakenintoconsiderationbesidesobservingtheminimumdistances.Ifyouhavequestionsconcerningthedirectroomhumidification,pleasecontactyoursupplier.

Furtherinformationisprovidedintheseparateinstallationandoperatinginstructionsforthefanunit.

5.3.2 Positioning and mounting of the fan unit

28

Important! Useoriginalsteamandcondensatehosefromyourunitsupplierexclusively.Othertypesofhosescancauseundesiredoperationalmalfunctions.Important! After installation the protective plastic tube around the steam hose must be removed.

Instructions for the hose layout

Thehoselayoutdependsonthepositionofthesteamdistributionpipe:

– Steam distribution pipe is mounted more than 500 mm above the top edge of the humidifier:

Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thenleadthehosewithaminimum upslope of 20%and/oraminimum downslope of 5% to the steam distribution pipe.

Thecondensatehoseisleddowntothehumidifierwithaminimum slope of 20 %,intheformofa siphon (min. hose bend radius Ø200 mm ),andinsertedabout2cmintothespecifiedopening.Note:Ifyourunitfeedsanumberofsteamdistributionpipes,theindividualcondensatehosesaretobeledintothedischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.

Note: forsteamcapacities≤20kg/htheseparatereturnofthecondensateviathecondensatehosecanbedispensedwithifthesteamhoseisinstalledinsuchawaythatthecondensatecanflowbackintothesteamcylinderunhinderedwithaconstantdownslope.

5.3.3 Installing the steam and condensate lines

5.3.3.1 Steam line with flexible hose

min.

300 m

m

Rmin.

300 m

m

min. 5 % min. 20 %

max.

4m

min.

300 m

m

Rmin.

300 mm

min. 20 %

max.

4m

min. 20 %

Ømin. 200 mm

min.

300 m

m min. 20 %

Ømin. 200 mm

29

– Steam distribution pipe is mounted less than 500 mm above the top edge of the humidifier:

Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thendowntothesteamdistributionpipewithaminimum slope of 5 %.

Thecondensatehoseisleddownwithaminimum slope of 20 %,intheformofasiphon (min. hose bend diameter Ø200 mm),directlyintoadischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.

– Thesteamhoseshouldbekeptasshortaspossible(max. 4 m)whileobservingtheminimum bend radius of 300 mm. Important!Allowancemustbemadeforapressure loss of 10 mm water column (approx. 100 Pa) per meter steam hose.Note:Ifyourparticularinstallationexceedsthemaximumsteamhoselengthof4mcontactyoursupplier. In any case, steam hoses longer than 4 m must be insulated in their entire length.

– Caution! Reducing the cross section or the complete closure of the steam pipe will cause an excessive increase in pressure in the steam cylinder when the unit is operat-ing and could lead to the risk of scalding accidents. Therefore you must comply with the following instructions:

– Wheninstallingmakesurethesteampipeisopenovertheentirelengthandthroughthewholecrosssection.Anysealingplugs,adhesivesealingsheetsetc.mustberemovedbeforeconnectingthesteampipeandreductionsincrosssectionbykinking,forexample,must be avoided.

– Steamhosesmustbepreventedfromsagging(condensatepockets);ifnecessary,sup-portsteamhosewithpipeclamps,trough,orwallbrackets,orinstallacondensatedrainatlowestpointinthesteamhose.

– It is not permitted to install a stop valve(e.g.amanuallycontrolledstopvalve,solenoidvalve,etc.)inthesteampipe.

– Important!Whendecidingonthelengthandlayoutofthehose,itshouldbenotedthatthesteamhosemaybecomesomewhatshorterwithprogressiveageing.

Securing the steam hose

Thesteamhosemustbesecuredtothesteamdistributionpipeandhumidifiersteamoutletbymeansofhose clamps.

max.

4m

min. 5 %

Rmin.

300 m

m

max.

4m

min.

300 m

m

min. 20 %

min.

300 m

m

min. 20 %min. 5 %

Rmin. 300 m

m

min. 20%

min.

300 m

m

min. 20 %

Ømin. 20

0 mm

min.

300 m

m

min. 20 %

Ømin. 20

0 mm

30

Usethefollowingchecklisttoascertainthatthesteaminstallationwasperformedcorrectly:

– Steam distribution pipe

Steamdistributionpipecorrectlypositionedandsecured(screwstightened)?

Aretheoutletorificesatrightanglestotheairflowdirection?

– Steam hose

Maximumlengthof4m?

Minimumbendradiusof300mm(100mmwithfixedpiping)?

Havetheinstructionsforhosepositioningbeenfollowed?

Isthesteampipeopenovertheentirelengthandthroughthewholecrosssection?

Steamhose:nosagging(condensatepocket)?

Rigidsteamlines:properlyinsulated?Correctinstallationmaterialused?Minimalinternaldiametermaintained?

Steamhosesecurelyattachedwithclamps?

Heatexpansionduringoperationandshorteningofthehosewithageingtakenintoconsidera-tion?

Hastheprotectiveplastictubearoundthesteamhosebeenremoved?

– Condensate hose

Downslopeofatleast20%?

Siphonexistingandfilledwithwater?

Condensatehosecorrectlyfixed?

Forsteamlineswithrigidpiping, thesameinstructionsapply to the layingof thepipingasalreadydescribed.Thefollowingadditionalnotesshouldbeobserved:

– The minimum internal diameter of 42 mm mustbeappliedoverthewholelengthofthepiping.

– Useexclusivelycopperpipe(operationwithuntreateddrinkingwater)orstainlesssteel(min.DIN1.4301,operationwithfullydemineralisedwater.

– Tominimizethecondensateformation(=loss),thesteampipesmustbeinsulated.

– The minimum bend radiusforsolidpipesis100 mm.

– Connectionofthesteampipestothesteamdistributionpipeandsteamhumidifieriseffectedbymeansofshortlengthsofsteamhosesecuredwithhoseclamps.Connectiontothesteamhumidi-fierissecuredviaaG11/4”coupling..

– Important! Allowancemustbemadeforapressure loss of approx. 100 Pa per meter length or per90°bend.

5.3.4 Inspecting the steam installation

5.3.3.2 Steam line with rigid piping

31

5.4 Water installation

Allworkconcerningthewaterinstallationmustbeperformedonly by adequately qualified personnel(e.g.plumbers).Ascertainingthequalificationsisthecustomer’sresponsibility.

Please observe all local regulationsconcerningtheinstallationofappliancestothemainsandwastewatersystems.

Warning - danger of electric shock!Forallinstallationwork,thesteamhumidifiermust be disconnected from the mains supply and secured against unintentional re-connection.

5.4.1 Performing the water installation

Overview water installation

1 Waterconnection,unionnutG1/2" 2 Watersupplypipe(min.innerØ:8mm) 3 WaterdrainØ40mm 4 Drainpipe(min.innerØ:40mm,min.30cmdirectedverticallydownwards) 5 Pressurereducingvalve(compulsoryforwaterpressures>10bar,buildingside) 6 Manometer(installationrecommended,buildingside) 7 Filtervalve(accessory“Z261”) 8 Funnel(buildingside) 9 Siphon(min.innerØ:40mm,buildingside)10 Drainline,buildingside(min.innerØ:40mm)

H2O (1...10 bar)

1

3

2

4

5 6 7

8 9 108 9

min

. 30 c

m

32

Water supply

Thewaterfeedpipe(min.internalØ:8mm)istobeconnectedviathefilter valve that is available as anaccessory,totheconnectionontheunit(seedetailedillustration).Alternatively,ashut-off valve and a water filter maybeinstalled.Theinstallationofthefiltervalveshouldbemadeascloseaspossibletothesteamhumidifier.

Warning - danger of damage! Union nutatthehumidifierconnectionmustbehand-tightened only.

Thefollowingconnectionspecificationsmustbeobserved:

– Connection on unit: G 1/2" (Union nut)

– Min.innerØofsupplyline:8 mm

– Admissible mains pressure 1.0 to 10.0 bar(hammer-freesystem)Formainspressures>10bar,connectionmustbemadeviapressurereducingvalve(adjustedto2.0bar).Formainspressures<1.0barpleasecontactyoursupplier.

– Supply rate: 1 l/min per 15 kg/h steam capacity

– Admissible supply temperature: 1…40 °C

– Notes on water quality:

– ForthewatersupplyoftheDefensorMk5,useexclusivelyuntreated drinking waterorfully demineralized water.Note:Theuseoffullydemineralizedwaterreducesthetimeformaintenanceandcleaningtoaminimum.

– The use of additivessuchascorrosioninhibitors,disinfectants,etc.isnot allowed, since these additivesmayendangerhealthandaffectproperoperation.

– IftheDefensorMk5shallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyoursupplier.

– The connection material must be pressure-proof andcertifiedforuseindrinking water supply systems.

Caution! Fullydemineralizedwaterisaggressive.Whenmakingconnectionstoafullydem-ineralizedwatersystem,useexclusivelyplasticorstainlesssteelinstallationmaterials(min.DIN1.4301).

– Important! Beforeconnectingthewaterlinetotheunit,thelinemustbeflushedthoroughly.

Water drain

Thewaterdrainageiseffectedwithoutpressure.Thus,inordertoavoidanydammingofthewater,thedrain pipe must be led straight down into a drainage funnel, through a piece of hose with a min. length of 30 cm.Subsequently,thedrainpipeisconnectedviasiphontothewastewatersystemofthebuilding.Theminimuminsidediameterof40mmmustbeobservedoverthewholelengthofthedrainpipe.Makecertainthatthedrainpipeiscorrectlyfixedandeasilyaccessibleforinspectionsandcleaning purposes.

Thefollowingconnectionspecificationsmustbeobserved:

– Drainage capacity: approx. 2,5l/min per 15 kg/h steam capacity

– Drainage temperature: 60…90 °C Warning! Use only temperature-resistant installation materials!Warning! Fully demineralized water is aggressive. Theconnectionsforademineralizedwatersystemshouldbemadeexclusivelyfrom stainless steel (min. DIN 1.4301) or chemi-cally resistant plastics (e.g. polypropylene).

– Connection on unit: hose connection Ø40 mm

Warning!Hosemustbesecuredtotheunitconnectionwithahoseclamp.

– Min.innerØofdrainline:40 mm

– Min.downslopeaftersiphon:10 %

33

5.4.2 Inspecting the water installation

Usethefollowingchecklisttoascertainthattheinstallationhasbeenperformedcorrectly:

– Water supply

Hasfiltervalveorshut-offvalveandfilter125µmrespectivelybeeninstalledinsupplyline?

Haveadmissiblewaterpressure(1.0–10bar)andtemperature(1–40°C)beenobserved?

Doessupplycapacitymatchthehumidifier(s)?

Areallpipesproperlysecured(threadedconnectionstightened)?

Isthefeedpipeproperlysealed?

– Water drain

Hasminimuminsidediameterofdrainpipesbeenmaintainedatleast40mmthroughouttheentirelength?

Hasdrainpipebeeninstalledwithadownslopeofatleast10%?

Hastheheatresistanceofthematerialusedbeenverifiedtobeatleast100°C?

Arehosesandlinesproperlysecured(hoseclampsandthreadedconnectionstightened)?

34

5.5 Electric installation

– Allworkconcerning theelectric installationmustbeperformedonlybyadequately qualified personnel (electrician or workman with equivalent training). Ascertaining thequalificationsisthecustomer‘sresponsibility.

– Warning - danger of electric shock!The steamhumidifiermaybe connected toelectricmainsonlyafterallinstallationworkhasbeencompleted.

– Please observe all local regulations concerning the electric installation.

– Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protec-tion)

5.5.1 Electric installation overview

1 Supply heating voltage Up 2 Supply control voltage Uc 3 InterfaceRS232/RS485 4 Remoteoperatingandfaultindications(option“RFS”) 5 Externalcontinuouscontroller 6 Humiditysensor(supplyair/room/exhaust) 7 Safetyhumidistat 8 Airflowmonitor

9 Ventilationinterlock10 Externalsafetycircuit11 Steamhumidifier 12 Internal continuous controller 13 Control voltage supply to second unit 14 Control line to second unit15 Secondunit(from50kg/h)

DefensorMk5(A)

DefensorMk5(B)

35

Theelectricalinstallationistobecarriedoutinaccordancewiththefollowingwiringdiagram.

Caution! Observetheinstallationnotesinthefollowingsection.

5.5.2 Wiring diagram

1 2

3 4

5 6

7 8

9 10

F2 (1

AF)

F1 (6

.3 AT

)

JP1

JP2

JP1

JP2

J7

X1

K1 Q3

A1

M

K3 B3 B2 B1

A2 A3

F3

X6

L1

N SK

1 P

N P1

SK

2

L1

L2

L3

L1L2

L3PE

Q4

F4

L1N

Q4T1

F4

L1N

PE

F2 (1

AF)

F1 (6

.3 AT

)

X1

K1

Q3

F3

X6

L1

N SK

1P

N P1

SK

2

L1

L2

L3

L1L2

L3PE

+–

P / P

I

V+IN

GND

V+

IN G

ND

V+IN

GND

ON-O

FF

140..

.10kΩ

S1

S2

S3

S4

J3

J6

JP2 F5

(2

00 m

AF)

ON 1

2 3

4

Com

-Por

t

200-240V / 50...60Hz

200-

240V

/ 50..

.60Hz

J K1

St

eam

K2

Erro

r K3

Se

rvice

K4

Un

it On

H1

INPU

T 44

0-50

0VΔ

p

max.ϕ

Q3

F3

L1N

PE

Q3

F3

L1N

PE

Unit

BUn

it ASu

pplymo

dule

Supplymo

dule

Contr

ol bo

ard

(Opti

on)

Switches (

K1...K

4) sh

own i

n idle

posit

ion

SetJP2

to

5V

SetJP2

to

24V

(Opti

on)

Unit B

Unit A

LC di

splay

36

Legend to wiring diagram

A1 Controller(active)orhumiditysensorA2 Controller(passive),setjumperJP2to5VA3 On/Offcontrol,setjumperJP2to24VB1 VentilationinterlockB2 AirflowmonitorB3 SafetyhumidistatF1 Internalfusesupplymodule(6.3A,slowacting)F2 Internalfusesupplymodule(1A,quickacting)F3 Externalfuseheatingvoltagesupply(seetableinthefollowingchapter)F4 Externalfusecontrolvoltage(max.10A,slowacting)F5 Internalfusecontrolmodule(200mA,quickacting)H1 Remoteoperatingandfaultindication(option“RFS”)J Shortcircuited,ifnoexternalmonitoringdevicesareconnectedJ3 ConnectionterminalforremoteoperatingandfaultindicationJ6 ConnectionterminalforcontrollinetounitB(forunitswith50...80kg/hsteamcapacityonly)J7 ConnectionterminalforcontrollinefromunitAJP2 Jumper(controlsignal)oncontrolboardunitAK1 Mainscontactor(heatingvoltage)unitA/unitBK3 Externalsafetycircuit(safetyhumidistat,airflowmonitor,etc.)M Fanunit(accessory“FAN3S..”)Q3 ExternalmainswitchheatingvoltagesupplyQ4 ExternalmainswitchcontrolvoltagesupplyT1 Auto-transformercontrolvoltagesupply(option“TRAF”)S1 Rotaryswitch"draininterval”S2 Rotaryswitch“maintenanceinterval”S3 Rotaryswitch“controlsignal”S4 DIP-switch“unitsettings”X1 ConnectionterminalforcontrolvoltagetosupplymoduleX6 ConnectionterminalforvoltagesupplyfromunitAtounitB

37

5.5.3 Notes on component installation

Important note:

– Allconnectingcablesintheelectricalinstallationaretobefedinviathecableglandsonthebaseoftheunit(theexceptiontothisistheheatingvoltageconnectioncable,forwhichthespecialclampisprovided).

– Thedetailsrelatingtoindividualcomponentsaretobenotedandfollowed.

Heating voltage supply Up

Caution!Beforeconnecting,ensurethatthemainsvoltagecorrespondswiththeheating volt-age for the unit (see mains code on the type label).Note:Onequipmentversionscombiningtwobasicunits,eachunithasatypelabel

Thehumidifier(inthecaseoftwinnedunits,eachseparateunit)istobeconnectedtothemainssupplyinaccordancewiththeconnectionschematic,viaaservice switch “Q3”(anallpoledisconnectingdevicewithaminimumcontactopeningof3mmisanessentialrequirement)andan“F3” fuse group (essentialrequirement:fusesaretobeasdetailedinthefollowingtable).Thesupplywiringistobefedintotheunitviathetension-relievingdevice(cableclamp)andconnectedtotheterminalsofthe“K1” mains contactor.

LC display

400 V/3~50…60 Hz

220 V/3~50…60 Hz

415 V/3P~50…60 Hz

240 V/1N~50…60 Hz

230 V/1N~50…60 Hz

200 V/3~50…60 Hz

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

P N max

. in kW

I N max

. in A

A L min.

in m

m2

F3 in

A, q

uick a

cting

Mk5 Visual 5-..Mk5 Process 5-..

3,8 5,5 1,5 10 3,4 9,0 2,5 16 4,0 6,0 1,5 10 4,0 17,0 2,5 20 4,0 16,5 4,0 20 3,0 8,2 1,5 10

Mk5 Visual 8-..Mk5 Process 8-..

6,0 8,7 1,5 10 5,5 14,4 2,5 16 6,5 9,0 1,5 10 6,5 27,2 6,0 32 6,0 26,0 6,0 32 4,5 13,1 1,5 16

Mk5 Visual 10-..Mk5 Process 10-..

7,5 11,0 1,5 16 6,7 17,7 2,5 20 8,0 11,5 1,5 16 8,0 33,0 10,0 40 7,4 32,0 10,0 40 5,5 16,1 2,5 20

Mk5 Visual 16-..Mk5 Process 16-..

12,0 17,4 2,5 20 10,9 28,7 6,0 32 13,0 18,1 2,5 20 ––– ––– ––– ––– ––– ––– ––– ––– 9,0 26,1 6,0 32

Mk5 Visual 20-..Mk5 Process 20-..

14,9 21,5 6,0 25 13,5 35,4 10,0 40 16,0 22,3 4,0 25 ––– ––– ––– ––– ––– ––– ––– ––– 11,1 32,2 10,0 40

Mk5 Visual 24-..Mk5 Process 24-.. 18,1 26,2 6,0 32 16,4 43,1 16,0 63 19,5 27,2 6,0 32 ––– ––– ––– ––– ––– ––– ––– ––– 13,5 39,2 16,0 63

Mk5 Visual 30-..Mk5 Process 30-..

22,3 32,3 10,0 40 20,2 53,1 16,0 63 24,0 33,5 10,0 40 ––– ––– ––– ––– ––– ––– ––– ––– 16,7 48,3 16,0 63

Mk5 Visual 40-..Mk5 Process 40-..

30,0 43,3 16,0 63 27,2 71,4 25,0 80 32,3 45,0 16,0 63 ––– ––– ––– ––– ––– ––– ––– ––– 22,4 64,9 25,0 80

Mk5 Visual 50-..Mk5 Process 50-..

A 14,9+

22,3

21,5+

32,3

6,0+

10,0

25,0+

40,0

13,5+

20,2

35,4+

53,1

10,0+

16,0

40+63

16,0+

24,0

22,3+

33,5

4,0+

10,0

25+40

––– ––– ––– ––– ––– ––– ––– –––11,1

+16,7

32,2+

48,3

10,0+

16,0

40+63B

Mk5 Visual 60-..Mk5 Process 60-..

A 22,3+

22,3

32,3+

32,3

10,0+

10,0

40,0+

40,0

20,2+

20,2

53,1+

53,1

16,0+

16,0

63+63

24,0+

24,0

33,5+

33,5

10,0+

10,0

40+40

––– ––– ––– ––– ––– ––– ––– –––16,7

+16,7

48,3+

48,3

16,0+

16,0

63+63B

Mk5 Visual 80-..Mk5 Process 80-..

A 30,0+

30,0

43,3+

43,3

16,0+

16,0

63,0+

63,0

27,2+

27,2

71,4+

71,4

25,0+

25,0

80+80

32,3+

32,3

45,0+

45,0

16,0+

16,0

63+63

––– ––– ––– ––– ––– ––– ––– –––22,4

+22,4

64,9+

64,9

25,0+

25,0

80+80B

AB

Note:Dependingonthesteamcapacitytheloadofthephasesmaybeasymmetric.

38

Control voltage supply Uc

Caution!Beforeconnecting,makesurethatthemainsvoltagecorrespondswiththecontrol voltage of the unit (200…240 V, 50…60 Hz).

Caution!Thehumidifiermustonlybeconnectedtoamains supply with a protective conductor.

TheconnectiontothecontrolvoltageUcismadeinaccordancewiththeconnectionschematic,totheterminal “X1” on the supply module. The customer is to install a service switch Q4 in the supply line (allpoledisconnectingdevicewithaminimumcontactopeningof3mm)andanF4 fuse (max. 10 A slow acting) (thesearebothessentialrequirements).Note:Onversionsinwhichtwounitsareincorporated,thecontrolvoltageconnectionismadetotheunitfittedwiththedisplayandoperatingfacility(unitA).Theterminal“X1”ofthesecondunit(unitB)remainsunused.TosupplythecontrolvoltagetounitB,theterminals“X6”onthesupplymodulesofboth units must be connected using the supplied cable.

Thecross-sectionofthemainscablemustcomplywiththeapplicablelocalregulations(minimumof1.5 mm2).

External safety circuit

Toensurethesafetyofthehumidifiersystem,itisessentialthataso-calledexternalsafetycircuitbeprovided to monitor the operation.

To this end, the potential-free contacts (max. contact loading 250V/5A) oftheexternalmonitoringdevices(e.g.maximumhumidistat,flowmonitor,ventilationinterlock,etc.)areconnectedin series with the corresponding contacts on the terminal “X1”,inaccordancewiththeconnectionschematic.

Caution, danger of electric shock!Themainsvoltage isconnected to terminal “X1”(up to240V).Thesteamhumidifiermustthereforebeisolatedfromthemainssupply(powerandcontrolcomponents),beforestartingtheconnectionwork.

If,forwhateverreason,noexternalmonitoringdevicesareconnected,aconnectingbridge“J”mustbeinstalledontheappropriatecontactsontheterminalstrip“X1”.

Do not apply any extraneous voltage to the terminals.

Thecross-sectionofthecablemustcomplywiththeapplicablelocalregulations(minimumof1mm2).

Remote operating and fault indication H1 (Option “RFS”)

TheoptionalremoteoperatingandfaultindicationPCBistobeconnectedviatheconnectionsocket“J3”onthecontrolboard.TheremoteoperatingandfaultindicationPCBcontainsthepotential-freerelaycontactsK1…K4fortheconnectionofthefollowingoperatingandfaultindications:

– K1“Steamproduction”: Thisrelayclosesassoonastheunitproducessteam.

– K2“Fault”: Thisrelayisactivatedifthereisafault.

– K3“Maintenance”: Thisrelayisactivatedwhenthesetserviceintervalhasexpired.

– K4“UnitOn”: Thisrelayclosesassoonastheunitisswitchedonviathemainswitch.

The maximum contact loading is 250V/5A.

Appropriatesuppressormodulesaretobeusedfortheswitchingofrelaysandminiaturecontactors.

39

Control signal / Humidity sensor signal

Theconnectionofanexternalactivecontroller“A1”,apassivecontroller“A2”,anOn/OffHumidistat“A3”orahumiditysensor(forcontrolviatheinternalcontroller),isaccomplishedontheappropriatecontactsontheterminalstripinaccordancewiththeconnectionschematic.Notethefollowingcon-nectioninformation:

External controller

Internal controller

Connection active controller “A1”

passive controller “A2”

On/Off controller “A3”

Humidity sensor

Pos. Jumper JP2

– neutral X X

– 5 V 140Ω...10kΩ

– 24 V X

Rotary switch S3

Pos. Signal0 No signal selected1 On/Off24V X2 0...5 V DC (Potentiometer) X3 0...10 V DC X X4 0...1 V DC X X5 1...5 V DC X X6 2...10 V DC X X7 0...20 V Phase intersect X X8 4...20 mA X X9 0...20 mA X X

Note:Thecontrollerhumiditysensoristobemountedatasuitablepositionintheductafterthesteamdistributionpipe,withaminimumseparationof5timesthehumidificationdistanceBN(butnotclosetotheheatingorcoolingunitsoftheventilationsystem).Please refer to theseparate installation instructions for thecontroller/sensorwhenpositioningandconnecting these components.

Control cable for versions with two units

Thesuppliedcontrolcable(flatribboncable)isconnectedtoterminal“J6”onthecontrolboardofunitAandtoterminal“J7”onthesupplymoduleofunitB.

Connecting the fan unit

Seeseparatedocumentation“Fanunit”.

RS232/RS485 connection

Seeseparatedocumentation“InterfaceRS232/485”

5V24VJP2

5V24VJP2

5V24VJP2

40

5.5.4 Inspecting the electrical installation

Inspectforcorrectinstallationinaccordancewiththefollowingchecklist:

Dothemainsvoltagesappliedcorrespondtotherespectivedetailsstatedontheratingplate/sforthepowerandcontrolcomponents?

Arethevoltagesupplies(Powerandcontrolcomponents)correctlyfused?

Istheserviceswitch“Q”installedinthesupplycabletothepowerandcontrolcomponents?

Areallcomponentscorrectlyconnectedinaccordancewiththeconnectionschematic?

Areallconnectioncablesfixed?

Aretheconnectingcablesfreeoftension(fittedthroughcableglands/securedwithcableclamps?)

Istherotaryswitch“S3”settocorrespondwiththecontroller(active,passive,On/Off)orhumiditysensor?

Isjumper“JP2”onthecontrolboardcorrectlysetforthecontrollerused?

41

6 Operation

6.1 Unit configuration

Warning - danger of electric shock! Disconnect the steam humidifier from the mains supply(heatingandcontrolvoltage)beforeopeningtheunit.

Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protection).

All adjusting elements are situated on the control board:– Rotaryswitch“S1”: draininterval– Rotaryswitch“S2”: maintenanceinterval– Rotaryswitch“S3”: controlsignal(seechapter5.5.3)– Rotaryswitch“S4”: unitsettings

Setting the drain interval (“S1”)

Theevaporationprocessincreasestheconcentrationofmineralsaltsinthesteamcylinder.Periodicflushingfollowedbyrefillingoffreshwatercankeeptheconcentrationofmineralsaltsatalowlevel.

Theintervaltimetobeselecteddependsonthequalityofthewaterandthetypeofunit.Itmayhavetobeadaptedtotheactualcircumstancesduringoperation.Thefollowingmaintenanceintervalscanbe selected.

Position “S1” drain interval at 100% steam capacity

Unit type Defensor Mk5 Visual/Process

5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 ∞

1 720 min.2 360 min. VE VE VE VE VE VE VE VE VE VE VE3 180 min.4 120 min. X5 60 min. X X6 30 min. X7 20 min. X X8 10 min. X X X X X9 5 min.

VE= SettingforfullydemineralizedwaterX= Standardsetting

Notes:

– Thestandardsettings(seeprecedingtable)refertoawaterhardnessof210ppm(12°dHor21°fH,respectively).

– IftheDefensorMk5isoperatedwithfullydemineralizedwater,theswitchcanbesetto“2”.

– IftheDefensorMk5shallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyoursupplier.

– Ifnohumidificationtakesplaceformorethan4hours,theunitwillproceedtoaflushingcycleandafloattestuponthenexthumidificationrequest.

42

Setting the maintenance interval (“S2”)

The maintenance interval for the small and the extended maintenance is set with switch “S2”. When the set time has expired, a maintenance message indicates that the unit should be serviced.

The intervals to be selected depend on the quality of the water and the type of unit. It may have to be adapted to the actual circumstances during operation. The following maintenance intervals can be selected:

Position “S2”

Interval for Unit type Defensor Mk5 Visual/Process

small maintenance extend. maintenance 5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 200 h 600 h1 300 h 600 h2 300 h 900 h3 450 h 900 h4 400 h 1200 h X X5 600 h 1200 h X X X X X6 500 h 1500 h X X X7 750 h 1500 h X8 3000 h 3000 h VE VE VE VE VE VE VE VE VE VE VE9 6000 h 6000 h

VE= Setting for fully demineralized waterX= Standard setting for water with medium hardness (12°dH, 21°fH, 210 ppm)

Note: The maintenance interval times refer to a steam output of 100 %. If less output is required in operation, the maintenance intervals are correspondingly increased. However, we recommend to carry out an extended maintenance at least once a year.

Setting the control signal (“S3”)

See informations in chapter 5.5.3

Unit settings (“S4”)

Various unit parameters can be set at the DIP switch “S4”. The unit parameters are preset at the factory and must only be changed by the customer in consultation with the supplier.

Switch Standard setting Description1 OFF Automatic temperature stabilization ON/OFF

When the automatic temperature stabilization is switched on, the water in the steam cylinder is maintained at a specific temperature when there is a break in steam produc-tion, so that steam can be immediately generated again on renewed demand.

2 OFF Switch pause control ON/OFFIn the “OFF” position the switching element’s pause (Triac and Contactors) is controlled normally (maintaining “Flicker”-regulations). In the “ON” position the pause is reduced to optimize the precision of control.

3 OFF On/off switch delay heating contactor ON/OFFIn the “OFF” position the on/off switch delay is set for optimal life of the contactors. In the “ON” position the on/off switch delay is reduced to optimize the precision of control (reduced life of heating contactors).

4 OFF Output Alarm 3 “Water Supply” as error via optional remote operating and fault indica-tion ON/OFF.When set to the “OFF” position, Alarm 3 is not output as Error. When set to the “ON” position, Alarm 3 is output as Error via the optional remote operating and fault indication.

43

6.2 Putting into operation

Thefollowingprocedureiscarriedoutinordertooperatethesteamhumidifier:

• Whenputtingthesteamhumidifierintooperationthefirsttimeorwhenput-tingthesteamhumidifierintooperationafterworkhasbeencarriedoutonthesteamsystem,thecommissioningpersonnelmustmandatorycheckwhetherthesteampipeisopenovertheentirelength.Todothisproceedasfollows:• Removethefrontdoor(s)oftheDefensorMk5.• Undotheupperhoseclampofthesteamhoseintheunitwithascrewdriver

andpullthehosedowntoremoveitfromthesteamconnection.• Startuptheventilationsystemandcheckwhetheracleardraughtthatcor-

respondsapproximatelytothepressureintheventilationsystem(positiveornegativepressure)canbedetectedattheopensteamoutletinsidetheunit.

Caution! A steam pipe that is reduced in cross section or com-pletely closed will cause an excessive increase in pressure in the steam cylinder when the unit is operating and could lead to the risk of scalding accidents. Therefore: Ifnodraughtoronlyaslightonecanbedetectedthesteampipemustbecheckedforblockagesandreductionsincrosssectionbeforecontinuingwithcommissioningandyoumustensurethat the steam pipe is open across the entire length and through the wholecrosssection.

• Examine the steam humidifier and installation for possible damage.Caution! Damaged unitsandunitswithdamagedordefectiveinstalla-tionfeaturesmust not be operated.

• Mountfrontdooroftheunitandlockit.

• Openthefilter valve/shut-off valveinthewaterfeedline.

• Switchontheserviceswitchforthemainssupply(Heatingandcontrolvoltage).

• Switchonthesteamhumidifiermainswitch.

Thesteamhumidifiercarriesoutasystem test. The adjacent display appears andthethreeLEDslightforapprox.3seconds.Ifafaultisdetectedduringthesystemtest,acorrespondingfaultmessageistriggered(seechapter6.7).

If the system test is successful,thesteamcylinderfillsupandafloattestiscarriedout(functioncheckonthelevelunit).Theadjacentdisplayappears.Note:Ifafaultisdetectedduringthefloattest,anappropriatefaultmessageistriggered(seechapter6.7).

Ifthefloattestissuccessful,theDefensorMk5willbeinnormal operating mode. The adjacent display appears and the green LED lights.

filling

Mk5 Visual

ready

test

44

• The following procedure should be carried out only on the first occasion that the unit is operated:

• Carryoutthesoftware-dependentequipmentsettings(bytheservicetechnicianofthesupplier).Note:Informationonthesettingsthatcanbemadebythecustomerisprovidedinchapter6.5).

• Checkforcorrectfunctioningofthemonitoringequipment(externalsafetycircuit).

• Checkthefunctionofthesteamhumidifier:Switch on the humidification by raising the set humidity value on the humidity controller/humidistat.Switch off the humidification byloweringthesethumidityvalueonthehumiditycontroller/humidistat.

• Setthedesiredhumidityvalueonthehumiditycontroller/humidistat.

Theheatingcurrentswitchesonassoonasthehumiditycontroller/humidistatdemands humidity. The greenLEDlightsandsteamisproducedafterashortdelay(approx.5minutes).

Operating status display on the unit

TheoperatingstatusisdisplayedintheLEDontheunitasfollows:

– Green LED lit: Unit producing steam

– Yellow LED flashing:Majororminorservicingdue.Therelevantnoticeisshowninthedisplay(seechapter6.6).

– Red LED flashing: There is a problem. The unit is trying to solve the problem. The relevant warn-ing message appearsinthedisplay(seechapter6.7).

– Red LED lit: Insoluble problem. The relevant error message appearsinthedisplay(seechapter6.7).

Remote operating and fault indication

Ifyoursteamhumidifierisequippedwiththeoptionalremoteoperatingandfaultindication(option“RFS”),theoperatingstatuswillbeshownasfollows:

Display on unit Meaning Activated remote display relay

Green LED lit Steamproduction K1 “Steam production”

Red LED lit Insoluble problem K2 “Error”

RedLEDflashing Fault elimination No message

Yellow LED flashing Steamcylinderservicedue K3 “Maintenance”

Unit switched on Unitreadyforoperation K4 “Unit on”

45

6.3 Taking out of operation

The followingprocedure is followedwhen it is required toshutdown thesteamhumidifier,e.g. formaintenancework:

• Closethefiltervalve/shut-offvalveinthewaterfeedline.

• Brieflydepressthedrainswitchformorethan7seconds.Theheatingvoltageisisolatedandthesteam cylinder empties.

• Waituntilthesteamcylinderisempty(approx.5-10minutes),thenoperatetheoff-switchonthesteamhumidifier.

• Emptythelimecollectortankviathedrainvalve.

Caution: Danger of scalding!Thewaterinthelimecollectortankmaybehot.

• Isolatethesteamhumidifierfromthemainssupply:Switchoffallserviceswitchesinthemainssup-plylines(heatingandcontrolvoltage)andsecurethemintheoffposition.

Caution: Danger of burning! Ifsteamwasproducedjustbeforetheunitistakenoutofoperation,waitbeforeopeningtheunitandletthesteamcylindercooldowntopreventdangerofburning.

46

6.4 Interrogation of the operating status

TheDefensorMk5operatinganddisplayunithasaso-called“displaylevel”fromwhichvariousoperat-ing parameters can be interrogated. Note: It is not possible to change the values on the display level.

Overview of the display level and operation

Operation: Call up the display level with <B> or <A> <B> next operating parameter <A> previous operating parameter Exit the display level with <Menu>Note: 1)appearsonlyif“controllerfunct”isactive(“on”) 2)appearsonlyif“softstart”isactive(“on”) 3)appearsonlyif“demineral.mode”isactive(“on”) 4) appears only on Mk5 Process units

Menu

Mk5 Visual

ready

steam-prod[kg/h]

ref.=50/act=25

analog input [%]

25

controller funct

on

ref.value rh[%]

45

P-band [%]

30

integr.time[min]

10

elapsed time

623

time to mainten.

600/1200

drain cycle

4: 120

stand-by heating

on

power limit [%]

100

softstart

on

softstart time

30 Min

softst. power

50 %

demineral. mode

on

demineral. delay

3

inlet valve cor.

100

Modbus address

01

analog signal

0 - 5V (poti)

software version

V 01.20

machine type

20kg/400V

1)

2)

4)

2)

1)

1)

3)

Normal service mode

Display levelor

47

steam-prod[kg/h]

ref.=50/act=25

– Steam production

Currentactualandnominalvalueofsteamproductioninkg/h.– Nominalvalue:max.unitcapacityxinputsignalvalue

Note:ifacapacitylimitationissetthenominalvalueisgiveninbrackets– Actualvalue:max.unitcapacityxinputsignalvaluexcapacitylimitation

Note:iftheinternalcontrollerisactivatedonlytheactualvalueisshown.

Underthefollowingconditionstheactualvaluemaydiffer fromthenominalvalue:uponactivationoftheheatingpower,ifcapacitylimitationisactive,dur-ingthefillingcycleofthesteamcylinder.

– Analog input (humidity demand)

Currentvalueofthesignalappliedtotheanaloginputin%ofitsmax.value.Note:Iftheinternalcontrollerisactivethedisplayedvaluecorrespondstothecurrentairhumidity(%rh).

– Internal controller

Internalcontrolleractivated(“on”)/deactivated(“off”).Note:Theinternalcontrollercanbeactivatedonthesettinglevel(seechapter6.5).

– Nominal value of relative humidity

Selectedvalueofrelativehumidityin%rh.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.

– Proportional range of the internal controller

Selectedproportionalrange(P-Range)oftheinternalcontrollerin%.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.

– Integral time of the internal controller

Selectedintegraltimeoftheinternalcontrollerinminutes.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.

– Working hours

Totalofworkinghourselapsedsinceinitialcommissioningofthesteamhumidifier.

– Time remaining to small/extended maintenance

Thetimeremaining(inhours)beforethenextsmall/extendedmaintenance.Note:Thestatedtimesarebasedon100%steamcapacity.Iftheoperationisatalessercapacity,thetimeshouldbeextendedaccordingly.Themaintenanceintervalsaresetusingtherotaryswitch“S2”onthecontrolboard.Pleasepayattention to the notes in chapter 6.1.

Description of the operating parameters on the display level

Thefollowingdescribestheindividualoperatingparametersthatcanbeselectedusingthekeys<B> and <A>,afterthedisplaylevelhasbeencalled-up.

analog input [%]

25

controller funct

on

ref.value rh [%]

45

P-band [%]

30

Integr.time[min]

10

elapsed time

623

time to mainten.

600/1200

48

power limit [%]

100

– Flushing cycle

Thefollowingindicationsareprovidedforthesetflushinginterval:Left: Switchsettingonrotaryswitch“S1”Right: Setflushinginterval

Note:Theflushingintervalissetonswitch“S1”onthecontrolboard.Pleaseobserve the notes in chapter 6.1.

– Stand-by heating

Stand-byheatingactivated(“on”)/deactivated(“off”).Note:Ifstand-byheatingisactivethewatertemperatureinthesteamcylinderisconstantlykeptatapprox.70°C.Stand-byheatingmaybeactivated/deac-tivatedwiththeDIPswitch“S4-1”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.

– Capacity limitation

Thesetcapacitylimitationasapercentageofthemaximumcapacity.

– Soft start

Softstartenabled(“on”)/disabled(“off”).Note:Afterrestartoraftertheunithasbeenidlefor4hours(stand-by)theSoftstartfunctionreducesthehumidificationcapacitytoapresetvalueforaselect-ableperiod(valuesettingsseeparametersbelow).

– Time limit for Soft start

SelectedtimelimitforSoftstartfunctioninminutes.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.

– Capacity limit for Soft start

SelectedcapacitylimitforSoftstartfunctionin%ofmaximumcapacity.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.

– Demineralization mode

Demineralizationmodeenabled(“on”)/disabled(“off”).Note:TheDemineralizationmodeflushesthesteamcylinderwithinanhourafterapresetnumberofscumdetectionshastakenplace(seeDemineraliza-tiondelay).Thispreventstheformationofscum.

– Demineralization delay

Selectedthedelayfordemineralization.Note:ThismenuitemisavailableonlyiftheDemineralizationmodeisenabled.

Note:Thisvaluedeterminesthenumberofscumdetectionsallowed(maxi-mumlevelinsteamcylinderisreached)beforethesteamcylinderisflushedforapresettime.

stand-by heating

on

drain cycle

4: 120

softstart

on

softstart time

30 Min

softst. power

50 %

demineral. mode

on

demineral. delay

3

49

– Inlet valve correction

Setinletvalvecorrection(cycleratio)in%ofstandardsettingvaluetobalanceoutwaterpressurevariations.Note:ThismenupointisavailableonlywithMk5Processunits.

– Modbus address

Actualmodbusaddressoftheunit.Note:Themodbusaddressisneededonlyforunitswithbuilt-intelemonitoringinterfaceorbuilt-inRS232/RS485serialinterface.Detailedinformationaboutthetelemonitoringinterfaceandtheserialinterfacecanbefoundintheseparatemanualsthataresuppliedwiththeseoptions.

– Analog signal

RangeoftheactiveanalogsignalinVormA,respectively.Note:Therangeoftheanalogsignalmaybeadjustedusingtherotaryswitch“S3”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.

– Software version

Currentsoftwareversionforthesteamhumidifier.

– Unit type

valueleft: Max.steamcapacityinkg/hvalue right: Heating voltage in VAC

Modbus address

01

analog signal

0 - 5V (poti)

software version

V 1.00

inlet valve cor.

100

machine type

20kg/400V

50

6.5 Setting the operating parameters

YoucanadaptvariousDefensorMk5steam-airhumidifieroperatingparameterstotheoperatingrequire-mentsonthesettinglevelofthecontrolanddisplayunit.Thesettinglevelisprotectedbyanaccesscodetoguardagainstunauthorizedaccess.

Caution!Thesettingsonthesettinglevelhaveadirectinfluenceontheoperatingbehaviorofthesteam-airhumidifier.ThesettingsmustthereforeonlybemadebypersonnelwhoarefamiliarwiththetechniquesofhumidificationandclimaticcontrolandwiththeDefensorMk5system.

Overview of the setting level and operation

Operation: – Forcall-upofthesettinglevelseethefollowing“Call-upofthesettinglevel” – <B> Next menu item – <A> Previous menu item – For change to set values see the section “Changing the set values” – Exit the setting level with <Menu>Note: 1) appears only on Mk5 Process units 2) appearsonlyif“controllerfunct”isactivate(“on”) 3) appearsonlyif“softstart”isactivate(“on”) 4) appearsonlyif“demineral.mode”isactivate(“on”)

Menu

Modbus address

(Enter=Entry)

diagnose pgm

(Enter=Entry)

faulthistory

. /. /6.B/6.A

erase history

(Enter=Entry)

integr.time[min]

(Enter=Entry)

softstart

(Enter=Entry)

softstart time

(Enter=Entry)

softst. power

(Enter=Entry)

demineral. mode

(Enter=Entry)

demineral. delay

(Enter=Entry)

language

(Enter=Entry)

power limit [%]

(Enter=Entry)

inlet valve cor.

(Enter=Entry)

controller funct

(Enter=Entry)

ref.value rh[%]

(Enter=Entry)

P-band [%]

(Enter=Entry)

adjust level

entry code

8808

Mk5 Visual

ready

1)

2)

3)

3)

2)

4)

2)

Normal service mode

and

Settinglevel

51

Mk5 Visual

ready

entry code

9999

entry code

8999

adjust level

language

English

Sprache

Deutsch

new data

entered

unchanged

ref.value rh [%]

045

ref.value rh [%]

045

XXXXXXXX

(Enter=Entry)

new data

not valid

Call-up of the setting level

WiththeDefensorMk5innormaloperation:

• Simultaneouslydepressthekeys<B> and <A>.

Youarenowpromptedtoenterthefourdigitaccesscode“8808”. The digit on thefarleftflashes.

• Entertheaccesscode“8808”asfollows:

Changethefirstdigitwiththekeys<B> and <A>.Acceptyourinputwiththekey<C>.Thenextdigitstartstoflash.Repeatthisstepfortheremainingdigits.

Afteracceptanceofthelastdigit,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouareonthesettinglevel.Thefirstmenuitemthenap-pears on the display.Note:Ifyouhaveenteredanincorrectcodethemessage“Incorrect Code”ap-pearsbrieflyonthedisplay.Theunitthenreturnstothenormalservicemode.

To change the set values

The unit is on the setting level.

• Pressthekey<C>,ifyouwishtochangethecurrentsetting.

– Menu items with selected values

• Pressthekey<B> or <A>,inordertoselectthedesiredsettingfromthelist.

• Acceptyourinputwiththe<C> key.

– Menu item with numerical set value

Thedigitonthefarleftstartstoflash.

• Pressthekey<B>,inordertoreducethevalueoftheselecteddigitorthekey<A>,inordertoincreasethevalueofthedigit.

• Acceptyourentrywiththe<C> key.Note:Ifthevaluetobeenteredisamulti-digitvalue,thenextdigitstartstoflash.Youcanchangethisdigitasdescribedabove.

Afterconfirmingthelastdigit(numericalsetvalue)andtheselectedsetvalue,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouhaveenteredanewvalue.Thentheselectedmenuitemappearsagain.Note:Ifaninvalidvaluehasbeenenteredinanumericalinput,theadjacentmessage appears.

Ifyouhaveexitedtheinputfieldwiththekey<C>,withouthavingchangedthesetvalue,theadjacentmessageappearsbrieflyonthedisplay.Thenthedis-playforalteringthesetvalueappearsagain.

Theprocessofchangingthevaluecanbeinterruptedatanypointbypressingthe <Menu> key.Thelaststoredsetvaluethenremainsunchanged.

52

Description of the menu items on the setting level

The following lists all the menu items that can be selected and changed after activation of the setting level.

– Language

Dialogue language of the display unit.Factory setting: depends on the countryOptions: german, english, french

Note: The display unit switches to the selected language immediately after the suitable language option has been confirmed.

– Capacity limitation

Limitation of the steam capacity (in %) in reference to the maximum steam capacity.Factory setting: 100 %Setting range: 10…100 %

Note: This parameter is used to limit the maximum performance in case the steam capacity exceeds the humidification required by your installation.

– Inlet valve correction

Setting the cycle frequency of the inlet valve in % of the standard setting.Note: This menu point is only given in Mk5 Process unit.Factory setting: 100 %Setting range: 10…200 %

Comment: The water feed quantity can be reduced (value <100) or increased (value >100) with this parameter in order to balance out variations in water pressure.

– Controller setup

Activation (“on”)/Deactivation (“off”) of the internal PI controller.Factory setting: offOptions: on (PI controller activated), off (PI controller deactivated)

Note: The internal controller must not be activated if an external controller is connected to the humidifier because the internal controller would interpret the analog signal of the external controller as the actual humidity value detected by a humidity sensor. This would cause the internal controller to switch the humidifier to 100% steam capacity if the input signal drops to 0% which, in turn, would lead to over-humidification.

– Nominal humidity value

Nominal humidity value in % rh.Note: This menu option is available only if the internal PI controller is active.Factory setting: 45 %rhSetting range: 10…100 %rh

language

English

power limit [%]

100

controller funct

off

ref.value rh [%]

045

inlet valve cor.

100

53

– Proportional range(P-band)oftheinternalPIcontroller

ProportionalrangeoftheinternalPIcontrollerin%.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.

Factory setting: 30 %Setting range: 4…100 %

Note: The P-Range is used to smooth the control characteristic. Increasing the P-Range boosts the smoothing applied to the control characteristic. However,thiscausesapermanentdeviation,proportionaltothebandwidthoftheP-Range.

– Integral timeoftheinternalPIcontroller

IntegraltimeoftheinternalPIcontrollerinminutes.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.Factory setting: 10 MinutesOptions: off(000/integraltimedisabled),2 - 100 Minutes

Note:Theintegraltimesettingdeterminestheperiodallowedtoreachthenominal humidity. Setting the integral time to the optimal value prevents the controlcharacteristicfromovershootingand,atthesametime,balancesthe permanent deviation caused by the P-Range value.

– Soft start

Enabling(on)ordisabling(off)theSoftstartfunction.Note:Enablethesoftstartfunctionifyouareusingsoftenedwaterorwaterwithahighconductivity.Factory setting: offAvailable settings: on(Softstartenabled),off(Softstartdisabled)

Note:Afterrestartoraftertheunithasbeenidlefor4hours(stand-by)theSoftstartfunctionreducesthehumidificationcapacitytoapresetvalueforaselect-ableperiod(valuesettingsseeparametersbelow).

– Time limit for Soft start

SelectthetimelimitfortheSoftstartfunctioninminutes.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.Factory setting: 30 minutesSetting range: 1…255 minutes

– Capacity limit for Soft start

SetthecapacitylimitfortheSoftstartfunctionin%ofmaximumhumidifica-tion capacity.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.

Factory setting: 50 %Setting range: 4…100 %

Integr.time[min]

010

P-band [%]

030

softstart

off

softstart time

30 Min

softst. power

50 %

54

Modbus address

01

Diagnose pgm

(ENTER=Entry)

erase history

(ENTER=Entry)

– Demineralization mode

Enabling(“on”)ordisabling(“off”)theDemineralizationmode.Note:Enable thedemineralizationmode ifyouareusingsoftenedwaterorwaterwithahighconductivity.Factory setting: onAvailable settings: on(Demineralizationmodeenabled) off(Demineralizationmodedisabled)

Note:TheDemineralizationmodeflushesthesteamcylinderwithinanhourafterapresetnumberofscumdetectionshastakenplace(seenextparameter“Demineralizationdelay”).Thispreventstheformationofscum.

– Demineralization delay

Setthedemineralizationdelayafterwhichatime-controlledflushingcyclewillbeinitiated.Note:ThismenuitemisavailableonlyiftheDemineralizationmodeisenabled.

Factory setting: 3Setting range: 1…9

Note: The demineralization delay determines the number of times themaximumlevel(scumdetection)maybereachedbeforeatime-controlledflushingcyclewilltakeplace.

– Modbus address

Setthemodbusaddressforunitswithbuilt-intelemonitoringinterfaceorbuilt-inRS232/RS485serialinterface.

Factory setting: 1Setting range: 1...16

Note:Detailedinformationaboutthetelemonitoringinterface(installation,correctaddressingofunitsinacluster)andtheserialinterface(installation,configura-tion)canbefoundintheseparatemanualsthataresuppliedwiththeseoptions.

– Diagnostic program

Thediagnosticprogramsimulatesvariousoperatingconditionsofthesteamhu-midifier.However,thediagnosticprogramrequiresin-depthknowledgeofpar-ticularinternalfunctionsoftheunit.Therefore,thediagnosticprogramshouldbeusedbytheservicetechniciansofyoursupplieronly.

– Error history

Numericalcodesofthelast4errorsencountered(oldestentryfarleft).Note: For detailed information on themeaning of particular error numberspleaserefertochapter6.7.

– Delete fault history

Faulthistoryisdeleted.Anappropriatemessageappearsfollowingthedeletion.

demineral. delay

3

faulthistory

. / . /9.A/9.A

demineral. mode

on

55

6.6 Maintenance

– All maintenance work must be performed only by adequately qualified and trained personnel familiar with the dangers involved.Ascertainingthequalificationsisthecustomer‘s responsibility.

– Instructionsanddetailsconcerningthemaintenanceworkmustbeobservedandad-heredtowithoutfail.

– Onlythetypeofmaintenanceworkoutlinedinthisdocumentationmustbecarriedout.

– Useoriginalsparepartsfromyoursupplierexclusivelytoreplacedefectiveparts.

– Before maintenance is initiated, the steam humidifier must be taken out of op-eration in accordance with instructions in chapter 6.3 and protected against unintentional switching on.

6.6.1 Notes on maintenance

Tosafeguard reliableoperation, themaintenanceof theDefensorMk5shouldbedevised in threestages.Adistinction ismadeherebetweenperiodic inspections,smallmaintenanceandextendedmaintenanceofthesteam-airhumidifier.

Theintervalsrequiredbetweensmallmaintenanceandextendedmaintenancedependonthewaterqualityandthequantityofsteamgeneratedandcanbepre-selectedontherotaryswitch“S2”onthecontrolboard(seechapter6.1).Afterexpiryoftheselectedinterval,theyellowLEDflashes/lightsandanappropriatemessagealternateswiththenormaloperationindication.Note:Werecommendtocarryoutanextendedmaintenanceatleastonceayear,independentlyfromthe maintenance counter.

Thefollowingisanoverviewoftheworkthatshouldbeundertakenforthethreemaintenancestages.

– Periodic inspectionsWhen: 1 per weekWork: • Inspectthewaterandsteaminstallationsforcorrectsealinganddamage. • Inspectthedrainlineforsoiling. • Inspecttheelectricalinstallationforloosecablesanddamagedcomponents. • Inspectthesteam-airhumidifierfordamage.

– Small maintenanceWhen: The yellow LED flashes andthemessage“sm. maintenance due”appears,alternat-

ingwiththenormaloperationindication.

Work: • Carryouttheperiodicinspectionitems • Emptythesteamcylinderandcleanthelimecollectortank.

– Extended maintenanceWhen: The yellow LED lightsandthemessage“lg. maintenance due”appears,alternating

withthenormaloperationindication.

Work: • Carryouttheperiodicinspectionitems • Emptythesteamcylinderandcleanthelimecollectortank. • Dismantleandcleanthesteamcylinder • Cleantheunitinnerchamber • Inspectthecomponentsinsidetheunitfordamage(e.g.heatingcableconnector

onthesteamcylinder,levelunit,etc.)

sm. maintenance

due

lg. maintenance

due

56

6.6.2 Dismantling and re-assembly work

Note:Thelimecollectortankmustbereplacedevery 5000 hours,orafter3 years at the latest.

Removal of the lime collector tankCaution!Beforecommencinganydismantlingwork,thesteam-airhumidifieristobetaken out of operation as described in chapter 6.3 and rendered safe from inadvertent operation.

1. Emptythelimecollectortankviathedrainvalve.

Caution: Danger of scalding!Thewaterinthelimecollectortankmaybehot.

2. Pressthesecuringknobonbothrotationlocks.Thenrotatebothrotationlocksclockwiseandremovethelimecollectortankdownwards,fromthebaseoftheunit.

Installation of the lime collector tank

Installationofthelimecollectortankiscarriedoutinthereversesequencetothatdetailedaboveforremoval.

Important! CheckO-ringsinthetankcouplingsleeveoftheunitandreplaceifdefective.Beforere-mountingthelimecollectortank,greasetheO-ringsinthetankcouplingsleevewithsiliconegrease.

Important! Turntherotationlocksanticlockwiseuptothestop(bothsecuringknobsmustengage).

Important! Closedrainvalveonlimecollectortank.

1 2

57

Removal and dismantling of the steam cylinderCaution!Beforecommencinganydismantlingwork,thesteam-airhumidifieristobetaken out of operation as described in chapter 6.3 and rendered safe from inadvertent operation.

Caution!Ifsteamhasbeenproducedshortlybeforediscontinuingoperation,the steam cylin-der will be hot.Well-insulatedglovesshouldthereforebewornwhencarryingouttheremovaloperation.

1. Releasethefrontdoorlockingdevicesusingascrewdriver(rotate90°left)andremovethefrontdoors.

2. Freetheupperhoseclampofthesteamhoseusingascrewdriverandpullthehosedownwardfromthe steam connection.

3. Removethetwoscrews,thenpresssnap-fasteningstogetherandthenremovetheheatingcableloomplugconnectorfromtheconnectorsocket.

4. Releasetheclampingring(steamcylinderfixation).

5. Liftthesteamcylindercarefullyfromthecouplingbushandremoveittowardsthefrontoftheunit.

Caution!Setthesteamcylinderdowncarefully.

6. Loosenthesteamcylindercoverclampingring.

1 2 3

4 5 6

58

7. Carefullyliftoffthecoverwiththeheatingrods.

Warning!Takecarewiththecoverwhilstitisremoved,soasnottodamagetheheatingrods.

Note:Ifthecovercannotberemovedduetoheavycalcification(maintenanceperiodexceeded),placethesteamcylinderinabasinofformicacid(8%)untilitcanberemoved(Caution! Observe instructionsonthesafeuseofthiscleaningagent).

8. Ifnecessary,loosenthecylinderinsertbylightlyrotatingitineitherdirectionandliftitfromthesteamcylinder.Thenremovethescreeninsertandthefunnelinsert.

9. Ifaheatingelementhastobereplacedduringservicing:firstmakeanoteofhowthecablesareconnectedandthepositionoftheheatingelement.Thendetachthecable,loosentheclampingnutand remove the heating element.

Assembly and installation of the steam cylinder

Assemblyofthesteamcylindertakesplaceinreversesequence.Pleasenotethefollowinginstructions:

– Installationofanyheatingelementswhichhavebeenremovedshouldfollowfigure9.Pleasetakecarethattheheatingelementsarecorrectlypositionedandthecablesarecorrectlyconnected(ac-cordingtoyournotes).

– BeforeinstallationofthesteamcylindercoverplacetheDurosealantaroundtheedgeofthecover.TheDurosealantmustbecleanandundamaged(replaceifnecessary).

– BeforeinstallationofthesteamcylinderintheunitcheckO-ringsinthecouplingboxfordamageandreplaceifnecessary.

– Insertsteamcylinderintheunitcorrectlyandfastenwithclampingring.

– Fastensteamhosewithhoseclamps.Aleakysteamhosecancausedampdamageintheinterioroftheunit.

– Theplugof theheatingcableboommustconnect in theconnectionboxand fastenedwith thescrews.

7 8 9

59

6.6.3 Notes on cleaning

Cleaning the steam cylinder, lime collector tank, steam cylinder insert

• Whereverpossible,chipoffthelimecoatingthathasformed.

• Washpartswithlukewarmsoapsudsandthenrinseoffwell.Note:Ifthecomponentsareheavilyscaled,placethemin8-percentformicaciduntilthescalehasdissolved. Then treat components as previously described.

Cleaning the heating elements

• Immersecoverwithheatingelementsfittedto2cmbelowtherimofthecoverinacontainerwith8-percentformicacid.Allowtheacidtotakeeffectuntilthescalecoatinghasdissolved.Note:Theheatingelementsdonothavetobeentirelyfreefromscale.

• Thenrinseheatingelementsthoroughlywithfreshwater.

Warning! Ensure that the electrical connections remain dry.Warning!Onnoaccountremovescalecoatingontheheatingelementswithtools(screwdriver,scraper,etc.)orbystriking.Thiscoulddamagetheheatingelements.

Cleaning the interior of the unit

Wipedowncomponentsinsidetheunitwithadampcloth(cleanwater).Severelyscaledcomponents,e.g.theinletfunnelandtheblow-offpump,shouldbecleanedusingcommerciallyavailablecleaningand descaling agents. Warning! Ensure that the electrical connections and electronic components remain dry.

Notes on cleaning agents

Diluteformicacidisobtainablefromanychemist’sshopordrugstore.Warning! Formicacidis indeedharmlesstotheskin,but itattacksthemucousmembranes.Protecttheeyesandrespiratorytractsthereforefromcontactwiththeacidanditsvapor(weargogglesandworkinawellventilatedroomoroutside).

Theuseofdisinfectantsisonlypermittediftheyleavenotoxicresidues.Thecomponentsmustberinsedthoroughlywithwateraftercleaninginallcases.

Caution! Do not use any solvents, aromatized or halogenized hydrocarbons, or other ag-gressive substances for cleaning purposes.

Theinformationandinstructionsregardingcleaningagentsaretobeunconditionallyobservedandimplemented.Inparticular:Informationrelatingtotheprotectionofpersonnel,environmentalconservation and restrictions regarding usage.

In all cases, local regulations relating to environmental protection must be implemented.

6.6.4 To reset the maintenance indication

Whenmaintenanceworkhasbeencompleted,themaintenance displaycanberesetasfollows:

• With the unit switched off,depressandholdthedrainswitch.

• Switchonthesteam-airhumidifierwiththeunitswitch.

• Continuetodepresstheblow-offpushbuttonuntilthesystemtesthasfinished(approx.10seconds).

60

Ifthecontrol,afterseveralattempts,failstosolvetheproblem(numberofattemptsdependsonthetypeofmalfunction)oriftheproblemobstructsfurtheroperation,theheatingvoltageisinterruptedviathe main contactor. The red LED stays lit and an error message appears in the display alternating withthenotice“Please turn off unit”.

Example of an “Error” indication

red LED stays lit Message in the display

6.7 Fault elimination

6.7.1 Fault indication

Incaseofmalfunctionduringoperation,thehumidifiercontrolcheckswhetherthereisatemporaryproblem(e.g.watersupplyinterruptedforashorttime)orwhetheritcanresolvetheproblembytakingnecessarymeasures.Suchmalfunctionssettheunitintothe“Alarm”status(faultelimination).Thered LED flashes and an alarm message appearsinthedisplayalternatingwiththenotice“recover-ing - please wait”.Note:Ifthecauseofthemalfunctiondisappearsofitsownaccordorifthecontrolscanrepairthemal-function,thealarmmessagewillautomaticallyswitchoff.

Example of an “Alarm” indication

red LED flashes Message in the display

please turn

off unit

Error code

Unit designation (A or B)

Note:Iftheunitisindisplayorsettinglevelthealarmmessageinthedisplaywillbesuppressed.

Error code

Unit designation (A or B)

Note:Iftheunitisinthedisplayorsettingleveltheerrormes-sageinthedisplaywillbesuppressed.

Error 1A

filling time

Alarm 1A

filling time

recovering

please wait

61

6.7.2 What, if..?

Mostoperationalmalfunctionsarenotcausedbyfaultyequipmentbutratherbyimproperinstallationordisregardingofplanningguidelines.Therefore,acompletefaultdiagnosisalwaysinvolvesathoroughexaminationoftheentiresystem.Often,thesteamhoseconnectionhasnotbeenproperlyexecuted,orthefaultlieswiththehumiditycontrolsystem.Thefollowingtablegivesalistofpossiblemalfunctions,theappropriatealarmorerrormessage,detailsoftheircause,andnotesonhowtodealwitheachproblem.

Malfunction/Indication Cause Remedy

Min. filling time not reachedError code: 1A/1B

Waterfeedtosteamcylinderheavilycalcified.Level in steam cylinder and level unit do not match.

Carry out major servicing.

Internal safety chain interruptedError code: 2A/2B

Connection to over-temperature switch on steam cylinder broken or over-temperature switch faulty.Steamcylinderoverheating,over-temperatureswitch has responded.Flat-band cable between control and power board interrupted or not connected.

Check connections or replace over-temperature switch.

Inspect steam cylinder, clean if necessary.replace over-temperature switch.Inspect connections, connect or replace flat-band cable.

Max. filling time exceeded (alarm message only)Error code: 3A/3B

Waterfeedblocked(mainwatertapclosed,filtervalve closed or blocked).Water pressure too low.Inlet valvedoesnotopen,filtersieve in Inletvalveblockedorinletvalvefaulty.

Feedhosesintosteamhumidifiernotconnectedor kinked.Level unit not connectedFloat in the level unit sticking or level unit faulty.

Checkwaterfeed(openmainwatertap,openorcleanfiltervalve.Raise water pressure (range 1-10 bar).InspectelectricalconnectionsandfuseF2onsupply module. Clean filter sieve or replaceInlet valve.InspecthosesintoUnitandconnectifnecessary.Replace Faulty Hoses.Connect level unit.Clean or replace level unit.

Max. vaporization time exceededError code: 4A/4B

Individualheatingelementsfaulty.Fusesonthepowerboardfaulty.Mainsvoltagetooloworfailureofaphase(L1,L2 or L3).Steamleadtoolongornotinsulated.

This error may also occur upon a cold start.

Replacefaultyheatingelements.Replacefusesonpowerboard.Check mains voltage and connections.

Maintain maximum lead lengths (max. 4 m), Insulate steam lead.EnableSoftstart(seechapter6.5).

Alarm 1A

filling time

Error 1A

filling time

Alarm 2A

safety chain int

Error 2A

safety chain int

Alarm 3A

water supply

Alarm 4A

steam time

Error 4A

steam time

62

Malfunction/Indication Cause Remedy

Max. flushing time exceededError code: 5A/5B

Drainpumpnotconnectedorfaulty.Outletleadfromunitkinkedorblocked.

Water outlet blocked (external outlet lead or siphon blocked.Hoses to level unit blocked.

Connect or replace drain pump.Inspectoutletleadfromunit,replaceifneces-sary.Clean water outlet lead and siphon.

Clean or replace hoses.

Invalid levelError code: 6A/6B

Levelunitfaulty.Magneticfieldinvicinityoflevelunit.

Replace level unit.Eliminatemagneticfield.

Steam pressure supervision (error only)Error code: 7A/7B

Steamhoseblockedorrestricted(watertrap).Pressure balance adapter into steam connection fittingblocked.

Duct pressure too high (>1500 Pa).

Inspect steam hose, clean if necessary andinstall correctly.Remove adapter and clean opening with a needle.Inspect ventilation settings.

Humidity sensor fault (error only)Error code: 8A/8B

Internal controller activated.Humidity sensor signal < 5 %.

Deactivate internal controller.Checkhumidity sensor.Recalibrate if neces-sary.

External safety chain interruptedError code: none

Ventilation interlock open.Automaticflowcontrolhasresponded.Maximum humidistat has responded.No heating voltage available.

Switchonventilator/ventilationsystem.Inspectventilator/filterofventilationsystem.Servicing,inspectsystemifnecessary.Check mains voltage.

Heating voltage dropped at Unit B. Inspect voltage supply to Unit B.

Alarm 6A

level indicat

Error 6A

level indicat

Error 7A

communication

safety chain

external A

mains failure

B

Alarm 5A

drain

Error 5A

drain

Notes on fault elimination

Warning: Danger of death!Inordertoeliminatefaults,thesteamhumidifiermust be switched off and secured against unintentional reconnection asdescribedinchapter6.3.Takecarethattheelectricitysupplytothemaincontactorisdisconnected(checkwithvoltagetester).

Onlyallowtrainedandqualifiedpersonneltorepairfaults.Faultsrelatingtoelectricalinstallation(e.g.changeofunitfuse)mustonlybecarriedoutbyauthorizedpersonneloryoursupplier’sservice technician.

Repairworkandreplacementoffaultycomponentsmustonlybecarriedoutbyyoursupplier’sservice technician!Exception: Replacing faulty components during servicing(seechapter6.6)andreplacing faulty unit fuses(seechapter6.7.3).

Error 8A

sensor fault

63

6.7.3 Replacing unit fuses

Warning Danger of death! Before replacing the unit fuse the steam humidifier must be switched off and secured against unintentional reconnection as described in chapter 6.3. Take care that the electricity supply to the main contactor is disconnected (check with voltage tester).

Warning! Electronic components are very sensitive to electrostatic discharge. To protect these components, measures must be taken against damage from electrostatic discharge when replac-ing the unit fuse (ESD protection).

The unit fuses may only be replaced by trained and qualified personnel.

Important! If the unit fuse blows this is generally due to a faulty unit component. Therefore you should check these components before replacing the fuse (see table below).

Only use the correct type of fuse according to the following table.

Warning! It is not permitted to use repaired fuses.

Power board (F1..F3, F1...F6 or F1...F9)

Supply module (F2)

Supply module (F1)

Control board (F5)

Fuse Specification Before replacing, check

F1 on supply moduleF2 on supply module

6.3 A, slow-acting

1 A, quick-acting

Drain pump (blocked or coil faulty)

Inlet valve (blocked or coil faulty)

F5 on control board 200 mA, quick-acting Control signal

F1…F3 on power board (Mk5 Visual/Process 5-.. and 8-..)

F1…F9 on power board (all other models)

16 A, super quick-acting

20 A, super quick-acting

Heating elements (on short-circuit)

Heating elements (on short-circuit)

6.7.4 Resetting fault indication “Error”

In order to return the steam humidifier to operation after fault elimination, the steam humidifier must be switched off for approx. 5 seconds and then switched on again.

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7 Technical data

DefensorMk5Visual/Process

5-.. 8-... 10-.. 16-.. 20-.. 24-. 30-. 40-.. 50-.. 60-.. 80-..

Steamoutput 0-100%infinitelyvariable

Numberofunits 1 1 1 1 1 1 1 1 2 2 2

Steamconnection G 1 1/4”

Resolution 1,0 %

Controlofsteamoutput

– active 0…20 V (Phase intersect), 0…10 VDC, 1…5 VDC, 0…5 VDC 0…4.25 VDC (Potentiometer), 0…1 VDC, 2…10 VDC

0…20 mADC, 4…20 mADC

– passive allpotentiometrichumiditysensorsfrom140Ω…10kΩ

–On/Offcontrol <2,5VDC-->Off;≥2,5 VDC…20 VDC --> On

Duct air pressure Overpressure max. 1500 Pa, Underpressure max. 1000 Pa (forductpressuresoutsidethesevaluescontactyoursupplier)

Permissible ambient temperature 1...40 °C

Permissible ambient humidity 1...75 %rh (non-condensing)

Waterfeed

– Connection G 1/2”

– Permissible water pressure 1...10 bar

– Feed temperature 1...40 °C

– Water quality untreateddrinkingwaterorfullydemineralizedwater(foroperationwithsoftenedorpartlysoftenedwaterpleasecontactyoursupplier)

Water outlet

– Connection Internal-ø=40mm

– Outlet temperature 60...90 °C

Weight in kg

– Operation 51 51 52 53 71 73 73 74 1x711x73

2x73 2x74

– Net 36 36 37 38 41 43 43 44 1x411x43

2x43 2x44

Dimensions in mm

– Height 1087 1087

– Width 500 594

– Depth 437 392

Contentoflimecollectortankinl 5 10

Testcertificate SEV,VDE,GS,CE,GOST

Typeofprotection IP21

65

Notes

Notes

© Condair Ltd., Printed in SwitzerlandTechnical modifications reserved

CONSULTING, SALES AND SERVICE:

Manufacturer:Condair Ltd.Talstrasse 35-37, 8808 Pfäffikon, SwitzerlandPh. +41 55 416 61 11, Fax +41 55 416 62 62info@condair.com, www.condair.com

Reg.No. 40002-2