DriSteem Ultra-sorb XV Installation and operating instructions

Ultra-sorb®Model XV
Steam Dispersion Panel
Installation, Operation,
and Maintenance Manual
For pressurized steam applications
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Page 2 • DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual
Table of contents
Field assembly
Unpackthedispersionassemblyandloosecomponents ........3
Verifythattheorderiscomplete ............................3
Layoutthepanelcomponents .............................. 4
Attachtheanges .........................................4
Attachthetopframeassembly ..............................4
Tightentheangelocknuts ................................. 4
Installthedispersiontubes .................................4
Installation
Panel and piping components ...............................5
Selectingthelocation ......................................6
Installationinacoldairstream .............................7
Placementupstreamofanelboworductsplit ................. 7
Installationabovevaluableequipment........................ 7
Recirculationunit .........................................7
Panelsupport ............................................. 7
Dispersiontubeorientation.................................8
Mountinginaduct ........................................ 8
Ductsmokedetector.......................................8
Mountinginanairhandlingunit ............................9
Traprecommendation ....................................10
Recommendationsforsteamabsorption.....................10
Steamandcondensateconnections .........................10
HeaderoverowP-trapwaterseal ..........................10
Preventingductstaticpressureloss .........................11
Liftingcondensate........................................11
Temperatureswitch.......................................12
Heatexchangershut-odelay ..............................12
Start-up and operation .................................... 13
Performance data ......................................... 14
Maintenance
Strainer .................................................15
Steamtraps ..............................................15
HeaderoverowP-trapwaterseal ..........................15
Valves ..................................................15
Dispersiontubes .........................................15
Heatexchanger ..........................................16
Replacement parts ........................................ 17
Troubleshooting ........................................... 18
Warranty .................................................. 20
ATTENTION INSTALLER
Read this manual before installing.
Leave manual with product owner.
DRI-STEEM technical support
800-328-4447
WARNING!
Steam humidification systems have
extremely hot surfaces.
To avoid burns, allow humidifier,
steam pipes, and dispersion
assemblies to cool before touching
any part of the system.
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DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual • Page 3
Field assembly
CAUTION!
The dispersion tubes are sleeved in clear poly film
for protection during processing, shipping, and
installation.
Leave the clear poly film on until installation is
complete so the insulation stays clean.
Equally important, remove and discard the clear
poly film before start-up by tearing it along the
perforations. Do not remove the white PVDF
insulation.
Unpack the dispersion assembly and loose components
• Ultra-sorb Model XV has high-efficiency dispersion tubes.
The tubes are insulated with polyvinylidene fluoride (PVDF)
insulation, which provides up to an 85% reduction in wasted
energy by significantly reducing airstream heat gain and
condensate production.
• Remove shipping materials from the dispersion assembly, being
careful not to bump or scrape the white PVDF dispersion tube
insulation
• Do not lay dispersion tubes (if shipped loose by request or by
shipping necessity) across or under anything that could compress
or damage the insulation. Compressing insulating material may
reduce its R-value.
• Avoid bumping or snagging the PVDF insulation. Although
PVDF is robust, rough handling can cause tears, which could
negatively impact performance.
• Before start-up, remove the clear poly film by tearing it along the
perforation. Do not use a knife or sharp object to remove the poly
film. Do not remove the white PVDF insulation.
Verify that the order is complete
Verify that all panel and piping components are included in the
delivery. Check the packing list, and see Tables 4-1 and 5-1.
• Keep the flame away from the insulating
material to avoid damage.
• PVDF is inherently resistant to UV light.
Indirect, low-intensity UV-C light from
germicidal lamps will not cause the
insulating material to degrade.
• Do not tighten mounting clamps or
fasteners to any part of the dispersion
tube.
Integral heat exchanger
• Ultra-sorb Model XV employs an integral
heat exchanger to pressurize and lift
condensate up to 12" per psi (300 mm
per 6.9 kPa) of steam pressure.
• Steam pressure entering the heat
exchanger must be at least 5 psig
(35 kPa).
• Condensate may be piped to the
condensate return main.
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Page 4 • DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual
Field assembly
Lay out the panel components
Orient the panel components on a large, flat working surface.
Attach the flanges
Guide the flanges onto the threaded studs of the header assembly,
and start the locknuts onto the threads finger-tight.
Attach the top frame assembly
Span the flanges with the top frame assembly. Align the locating
buttons on the flanges and top frame, and push the eight panel
fasteners into place.
Note: Compress the toggles to remove a panel fastener.
Tighten the flange locknuts
Torque the eight flange locknuts to 16 ft-lb (22 N-m) at 100 rpm
maximum using a 7/16" deep-well socket.
Install the dispersion tubes
Note: Do not remove the poly film from the dispersion tubes until
after the panel is installed.
Ensure that each dispersion tube has the seal and spring in place (see
Figure 5-2). Push the dispersion tube plug end into the top frame
hole to compress the spring. Seat the seal end in the corresponding
header hole on the bottom. Rotate the dispersion tubes so the
tubelets discharge steam perpendicular to the airstream. See
Figure 8-1.
Header assembly
Figure 4-1:
Model XV components
Table 4-1:
Model XV panel components
Component Qty.
Header assembly 1
Dispersion tube Varies
Top frame assembly 1
Flanges 2
Panel fasteners 8
Flange locknuts 8
Flange locknut
Panel fastener
Flange
OM-7484
Top frame assembly
Dispersion tube assembly
Note: These assembly instructions are for
Ultra-sorb Model XV panels shipped
unassembled by request or as required.
Panels with overall height more than
98" (2490 mm) are shipped unassembled.
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DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual • Page 5
Installation
Panel and piping components
The Ultra-sorb Model XV dispersion panel and piping components
are shown in Figure 5-1.
Panel location choices, installation instructions, and system options
are provided in the following subsections.
Figure 5-1:
Piping components
OM-7494
Table 5-1:
Piping components
Component Qty.
Modulating steam valve 1
On/Off valve for pressurized steam input 1
Temperature switch 1
Inlet strainer 1
Float & thermostatic (F&T) trap 1
From pressurized
steam source
Modulating steam valve
To condensate return main
Temperature
switch
On/off valve
Inlet strainer
F&T trap
Model XV steam dispersion panel
Dashed lines indicate provided by installer.
F&T trap
Figure 5-2:
Dispersion tube
Spring
Plug
Ring
Seal
OM-7484
Insulation
Install
this
end
up
To condensate return main
Access port and overflow
(see Figure 11-1)
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Page 6 • DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual
Selecting the location
DRI-STEEM has cataloged the distance unabsorbed steam travels in
an airstream (see Figure 15-1). Dispersed steam must be absorbed
into the airflow before it comes in contact with duct elbows,
fans, vanes, filters, or any object that can cause condensation and
dripping.
A. Install the Ultra-sorb panel in a location where discharged water
vapor being will be absorbed by the airstream.
B. In general, place the Ultra-sorb panel where the air tempera-
ture is capable of absorbing discharged steam without causing
condensation at or after the unit. This will normally be down-
stream of the heating coil where the air is warmest.
C. Do not place the Ultra-sorb panel in an outside air intake unless
the air is tempered with a preheat coil.
D. Do not place the Ultra-sorb panel near the entrance of a
high-efficiency filter. The filter will remove visible moisture
and become waterlogged. See the CAUTION about absorption
(non-wetting) distance in the Performance data section.
E. Do not place the Ultra-sorb panel where discharged visible mist
will impinge directly on a metal surface.
Installation
Outside air
Relief air
Preheat coil
Motorized
air dampers
Supply airflow
Filters
Economizer
control device
Heating coil
Cooling coil 8' to 12' (2.4 to 3.7 m)
Duct high limit humidity control for dispersion
locations A, B
Airflow proving switch
Airflow proving switch
Duct high limit humidity control
for dispersion location C
Return airflow
8' to 12'
(2.4 to 3.7 m)
3' to 5'
(1 to 1.5 m)
Fan
Figure 6-1:
Placing a dispersion assembly in an AHU
ABD
C
Exterior
building wall
Panel placement in an air handling unit
(see Figure 6-1)
• Location A is the best choice.
Installing downstream of heating and cooling
coils provides laminar flow through the disper-
sion unit; plus, heated air provides an environ-
ment for best absorption.
• Location B is the second-best choice.
However, in change-over periods, the cooling coil
will eliminate some moisture for humidification.
• Location C is the third-best choice.
Air leaving a fan is usually very turbulent and
can cause vapor to not absorb at the expected
absorption distance. Allow for more absorption
distance if installing downstream of a fan.
• Location D is the poorest choice.
The cooler air at this location requires an
increased absorption distance.
DC-1081
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DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual • Page 7
Installation
Elbow Duct
Airflow
Airflow
Ultra-sorb
Ultra-sorb
Duct split
Figure 7-3:
Upstream placement
Non-wetting
distance from
Figure 14-1
Cold
airflow
Ultra-sorb Extended trails of
fog may develop
High-limit duct humidistat 10-15 feet
(3-4 m) downstream from Ultra-sorb
Figure 7-2:
Installation in a cold air stream
Installation in a cold air stream
When a humidifier is installed in a duct that will carry cold air,
determine the dew point temperature. If the psychrometric chart
reveals that saturation may occur, protection should be provided. A
high-limit humidistat or thermostat set to cut off the humidifier at a
safe temperature can be used for this purpose. See Figure 7-2.
Placement upstream of an elbow or duct split
Due to Ultra-sorb's rapid steam absorption performance,
installation upstream from elbows or duct splits can be done with
confidence. See Figure 7-3.
Installation above valuable equipment
Water piping and humidifiers should not be installed above
expensive equipment. A condensing or leaking water pipe or
other accidental water spillage could cause serious damage to the
equipment below. When such an installation cannot be avoided,
install a galvanized drip pan under the humidifier piping, valve, etc.
to catch and drain away unintended water. See Figure 7-4.
See the Header overflow P-trap water seal section.
Recirculation unit
In applications where no duct system exists, or if the air is too cool
for proper humidity absorption, a recirculation fan can be used.
The fan circulates room temperature air across the humidifier and
discharges humidified air into the space. Select the air discharge
point carefully to avoid condensation on building or equipment
surfaces. See Figure 7-1.
Panel support
The duct or air handler section and Ultra-sorb panel must be
properly supported to carry the weight of the assembly. The weight
of the piping must be supported by the building structure rather
than by the Ultra-sorb unit. Otherwise, the weight may impose
stress on the connections, causing them to fracture and leak.
Ultra-sorb
Airflow
Drip pan
Pipe to drain size as required
Ceiling line
Vapor
absorption
area
* This duct length should have sealed seams and should
be at least three times the published non-wetting
distance.
Ceiling line
Ultra-sorb
Airflow
Blower
Figure 7-4:
Installation above valuable equipment
2" (50 mm)
Figure 7-1:
Recirculation unit
*
Vapor
absorption
area
*
* This duct length
should have sealed
seams and should
be at least three
times the published
non-wetting
distance.
OM-197
OM-178
OM-198
OM-179
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Page 8 • DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual
Installation
Dispersion tube orientation
Verify that the steam discharge tubelets are perpendicular to the
airstream (see Figure 8-1). The spring-loaded dispersion tubes
easily rotate for proper orientation.
Figure 8-2:
Model XV in a duct
OM-7490
Airflow
Tubelet
Figure 8-1:
Dispersion tube orientation
Dispersion tube
Mounting in a duct
To avoid puncturing the header, screw penetration into the
header assembly must not exceed ¾" (20 mm).
The Model XV panel is designed for horizontal airflows only.
Mounting flanges on both sides of the unit and the header and
frame can be used as mounting surfaces (see Figure 8-2). A
matching flange or metal frame is required on the ductwork for
connection to the Ultra-sorb flanges. The recommended fastener is
a #12 self-drilling and tapping screw ¾" (20 mm) long, spacing not
to exceed 12" (305 mm). If an angle-iron frame is provided on the
duct section, a longer screw may be required.
Airflow
Attach duct flange to
top frame assembly
1/2" (13 mm)
1/2" (13 mm)
Screws OK
ws OK
ws
OK
Attach duct flanges
to 1.5" (38 mm)
mounting flanges
Slope header toward steam inlet 1/16" per foot (1 mm per 190 mm) maximum
Attach duct
flange to header
assembly
Screws OK
No screws
No screws
OM-150a
Duct smoke detector
Do not install a duct smoke detector downstream
from the Ultra-sorb panel. If downstream
installation is required, install it far enough from
the Ultra-sorb panel to avoid false alarms.
Figure 8-3:
Preventing duct static pressure loss
Top
outside
corners
Four inside
corners
Both sides of
cover seam
Perimeter of top frame
along duct flange
OM-7483
Ultra-sorb panels that penetrate a duct section must
be sealed with HVAC caulking or a similar weather
sealant to prevent air leakage.



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DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual • Page 9
Installation
Mounting in an air handling unit
Model XV must be used in pressurized steam applications and in
horizontal airflows only, as shown in Figure 9-1.
Metal support frames should be anchored to the air handler casing.
Recommended fasteners for mounting the Ultra-sorb to a metal
support frame are ¼ - 20 nuts and bolts or #12 self drilling and
tapping screws.
Due to possible forces exerted on this application, DRI-STEEM
recommends fastener spacing not to exceed 6" (150 mm).
Figure 9-1:
Model XV in an air handler
Tubelets perpendicular to airflow
Header
Humidification
steam in
Pressurized condensate out to return mainPressurized steam into
heat exchanger*
OM-7489
From
pressurized
steam source
Install strainer
within 3' (1 m)
of Ultra-sorb
AHU wall
AHU width
AHU
height
Coil width
Coil
height
Modulating steam valve
Temperature switch
F&T trap
On/Off solenoid valve
Tub
ele
ts
per
pen
dic
u
Dashed lines indicate provided by installer.* Minimum steam pressure 5 psig (35 kPa)
Slope header toward steam inlet 1/16"
per foot (1 mm per 190 mm) maximum
Connection end of header
Pressurized
steam in* Pressurized
condensate
out
Access port and
overflow
Humidification
steam in
Optional header
overflow P-trap
water seal
Priming filler cap
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Page 10 • DRI-STEEM Ultra-sorb Model XV Steam Dispersion Panel Installation, Operation, and Maintenance Manual
Installation
Trap recommendation
The steam supply line should be dripped immediately ahead of the
steam valve through a steam trap.
Low pressure, up to 15 psi (103 kPa) — F&T trap
High pressure, more than 15 psi (103 kPa) — Inverted bucket trap
Install a wye strainer ahead of the steam valve (see Figure 10-1).
Recommendations for steam absorption
To ensure driest steam, take humidifier steam off the top of the
steam main (not the side or bottom).
An airflow proving switch is recommended to prevent the steam
valve from opening if air is not moving in the duct.
To prevent over saturation when duct air is cooler than 70 °F
(21 °C), a high-limit (duct mounted) humidistat at least 15 feet
(4.5 m) downstream and set at 80-90% is recommended.
Steam and condensate connections
Use a back-up wrench when tightening connections onto any
Ultra-sorb threads (see Figure 10-2).
Humidification steam inlet
Because the heat exchanger vaporizes all dispersion tube-
generated condensate, all steam entering the humidification steam
inlet exits the tubelets and is dispersed in the airstream.
Pressurized boiler steam inlet
Steam pressure entering the heat exchanger must be least 5 psig
(35 kPa) to vaporize condensate in the header.
Pressurized condensate outlet
Condensate exiting the heat exchanger is piped to the condensate
return main. See Lifting condensate on the facing page.
Header overflow P-trap water seal
Ultra-sorb Model XV is designed to vaporize the condensate
generated in a properly designed, installed, operated, and
maintained system. An optional, fail-safe header overflow
installation is recommended if any of the following are true:
• Operating parameters exceed design criteria.
• Boiler chemicals are causing heavy material deposition on the
heat exchanger (see Heat exchanger in the Maintenance section).
• System overflow prevention is critical.
Figure 10-2:
Steam and condensate connections
Humidification
steam inlet
1” or 2” NPT,
internal thread
Pressurized boiler
steam inlet
3/4” NPT, internal
thread
Pressurized
condensate outlet
3/4” NPT, internal
thread
Access port and overflow
1/2” NPT, internal thread
Figure 10-1:
Ultra-sorb strainer
Install strainer same size as valve
and within 3' (1 m) of Ultra-sorb
Valve
From pressurized
steam source
DC-1097
OM-7482
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