Nordmann ES4 Owner's manual

INSTALLATION- AND OPERATING INSTRUCTIONS
Steam air humidier
Nordmann ES4
2559439 EN 1310
NORDMANN
ENGINEERING

3
Contents
1 Introduction 4
1.1 To the very beginning 4
1.2 Notes on the installation and operating instructions 4
2 For your safety 6
3 Product Overview 8
3.1 Models overview 8
3.2 Identicationoftheunit 9
3.3 Steamhumidierconstruction 10
3.4 Functional description 11
3.5 Humidicationsystemoverview 13
3.6 Options 15
3.7 Accessories 16
3.7.1 Accessories overview 16
3.7.2 Accessory details 17
3.8 Standarddelivery 20
3.9 Storing/Transportation/Packaging 20
4 Notes for the planning engineer 21
4.1 Selecting the unit version 21
4.1.1 Calculating the maximum required steam capacity 21
4.1.2 Selecting the unit 22
4.2 Selecting the options an accessories 22
4.3 Selecting the control system 23
5 Mounting and installation work 25
5.1 Importantnotesformountingandinstallationwork 25
5.2 Installation overviews 26
5.3 Mounting the unit 28
5.3.1 Notes on locating the unit 28
5.3.2 Mountingthehumidier 30
5.3.3 Inspecting the installed unit 31
5.4 Steam installation 32
5.4.1 Overview steam installation 32
5.4.2 Positioningandmountingofthesteam
distribution pipes 33
5.4.3 Installing the steam distributors 37
5.4.4 PositioningandmountingofthefanunitsFAN4N... 38
5.4.5 Installingthesteamhose 39
5.4.6 Common steam and condensate line errors 43
5.4.7 Inspecting the steam installation 44
5.5 Water installation 45
5.5.1 Overview water installation 45
5.5.2 Notes on water installation 46
5.5.3 Inspecting the water installation 47
5.6 Electric installation 48
5.6.1 Wiring diagram Nordmann ES4 48
5.6.2 Notesonelectricinstallation 49
5.6.3 Unitconguration 52
5.6.4 Inspecting the electrical installation 53
6 Operation 54
6.1 Functionofthedisplayandoperatingelements 54
6.2 Commissioning 55
6.3 Notes on operation 56
6.3.1 FunctionoftheLED'sininfomode 56
6.3.2 Remoteoperatingandfaultindication 56
6.3.3 Inspections during operation 57
6.4 Carrying out manual draining 57
6.5 Takingtheunitoutofoperation 57
7 Maintenance 58
7.1 Important notes on maintenance 58
7.2 Maintenancelist 59
7.3 Removingandinstallingpartsformaintenance 60
7.3.1 Removalandinstallationofthesteamcylinder 60
7.3.2 Removalandinstallationofthedraincup 63
7.3.3 Removalandinstallationofthewatercup
and the water hoses 64
7.3.4 Removalandinstallationofthedrainvalve 65
7.3.5 Removalandinstallationoftheinletvalve 66
7.4 Notes on cleaning the unit components 67
7.5 Notes on cleaning agents 68
7.6 Resetting the maintenance indication 68
8 Fault elimination 69
8.1 Faultindication 69
8.2 Malfunctionlists 70
8.2.1 Systemfaults 70
8.2.2 Unitfaults 70
8.3 Notesonfaultelimination 72
8.4 Resettingtheerrorindication(redLEDlights) 72
9 Taking out of service/Disposal 73
9.1 Takingoutofservice 73
9.2 Disposal/Recycling 73
10 Productspecications 74
10.1 Technicaldata 74
10.2 Unitdimensions 75

4
1 Introduction
1.1 To the very beginning
We thank you for having purchased the steam humidier Nordmann ES4.
The steam humidier Nordmann ES4 incorporates the latest technical ad
van ces and meets all recognized safety standards. Nevertheless, improper
use of the Nordmann ES4 may result in danger to the user or third parties
and/or impairment of material assets.
To ensure a safe, proper, and economical operation of the steam humidier
Nordmann ES4, please observe and comply with all information and safety
instructions contained in the present installation and operating instructions
as well as the instructions given in the manuals for the components used
in the humidication system.
If you have questions, which are not or insufciently answered in this
documentation, please contact your Nordmann supplier. They will be glad
to assist you.
1.2 Notes on the installation and operating instructions
Limitation
The subject of these installation and operating instructions is the
steam humidier Nordmann ES4. The various accessories (e.g. steam
distributor, steam distribution system, etc.) are only described insofar as this
is necessary for proper operation of the equipment. Further information on
accessories can be obtained in the respective instructions.
These installation and operating instructions are restricted to the installa-
tion, commissioning, operation, servicing and trouble shooting of the
steam humidier Nordmann ES4 and is meant for well trained personnel
being sufciently qualied for their respective work.
These installation and operating instructions are supplemented by various
separate items of documentation (spare parts list, manuals for accessories,
etc.). Where necessary, appropriate crossreferences are made to these
publications in the present documentation.

5
Explanation of the symbols used in this manual
CAUTION!
The catchword “CAUTION” designates notes in this documentation that, if
neglected, may cause damage and/or malfunction of the unit or other
material assets.
WARNING!
The catchword “WARNING” used in conjunction with the general caution
symbol designates safety and danger notes in this documentation that, if
neglected, may cause to injury to persons.
DANGER!
The catchword “DANGER” used in conjunction with the general caution
symbol designates safety and danger notes in this documentation that, if
neglected, may lead to severe injury or even death of persons.
Safekeeping
Please safeguard these installation and operating instructions in a safe place,
where it can be immediately accessed. If the equipment changes hands,
the documentation should be passed on to the new operator.
If the documentation gets mislaid, please contact your Nordmann supplier.
Language versions
The present installation and operating instructions are available in various
languages. Please contact your Nordmann supplier for information.
Copyright protection
The present installation and operating instructions are protected under the
Copyright Act. Passingon and reproduction of the manual (or part thereof)
as well as exploitation and communication of the contents are prohibited
without written permission by the manufacturer. Violation of copyright terms
is subject to legal prosecution and arises liability for indemnication.
The manufacturer reserves the right to fully exploit commercial patent rights.

6
2 For your safety
General
Every person working with the Nordmann ES4 must have read and under-
stood the present installation and operating instructions before carrying
out any work.
Knowing and understanding the contents of the installation and operating
instructions is a basic requirement for protecting the personnel against any
kind of danger, to prevent faulty operation, and to operate the unit safely
and correctly.
All ideograms, signs and markings applied to the unit must be observed
and kept in readable state.
Qualication of personnel
All actions described in the present Installation and operating instructions
(installation, operation, maintenance, etc.) must be carried out only by well
trained and sufciently qualied personnel authorised by the owner.
For safety and warranty reasons any action beyond the scope of this
manuals must be carried out only by qualied personnel authorised by the
manufacturer.
It is assumed that all persons working with the Nordmann ES4 are familiar
and comply with the appropriate regulations on work safety and the preven-
tion of accidents.
This unit may not be used by persons (including children) with reduced
physical, sensory or mental abilities or persons with lacking experience and/
or knowledge, unless they are supervised by a person responsible for their
safety or they received instructions on how to operate the unit.
Children must be supervised to make sure that they do not play with unit.
Intended use
The steam humidier Nordmann ES4 is intended exclusively for air hu-
midication via a steam distributor or a fan unit approved by the
manufacturer within the specied operating conditions (see chapter 10
“Product specications”). Any other type of application without the express
written consent of the manufacturer is considered as not conforming with the
intended purpose and may lead to the Nordmann ES4 becoming dangerous.
Operation of the equipment in the intended manner requires that all the
information in these instructions is observed (in particular the safety
instructions).

7
Danger that may arise from the unit
DANGER!
Danger of electric hazard!
The Nordmann ES4 is mains powered. One may get in touch with live
parts when the unit is open. Touching live parts may cause severe
injury or danger to life.
Prevention: Before carrying out any work set the Nordmann ES4 out of
operation as described in chapter 6.5 (switch off the unit, disconnect it
from the mains and stop the water supply) and secure the unit against
inadvertent powerup.
WARNING!
Hot water vapour - Danger of scalding!
The Nordmann ES4 produces hot water vapour. There is danger of
scalding when getting in touch with hot water vapour.
Prevention: Do not carry out any work on the steam system during
operation (steam lines, steam distributor, etc.). If the steam system is
leaky set the Nordmann ES4 immediately out of operation as described
in chapter 6.5. Correctly seal the steam system before putting the unit
into operation again.
WARNING!
Danger of burning!
During operation the components of the steam system (steam cylinder,
steam distributor, etc.) get very hot (up to 100 °C). There is danger of
burning when touching the hot components.
Prevention: Before carrying out any work on the steam system set the
Nordmann ES4 out of operation as described in chapter 6.5, then wait
until the components have cooled down sufciently thus preventing dan-
ger of burning.
Behaviour in case of danger
If it is suspected that safe operation is no longer possible, then the
Nordmann ES4 should immediately be shut down and secured against
accidental power-up according to chapter 6.5. This can be the case
under the following circumstances:
– if the Nordmann ES4 is damaged
– if the electrical installations are damaged
– if the Nordmann ES4 is no longer operating correctly
– if connections and/or piping are not sealed
All persons working with the Nordmann ES4 must report any alterations to
the unit that may affect safety to the owner without delay.
Prohibited modications to the unit
No modications must be undertaken on the Nordmann ES4 without the
express written consent of the manufacturer.
For the replacement of defective components use exclusively original ac-
cessories and spare parts available from your Nordmann supplier.

8
3 Product Overview
3.1 Models overview
Steam air humidiers Nordmann ES4 are available with different heating
voltages and steam capacities ranging from 5 kg/h up to a max. of
65 kg/h.
Heating voltage ** Max. steam capacity
in kg/h
Model
Nordmann ES4
Unit size
Unit small Unit large
400V3
(400 V/3~/50...60 Hz)
5 534 1
8 834 1
15 1534 1
23 2364 1
32 3264 1
45 4564 1
65 6564 1
400V2
(400 V/2~/50...60 Hz)
5 524 1
8 824 1
230V3
(230 V/3~/50...60 Hz)
5 532 1
8 832 1
15 1532 1
23 2362 1
32 3262 1
230V1
(230 V/1~/50...60 Hz)
5 522 1
8 822 1
** Other heating voltages on request
Key model designation
Example:
Nordmann ES4 4564 400V3
Product designation:
Unit model:
Heating voltage:
400V/3~/50...60Hz: 400V3
400V/2~/50...60Hz: 400V2
230V/3~/50...60Hz: 230V3
230V/1~/50...60Hz: 230V1

9
3.2 Identicationoftheunit
The identication of the unit is found on the type plate:
Nordmann Engineering AG, CH-8808 Pfäfkon
Type: ES4 4564 Ser.Nr.: XXXXXXX 02.10
Heating voltage: 400V / 3~ / 50...60Hz Power: 33.8 kW
Steam capacity: 45.0 kg/h Ctrl. Voltage: 230V / 1~ / 50...60Hz
Water pressure: 1...10 bar
Made in Switzerland
Type designation Serial number (7 digits) Month/Year
Heating voltage
Maximum steam capacity per unit
Admissible water supply pressure
Power consumption
Control voltage
Field with certication symbols

10
3.3 Steamhumidierconstruction
1 Housing (small, large)
2 Cable openings, top side
3 SC pump (option)
4 Main contactor
5 Power board
6 Terminals heating voltage (option)
7 Remote operating and fault
indication board (option)
8 Control board with ES4 Card
9 Power supply unit 24 V (option)
10 Drain/info key
11 Operation status indicators
12 Unit switch
13 Water cup
14 Filling hose
15 Water supply hose
16 Overow hose
17 Drain valve
18 Inlet valve
19 Water supply connector
20 Drain connector
21 Cable openings, bottom side
22 Type plate
23 Steam cylinder
24 Level sensor
25 Electrode plug
26 Steam outlet
gure shows small unit
3
2
1
4
5
6
7
9
12
11
10
8
19
20
21
23
24
25
26
22
13
15
18
17
14
16

11
3.4 Functional description
The steam humidier Nordmann ES4 is a pressureless steam generator
that utilizes an electrode heating. The steam humidier Nordmann ES4 is
designed for air humidication via a steam distributor (steam distribution
pipe, fan unit or steam distribution system MultiPipe).
Steam distribution pipe
Condensate hose
with siphon
Steam hose
Water cup
Overow hose
Filling hose
Water supply hose
Inlet valve
Base tub
Drain valve
Steam cylinder
Electrodes
Level sensor
Control board Power board
Unit switch
Main
contactor
Current sensor
Steam generation
Any time steam is requested, the electrodes are supplied with voltage via
main contactor. Simultaneously, the inlet valve opens and water enters the
steam cylinder from the bottom via water cup and supply line. As soon as the
electrodes come in contact with the water, current begins to ow between
the electrodes, eventually heating and evaporating the water. The more the
electrode surface is exposed to water, the higher is the current consumption
and thus the steam capacity.

12
Upon reaching the requested steam capacity, the inlet valve closes. If the
steam generation decreases below a certain percentage of the required
capacity, due to lowering of the water level (e.g. because of the evapora-
tion process or drainage), the inlet valve opens until the required capacity
is available again.
If the required steam capacity is lower than the actual output, the inlet valve
is closed until the desired capacity is achieved by lowering of the water level
(evaporation process).
Level monitoring
A sensor provided in the steam cylinder cover detects when the water level
gets too high. The moment the sensor comes in contact with water, the
inlet valve closes.
Drainage
As a result of the evaporation process, the conductivity of the water increases
due to an escalating mineral concentration. Eventually, an inadmissibly high
current consumption would take place if this concentration process were
permitted to continue. To prevent this concentration from reaching a value,
unsuitably high for the operation, a certain amount of water is perio dically
drained from the cylinder and replaced by fresh water.
Control
The steam production can be controlled with an external 010V continuous
controller or an external humidistat (24 VDC On/Off control).

13
3.5 Humidicationsystemoverview
System overview duct humidication
 1 Steamhumidier
 2 Steamconnector
 3 Waterdrainconnector
 4 Watersupplyconnector
 5 WaterconnectionhoseG3/4"-G3/8"
(includedinthedelivery)
 6 Filtervalve(accessory“Z261”)
 7 Manometer(installationrecommended)
 8 Funnelwithsiphon(buildingside)
 9 Waterdrainhose(includedinthedelivery)
10 Serviceswitchcontrolvoltagesupply(buildingside)
11 Serviceswitchheatingvoltagesupply(buildingside)
12 Steamhose(accessory“DS..”)
13 Condensatehose(accessory“KS10”)
14 Steamdistributionpipe(accessory“DV41-..”/“DV71-..”)
15 Steamdistributionsystem(accessory“MultiPipe”)
16 Humiditycontroller0-10VorHumidistat
17 Safetyhumidistat
125...1250µS/cm
1...10bar
1...40°C
16
15
ONOFF
1
2
3
4
5
6
7
DS35
DS22
Z261
ONOFF
12
13
17
KS10
11
10
14
DV41
DV71
MultiPipe
8
9

14
System overview room humidication
125...1250 µS/cm
1...10 bar
1...40 °C
1 Steam humidier
2 Steam connector
3 Water drain connector
4 Water supply connector
5 Water connection hose G 3/4"- G 3/8"
(included in the delivery)
6 Filter valve (accessory “Z261”)
7 Manometer (installation recommended)
8 Funnel with siphon (building side)
9 Water drain hose (included in the delivery)
10 Service switch control voltage supply (building side)
11 Service switch heating voltage supply (building side)
12 Steam hose (accessory “DS..”)
13 Condensate hose (accessory “KS10”)
14 Ventilation unit (accessory “FAN4 N...”)
15 Humidity controller 010V or Humidistat
16 Safety humidistat
ONOFF
ONOFF
10
11
15
16
1
3
4
5
6
7
Z261
DS80
KS10 13
12
FAN4 N S W
FAN4 N M W
FAN4 N L W
2
8
9
14

15
3.6 Options
Nordmann ES4...
522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Remote operating and fault indication
PCB with relay contacts for the connection of remote
displays for “Operation”, “Steam”, “Fault” and “Service”.
1xRFI
Overpressure set
Kit for mounting the water cup to the unit cover when
operating the steam humidi ers in systems with a duct
air pressure of up to 10 kPa.
1xOPS
Terminals heating voltage
Separate terminals for systems where direct connection
of heating voltage to main contactor (standard version)
is not permitted by local regulations.
1x
S-THV
1x
M-THV
1x
L-THV
Steam hose connector with condensate trap 1xCT22 1xCT35 2xCT35
Cable glands (with metric thread) CG
Internal control voltage 1x
S-CVI
1x
M-CVI
1x
L-CVI
Transformer (400V/230V) 1xM-Trafo 1xL-Trafo
SC pump (lime management system)
The SC pump keeps the solved minerals in the water of
the steam cylinder in motion, in order to discharge them
with the automatic drain cycles.
1xSC
24 VDC power supply
24 VDC power supply for the external humidity sensor
1x24VDC
Nordmann ES4... (400 V/3~/50...60 Hz)
534 834 1534 2364 3264 4564 6564
Steam cylinder for low water conductivity
from 80 to 125 µS/cm
1x
534A-L
1x
834A-L
1x
1534A-L
1x
2364A-L
1x
3264A-L
1x
4564A-L
___

16
3.7 Accessories
3.7.1 Accessories overview
Accessories for water installation
Nordmann ES4...
522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Filter valve Z261 (1 pcs. per system)
Accessories for steam installation
Nordmann ES4...
522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Steam distribution pipe
(details see chapter 3.7.2)
1xDV41-... 1xDV71-... 2xDV71-...
Steam distribution system MultiPipe
(details see chapter 3.7.2)
--- System 1 System 2
Fan unit
(details see chapter 3.7.2)
FAN4 N S W FAN4 N M W FAN4 N L W
Steam hose / meter 1xDS22 1xDS35 2xDS35
EcoTherm insulation hose / meter 1xECT22 1xECT60 2xECT60
Condensate hose / meter 1x KS10
Accessories for humidity control
Nordmann ES4...
522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Duct humidistat HBC (1 pcs. per system)
Room humidistat HSC (1 pcs. per system)
General accessories
Nordmann ES4...
522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
All-weather protective housing Layout according to the separate data sheet

17
3.7.2 Accessory details
3.7.2.1 Steam distribution pipe DV41-.../DV71-...
The steam distribution pipes are selected on the basis of the duct width
(for horizontal installation) or the duct height (for vertical installation) and
the capacity of the steam humidier.
Important! Always select the longest possible steam distribution pipe (opti
mum humidication distance).
L
B
Steam distribution pipes for
Nordmann ES4 1)
Length (L) steam
distribution pipe
Duct width (B)
Type DV41-.. Type DV71-.. in mm 2) in mm
41-200 200 210...400
41-350 71350 350 400...600
41-500 71500 500 550...750
41650 71650 650 700...900
41-800 71800 800 900...1100
41-1000 711000 1000 1100...1300
41-1200 711200 1200 1300...1600
711500 1500 1600...2000
711800 1800 2000...2400
712000 2000 2200...2600
712300 2300 2500...2900
712500 2500 2700...3100
1) Material: CrNi steel 2) special length on request
Note: If the humidication distance (see chapter 5.4.2) has to be reduced
for technical reasons, the amount of steam per basic unit must be divided
between two steam distribution pipes or the steam distribution system
MultiPipe must be used. If this is the case, contact your Nordmann supplier.

18
3.7.2.2 MultiPipe steam distribution system
H
B
The MultiPipe steam distribution system is used in ventilation ducts with a
short humidication distance (for the calculation of the humidication dis-
tance refer to chapter 5.4.2). When ordering an MultiPipe system the duct
dimension must be specied. Please consult the data in the following table.
MultiPipe Number of steam
connectors
Max. steam
capacity
in kg/h 1)
Duct dimensions
Width B
in mm
Height H
in mm
System 1 1 32 (23) 450-1500 4501650
System 2 2 65 (45) 450-2200 450-2200
1) For duct widths <600 mm the value in brackets apply

19
3.8.2.3 Fan units FAN4 N...
The fan units FAN4 N... – in combination with the steam humidiers Nor-
dmann ES4 – are used for direct room humidication. They are mounted
above the unit to the wall.
The type of fan unit is dependent on the steam capacity and on the type of
the humidier and can be gathered from the table in chapter 3.7.1.
Note: Further information on the fan units FAN4 N... can be found in the
separate manual supplied with the fan unit.

20
3.8 Standard delivery
The standard delivery includes:
– Steam humidier Nordmann ES4 with water drain hose and water con-
nection hose G 3/4"  G 3/8" equipped with the options ordered according
to chapter 3.6, xing set and installation and operating instructions (this
document), packaged in cardboard box
– Unit small (WxHxD): 445 mm x 755 mm x 360 mm, shipping weight:
26 kg
– Unit large (WxHxD): 560 mm x 820 mm x 435 mm, shipping weight:
31 kg
– Ordered accessories with operating instructions according chapter 3.7,
packed separately
– Spare parts list
3.9 Storing/Transportation/Packaging
Storing
Store the unit in a protected area meeting the following requirements:
–Room temperature: 1 ... 40 °C
– Room humidity: 10 ... 75 %rh
Transportation
For optimum protection always transport the unit in the original packaging.
The weight of the small and the large unit is more than 20 kg (weight without
packaging: small unit 23 kg, large unit 28 kg). Therefore, always transport
the unit with the help of another person or use a forklift or a crane. Always
place the unit on its back side.
Packaging
Keep the original packaging of the Nordmann ES4 for later use.
In case you wish to dispose of the packaging, observe the local regulations
on waste disposal. Never dispose of the packaging to the environment.