VAPOR-LOGIC3 - dristeem-media.com · 4 VAPOR-LOGIC®3 main control board connections J1 Wire...

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VAPOR-LOGIC®

3 Installation and operation manual

Microprocessor-based humidifier control system

PLEASE: read this manual!

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1

Product overview

Product overview:

Summary of features

VAPOR-LOGIC®

3 features overview.

Accurate, responsivemicroprocessor control

Our newest controller, VAPOR-LOGIC3,provides unprecedented, comprehensive control forDRI-STEEM humidifiers. With expandedcapabilities, easy-to-use keypad, and modular, openprotocol design, the VAPOR-LOGIC3 efficientlycontrols all humidifier functions.

Navigating the keypad to adjust or review humidifierfunctions is an intuitive process of walking througheasily-read screen menus. The controller’s open-protocol design allows seamless integration withbuilding management systems.

You will find no other controller in the humidifiermarket able to provide such functionality, ease ofuse, and accurate RH control.

Control mode options

• On-off operating mode controls single ormultiple electric staged outputs.

Expected accuracies: ±5-7% RH

• Time proportioning function controlshumidifier outputs via cyclic actions onelectrical contactors or a modulated signal toour solid state zero cross-fired SSR powercontrollers.

Expected accuracies:

– Contactor action: ±2-4% RH– SSR action: ±1-3% RH

• Proportional action controls modulating steamor hot water valves or GTS burners by providinga linear analog signal to the motors (for STS,LTS or GTS humidifiers).

Expected accuracies: ±2-5% RH

More on next page ...

2

Summary of features

• PID control provides the most accurate,responsive and adjustable relative humidity(RH) control.

• Self-diagnostic test at start-up

• End of season auto-drain

• Real-time clock allows time-stamped alarmtracking, and three ways to program drain andflush cycles:

1. Usage (after a set number of lbs/kg havecycled through)

2. Usage and time (set number of lbs/kg plusdefined period of time)

3. Scheduled intervals

• Redesigned keypad has an intuitive interfacewith backlit display and provides:

– menu-driven access to all system functions– default screen for quick view of system status

and set points– data reports to track performance and

efficiency– system diagnostics and alarm tracking for

troubleshooting– single-point multiple-humidifier control

without an additional system controller– password protection of setup parameters– wall-mounting with a standard telephone

plate, flush mounting, or hand-held options

• Tank temperature sensor:

– preheats tanks for uninterrupted operation– senses for freeze protection– senses for low water/over temperature

protection

• Sensitivity to low-conductivity water(important when using a standardhumidification system with low-mineral-contentwater)

• Uses Echelon’s LonTalk®, an opencommunications protocol used by most majorcontrol companies, allowing full interactionwith building management systems

• Single-controller platform; modular design

The new VAPOR-LOGIC3 controller will soonbe standard on all DRI-STEEM humidifiers.The base configuration includes a maincontroller board and keypad. Expansionmodules will increase capability, therebyallowing all systems to use the same controllerplatform and keypad interface.

• Year-2000 compliant

Product overview

VAPOR-LOGIC®

3 features overview.

Product overview:

Summary of features

3

Figure 3-1: VAPOR-LOGIC3 printed circuit board

Product overview

VAPOR-LOGIC®

3 circuit board.

To expansionboard (ribboncable)

R=Resistive inputI=Current inputV=Voltage input

Jumper connector

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Product overview:

Printed circuit board

5/64" dia.(6) mounting holes

3.548

RJ-11Cablekeypad

RJ-45Cablenetwork

Powerindicator

Readywaterindicator

Serviceindicator

Ana

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OM-VL3-3

4

VAPOR-LOGIC®3 main control board connections

J1 Wire terminal supplies 24 VAC to power theVAPOR-LOGIC3 control board.

• Double terminal T1 – 24 VAC, 10 VAmaximum load

• Triple terminal T2 – 24 VAC common

J2 RJ11 female modular jack connection for supplyvoltage and FTT-10A communication tokeypad/display

J3 RJ45 female modular jack connection for FTT-10A communication to LonTalk® network

J4 Wire terminal connection for FTT-10Acommunication to LonTalk network. TerminalsA and B provide the communication lines. Thelast terminal is earth ground.

J5 End of line communication terminator pins

J6 1/4" push-on connector for earth ground

J7 0-15 VDC analog output, typically connected tothe input of a steam or hot water valve.Terminal 34 is the positive output signal andterminal 35 is common.

J8 Connector receives necessary continuity inputsignals from water detection devices:

• Probe system water level detection– Terminal 30 detects maximum water level

from top probe rod and brown plug wire.– Terminal 31 detects water level at refill

point from middle probe rod and orangeplug wire.

– Terminal 32 detects water level at its lowestpoint from lower probe rod and purple plugwire.

– Terminal 33 is the common return path forall water detection rods from the humidifiertank machine ground back toVAPOR-LOGIC3 control.

• DI/RO system detection– Terminals 30 and 31 are not used.– Terminal 32 is connected to the humidifier

tank low water float switch (normallyopen).

– Terminal 33 is the return signal from thefloat switch to VAPOR-LOGIC3 control viamachine ground.

J10 Ribbon cable connector for VAPOR-LOGIC3expansion modules


Product overview

Main control board connections.

Product overview:

Main control board connections

5

Main control board connections (cont.)

Important note about J17, J18 and J19:

All connection diagrams show connector shuntson J17, J18 and J19. The connector shunts andappropriate software have been selected byDRI-STEEM based on original customer orders.Field changing the input connector shunts willrequire control input modification: See Page23 “Changing Control Input.”

J17 Jumper pins determine the configuration of thetype of input control into the RH sensor input(terminals 21 through 23) for wire terminalconnector J26.

• R = Resistance, 0-150 ohms range– Used with on-off humidistats, staging

switches, PE switches– Used with analog 0-150 ohm input device

(pneumatic transducer or humidistat)

• I = Milliamp, 0-20 mA range– Used with any humidity sensor with

4-20 mA output– Used with any computer or energy

management system with 4-20 mA output– Internal resistance 249 ohms, terminal 22

proportional signal, terminal 23 signalground

• V = Volts DC, 0-15 volt range– Used with any control humidistat 0-15V DC– Terminal 21 provides positive 21 VDC

supply, terminal 22 proportional signal,terminal 23 signal ground

Product overview

Main control board connections (cont.).

Product overview:


J18 Identical to J17 input selector pins except usedto configure duct high limit RH input (terminals24 through 26) for wire connector terminal J27

J19 Identical to J17 input selector pins except usedto configure window temperature sensor input(terminals 27 through 29) for wire connectorterminal J28

J20 Wire terminal connector supplies 24 VACvoltage via terminals 1 and 2 to the fill valveand via terminals 3 and 4 to the drain valve.

J21 Wire terminal connector supplies 24 VACvoltage via terminals 5 and 6 to the powercontactor and via terminals 7 and 8 to the SDUrelay.

J22 Wire terminal connection allows for remotefault indication. Relay closure is provided(1 amp max.).


6

Main control board connections (cont.)

J23 Wire terminal connection provides opticallyisolated connection to air flow proving switchand safety circuit. Terminal 12 supplies 24 VACto proving switch circuit, SPST, which closeswhen air flow is present. Terminal 13 is thereturn connection from the proving switch intothe VAPOR-LOGIC®

3 control. Terminal 14supplies 24 VAC to safety circuit, SPST, whichis closed under normal operating conditions.Terminal 15 is the return connection from thesafety circuit into the VAPOR-LOGIC3 control.

J25 Wire terminal connector provides input for RTDtank temperature sensor. Terminal 19 supplies 21VDC to temperature sensor. Terminal 20 is thereturn connection from the temperature sensorinto the VAPOR-LOGIC3 control. Terminal 18has no connection.

J26 Wire terminal connector receives the necessarysignal from the controlling RH sensor.

• Terminal 21: Positive polarity 21 VDC supply(25 mA max)

• Terminal 22: Control signal• Terminal 23: Signal ground• Input selector pin J17 configures J26 input

Product overview

Main control board connections (cont.).

Product overview:


J27 Wire terminal connector receives the necessarysignal from the duct high limit RH sensor.



J28 Wire terminal connector receives the necessarysignal from the window temperature sensor.



7

Product overview

Expansion board connections.

Product overview:

Expansion board connections

GTS® and VAPORSTREAM® expansion boardconnections

J1 1/4" push-on connector for earth ground

J2 Blower # 2 control:


• Terminal 22: Blower tachometer feedback• Terminal 23: PWM output to blower• Terminal 24: Common

J3 Blower # 1 control:


• Terminal 18: Blower tachometer feedback• Terminal 19: PWM output to blower• Terminal 20: Common

J5 Ribbon cable connector for VAPOR-LOGIC®3main controller connection

J6 Ribbon cable connector for additionalVAPOR-LOGIC3 expansion modules

J7 Wire terminal supplies 24 VAC to power theVAPOR-LOGIC3 expansion module.

• Terminal T1 – 24 VAC, 10 VA maximumload

• Terminal T2 – 24 VAC common

J8 Wire terminal connector supplies 24 VAC voltagewith terminal pairs 1 and 2, 3 and 4, and 5 and 6to either contactors or GTS ignition controllers.(Terminals 1, 3 and 5 supply the 24 VAC.Terminals 2, 4 and 6 provide the 24 VACcommon.)

J9 Wire terminal connection provides opticallyisolated connections for the gas valve feedback.Terminals 7 and 9 provide 24 VAC and are notused. Terminal 8 receives a 24 VAC signal backfrom gas valve #1. Terminal 10 receives a 24VAC signal back from gas valve #2.

J10 Wire terminal connection provides opticallyisolated connections for the combustion airdamper limit switch, power vent pressure switchand flue differential pressure switch. Terminal 11supplies 24 VAC to the combustion air damperlimit switch, which closes when the damper hasopened. Terminal 12 is the return connectionfrom the limit switch into the VAPOR-LOGIC3expansion module. Terminal 13 supplies 24 VACto the power vent pressure switch which closeswhen the fan has started. Terminal 14 is thereturn connection from the pressure switch intothe VAPOR-LOGIC3 expansion module. Terminal15 supplies 24 VAC to the flue differentialpressure switch which closes when the blowershave started. Terminal 16 is the returnconnection from the differential pressure switchinto the VAPOR-LOGIC3 expansion module.

8

Program code nomenclature.

Product overview

Product overview:

Program code nomenclature

Program code explained

A 14-digit VAPOR-LOGIC®3 program code appears on

the front of the control cabinet and on the wiringdiagram inside the control cabinet. The program codespecifies the parameters of the VAPOR-LOGIC3microprocessor, which controls your humidificationsystem. An explanation of the program code isdetailed below.

VAPOR-LOGIC3 program code

A. Type of units:E = EnglishM= Metric

B. VAPOR-LOGIC3 system type:G = GTS®

S = STS®

L = LTS®

V = VAPORSTREAM®

M = VAPORMIST®

C = CRUV®

U = ULTRA-FOG®

N = Steam Injection

C. VAPOR-LOGIC3 board classification:1 = One-tank system2 = Two-tank system3 = Three-tank system4 = Four-tank system5 = Five-tank system6 = Six-tank system

D. Digital display/keypad features:1 = Single keypad

E. Type of outputs (0-4):0 = Steam valve/100% SSR1 = One heat stage2 = Two heat stages3 = Three heat stages4 = Four heat stages

F. System pounds output:##### = Output capacity(e.g., 00285 = output capacity in lbs/hr)

G. Type of water level control:D = DI w/ manual drainE = DI w/ end of season drainM = Standard w/ manual drainA = Standard w/ autodrain

H. Operating mode:1 = Single staged2 = Externally staged6 = GTS7 = TP8 = SSR9 = Steam valve

I. VAV options:V = Option presentO = Option not selectedS = SDU option

J. Temperature compensation options:T = Option presentO = Option not selected

K. Type of humidity sensing device:N = None, for on/offC = 0-135 ohm humidistatD = 6-9 VDC humidistatH = 0-10 VDC humidistatE = 4-20 mA humidistatX = 4-20 mA transmitterQ = Dew point transmitterS = Special

9

Program code nomenclature.

Product overview

Product overview:

Program code nomenclature

Program code example

A. English

B. VAPORMIST®

C. One-tank system

D. Single keypad

E. One heat stage

F. 48 lbs/hr capacity

G.. Standard water with autodrain

H.. TP operating mode

I. No VAV option

J. No temp comp option

K. 4-20 mA transmitter

E M 1 1 1 00048 A 7 O O X

10

DRI-STEEM Humidifier Company (“DRI-STEEM”)warrants to the original user that its products will befree from defects in materials and workmanship for aperiod of two (2) years after installation or twenty-seven (27) months from the date DRI-STEEM shipssuch product, whichever date is the earlier.

If any DRI-STEEM product is found to be defectivein material or workmanship during the applicablewarranty period, DRI-STEEM’s entire liability, andthe purchaser’s sole and exclusive remedy, shall bethe repair or replacement of the defective product, orthe refund of the purchase price, at DRI-STEEM’selection. DRI-STEEM shall not be liable for anycosts or expenses, whether direct or indirect,associated with the installation, removal or re-installation of any defective product.

DRI-STEEM’s limited warranty shall not be effectiveor actionable unless there is compliance with allinstallation and operating instructions furnished byDRI-STEEM, or if the products have been modifiedor altered without the written consent of

DRI-STEEM, or if such products have been subjectto accident, misuse, mishandling, tampering,negligence or improper maintenance. Any warrantyclaim must be submitted to DRI-STEEM in writingwithin the stated warranty period.

DRI-STEEM’s limited warranty is made in lieu of,and DRI-STEEM disclaims all other warranties,whether express or implied, including but not limitedto any IMPLIED WARRANTY OFMERCHANTABILITY, ANY IMPLIEDWARRANTY OF FITNESS FOR A PARTICULARPURPOSE, any implied warranty arising out of acourse of dealing or of performance, custom or usageof trade.

DRI-STEEM SHALL NOT, UNDER ANYCIRCUMSTANCES, BE LIABLE FOR ANYDIRECT, INDIRECT, INCIDENTAL, SPECIAL ORCONSEQUENTIAL DAMAGES (INCLUDING,BUT NOT LIMITED TO, LOSS OF PROFITS,REVENUE OR BUSINESS) OR DAMAGE ORINJURY TO PERSONS OR PROPERTY IN ANYWAY RELATED TO THE MANUFACTURE ORTHE USE OF ITS PRODUCTS. The exclusionapplies regardless of whether such damages aresought based on breach of warranty, breach ofcontract, negligence, strict liability in tort, or anyother legal theory, even if DRI-STEEM has notice ofthe possibility of such damages.

By purchasing DRI-STEEM’s products, thepurchaser agrees to the terms and conditions of thislimited warranty.

Two-year limited warranty.

Product overview

Product overview:

Warranty

11

Installation checklist.

Installation

Before installing your VAPOR-LOGIC®3 control

system, review this checklist to ensure properinstallation of the product. Failure to follow therecommendations listed below could result in failureor damage to the humidifier or microprocessor.

Read this manual and information beforestarting.

See wiring diagram and information locatedinside the control cabinet door. Return allinformation to the control cabinet afterinstallation.

Position the control cabinet so that it is in sightof the humidifier tank.

Position the control cabinet so that the wirelength from the control cabinet to thehumidifier is 50 feet or less.

Connect an approved electric earth ground tothe earth ground lug in the control cabinet.

Never route the low voltage field control wiresnear the line voltage section of the controlcabinet or in the same conduit as line voltagewires.

Never use shielded cable for water level probewiring.

Attach the heater/machine ground lug in thejunction box, on the humidifier, to the subpanelmachine ground lug with the appropriate wire,sized per equipment grounding section of TheNational Electric Code.

Use 2-wire, 18 gauge shield plenumnonconduit-rated cable with drain wire for allhumidity and temperature sensor wiring. (UseBelden Company cable #88760 or equivalent;see wiring diagram for appropriate connections.)

Never ground shield at sensor end. A shieldgrounding lug is provided on the control cabinetsubpanel to ground the cable shielding.

Keypad installation precautions:

Do not locate keypad inside control cabinet.Route modular cable within control cabinetseparated from line voltage circuits.

Verify that VAPOR-LOGIC3 program code,which is detailed on Pages 8 and 9 of thismanual, matches field requirements.

Follow the recommended control cabinet fieldconduit knockout locations shown on the nextpage as Figure 12-1.

Installation:

Installation checklist

12

Proper wiring procedures.

Installation

Proper wiring prevents electrical noise

Electrical noise can produce undesirable effects onelectronic control circuits, thereby affectingcontrollability. Electrical noise is generated byelectrical equipment, such as inductive loads, electricmotors, solenoid coils, welding machinery, orfluorescent light circuits. The electrical noise orinterference generated from these sources (and theeffect on controllers) is very difficult to define, butthe most common symptoms are erratic operation orintermittent operational problems.

Most noise problems can be prevented by usingproper wiring practices and techniques to preventcoupling or inducing of electrical interference intocontrol circuits. The following simple wiringpractices should minimize interaction of noise andcontrols:

• Connect humidifier and control cabinets to acode-approved earth ground.

• Separate the line voltage wiring from lowvoltage control circuit wiring when routingelectrical wiring inside the control cabinet.

• Use separate electrical conduits for line and lowvoltage control wiring from the humidifier tohumidity sensors, airflow switches, etc.

More on next page . . .

Installation:

Wiring techniques

Figure 12-1: Control cabinet knockout locations for power and control

Knockoutsfor heater wiring(for VAPORSTREAM®, STS®, LTS®)

Knockouts forpower wiring

CAUTION: When making holes andknockouts in the control cabinet, protectall internal components from debris, andvacuum out cabinet when finished.Failure to comply with this warning maydamage sensitive electronic componentsand void the DRI-STEEM warranty.

Knockoutsfor controlwiring

OM-762

13

Figure 13-1: Probe wiring

Brown (full) top probe rod Level A

Orange (refill) middle probe rod Level B

Violet (low water) bottom probe rod Level Cor DI model low-water cutoff switch Probe wiring to be

18-gauge strandedwire run in conduitindependent of linevoltage wiring.

Do not use shieldedcable for probewiring.

Installation:

Wiring techniques

Proper wiring procedures (cont.).

Installation

Proper wiring prevents electrical noise (cont.)

• Do not use chassis or safety grounds as current-carrying commons. No safety grounds shouldever be used as a conductor or neutral to returncircuit current.

• When wiring external electrical connections tohumidistats, room/duct humidity andtemperature transmitters, or control signal inputconnections from a building control system, use18-gauge (minimum) plenum-rated twisted-pairwire, Belden #88760, with cable shielding anddrain wire for grounding.

• Return all shielded cable connections to thecontrol cabinet for grounding. Do not groundshield at the device end.

• IMPORTANT: Locate the control cabinetso that wire lengths are 50 feet or less to thehumidifier.

• Use 18-gauge stranded wire run in conduit (seeFigure 13-1) for probe and low-water cut offwiring.

• IMPORTANT: Do not use shielded cablefor probe wiring.

OM-VL3-11

14

Control cabinet installation and wiring.

Installation

Installation:

Control cabinet installation and wiring

The VAPOR-LOGIC®3 control board is shipped

mounted with all internal wiring completed within acontrol cabinet. All software has been customprogrammed into your VAPOR-LOGIC3 systemaccording to the original order requirements.

Important control cabinet installation points:

• All humidifier power wiring is represented onthe humidifier wiring diagram located with aninstallation guide on the inside of the controlcabinet door. Return all instructions to thecontrol cabinet after installation.

• Refer also to the VAPOR-LOGIC3 controlboard drawing on Page 3 of this manual fordetail of the board and connection points.

• Pick a location within sight of the humidifiertank that will allow for easy access to thecontrol cabinet and internal electricalcomponents.

IMPORTANT: Locate the control cabinetso that wire lengths are 50 feet or less to thehumidifier.

• Mount control cabinet using the mounting tabs.

• Always wire the VAPOR-LOGIC3 controlboard per local and national electric codes.

• VAPOR-LOGIC3 is powered by a low voltageClass 2 control transformer. The transformerprovides a 24 VAC supply, and is protected byan integral manual reset circuit breaker.

• Follow field wire torque requirements shown onthe humidifier wiring diagram when connectingthe power and control wiring inside thehumidifier control cabinet.

• Use only a 1/8" straight blade screwdriver onVAPOR-LOGIC3 control board terminal blocks.

• Use a single 18-gauge pre-tinned wire in eachterminal at the VAPOR-LOGIC3 terminal block.Torque to 5 inch-pounds.

• When terminating multiple wires to theVAPOR-LOGIC3 control board terminal block,secure the multiple wires and oneadditional wire with an appropriately sized wirenut. Use the single additional wire's oppositeend to connect to the VAPOR-LOGIC3 terminalblock.

• Never run the control system wires bundledwith, or in the same conduit as, power wires.

15

Keypad/display installation.

Installation

Installation:

Keypad/display installation

Installing modular cable

IMPORTANT: When routing modular cableinside the control cabinet, route cable away from allpower wiring and connect the male modular plug intothe VAPOR-LOGIC®

3 printed circuit board-mountedfemale modular receptacle, J2. Push male plug inuntil you hear a “click.” (The cable should beplugged into the keypad/display as well.) The six-wire cable provides the AC power to the keypad/display and completes the FTT-10A-type digitalcommunication between the keypad/display and theVAPOR-LOGIC3 control board.

CAUTION: If a longer cable is needed, do notattempted to fabricate one. Improper wiring canpermanently damage the VAPOR-LOGIC3 board,keypad or display. Please contact your localDRI-STEEM representative for longer cable options.

Installing the keypad/display

IMPORTANT: Do not locate the keypad/displayinside the control cabinet. The hardware ispremounted in the keypad/display case with frontaccess to the digital display and keypad. Position thecase in a convenient location for easy access.

Note that the keypad/display requires an ambienttemperature range of 32°F to 122°F (0°C to 50°C) tooperate properly. Exceeding these limits will result ina poor reading or no reading at all.

We recommend that you mount the keypad/display toa surface using a field-supplied network phone wallplate. To mount, simply slide the keypad/display ontothe tabs on the phone plate.

16

Sensing devices and humidity control.

Installation

Important to properly place sensing devices

Humidity sensing devices must be properly placed toachieve accurate humidity control. A typical small airhandling system is shown in the drawings on Pages17 and 18 (Figures 17-1 and 18-1). For the bestcontrol, place the humidity sensing device in thecenter of a room, or just inside the return air duct(location “A”). These locations will provide the leastamount of variation caused by air flow patterns androom temperature. Placement of the duct humiditysensing device within the outlet of the air handler(location “D”) is ideal for duct high limit control, butthe actual placement must be downstream fromdispersion tubes a sufficient distance to ensure steamabsorption has taken place. Accurate control oftemperatures in rooms and ducts is also veryimportant to improve control of relative humidity.

Other factors that affect humidity control

Unsatisfactory humidity control may involve morethan just the controller’s capability to control thesystem. Other factors that play an important role inoverall system control are:

• Size of the humidification system relative toload

• Overall system dynamics associated withmoisture migration time lags

• Accuracy of humidistats and humiditytransmitters and their location

• Dry bulb temperature accuracy in space or duct

• Velocities and air flow patterns in ducts andspace environments

• Electrical noise or interference

Installation:

Sensing devices and humidity control

17

System Diagram.

Installation

Installation:

Component placement

Figure 17-1: System diagram

OM-3007

ULTRA-SORB®

dispersion unit

VAPORSTREAM®

VLC humidifier

Line voltage

Liquid level detectors

Electrical supply

Control cabinet

24 voltLine voltage

Keypad/display

18

Temperature compensation transmitterlocated on lower corner of the insidesurface of double pane window glass

B

A

North or northeastfacing window

B

A

B

C

(Air handling unit)AHUBReturn airRelief air

D

Outside air

Point of vaporabsorption

Vapor absorptionhas taken place

Air flow switch(sail typerecommendedfor VAVapplication)

High limit humidistator high limit transmitter(set at 90% RH max.)placement for VAVapplications

10' min.(3 meters)

Placement of sensing devices.

Installation

Installation:

Placement of sensing devices

Figure 18-1: Recommended sensor locations

A Best

B Alternative location

C Not recommended

D Best duct high limit humidistat

Humidifier tank

OM-3008

19

12 mA - 4 .16

Wiring of sensing devices.

Installation

Wiring on-off humidistats

DRI-STEEM provides three types of on-off controls:wall-mounted humidistat, duct-mounted humidistat,or pneumatic/electric relay. The wiring diagram(found on the inside of the humidifier controlcabinet) will show proper wiring for these controls.

Wiring modulating humidistats

The signal from a humidistat directly controls theamount of output from the humidifier. The standardmodulating humidistat controllers DRI-STEEMprovides are either duct or wall-mounted.

The humidistats are powered by a 21 VDC supplyprovided by the VAPOR-LOGIC®

3 control board. Avariable control signal is returned to provide themodulating function on the humidifier.

For a pneumatic modulating signal, DRI-STEEMmay provide a transducer, which accepts a 3-20 psipneumatic input range.

Wiring modulating humidityor temperature transmitters

Transmitters provide an analog signal proportional tothe process variable being measured. All transmittersprovided by DRI-STEEM are two-wire devices. (Seeyour wiring diagram for proper connections.) Thehumidity transmitters have a range of 0-100% RHwith an output of 4-20 mA. The temperaturetransmitter has a range of -20° to 160°F(-29° to 71°C) with a 4-20 mA output.

Calculation of transmitter % RH

% RH =

Example: = 50%

(milliamp reading minus 4) .16

Installation:

Wiring of sensing devices

20

Figure 20-1: Example of proper shielding techniques whenconnecting humidity or temperature devices to VAPOR-LOGIC®

3 control inputs

IMPORTANT: Consult control cabinet wiring diagram. Control changes require wiring and programming changes.

Note: The wiring diagram (found on the inside of thehumidifier control cabinet) will show the proper controlswiring.

Wiring of sensing devices.

Installation

Installation:

Wiring of sensing devices

OM-VL3-17

21

Installation

Wiring VAV sensing device.

Variable air volume (VAV) option

This option is identified as a “V” in the third-from-lastplace of your program code nomenclature (forexample: EV11400285A7VOX).

When the VAV control option is requested we providea duct mounted humidity transmitter (4-20 mA outputover 0-100% RH range). Install using shielded cable(see Figure 21-1 below).

The modulating high limit transmitter signal operatesin conjunction with the room or duct controllingtransmitter signal through the VAPOR-LOGIC®

3control system to prevent over humidification in theduct work. VAPOR-LOGIC3 will start lowering thehumidifier output when the duct relative humidity iswithin six percent of the duct high limit set point.

Figure 21-1: Shielded cable

NOTE: Ground shield at control panel end only.Do not ground shield at device end.

When this occurs, the keypad/display will show themessage “VAV output limit.” If necessary, thereduction of the humidifier output will continue untilmaximum high limit set point has been reached,shutting off the humidifier completely.

When the high relative humidity starts to decrease inthe duct, VAPOR-LOGIC3 will slowly start toincrease the production of steam vapor. When theduct relative humidity decreases to a point greaterthan six percent below the duct high limit set point,the control transmitter will be restored as the primarycontroller and the keypad/display will no longershow the “VAV output limit” text, returning thecontrol system to normal operation.

Installation:

Wiring VAV sensing device

OM-VL3-18

22

Figure 22-1: Temperature compensationtransmitter placement

Doublepanewindowglass

Secure temperaturesensor tip to insidesurface of window glassusing clear RTV siliconeadhesive

Typicalsensorcord routing

Surface-mountedthermostattemperaturecontrolbox on wall

Thermostatcontrol wires

Windowframing

Temperature compensation offset option

This option is identified as a “T” in the second-from-last place of your program code nomenclature (forexample: EV11400285A7OTX).

When selected as an option, DRI-STEEM provides atemperature compensation (temp comp) transmitter.The temperature compensation transmittercontinually monitors the interior window glasstemperature and transmits this temperature toVAPOR-LOGIC®

3. VAPOR-LOGIC3 then comparesthe glass temperature to the desired RH set point inthe humidified area and calculates the dew point (°F)for the space.

VAPOR-LOGIC3 will lower (offset) the desired RHset point so that moisture does not form on windows.The keypad/display will show the amount of offsetthat has taken place as a modified set point. As theinterior window glass temperature increases,VAPOR-LOGIC3 will reduce the offset and restoresystem control to the normal RH set point for thespace.

Installation:

Temperature compensation transmitter

Installation

Temperature compensation transmitter.

The transmitter provided with VAPOR-LOGIC3 iscalibrated for -20°F to 160°F (-29°C to 71°C) withoutput from 4-20 mA. For example, a temperaturereading of 70°F should produce a measurement of12 mA.

Install using an 18-gauge plenum-rated shieldedcable for transmitter wiring with grounding shield atthe shield ground lug in the control cabinet (seeFigure 21-1 on the previous page).

Temperature compensationtransmitter placement

See Figure 22-1 below.

1. Position the temperature compensationtransmitter control box on a wall adjacent to awindow frame facing north or northeast.

2. Place flat surface of temperature sensor tip onlower corner of glass surface.

3. Temporarily hold the sensor tip in place withstrips of masking tape.

4. Apply a small amount of clear RTV siliconeadhesive over and around the sensor tip (makingsure the sensor tip is in contact with the windowglass).

5. After adhesive has cured, remove masking tape.

OM-337

23

Changing control input

VAPOR-LOGIC®3 has the ability to accept different

types of demand signals from either an energymanagement system or a humidistat. Follow thesesteps when a signal change is needed:

1. Remove the old signal wires from the board(terminals 21, 22 and 23).

2. Refer to program code nomenclature on Pages 8and 9. Refer to: “K. Type of humidity sensingdevice” to identify the new signal that is needed.

3. Enter the “Set Up” screen on theVAPOR-LOGIC3 keypad and scroll to the“Configuration String” screen.

Installation:

Changing control input

Installation

Changing control input.

4. Change the last character in the configurationstring to the desired input signal type identifiedfrom the program coded nomenclatureinformation on Pages 8 and 9.

5. Adjust the shunt connector J17 to the propersignal type, if necessary:

– If the signal is current, the jumper should beon I.

– If the signal is voltage, the jumper should beon V.

– If the signal is resistance, the jumper shouldbe on R.)

6. Connect the new signal to the board.

24

Start-up checklist.

Operation

Note:Your humidification system may not have allof the options listed below. If an item does notappear, skip to the next item and continue theprocess.

Verify that wiring is done per instructions in thismanual and the unit wiring diagram.

Make sure that the keypad/display is not insidethe control cabinet.

Check water level control voltages. The readingshould be 2.5 VAC without water; and 0 VACwith water from ground (Pin 33-J8) to probeinputs (Pins 30, 31 and 32-J8).

Check the proportional band setting in the“System Set Up” menu of the keypad/display(default is 10%).

Check the cycle setting in the “System Set Up”menu of the keypad/display (default is 60seconds; 2 seconds for SSR).

Check the proportional gain setting in the“System Set Up” menu of the keypad/display(default is 80).

Check the integral gain setting in the“System Set Up” menu of the keypad/display(default is 40).

Check the derivative gain setting in the“System Set Up” menu of the keypad/display(default is 0).

Check drain duration (default is 8 minutes).

Check flush duration (default is 8 minutes).

Check RH setting.

Check control signal.

Check amp draw of heaters for electric units;refer to wiring diagram for proper rating. If unitis powered by steam, check for steam flow. Forgas fired units, verify gas flow and combustion.

Confirm that the control signal being connectedto the VAPOR-LOGIC®

3 system is compatiblewith the VAPOR-LOGIC3 program. Identify theVAPOR-LOGIC3 program code on the wiringdiagram or on the outside of the control cabinetdoor. Refer to the VAPOR-LOGIC3 manual todecipher the code using the nomenclaturedescription on Pages 8 and 9.


Operation:

Start-up checklist

25

Start-up checklist (cont.).

Operation

Operation:

Start-up checklist

Confirm that all wiring is correct per the wiringdiagram.

Confirm that proper grounding and an approvedearth ground are provided.

Confirm that the J17, J18 and J19 shuntconnectors on the VAPOR-LOGIC®

3 board arein their correct position per the wiring diagram.See Page 3 for the physical locations.

Confirm that the keypad/display is mounted onthe outside of the control cabinet with modularcable routed away from high voltage circuitsand connected to the J2 female connector on thecontrol board.

Turn water supply on and confirm that the drainvalve (if available) is closed.

Turn power on and confirm that the displayshows the “Main Menu” screen with anoperational clock.

Enter the “Control Modes” screen and makesure the system is in auto mode.

When the keypad/display shows “Filling” aspart of the idle screen information, confirm thatthe tank is filling with water.

Confirm that the airflow switch is closed.

Confirm that the high limit humidistat input isclosed or that the variable air volume (VAV)control system high limit transmitter isconnected.

With sufficient water in the tank, the air flowswitch closed, the high limit humidistat closed,the safety interlock circuit closed, and a call forhumidity, verify that the heat outputs areactivated.

IMPORTANT: Confirm that the tank hassufficient water. If the tank does not containwater and the heat outputs are activated, or theburners are fired by the VAPOR-LOGIC3control system, a serious failure will result. Ifthis happens, immediately remove power fromthe system and verify that all wiring is done perthe wiring instructions in this manual and theunit wiring diagram.

During normal operation, the keypad/displaywill show humidifier operating status. See Pages27 through 36 for descriptions of keypad/display menu items. To change any of theoperating parameters, please refer to the abovepages.

If you experience difficulties, have the aboveinformation available with the model and serialnumbers of the humidifier and theVAPOR-LOGIC3 program code and callDRI-STEEM for help.

26

Components of the keypad/display

The VAPOR-LOGIC®3 keypad/display consists of

(see Figure 26-1 below):

• A 128 x 64-pixel backlit LCD display• A power light• An alarm light• Eight keys:

– Four arrow keys– An Enter key– Three soft keys

A soft key’s function is determined by the screencurrently displayed.

The arrow keys are used to adjust the values of thedifferent parameters of the humidifier.

The Enter key is used to make selections on variousscreens.

The power light is illuminated whenever power isapplied to the keypad/display.

The alarm light is activated any time a fault conditionis detected.

Keypad/display overview.

Operation

Figure 26-1: VAPOR-LOGIC3 keypad/display

Operation:

Keypad/display overview

The menu system

The VAPOR-LOGIC3 keypad/display softwareorganizes the control of the humidification systemunder six top-level screens:

• Status• Control Modes• Alarms• Set Up• Diagnostics• Reports

Each one of these screens is used to view or modify adifferent characteristic of the humidifier. To accessany of these screens, activate the Main Menu of thekeypad by depressing the “Main” soft key wheneverit is visible. This will immediately take you to theMain Menu selection screen, allowing you to choosewhere you would like to go next using the up anddown arrow keys followed by the Enter key. Themenu structure is diagramed on the opposite page,with a brief description of the submenus on the pagesfollowing.

27

Main Menu

1) Status

Soft key) Main – Returns to the Main Menu screen

Soft key) Back – Scrolls to the previous Status item

Soft key) Next – Scrolls to the next Status item

2) Control Modes

1) Auto Mode

2) Test Mode

3) Manual Drain

4) Standby


Soft key) Idle – Switches display to the Idle screen

3) Alarms


Soft key) Acknlg – Acknowledges the selected Alarm

Soft key) Clear – Clears the selected Alarm

4) Set Up


Soft key) Back – Scrolls to the previous Set Up item

Soft key) Next – Scrolls to the next Set Up item

5) Diagnostics


Soft key) Back – Scrolls to the previous Diagnostics item

Soft key) Next – Scrolls to the next Diagnostics item

6) Reports

1) H2O Converted

2) Energy Used


Soft key) Idle


Soft key) Control – Switches display to the Control Modes screen

Soft key) Alarms – Switches display to the Alarms screen

VAPOR-LOGIC®

3 menu structure.

Operation

Operation:

Menu structure

28

“Set Up” menu information.

Operation

Operation:

“Set Up” menu information

“Set Up” menu “Set Up” menu Range Defaultreadout description

RH Set point Relative humidity set point 20-80% RH 35%RH Offset RH offset calibration ±20% RH 0%Dewpoint Set point Dew point set point 20-80°F/-7-27°C 50°F/10°CDewpoint Offset Dew point offset calibration ±20°F/±20°C 0°F/0°CPID Band PID loop modulation band 1-20% RH 10%Kp Proportional gain factor 1-1000 80Ki Integral gain factor 0-1000 40Kd Derivative gain factor 0-1000 0Duct High Lim RH Duct high limit RH set point 50-95% RH 80%DuctRH Offset Duct RH offset calibration ±20% RH 0%Temp Comp Offset Temp comp sensor calibration ±20°F/±20°C 0°F/0°CADS Mode ADS operating mode Use Use

Use + IntervalInterval

Lbs of H20 until ADS Lbs/kg of water 6-32,767 lbs/ Systemthat must be boiled 3-14,863 kg dependentfor ADS to start

ADS Day Day to start ADS sequence Sunday - Saturday 1Today Current day of the week Sunday - Saturday 1ADS Hour Hour to start ADS sequence 0-23 0

(midnight–11:00 p.m.)ADS Interval Number of days 0-180 days 7 days

between ADS cyclesADS Duration Autodrain sequence duration 0-120 minutes 8 minutesAFS Duration Auto flush sequence duration 0-15 minutes 8 minutesService Setpoint Service interval set point 100-3,276,700 lbs/ System

100-1,486,300 kg dependentSkim Duration Skim time duration 0-120 seconds 3 secondsHeater Cycle Time Cycle time 30-99 seconds 60 seconds(TP-type control)Heater Cycle Time Cycle time 1-30 seconds 2 seconds(SSR-type control)SDU Duration SDU delay duration 1-30 minutes 2 minutesAquastat Aquastat set point 40-180°F/4-82°C 40°F/4°CInactivity Until EOS Inactivity time until EOS 1-168 hours 72 hours

drain cycle startsSet Up Password Password required to 0-32767 0

enter the “Set Up” screen (0 = password disabled)Configuration String See program code nomenclature System dependent System

dependentReal Time Clock Clock and date settings N/A Current

date/time

29

Readout displayed Description

Filling The unit is filling with water.

Skimming The unit has completed a fill cycle and is now skimming.

Draining The unit is draining.

Flushing The unit is flushing.

No Duct Air Flow The air flow proving switch is open.

Interlock Disable The interlock circuit is open.

VAV Output Limit The unit is approaching or has reached the duct RH high limit set point.

Preheating Tank The unit has received a call for humidity and is preheating the tank.

Freeze Protection The tank temperature has fallen below the aquastat set point and the unitis being heated.

End of Season Drain The unit is in end of season drain mode.

End of Season The unit is in end of season.

Low Tank Level The water level is below the probes on a standard water unit or belowthe float on a DI/RO water unit.

Temp Comp The RH set point has been temporarily modified to prevent moisturefrom forming on the windows. The modified set point is identified with an asterisk.

Duct RH High Limit The duct high limit RH has been reached.

Service Humidifier It is time to perform routine service on the humidifier.

Replace Probes The system has detected the need to clean or replace the proberod assembly.

Keypad/display readouts.

Operation

Operation:

Keypad/display readouts

30

Main menu: 1) Status.

Operation

Status

The Status screen is used to view some of theoperating parameters of the humidification system.Some of the parameters that may be displayedinclude:

• RH setpoint

• Room RH

• Dewpoint setpoint

• Measured dewpoint

• Duct setpoint

• Duct RH

• Window temp

• System demand (%)

• System output (pounds/hour or kilograms/hour)

• Tank temp (°F or °C)

• Water until ADS

• Water until service

Operation:

Main menu: 1) Status

31

Main menu: 2) Control Modes.

Operation

Control Modes

In the Control Modes screen, the operational mode ofthe humidifier can be set. You may choose from auto,test, manual drain or standby.

In Auto Mode, the humidifier operates normally. Allinputs and outputs are monitored and controlled. Ifthere is a call for humidification, the system willreact.

In Test Mode, the controller sequentially cyclesthrough all outputs so that their operation may beconfirmed. Once all outputs have been cycled on andoff, the controller reverts to the Standby Mode.

In Manual Drain Mode, the automatic drain valve(if so equipped) is opened and the tank is drained. Allhumidifier operation is suspended and the drain valveis held open until the unit is taken out of ManualDrain Mode.

In Standby Mode, the humidification system istaken off line. All humidity control inputs aredisplayed but not acted upon.

To select a new mode, use the vertical arrow keys tomove the selection pointer on the left hand side of thescreen up or down. When the pointer is positionednext to your new selection, press the Enter key. Yournew selection will now appear as inverted text.

Note that the current mode of the humidifier isalways shown as inverted text on this screen.

Operation:

Main menu: 2) Control Modes

32

Operation

Alarms

The Alarms screen is used to view the alarm log. Usethe vertical arrow keys to scroll through the alarmlog. The alarm log contains a record of the previous10 faults that have occurred on the humidifier. Thealarms may either be acknowledged or cleared usingthe soft keys below the display. If an alarm isacknowledged, it will be cleared and left in the logfor future reference. If an alarm is cleared, it will becleared and removed from the log.

Main menu: 3) Alarms.

Operation:

Main menu: 3) Alarms

33

Operation

Set Up

In the Set Up screen, the operational parameters ofthe humidifier can be set. Depending on systemoptions, parameters available may include:

• RH setpoint

• RH offset

• Dewpoint setpoint

• Dewpoint offset

• Duct high lim RH

• Duct RH offset

• Temp comp offset

• PID band

• PID gains (Kp, Ki, Kd)

• ADS mode

• Lbs of H2O until ADS

• ADS day

• Today

• ADS hour

• ADS interval

• ADS duration

• AFS duration

• Inactivity until EOS

• Service setpoint

• Water until service

• Heater cycle time

• Skim duration

• SDU duration

• Aquastat

• Configuration string

• Date/Time set

• Set up password

Main menu: 4) Set Up.

Operation:

Main menu: 4) Set Up

To modify a value, use the Next and Back soft keys tolocate the parameter in need of modification. Once theparameter has been located, use the vertical arrowkeys (or + and - keys) to change values, and use theleft and right arrow keys to move to different placeholders. When you are finished, you must presseither the Next or Back soft keys, or the Enter keyto save your change. If you press the Main soft keywithout first pressing one of these other keys, yourmodification to that particular parameter will be lost.

34

Operation

Diagnostics

The Diagnostics screen enables you to troubleshootsome of the hardware input and output points of theVAPOR-LOGIC®

3 control system. The soft keys Nextand Back are used to move through the diagnosticoptions. Once you have found the item you wouldlike to troubleshoot, view the reading and compare itwith what the value should be.

For example, if you were going to troubleshoot theRH signal input, you would select RH Signal on theDiagnostics screen. The display would then tell youwhat the current input signal is in mA. It would alsotell you what this voltage translates to in terms ofrelative humidity. You can then verify that the input isworking correctly.

Main menu: 5) Diagnostics.

Operation:

Main menu: 5) Diagnostics

Depending on system options and type, diagnosticsavailable may include:

• RH input

• Demand input

• Dewpoint input

• Duct HL input

• Temp comp input

• High probe voltage

• Mid probe voltage

• Low probe voltage

• DI float

• Tank temp input

• Air flow switch

• Safety interlock

• Blower #1 RPM

• Blower #2 RPM

• Burner #1 gas valve

• Burner #2 gas valve

• Combustion air switch

• Power vent switch

• Flue differential pressure switch

35

Operation

Reports

The Reports screen is useful for viewing historicalinformation about your humidifier. In this section,you are able to view the amount of water that hasbeen used by your humidifier and the amount ofenergy it has consumed.

Main menu: 6) Reports.

Operation:

Main menu: 6) Reports

36

Idle Screen

The Idle screen allows you to monitor thehumidifier’s basic operation. Depending on systemoptions, you may view system set point, the actualspace condition and the system demand.

The top line of the display informs you of the currentmode of the humidifier.

The second line is a system status line. This line willcontinuously scroll through any system status itemsthat are currently present. This may include(depending on your system’s options) Filling,Skimming, No Duct Air Flow, High Limit Disable,etc. The soft keys in this mode provide quick, directaccess to the Control Modes screen, the Alarmsscreen or back to the Main Menu screen.

Operation:

Main menu: Idle screen

Main menu: Idle screen.

Operation

37

On-off control

On-off control is the simplest control scheme, anddoes exactly what its name implies: the output deviceturns fully on, then fully off.

The on-off humidistat differential is designed into thecontrol action between the on and off switchingpoints. The differential is established at a rangesufficient to prevent output short-cycling. In otherwords, the humidity level will have to fall a littlebelow set point before the humidistat will close andenergize the humidifier. Once the humidifier isenergized, the humidistat will stay closed until thehumidity is a little above set point. This creates anoperating range that prevents the humidifier fromrunning for very short periods of time.

This type of operation is applicable to allDRI-STEEM humidification systems controlled byVAPOR-LOGIC®

3. In applications where there aremultiple contactor outputs, such as aVAPORSTREAM®, the contactors for the differentheat stages are pulled in one at a time with a twosecond interval between them. In applications with avariable output stage, such as an STS® or GTS®, theoutputs are ramped up until they reach 100%.

Demand signal control

With demand signal control, the VAPOR-LOGIC3controller provides the output level that a mastercontrol signal calls for. This signal can either begenerated by a humidistat or by a building energymanagement system. The signal that is sent to theVAPOR-LOGIC3 board is a modulating signal(typically 4-20 mA or 0-10 VDC). The boardresponds to this signal by producing a directlyproportional output. In other words, with a4-20 mA signal, a command of 4 mA would produceno output. A command of 12 mA would have thehumidifier running at 50% capacity, and a commandof 20 mA would have the humidifier running at100% capacity. With a humidistat provided byDRI-STEEM providing this signal, the humidity setpoint is set at the humidistat. The keypad/display isthen used for maintaining and troubleshooting thehumidification system, with humidifier controlstemming from the humidistat itself. With an energymanagement system (EMS) providing the signal, thehumidity set point is established somewhere on theEMS and the humidifier responds to the EMScommands.

Transmitter control

With transmitter control, the VAPOR-LOGIC3 boardreceives a linear signal that corresponds to the actualhumidity level being measured. (With aDRI-STEEM-provided transmitter, the signal is4-20 mA, which corresponds with 0-100% RH.) TheVAPOR-LOGIC3 controller then uses this humiditymeasurement, along with a user defined desiredhumidity set point, and calculates a demand level.This demand level is the level at which thehumidifier will run.

Control modes.

Operation

Operation:

Control modes

38

TP modulation

The standard form of modulation with an electrichumidifier is TP (time-proportioning) modulation.With this type of modulation, the outputs are cycledon and off at a certain rate to approximate humidifierdemand.

For example, if a VAPORSTREAM® humidifier hasfour heat output stages (four contactors) and ademand of 55%, two of the contactors will beenergized all of the time, one contactor will becycling on and off at a certain rate, and one contactorwill be off all of the time. The rate at which the thirdcontactor cycles is determined by the demand and theTP cycle time. Continuing with our example, if wehave a TP cycle time of 60 seconds and a demand of55%, the third contactor will be cycling at a rate of12 seconds on and 48 seconds off.

To calculate the above example, imagine that eachcontactor represents 25% of the output of thehumidifier. With a 55% system demand, we need twofull contactors plus 5/25 of a third contactor.Therefore, two contactors will be full on and a thirdcontactor will be on for 5/25 of 60 seconds, or 12seconds.

To minimize wear on the contactors that are cycling,VAPOR-LOGIC®

3 keeps track of the number ofcycles on all contactors and it will rotate the TPcycling contactor through the stages to ensure thatthey all get equal wear. In addition, no contactor willever have a cycle time of less than two seconds orgreater than two seconds less then the TP cycle time.In other words, if a contactor needs to be on for lessthan two seconds because of the way the math turnsout, the contactor will be energized for the minimumtwo second period. Also, if a contactor needs to bede-energized for less than 2 seconds, it will stay on.This prevents quick cycling of the contactors andextends their life. On a TP system with contactors,the TP cycle time is user-adjustable and can be setfrom 30 seconds to 99 seconds via theVAPOR-LOGIC3 keypad/display.

Operation:

TP modulation

Modulation types: TP modulation.

Operation

39

There are two basic types of SSR modulation: SSRmodulation with contactors, and 100% SSRmodulation.

SSR modulation with contactors

With SSR modulation with contactors, the operationof the unit is the same as it is with TP Modulation. Inthis scenario, one of the cycling contactors isreplaced with an SSR. The SSR is now the devicethat carries out all of the cycling duties. Thecontactors will always be either on or off. Any TPcycling that is needed will be handled by the SSRstage.

This provides two distinct advantages over standardTP modulation. First, an SSR can turn on and offmuch faster than a contactor can. Therefore, as theunit modulates around a demand signal, tightercontrol is achieved because the cycle time on an SSRsystem is factory-set at one second. This means thatevery second, the controller can adjust the on and offtimes on the SSR to very closely track the desireddemand.

The second major advantage over standard TPmodulation is reliability. With a solid state devicelike an SSR, component wear and tear is almostnonexistent when compared with anelectromechanical device such as a contactor.Therefore, with the SSR doing all of the heavycycling work, the life expectancy of the contactors isextended.

100% SSR modulation

The ultimate in electric humidifier modulation is 100%SSR Modulation. With this type of control, all heatstages are controlled by SSRs. This allows the outputof the humidifier to track the actual demand veryclosely because all heat stages can now cycle on andoff at the rapid SSR cycle rate.

With 100% SSR modulation, a contactor is stillprovided in series, with the SSR device as anadditional safety feature. This contactor is energizedany time there is demand on the humidifier, andremains energized until the demand is satisfied. Inthis way, if there is a failure in the SSR device, thecontactor is there as a backup to shut the humidifierdown.

Modulation types: SSR modulation.

Operation

Operation:

SSR modulation

40

STS®, LTS® and ULTRA-FOG® valve modulation

With a valve system, the modulation is very simple.The demand signal simply determines how far thevalve is going to open. In other words, if the systemdemand is 25%, the valve will be open 25%.

GTS® burner modulation

The burner modulation technique used on a GTS isprobably the most complicated. The burners canoperate anywhere from 25% to 100% of theircapacity. To accomplish this turndown, the blowerspeed is varied by the VAPOR-LOGIC®

3 controller.(The blowers used on the GTS are variable speedblowers with a tachometer feedback. TheVAPOR-LOGIC3 controller monitors this feedbackand uses it, in conjunction with the demand signal, tocontrol the blower speed.) As the blower speedvaries, the gas valve automatically adjusts the amountof gas being introduced into the burner. This variablecombination of gas and air results in cleancombustion in the range of 25-100% of burnercapacity.

When individual burner demand falls to below 25%of capacity, the operation changes. Basically, a one-burner GTS has full modulation in the range of25-100%. Below 25%, the unit essentially timeproportions. A two-burner GTS has full modulationin the range of 13-100%. Below 13%, the two-burnerunit will time proportion.

To explain this, lets first look at the operation of aone-burner GTS. As the demand on the unit increasesfrom 0, the unit will remain off until the demandreaches 14%. Once 14% demand is reached, thecontroller will fire the burner and run it at 25% of itsrated capacity. (When a GTS burner fires, it fires at72% of its rated capacity. If the tank is warm, then itimmediately modulates up or down to the desireddemand. This is done to provide the smoothest,quietest, most reliable ignitions. If the tank is cold,the unit will run at 100% capacity to preheat the tank.Once the tank is hot, it will resume normaloperation.) The lit burner will stay at 25% of its ratedcapacity unless the demand on the system exceeds

25%. At this point, the burner output will exactly trackwith the demand. In other words, if the demand on thesystem is 55%, the burner will be running at 55%output. As the system demand drops down below25%, the burner will continue to run at 25% until thesystem demand drops to 11%. At this point, theburner will be shut down. The controller will not firethe burner again until the demand goes back to 14%or higher. Then, the burner will again fire and run at25% of its rated capacity. What this results in is amodified time proportioning system for a systemdemand below 25%, and exact demand tracking forany system demand over 25%.

A two-burner GTS operates in much the same waywith a few slight differences. As demand increasesand reaches 8%, one of the burners will fire and runat 25% of its rated capacity. This burner will run at25% of its capacity until the system demand reaches13%. At this point, the lit burner will be ramped up inoutput, tracking with the total system demand. Oncethe system demand reaches 30% (60% demand onthe one lit burner), the controller will fire the secondburner. Both burners will now be lit and running andthey will track the system demand together. In otherwords, if the system demand is 48%, both burnerswill be running at 48% of their rated capacities. Next,as the system demand falls and reaches 25%, one ofthe burners will shut off and the other burner will bebrought back up to 50% of its rated capacity. Thisresults in an overall system output of 25%. As thedemand continues to fall and reaches 13%, the oneoperating burner will remain at 25% of its ratedcapacity. When the total system demand fallsand reaches 5%, the one burner left running will beshut off.

Operation:

Valve and burner modulation

Modulation types: valves and burners.

Operation

41

Adjust set point through Set Up menu

Set point adjustments are accomplished through theSet Up menu, which is under the Main Menu (refer tothe menu structure diagram on Page 27).

Once you have accessed the Set Up menu, you will beable to adjust a number of parameters including theset point of the unit. To adjust the humidity set point,your unit must be configured for a humiditytransmitter. You may enter a desired humidity setpoint anywhere in the range of 20% to 80%. Your setpoint modifications will take effect as soon as youpress the Enter key or move to another parameterusing the Next or Back soft keys, or exit the set upmenu using the Main soft key.

Control functions: adjusting set point.

Operation

Operation:

Adjusting set point

Depending on your options, you may also be able toadjust the high limit humidity set point and the dewpoint set point. The high limit set point has a validrange of 50% to 95%. The dew point set point has avalid range of 20°F (-7°C) to 80°F (27°C). If yourunit is equipped with the dew point control option,you will not have a desired humidity set point option.

42

Tune your system with PID loop

When your unit is equipped with a humidity or dewpoint transmitter (when you are able to adjust the setpoint through the keypad/display) control isaccomplished through a PID control loop. PID standsfor Proportional, Integral and Derivative.

With a PID loop, you are able to �tune� your systemfor maximum performance using the proportional(Kp), integral (Ki) and derivative (Kd) gain terms.These gain factors work in the following way: Theoverall demand in a PID system is made up of threedistinct parts that are added together. There is theproportional piece, the integral piece and thederivative piece. Each one of these parts is calculatedand then multiplied by a gain factor. These gainfactors are the setup variables that you have accessto. By making a gain factor larger, you increase itscomponent�s overall influence on the system demandequation. Once the multiplication has taken place, allthree terms are added together to determine theoverall demand percentage. One other term that isuser-controlled in the PID equation is theproportional band.

The proportional term

The proportional band is the band (in % RH, or °F/°Cfor dew point control) in which the humidifier willmodulate.

For example, if starting with a set point of 35% and aproportional band of 10%, the humidifier operationwill be as follows: On initial start-up, assume anactual humidity level of 15%. The proportional bandis 10% so the humidifier will modulate when theactual humidity is in the range 25-45%. If the actualhumidity is lower than 25%, the humidifier will befull on. If the actual humidity is above 45%, thehumidifier will be full off. In the example, starting atan actual humidity level of 15%, the humidifier willbe full on. As the actual humidity level climbs intothe range of the proportional band (25-45%), thehumidifier will begin to modulate down. Once the setpoint of 35% is reached, the humidifier will be fulloff.

Looking at this scheme a little closer, a problem canbe found. In almost all applications there will besome constant load on the humidifier just as there is aconstant load on the heating equipment. With thiscontrol scheme, the actual humidity must be less thanthe set point for the humidifier to be on. What endsup happening is the humidifier finds a �happymedium� where the actual humidity is something lessthan the set point, which allows the humidifier tocontinue to run. This difference between the set pointand the actual running humidity level is called the�droop.� This droop can be corrected using the nextterm, the integral gain.

The integral term

The integral gain affects how fast the humidifier willreact to a droop condition. The higher the number,the faster the reaction. (An integral term of zerodisables this variable and allows the unit to run on theproportional band only.) The way this term works isas follows: When the actual humidity is in theproportional band, the humidifier demand issomewhere between 0 and 100 percent. Every 1/2

Operation:

PID tuning

Control functions: PID tuning.

Operation

43

second the demand is updated. With an integral gainterm greater than zero and an actual humidity belowset point, each time the demand is updated it isincreased slightly. If the actual humidity is above setpoint, the demand will be decreased slightly. Theamount it is increased or decreased is dependent onthe difference between the actual humidity and setpoint. (The closer you are to the set point, the smallerthe addition or subtraction.)

When looking at this control scheme, somethinginteresting is found. The total demand signal for thehumidifier is the sum of the proportional part, theintegral part and the derivative part. As the actualhumidity approaches the set point, the integralportion makes up the majority of the demand and theproportional part makes up very little. Once the setpoint is achieved and the unit stabilizes, the entiredemand is made up of the integral part because theproportional part is zero. If the actual humidity goesover the set point, the integral term will start todecrease. In addition, the proportional term will gonegative and actually start to subtract from the totalsystem demand. These two items work in conjunctionwith each other to bring the humidifier back to setpoint.

The derivative term

A derivative term�s basic function in a PID loop is toanticipate where the demand is going and to help itget there. Its basic operation is as follows: As thehumidifier is running, the PID loop is generating anerror term. (The error term is the mathematicaldifference between the RH set point and the actualmeasured RH.) If the actual measured RH is belowset point and is rising, the derivative term will

subtract from the demand in anticipation of theapproaching set point. If the actual measured RH isbelow set point and is falling, the derivative term willadd to the demand in anticipation of the need to getthe demand up faster and start climbing toward setpoint. The same is true for situations above the setpoint. If the actual measured RH is above set pointand is rising, the derivative term will subtract fromthe total demand in anticipation of needing to reducedemand and get closer to set point. If the actualmeasured RH is above set point and falling, thederivative term will add to the overall demand inanticipation of the approaching set point. In themajority of control situations, the derivative term isnot needed and is simply set to zero. Theproportional term and integral term will provide verytight, accurate control without the addition of thederivative term.

PID setup tips

A large proportional band (10 to 20%) will yieldtighter and more stable control with longer responsetimes. A small proportional band will producequicker response times but control may becomeunstable. As a rule of thumb, start with a band of10%. If the unit does not �hunt� and a quickerresponse is needed, the band can be lowered. If theunit hunts or the fast response is not needed, increasethe band. This will result in more system stability.(To increase or decrease the effect of the proportionalband on system performance, the proportional gainfactor may be adjusted. However, for the majority ofsystems, the factory default setting of 80 issufficient.) A moderate integral gain term (30 to 50)will also yield tighter and more stable control with alonger response time. A large integral gain willquicken the response but may cause the system tobecome unstable. As a rule of thumb, start with anintegral term of 40. If the unit does not hunt andquicker response is needed, raise the integral gain. Ifthe unit hunts or does not need the fast response,decrease the integral gain.

Control functions: PID tuning (cont.).

Operation

Operation:

PID tuning

44

VAV control

With VAV control, the system is equipped with a ducthigh limit transmitter. This transmitter sends a signalback to the VAPOR-LOGIC®

3 controller. The controllerthen compares the measured duct RH with the highlimit set point (Duct High Lim RH) that is enteredthrough the keypad/display in the Set Up screen. Asthe measured duct RH approaches the high limit setpoint, the system output is proportionally throttledback. (This scaling of the output starts once themeasured RH is within 6% of the high limit set point.)Once the measured duct RH drops, full system outputis automatically restored.

Temperature compensation control

With temperature compensation (temp comp) control,the system is equipped with a window temperaturetransmitter. This transmitter sends a signal back to theVAPOR-LOGIC3 controller. As the window glasstemperature decreases and approaches the dew pointof the room, the RH set point is automaticallydecreased to prevent moisture or ice from forming onthe window. Once the window temperature rises, theoriginal RH set point is restored. This option is onlyavailable when the system is equipped with an RHtransmitter. It is not available when a remotehumidistat or energy management system is used tocontrol the humidifier.

Dew point control

Dew point control functions in exactly the same wayas RH control except the dew point is beingmeasured instead of the RH. The dew pointtransmitter sends a signal back to theVAPOR-LOGIC3 controller. The user is able tomodify the dew point set point and PID parametersthrough the keypad/display just as they could with anRH transmitter.

Operation:

VAV, temp comp, dew point control

VAV, temp comp, dew point control.

Operation

45

Aquastat operation

The aquastat set point is the minimum tanktemperature the VAPOR-LOGIC®

3 controller shouldmaintain. It is adjusted through the Set Up screen.This feature is typically used to keep the tank fromfreezing in a cold environment. However, it can alsobe used to hold a higher minimum temperature if aquick response to a demand signal is needed. Forexample, if the aquastat is set at 180°F (82°C), whena call for humidity occurs, the tank will only need towarm up 32°F (18°C) to reach the boiling point andstart producing steam. However, if the aquastat is atits minimum setting of 40°F (4°C) and the tank is inan average-temperature occupied room, the tank willbe sitting at about 70°F (21°C). Now, when a call forhumidity occurs, the tank will need to warm up142°F (79°C) to reach the boiling point and beginproducing steam. This feature is standard on allDRI-STEEM humidifiers with VAPOR-LOGIC3control except ULTRA-FOG® and Steam Injectionhumidifiers.

Tank heat-up feature

The tank heat-up feature uses the tank temperaturesensor to quickly heat a tank in response to a demandsignal. Its operation is as follows: If the tank is cold(70°F) and a small demand signal is delivered, theVAPOR-LOGIC3 controller will override thedemand signal and run the humidifier at 100%demand until the tank temperature is 190°F (88°C). Atthis point, control will be returned to the originaldemand signal and the humidifier will begin normaloperation. This allows the system to respond quicklyto even the smallest demand. This feature is standardon all DRI-STEEM humidifiers withVAPOR-LOGIC3 control except ULTRA-FOG andSteam Injection humidifiers.

SDU timer

If your humidifier is equipped with a SpaceDistribution Unit (SDU) or an Area-Type fan, youhave the option of controlling how long the fan willrun after a call for humidity has ended. This delay(SDU Duration) is adjustable in one-minute intervalsthrough the Set Up screen.

Sensor offsets

All external transmitters shipped withVAPOR-LOGIC3 can be field calibrated using thekeypad/display through the Set Up screen. Forexample, if the system is equipped with an RHtransmitter, there will be an RH offset setting. Thefactory default for all transmitter settings is zero.However, if an adjustment is necessary, the keypadcan be used to adjust the transmitter reading up ordown through this setting. The sensors that have thisadjustment capability are the humidity, VAV highlimit, temp comp and dew point transmitters.

Metric conversion

VAPOR-LOGIC3 is capable of displaying allinformation in metric as well as standard units.

Aquastat, heat-up, SDU, offsets, metric.

Operation

Operation:

Aquastat, heat-up, SDU, offsets, metric

46Operation:

Conductivity probe

Water level control: conductivity probe.

Operation

Probe system

Standard water systems use a conductivity probe tocontrol water levels for optimum operatingefficiency. The three-probe system is monitored bythe VAPOR-LOGIC®

3 board, which performs all thenecessary logic and timing functions to provide totalwater level control and safety shutdown.

VAPOR-LOGIC3 automatically maintains the waterlevel between the upper two probes A and B (seeFigures 46-1 and 46-2 below). When the water levelfalls below probe B, the fill valve is opened until thewater level reaches the upper probe A. Water mustremain in contact with the probe surface for aminimum of two seconds for VAPOR-LOGIC3 todetermine that the water is at the probe's level,ensuring that turbulence does not cause an incorrectlevel reading.

Water level - A

Water level - B

Water level - C

Figure 46-1: Conductivity probe system for GTS®, VLC®, VAPORMIST® and CRUV®

Water level - C

Water level - B

Water level - A

Each time the fill valve is energized, the probe systemis tested by the VAPOR-LOGIC3 system. If the signalfrom the probe assembly is beginning to deteriorate,the message �Replace probes� will appear. Once theprobe system has reached its maximum usable life, thehumidifier will shut down and the message �Probefault� will appear.

An adjustable skim time allows for an extended skimperiod (0-120 seconds) to reduce surface mineralaccumulation. When skimming, the fill valve remainsenergized for the designated delay time after thewater level reaches the upper probe A.

Probe C provides low water protection for theheating elements. If the water level falls below probeC, the heaters are de-energized.

Figure 46-2: Conductivity probe systemfor STS® and LTS®

OM-632 OM-270

47Operation:

Float valve

Water level control: float valve.

Operation

Float valve system

DI/RO water systems (except for ULTRA-FOG®) usea float valve system to control water levels foroptimum operating efficiency. DI/RO systems areused where water/steam purity is important, wheredemineralized water is needed to improveperformance or lessen maintenance requirements, orwhere a potable water source has minimal or noconductivity, thus requiring a float rather than aprobe to sense water levels.

The float valve system consists of a fill float and alow-water cutoff float.

The fill float regulates how much water is addedto the tank via a float, float arm and mechanicalvalve. The valve is adjusted to within 1/4" of theoverflow (skimmer) port allowing heated andtherefore expanded water at start-up to fill theexternal P-trap.

The low-water cutoff float has an electrical switchthat closes when a ready-water condition isreached. A low voltage AC current runs from theVAPOR-LOGIC®

3 controller to the switch allowingthe controller to sense when the voltage drops as theswitch closes to ground at a ready-water condition.

Figure 47-1: Float valve systemused with DI/RO systems

OM-3009

Stripe mark indicates proper float ball placement onstem. Switch is normally open when float ball is at itslowest point on stem.

Stem

48

Drain and flush options

VAPOR-LOGIC®3 is preprogrammed to enter an

automatic drain, flush and refill cycle to help keepmineral concentrations in the tank to a minimum. Themethod by which this is accomplished is selected bythe user through the keypad/display in the Set Upscreen. The three options available are:

1. Flush after usage

2. Flush at a certain time after usage, and

3. Flush at a certain time

Please note that these options are only available witha standard water system having an automatic drainvalve. If the humidifier is configured for DI/ROwater, or if the unit has a manual drain valve, thesedrain and flush options are not available.

In the flush after usage mode, the humidifier willenter the drain and flush sequence after a user-selected amount of water has been converted tosteam. In other words, if the user set the drain andflush interval to 10,000 pounds, the unit will enter thedrain and flush sequence the moment 10,000 poundsof water have been boiled.

In the flush at a certain time after usage mode, thehumidifier will enter the drain and flush sequence ata specific time after a user-selected amount of waterhas been converted to steam. In other words, if theuser sets the drain and flush interval to 10,000pounds and the ADS Hour to 2, the unit will enter thedrain and flush sequence at 2:00 am after 10,000pounds of water have been boiled. This allows theuser to keep the humidifier on line until a convenienttime for the drain and flush sequence.

Operation:

Drain and flush, skim

Drain and flush, skim.

Operation

In the flush at a certain time mode, the humidifier willenter the drain and flush sequence at a specific time,ignoring the amount of water that has been convertedto steam. In other words, if the user sets the ADSHour to 2, and the ADS Interval to 7 days, the unit willenter the drain and flush sequence every 7 days at2:00 am.

When VAPOR-LOGIC3 initiates the drain and flushsequence, all activated heat sources are deactivated.The drain valve is then opened to allow the tank todrain. The drain valve remains open during the flushsequence for drainage while the fill valve is open. Atthe completion of the flush cycle, the drain valvecloses allowing the fill valve to refill the tank. Formultiple tank systems, only one tank at a time entersthe drain and flush sequence in order to keep as muchcapacity available as possible.

Skim timer

With a standard water configuration, theVAPOR-LOGIC3 controller comes equipped with askim timer. This timer is activated at the end of eachfill cycle. The timer keeps the fill valve open for auser-determined amount of time after the tank hasfilled to skim minerals off the water surface. Theskim time is adjusted through the Set Up screen onthe keypad/display.

49

Service interval, EOS, date set.

Operation

Operation:

Service interval, EOS, date set

Service interval

The VAPOR-LOGIC®3 controller keeps track of how

much water has been converted to steam. After auser-defined number of pounds/kilograms have beenboiled, a service humidifier message will appear onthe keypad/display. However, the humidifier willcontinue to operate after the message appears. Themessage is simply to notify the user that the serviceinterval has been reached. This service interval isadjustable through the Set Up screen on the keypad/display.

End of season drain

If there is no call for humidity for a preset timeperiod, the humidifier will be placed in End ofSeason (EOS). When the unit enters End Of Season,the humidifier is placed in Standby Mode. The drainvalve is held open for one hour to allow the tank todrain and then it is closed. If the humidifier receivesa call for humidity after the end-of-season drain, itautomatically leaves the Standby Mode and returns tothe Auto Mode. The tank is refilled and thehumidifier resumes normal operation. The amount ofinactivity time that is needed before the humidifierenters End Of Season is adjustable through the SetUp screen on the keypad/display (Inactivity UntilEOS). This option is only available on units that areequipped with automatic drain and fill valves.

Setting date and time

The VAPOR-LOGIC3 controller contains a real-timeclock that is used for several features including thedrain and flush sequence and the logging of alarms.If it becomes necessary to reset the date or time, theyare accessible through the Set Up screen on thekeypad/display.

50Operation:

Fill timer, over-temp fault

Safety features.

Operation

Fill timer

The VAPOR-LOGIC®3 controller keeps track of

approximately how much water, in the form of steam,has left the tank. If this total amount exceeds a presetlimit without the fill valve being energized, a low watercondition is assumed and the humidifier is shut down.Each time the fill valve is energized, the total is resetto zero. Note that this system is not used on a DI/ROhumidifier because the fill valve is not an electric-solenoid type. On a DI/RO tank, a mechanical fillvalve maintains the proper water level. This fill valveoperates independently of the VAPOR-LOGIC3controller. Therefore, on a DI/RO system, there is noway to reset the steam total to zero as the tank fills.

Over-temp fault

The tank temperature is constantly monitored by theVAPOR-LOGIC3 controller. If the temperature everrises above a preset limit, the humidifier is shut downand a thermal trip fault is given on the Alarms screenof the keypad/display. This fault must be cleared oracknowledged on the Alarms screen by the userbefore humidifier operation will resume.

51

Fault messages, diagnostics.

Operation

Operation:

Fault messages, diagnostics

Alarms screen

The Alarms screen on the keypad/display logs thelast ten alarms that have occurred on the humidifier.To scroll through the alarms, use the up and downarrow keys. You can acknowledge or clear any oneof the alarms using the appropriate soft keys. If analarm has occurred that you would like to get moreinformation about, highlight that alarm using thearrow keys and then press the Enter key. A screenwill appear that gives you the time and date the alarmoccurred as well as a more detailed explanation ofwhat the alarm means.

Sensor faults

The following is a list of sensor faults that can occur.Please note that this is a complete list of faults. Yoursystem may not have all of these options. The text inparentheses is what will actually appear in the alarmlog.

� Humidity transmitter fault (RH Trans Fault)The humidity sensor is incorrectly wired or bad.

� Dew point transmitter fault (DP Trans Fault)The dew point sensor is incorrectly wired orbad.

� VAV humidity transmitter fault(VAV Tran Fault)The duct humidity sensor is incorrectly wired orbad.

� Temp comp transmitter fault(Temp Trans Flt)The temperature compensation sensor isincorrectly wired or bad.

Fill and drain faults

The following is a list of fill and drain faults that canoccur. Please note that this is a complete list of faults.Your system may not have all of these options. Thetext in parentheses is what will actually appear in thealarm log.

� Fill fault (Fill Fault)The fill valve has been energized for more than40 minutes without the water reaching the topprobe.

� Drain fault (Drain Fault)The drain valve has been energized for morethan 20 minutes without the water falling off thebottom probe.

� Low water timer fault (Fill Time Flt)The unit has run too long without the fill valveopening.

� LL probe fault (LL Probe Fault)The water in the tank has reached the middle orupper probe without reaching the lower probe.

� ML probe fault (ML Probe Fault)The water in the tank has reached the upperprobe without reaching the middle probe.

� Probe assembly fault (Probe Assy Flt)The system has detected the deterioration of theprobe assembly to a point that replacement isnecessary.

52

Humidifier faults

The following is a list of humidifier faults that canoccur. Please note that this is a complete list of faults.Your system may not have all of these options. Thetext in parentheses is what will actually appear in thealarm log.

� Temperature sensor fault (Tank Temp Flt)The temperature sensor on the humidifier tank isincorrectly wired or bad.

� Thermal trip fault (Thermal Trip)The tank temperature has exceeded 245°F(118°C).

� SDU fault (SDU Fault)The SDU blower pressure switch failed to closewhen the SDU was started.

� EEPROM fault (EEPROM Fault)The controller has detected a check sum fault inthe EEPROM memory.

� Flue fault (Flue Fault)The air damper limit and/or the power ventpressure switch failed to close.

� Burner # fault (Burner # Fault)The burner failed to light after three ignitionattempts.

� Ignitor # fault (Ignitor # Fault)The ignition module failed to energize the gasvalve.

� Blower # fault (Blower # Fault)The blower was unable to reach the desiredspeed.

� GTS® only: Slave # fault (Slave # Fault)One of the humidifiers in a multiple tank systemis not responding to communication requests.

� Boil time fault (Boil Time Flt)The water in the tank failed to boil within themaximum boil time.

Sensor meter feature

The Diagnostics screen on the keypad/displaycontains the sensor meter feature. This feature allowsthe user to read the state of all of the current inputs tothe VAPOR-LOGIC®

3 controller.

To scroll through the screens, use the Next and Backsoft keys to select the input you wish to check. Whenyou are done, press the Main soft key to return to theMain Menu screen.

Operation:

Fault messages, diagnostics

Fault messages, diagnostics (cont.).

Operation

53

Reports, multiple tank systems.

Operation

Operation:

Reports, multiple tank systems

Energy usage report

The energy usage report gives an approximate total ofhow much energy has been consumed by thehumidifier since the last service interval. Dependingon the system type, this number may be in KWH,MBTU, therms, etc.

Water usage report

The water usage report gives an approximate total ofhow many pounds/kilograms of water have beenconverted to steam since the last service interval.

Multiple tank systems

The VAPOR-LOGIC®3 controller has the ability to be

connected via a LonTalk® network to control up to sixtank humidification systems. These multiple tanksystems operate in exactly the same way as singletank systems. The multiple tanks work together togenerate the desired level of humidity. Thehumidifiers are brought on line sequentially, whichmeans that one humidifier must be running at fullcapacity before the next one is brought on line.However, the VAPOR-LOGIC3 controller monitorsthe demand signal and will begin to preheatadditional tanks as the demand signal rises so thatthere is a seamless transition in output whenadditional tanks are brought on line.

54

Operation

Operation:

Troubleshooting introduction

Troubleshooting 1, 2, 3.

1.Review troubleshooting index

If you find that you are having a control-relatedproblem, first check the problem list on the nextpage. If you are having a tank- or dispersion-relatedproblem, you may also need to refer to those specificproduct manuals.

2.Review possible causes andrecommended actions

The troubleshooting section presents possible causesand recommended actions for typical problems.

3.Call us if you’re still having problems

If the troubleshooting guide does not help you solveyour problem, call us with the following informationavailable:

1. Product name, program code, and ordernumberYou�ll find this information on the wiringdiagram and on the outside of the control cabinetdoor.

2. Problem definition(Water leaking, low humidity, high humidity,etc.)

3. Time problem began(Always, after remodel, after a change inweather)

4. System changes(Pressure, new boiler, new service, newcontroller, relocation, change in maintenance)

Humidifier model number ___________________

Humidifier serial number ___________________

VAPOR-LOGIC3 program code ________________

55

Index to troubleshooting guide.

The following is an index to possible control-related problems described on the following pages. To findsolutions, refer to either the problem number or the page number shown.

# Description

1. Green power indicator light is off .................. Page 562. No remote fault indication ............................. Page 563. No readable information on keypad/display .. Page 56

Faults4. Humidity transmitter fault .............................. Page 565. Dew point transmitter fault ............................ Page 566. Humidistat fault .............................................. 7. VAV humidity transmitter fault ..................... Page 578. Temp comp transmitter fault .......................... Page 579. Fill fault .......................................................... Page 5710. Drain fault ...................................................... Page 5811. Low water timer fault ..................................... Page 5812. LL probe fault ................................................ Page 5813. ML probe fault ............................................... Page 5914. Replace probes fault ....................................... Page 5915. Probe assembly fault ...................................... Page 5916. Temperature sensor fault ................................ Page 5917. Thermal trip fault ........................................... Page 5918. SDU fault ........................................................ Page 5919. EEPROM fault ............................................... Page 5920. Flue fault ........................................................ Page 6021. Burner # fault ................................................. Page 6022. Ignitor # fault .................................................. Page 6023. Blower # fault ................................................. Page 6024. Slave # fault .................................................... Page 61

Operation problems25. Control does not energize ............................... Page 6126. Unit does not fill with water ......................Page 61-6227. Fill valve does not close ............................Page 63-6428. Reduced or no output ..................................... Page 6429. Fill valve cycles on and off frequently ........... Page 6530. Heater burnout ................................................ Page 6531. Noisy operation .............................................. Page 6632. Humidity below desired level ...................Page 67-6833. Humidity above set point ..........................Page 68-6934. Hunting ........................................................... Page 6935. Will not perform autodrain ............................. Page 70

Operation

Operation:

Index to troubleshooting guide

56

� No control voltagepresent

� Heater fuses open

� Transformersecondary circuitbreaker tripped

� Field wiring notinstalled

� Field-supplied remotefault indicator lamp isburned out.

� Remote faultVAPOR-LOGIC3relay is not switching.

� No power, orincorrect voltage toVAPOR-LOGIC3board

� Modularcommunication cableis disconnected.

� Open, shorted, orincorrect wiring oftransmitter

� Open, shorted, orincorrect wiring oftransmitter.

Operation

Operation:

Troubleshooting guide

Troubleshooting guide.

1

2

3

4

5

Green power indicatorlight is off.

No remote faultindication

No readableinformation onkeypad/display

Humidity transmitterfault

Dew point transmitterfault

� Check for proper supply voltage.

� Check heater fuses for voltage presentat transformer.

� Check for wiring shorts; reset breaker.

� Provide field wiring to a remote faultindicator from VAPOR-LOGIC®

3terminal block J22.

� Check if lamp by others is burned out;replace if needed.

� Check relay continuity(VAPOR-LOGIC3 terminal J22) forcontact closure.

� Check main power supply.

� Connect modular cable.

� Check wiring terminals(VAPOR-LOGIC3 terminal J26) forcorrect wiring and voltages.


Problemnumber

Problem Possible cause Action


57

� Open, shorted, orincorrect wiring ofhumidistat

� Signal by others isincorrect, out ofrange, or miswired.

� Control signal byothers has exceededthe range limits.



� Sensor improperlylocated

� When in the fillsequence,VAPOR-LOGIC3allows 40 minutesfor the water to reachthe maximum properlevel.

� If the water does notreach the designatedlevel, and the probesystem is notsatisfied, a fault willbe indicated.

Operation

Operation:



Problemnumber


Humidistat fault

VAV humiditytransmitter fault

Temp comptransmitter fault

Fill fault

� Check wiring terminals(VAPOR-LOGIC®

3 terminal J26) forcorrect wiring and voltages.


� Correct control signal to 0-20 mA,0-135 ohms, or 0-15 VDC.



� Transmitter must be on inside windowglass only.

� Check water supply shut-off valve. If itis closed, open the valve.

� Check if the in-line strainer or valvesare plugged. Clean them as needed.

� Check if there is 24 VAC present atcontrol board terminals 1 and 2. If yes,replace valve.

� Verify proper fill valve wiring.� Clean or replace probe.� Verify drain valve is closed.� Verify proper water pressure,

minimum 25 psi.

6

7

8

9


58

Operation

Operation:



Problemnumber


10

11

12

Drain fault

Low water timer fault

LL probe fault

� When in autodrainsequence, end-of-season, or manualdrain,VAPOR-LOGIC®

3allows 20 minutesfor the water level todrop from the topprobe to below thelowest probe. If thetank does not drainto this level in thetime allotted, a faultwill be indicated.

� Fill valve is stuckopen.

� Fill valve is installedbackwards.

� Water probes havenot proven.

� Improper water levelchanges inside thetank

� Check drain valve wiring.� Check for voltage present at the valve.

If present, clean or replace valve.� Check if the tank drain outlet is

plugged. Clean outlet if needed.

� Check valve for foreign matter.

� Check arrow direction on strainer. �In�should be visible on fill valve body.

� Drain valve may be stuck open. Cleanor replace valve.

� Water is not conductive for probesystem. Add salt or convert to DIcontrol.

� Verify proper wiring of probe system.� Clean or replace probe rod assembly.� Rewire probes using nonshielded 18-

gauge wire routed in conduit separatefrom power wiring.

� Check that wiring between controlcabinet and humidifier does not exceedthe recommended 50-foot limit.

� Check for plumbing problems.


59

Operation

Operation:



Problemnumber


13

14

15

16

17

18

19

ML probe fault

Replace probes fault

Probe assembly fault

Temperature sensorfault

Thermal trip fault

SDU fault

EEPROM fault

� Improper water levelchanges inside thetank

� Dirty probes

� Deterioration of proberod assembly

� Open, shorted, orincorrect wiring ofsensor

� Unit has overheated.

� SDU blower or AFPSis incorrectly wired.

� SDU blower motor isdefective (SDU fandoes not start).

� Internal programchanged(VAPOR-LOGIC3detected a changefrom its previousprogram check)

� Verify proper wiring of probe system.� Clean or replace probe rod assembly.� Rewire probes using nonshielded 18-

gauge wire routed in conduit separatefrom power wiring.

� Check that wiring between controlcabinet and humidifier does not exceedthe recommended 50-foot limit.

� Check for plumbing problems.

� Clean probes.

� Replace probe rod assembly.

� Check wiring terminals(VAPOR-LOGIC®

3 terminal J25) forcorrect wiring and voltages.

� Check for proper water level in tank.

� Check SDU for proper wiring.

� Replace SDU blower.

� Consult DRI-STEEM forreprogramming instructions.


60

Operation


Problemnumber


20

21

22

23

Flue fault

Burner # fault

Ignitor # fault

Blower # fault

� The combustion airdamper is incorrectlywired or has failed toopen.

� The power ventpressure switch isincorrectly wired orthe power vent hasfailed to start.

� No gas supply to unit

� Gas valve is off orthere is no power tothe valve.

� Broken ignitor

� Gas valve/ignitor/sensing electrode isout of sequence

� Gas valve outletpressure is too low.

� Blower inlet is dirtyor obstructed.

� Broken ignitor

� Gas valve/ignitor/sensing electrode isout of sequence.

� The blower isincorrectly wired orthe blower failed tostart.

� Check for proper combustion airdamper wiring.

� Check for proper power vent wiring.

Verify that gas service valve is on andreceiving minimum pressure tomanifold per rating plate.

� Verify that valve is in �on� position andthat there is power to the valve.

� Verify that ignitor glows.

� Verify wire connections to thesecomponents.

� Verify out pressure is set per ratingplate.

� Clean inlet and check for obstructions.

� Verify that ignitor glows.

� Verify wire connections to thesecomponents.

� Check for proper blower wiring.


Operation:


61

Operation


Problemnumber


24

25

26

Slave # fault

Control does notenergize.

Unit does not fill withwater.

� LonTalk®

communications cableis not connectedbetween boards.

� Slave board does nothave power or hasincorrect power.

� Nonexistent supplyvoltage to unit

� Nonexistent controlvoltage

� Heater over-temperaturethermostat open

� Malfunctioning fillvalve

� No water supply to fillvalve

� Connect LonTalk communicationscable.

� Verify power wiring on slave board.

� Check main line fuse.� Check main line safety switch.� Check heater fuses.

� Check for proper supply.� Verify proper transformer voltage

characteristics.� Verify proper wiring of transformer.� Check for control circuit voltage, 24

VAC. If voltage is not present, checktransformer circuit breaker. Reset ifneeded.

� Reset manual switch located aboveheater or humidifier cover.

� First, disconnect brown wire and thenthe orange wire from VAPOR-LOGIC®

3board terminals 30 and 31 of terminalblock J8. Fill valve should open.

� If fill valve does not open, verifyproper 24 VAC (terminals 1 and 2) tofill valve. If voltage is present andvalve does not open, replace valve orvalve coil.

� Verify that coil is 24 VAC.� Verify that valve stem moves freely.

� Check if water supply line strainer isplugged.

� Verify that manual water line shut-offvalve is open and that pressure exists.


Operation:


62

Operation

Operation:



Problemnumber


26 Unit does not fill withwater (cont.).

� Unit is not in automode.

� VAPOR-LOGIC®3

control is in �end ofseason� drain mode.

� Malfunctioning levelcontrol system

� Inlet water needlevalve is closed.

� Go to Control Modes screen and selectAuto Mode.

� Check for humidity demand(VAPOR-LOGIC3 control boardterminals 21, 22 and 23 of terminalblock J26).

� Disconnect brown and orange wiresconnected to VAPOR-LOGIC3 boardterminals 30 and 31 of terminal blockJ8. If fill valve does not open, checkfor proper 24 VAC (terminals 1 and 2)to fill valve coil. If proper voltage isnot present, the control board isdefective.

� Check terminals 30, 31, 32 and 33 onVAPOR-LOGIC3 control boardterminal block J8 for correct voltage:� 32 (purple) to 33 (yellow),

no water present > 2 VAC� 32 (purple) to 33 (yellow),

water present < 1/4 VAC� 31 (orange) to 33 (yellow),

same readings as above� 30 (brown) to 33 (yellow),

same readings as above

� Check needle valve.


63

Operation

Operation:



Problemnumber


27 Fill valve does notclose.

� Open drain valve


� If automatic drain valve is locked inmanual open position, reset toautomatic.

� Replace valve if there is a brokenreturn spring on the drain valve.

� Clean or replace drain valve if anobstruction in the valve will not allowcomplete closure.

� Close manual drain valve, if it is open.� If VAPOR-LOGIC®

3 shorted output tofill valve coil, replace board.

� Check if probe head is fully pluggedin.

� If needed, clean probe rod tips.� Verify if VAPOR-LOGIC3 control

board with nylon mounting standoffsterminal 33 needs to be grounded.

� If there is low water conductivity, addsalt to tank water. (If this solves theproblem, consult DRI-STEEM forfurther advice.)

� Replace board if VAPOR-LOGIC3control board is defective.

� Verify that system is in auto mode.� Verify that probe is wired correctly.� Check terminals 30, 31, 32 and 33 on

VAPOR-LOGIC3 control boardterminal block J8 for correct voltage:� 32 (purple) to 33 (yellow),

no water present > 2 VAC� 32 (purple) to 33 (yellow),

water present < 1/4 VAC� 31 (orange) to 33 (yellow),

same readings as above� 30 (brown) to 33 (yellow),

same readings as above


64

Operation

Operation:



Problemnumber


27

28

Fill valve does notclose (cont.).

Reduced or no output(even though waterlevel is correct)

� Fill valve is stuck

� Heatermalfunctioning

� Malfunctioningcontrol system

� Check if fill valve is installedbackwards. If yes, repipe.

� If there is a faulty internal spring ordiaphragm in the fill valve, replacevalve.

� Check if there is an obstruction thatwill not allow valve to seat properly.Clean or replace valve as needed.

� Check for control voltage across fillvalve coil. (Check wiring andcontrols.)

� Verify that proper voltage is beingapplied to heaters.

� Check heater amperage.� If heater contactor is not functioning,

replace.

� Check if heater fuses are blown andreplace if required.

� Check if auxiliary limit controls arenot allowing system to operate (i.e.,duct humidistats, air flow provingswitch, etc.). Reset, replace orcalibrate as needed. (Air flow switch,terminals 12 and 13, measures 24VAC if open. On-off high limit,terminals 25 and 26, measures 21VDC if open.)

� Check if the (optional) heater over-temperature thermostat has beentripped. Reset if necessary.

� Replace zone valve if end switch isnot closing.


65

Operation

Operation:



Problemnumber


29

30

Fill valve cycles on andoff frequently (severaltimes per minute).

Heater burnout


� Drain valve not fullyclosed

� Water level is too low.

� Improper wiring

� Mineral buildupimpeding heat transferto water

� Heater corrosion

� If needed, clean probe tips.� Check water conductivity. (Minimum

conductivity for proper operation oflevel control system is 100 micromhosper centimeter or 2 grains per gallon.)

� Verify that probe wiring is correct.

� If an obstruction will not allow drainvalve to fully close, clean valve.

� If there is a broken or weak returnspring on drain valve, replace thevalve.

� Check if 24 VAC is present at valve. Ifso, check wiring of VAPOR-LOGIC®

3control board terminals 3 and 4.

� Check probes and clean tips ifnecessary.

� Clean probe still-well area in tank.� Check drain valve and clean, repair, or

replace as needed.

� Verify proper voltage applied to heater.� Verify proper electrical connections.

� Inspect tank for severe mineral buildupon or around heater. Increaseskimming quantity, frequency of draincycle, and/or frequency of cleaning.Use softened makeup water.

� Inspect heater for surface corrosion orpitting. If evident, consultDRI-STEEM.


66

Operation

Operation:



Problemnumber


31 Noisy operation � �Thunder�-typenoise coming fromtank during refill

� Contactor noise

� Fill valve noise

� Normal on larger units, caused by thecold fill water collapsing steam in thetank. Reduce psi (minimum of 25 psi)if inlet water pressure is too high.

� Contactor normally makes a �clunk�as it pulls in. A continuous chatteringnoise is not normal and issymptomatic of a failing contactor ormalfunctioning controls. Replacecontactor or troubleshoot the controlsystem.

� A clicking sound as fill valve opensor closes and a hissing sound duringfill are normal. A slamming sound asfill valve closes is �water hammer�and can be minimized by installing ashock arrester.

� A loud buzzing sound indicates pooralignment of valve stem. Replacevalve.


67

Operation

Operation:



Problemnumber


32 Humidity belowdesired level

� Unit operating butfails to meet requiredhumidity output

� No call for humidityfrom humidistat orfrom control and highlimit humiditytransmitters

� Excessive outside airvolume

� Unit undersized; replace with a largerunit or add additional humidifier.

� Skimmer rate is too high.� If drain valve will not close fully,

determine the cause and clean, repairor replace as needed.

� If drain pipe water seal is allowingsteam to go down the drain, repair asneeded.

� If there is an improper water sealheight, increase to recommendedheight. (See humidifier tank manual.)

� If there is excessive internal steampressure, determine the cause of thehigh pressure (e.g., high duct staticpressure, undersized orifices indispersion tubes, water, or crushedvapor hose) and repair as required.

� Replace leaking gasket or vapor hose.� Recalibrate if controls are out of

calibration.� If fill valve is stuck open, repair or

replace.� If zone valve will not open, repair or

replace.

� Low or no signal strength fromhumidistat. Check for proper wiring.

� Check humidity transmitters (4-20 mAoutput).

� Adjust set point if VAPOR-LOGIC®3

set point is too low.

� Verify proper operation of fans,dampers, VAV systems, etc.


68

Operation

Operation:



Problemnumber


32

33

Humidity belowdesired level(cont.)

Humidity above setpoint

� Heating elementsnot operating

� Humidity controlinput type not thesame asVAPOR-LOGIC3software

� High enteringrelative humidity

� Unit oversized

� Reduced air flow

� Improperly locatedhumidistat orhumiditytransmitters

� If heaters are burned out, refer toProblem #30 �Heater burnout.�

� Verify that humidistat is calling forhumidity.

� Check for control voltage if limitcontrols (air flow proving switch, zonevalves, etc.) are not allowing unit tooperate.

� Check fuses and replace if they areblown.

� Check if the (optional) heater over-temperature has been tripped. Reset ifnecessary.

� Check VAPOR-LOGIC®3 control board

connections J26, J27 and J28. ConsultDRI-STEEM.

� Dehumidify.

� Consult DRI-STEEM.

� Check fans, dampers, VAV systems,etc.

� Relocate using guidelines establishedin this manual (see Pages 16-23).


69

Operation

Operation:



Problemnumber


33

34

Humidity above setpoint (cont.)

Hunting(humidity swingsabove and belowdesired set point)

� Malfunctioningcontrols

� Malfunctioningcontrol system

� Air volume is varyingrapidly.

� Air temperature isvarying rapidly.

� Check for incorrect supply voltage.� Check for incorrect control signal.� Check for improper wiring hookup.� If humidity controller or transmitter are

out of calibration or malfunctioning,repair or recalibrate.

� If zone valve end switch is not opening,repair or replace.

� Check if SSR shorted. Repair orreplace as needed.

� If there is a faulty or inaccuratehumidity controller or transmitter,repair or replace.

� Check for proper VAPOR-LOGIC®3

control settings: RH set point, HL setpoint, cycle rate, PID tuning, etc.

� Relocate poorly located controlcomponents. See humidity controlplacement information on Pages 16-23for recommendations.

� If inappropriate control components arebeing used, change components.

� On SSR units: Control wire and powerwires must be physically separatedfrom each other. If they are not, aninduced control voltage may occur,causing erratic operation.

� Verify that 6-wire modular cable isisolated from power wiring.

� Stabilize.

� Stabilize to ±1°F.


70

Operation

Operation:



Problemnumber


� System may not haveautomatic drainsystem

� Drain fault, pluggeddrain valve or pluggeddrain pipe

� Malfunctioningautodrain sequence

� No power toautomatic drain valve

� Defective automaticdrain valve

� Inspect unit to verify that automaticdrain valve was furnished.

� Clean drain valve piping.

� Check VAPOR-LOGIC®3 main menu

settings and reset if necessary.

� Check if 24 VAC is present atVAPOR-LOGIC3 control boardterminals 3 and 4 and drain valve.

� Valve should be replaced if voltage ispresent at valve and it still does notopen.

35 Unit does not performautodrain sequence.

73

Printed on recycled paper with agribased inksPrinted on recycled paper.Minimum 10% Post Consumer Waste.

Continuous product improvement is a policy of The DRI-STEEM Humidifier Company therefore,product features and specifications are subject to change without notice.

VAPOR-LOGIC, GTS, STS, LTS, CRUV, VAPORSTREAM, VAPORMIST, ULTRA-FOG and ULTRA-SORB

are registered trademarks of The DRI-STEEM Humidifier Company.

14949 Technology Drive • Eden Prairie, MN 55344Phone: (612) 949-2415 • Fax: (612) 949-2933E-Mail: [email protected] • Web: www.dristeem.comEuropean Office :Bell Place, Bell Lane • Syresham, Brackley • NN13 5HP, U.K.Phone: +44 1280 850122 • Fax: +44 1280 850124E-Mail: [email protected]

Form No. VL3OM-0799 Copyright © 1999 DRI-STEEM Humidifier Company, Inc. Printed in U.S.A.

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