Nordmann AT4 D Series User manual

SERVICE MANUAL
Steam generator
Nordmann AT4 D
2567909 EN 1412
NORDMANN
ENGINEERING

3
Contents
1 Introduction 4
2 Settings in the engineering level 5
2.1 Launching the Engineering level 5
2.2 Setting the intensity levels for the fragrance pumps 5
2.3 Setting the replacement interval time for the steam cylinder 6
2.4 Activating/deactivating the drain cooling 6
2.5 Setting GFCI operation 6
2.6 Setting the heating current monitoring 8
2.7 Setting the On/Off hysteresis 9
2.8 Setting the Stop Mode for bathing operation 9
2.9 Setting-up temperature sensor monitoring function 10
2.10 Resetting the control to factory settings 11
2.10 Setting-up countdown function/resetting countdown 12
3 Malfunctions 14
3.1 Operating malfunctions 14
4 Control matrix Steam bath control /
Principle diagram P-regulation 25
4.1 Control matrix Steam bath control 25
4.2 Principle diagram P-regulation 26
4.3 On/Off hysteresis of the supply and the exhaust fan (2-fan operation) 27
5 Water management 28
5.1 The SC system of the Nordmann AT4 D 28
5.2 The use of softenend water for the operation of the Nordmann AT4 D 29
6 Block diagrams 31
6.1 Block diagram CPU 31
6.2 Block diagram power board 32
6.3 Block diagram steam bath board 33

4
1 Introduction
The present service manual is meant for the Nordmann service technician
and assumes a profound knowledge on the Nordmann AT4 D. It is also as-
sumed that the Service technician has notice of the mounting instructions
as well as of the operating instructions of the Nordmann AT4 D and that he
is familiar with the dangers when working on the unit.
The present service manual includes the following information:
– Description of the settings in the engineering level of the Nordmann AT4
D control.
– Information on operational malfunctions
– Information on the control matrix of the steam bath control
– Information on the water management
– Block diagrams of the control electronics

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2 Settings in the engineering level
2.1 Launching the Engineering level
Select the engineering settings menu:
Path: Main menu > User > Password entry: 1055 > Engineering
Press the <>and < > keys in order to select the individual settings in the engineering level. Detailed
information on the different settings are found in the following chapters.
2.2 Setting the intensity levels for the fragrance pumps
Select “Fragrance” in the engineering menu, then press the <Set> key. Select the intensity level (levels
1 to 5) whose values you would like to modify, then press the <Set> key.
Set the desired interval time in minutes and the pulse duration in seconds for the selected intensity level.
Setting range interval time: 2...20 minutes
Setting range pulse duration: 2...10 seconds
Factory setting: Level 1 = interval time: 10 minutes, pulse duration: 2 seconds
Level 2 = interval time: 8 minutes, pulse duration: 3 seconds
Level 3 = interval time: 6 minutes, pulse duration: 3 seconds
Level 4 = interval time: 4 minutes, pulse duration: 4 seconds
Level 5 = interval time: 3 minutes, pulse duration: 5 seconds
Note: the fragrance pump is active only, if the main contactor of the steam generator is activated and
the system is in steam bath operation.
Engineering Code
1055
Enter Number
Conrm with Set
Esc Set
FactoryReset:Set
Instab.Temp.:Set
Stop Mode :Switch
Min.Request :25/20%
Engineering
Max.op.hr SC:5000h
Drain Cool :On
GFCI :Set
Fragrance :Set
Overcurrent :Float
Esc Set
Level 1
Impulse :2s
Interval :10min
Esc Set
Level 1
Impulse :2s
Interval :10min
Esc Set
Fragrance
Level 2 :Set
Level 3 :Set
Level 4 :Set
Level 1 :Set
Level 5 :Set
Esc Set
Interval
10 min
10 min
Esc Set
Impulse
2 s
2 s
Esc Set
Engineering
Max.op.hr SC:5000h
Drain Cool :On
GFCI :Set
Fragrance :Set
Overcurrent :Float
Esc Set
Main Menu
Light-2 :O
User :Set
Engineering :Set
Fragrance :Set
Diagnostic :Set
Esc Set
Menu
AT4D 65kg/h 400V3
Steam Bath :Standby
Temperature :34°C
Setpoint :48°C
2011-08-31 12:00:00
Light Start
Count Down :Set

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GFCI
GFCI :Set
GFCI-Mode :On
Esc Set
GFCI-Mode
O
On
Ship
On
Esc Set
Max.op.hr SC
5000
5000
Esc Set
2.3 Setting the replacement interval time for the steam cylinder
Select “Max.op.hr SC” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue set the desired interval time for the replacement of the steam
cylinder in hours (max. operating hours). The interval time to be set depends on the water quality on site.
Note: First priority for the determination of the maximum operating hours of the steam cylinder has
always the maximum level counts via the level sensor.
Factory setting: 5000 h
Setting range: 100...8000 h
2.4 Activating/deactivating the drain cooling
Select “Drain Cool” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue activate (On) or deactivate (Off) the drain cooling function. With
activated drain cooling the inlet valve opens during the drain cycle, thus reducing the drain water tem-
perature.
Factory setting: On
Options: On (Inlet valve opens during drain cycle)
Off (Inlet valve remains closed during drain cycle)
2.5 Setting GFCI operation
Select “GFCI” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue select whether or not the Nordmann AT4 D is connected to a
fault current relay protected mains supply or whether the Nordmann AT4 D is operated on a vessel with
special requirements concerning fault current measurement.
Factory setting: On
Options: On (mains supply with fault current relay protection, main contactor is switched
off during drain cycle)
Off (mains supply without fault current relay protection, main contactor remains
activated during drain cycle)
Ship (mains supply with special requirements concerning fault current measure-
ment, main contactor is switched off during lling and draining cycle)
Engineering
Max.op.hr SC:5000h
Drain Cool :On
GFCI :Set
Fragrance :Set
Overcurrent :Float
Esc Set
Engineering
Max.op.hr SC:5000h
Drain Cool :On
GFCI :Set
Fragrance :Set
Overcurrent :Float
Esc Set
Drain Cool
O
On
On
Esc Set
Engineering
Drain Cool :On
GFCI :Set
Overcurrent :Float
Max.op.hr SC:5000h
Min.Request :25/20%
Esc Set

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Notes on the function “Ship”
The “Ship” function is used if the Nordmann AT4 D is installed on a vessel. On vessels fault currents are
monitored much more exactly than elsewhere, since these lead to an increased corrosion of the ship trunk.
Due to the fact that small fault currents can ow via the inlet line to earth/mass also during lling, the
main contactor is switched off also during lling cycle with the “Ship” function.
Since no current measurement is possible during lling with deactivated main contactor, the lling time
is controlled via the inlet factor.
Select “Ship” in the GFCI menu, then press the <Set> key.
In the upcoming modication dialogue set the desired inlet factor.
Factory setting: 1(Filling cycle 30 seconds)
Setting range: 0.5 (Filling cycle 10 seconds) up to 2.0 (Filling cycle 60 seconds)
Note: With inlet factor 1 the lling cycle takes 30 seconds then, the inlet valve is closed and the main
contactor is activated, in order to check the current rise. If the desired current value is not yet achieved
(110% of the nominal current), the main contactor is deactivated again, and another lling cycle of
30 seconds starts.
If the current is always too high after a lling cycle of 30 seconds (InletFactor 1), the lling time can be
reduced up to 15 seconds (=> inlet factor 0.5).
Or vice versa if it always takes 2 – 3 lling cycles to reach the desired current value, the lling time can
be increased up to 60 seconds (=> inlet factor 2).
GFCI
GFCI :Set
GFCI-Mode :On
Esc Set
GFCI
InletFactor :1.0
GFCI :Set
GFCI-Mode :On
Esc Set
GFCI-Mode
O
On
Ship
Ship
Esc Set
GFCI
InletFactor :1.0
GFCI-Mode :On
Esc Set
InletFactor
1.0
1.0
Esc Set
Engineering
Drain Cool :On
GFCI :Set
Overcurrent :Float
Max.op.hr SC:5000h
Min.Request :25/20%
Esc Set

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2.6 Setting the heating current monitoring
Select “Overcurrent” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue you determine whether the current monitoring shall take place
with a xed (Fixed) or a floating over current threshold (Float).
Factory setting: Float
Setting range: Float (floating over current threshold) or Fixed (fixed over current threshold)
Notes on settings
For the heating current monitoring, there are two over current thresholds:
– The threshold for the excess current is set to 135% of the maximum nominal current (violet, narrow
dashed line in the following diagram). This threshold value is xed and leads always to a draining
of the cylinder and to an emergency shut-down (Error E25) when exceeded.
– The threshold for the over current is set to 125% of the maximum nominal current (W24/E24). If
this threshold value is exceeded the unit tries to reduce the current under 125 % by repetitive drain-
ings. If after 5 repetitive drainings the current value is still above the threshold value of 125 % the
unit goes on error (Error 24).
This threshold is xed based on the maximum nominal current if Fixed is selected (light blue, con-
tinuous line in the following diagram).
With the function Float the over current threshold (red, dash-dotted line in the following diagram)
can be attened. The function Float allows a faster reaction to changes of the control signal.
Overcurrent
Fixed
Float
Float
Esc Set
Engineering
GFCI :Set
Overcurrent :Float
Min.Request :25/20%
Drain Cool :On
Stop Mode :Set
Esc Set
Example:
Nominal current at 100% steam pro-
duction with 400V 10kg/h = 10 A
Actual steam demand 30%
––> Current setpoint value = 3 A
Draining as a result of over current at
4.5 A with setting “oat”
Draining as a result of over current at
12.5 A with setting “Fixed”
20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
Draining characteristics with over current
Nominal current 100%
Current setpoint value
Draining if current value exceeds the set point value by a factor of 1.5 (setting “Float”)
Draining if current value reaches 125 % of the maximum nominal current value (setting “Fixed”)
Forced draining if current value reaches 135 % of maximum nominal current value
Current value in %
Steam production demand in %

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2.7 Setting the On/Off hysteresis
Select “Min.Request” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue you determine the minimum demand for switching the unit on
(rst value) and off (second value) (On/Off hysteresis).
Factory setting: 25/20%
Options: 25/20%
17/12%
Notes on settings
To ensure an optimal current measuring/regulation with electrode based steam generators the hysteresis
is set to 25 % (switch on) and 20 % (switch off).
However you can reduce the hysteresis to 17% (switch on) and 12% (switch off).
2.8 Setting the Stop Mode for bathing operation
With this function you can determine whether or not the <Stop> key is suppressed during bathing operation.
Select “Stop Mode” in the engineering menu, then press the <Set> key.
In the upcoming modication dialogue you determine whether the bathing time is automatically controlled
via the set bathing time (setting “Timer”) whilst the <Stop> key is suppressed or whether the bathing
time can be stopped at any time by pressing the <Stop> key (setting “Switch”).
Factory setting: Switch
Options: Switch (bathing time can be stopped at any time with the <Stop> key)
Timer (the bathing time is automatically controlled via the set bathing time, the
<Stop> key is suppressed)
Engineering
Overcurrent :Float
Min.Request :25/20%
Stop Mode :Set
GFCI :Set
Instab.Temp.:Set
Esc Set
Min.Request
25/20%
17/12%
25/20%
Esc Set
Stop Mode
Switch
Timer
Switch
Esc Set
Engineering
Min.Request :25/20%
Stop Mode :Switch
Instab.Temp.:Set
Overcurrent :Float
FactoryReset:Set
Esc Set

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2.9 Setting-up temperature sensor monitoring function
In order to detect a manipulation on the temperature sensor, the steam bath control features the function
“Instab.Func”. If this function is activated the temperature curve of the temperature sensor is monitored
during steam bath operation. If the temperature decreases by cooling the temperature sensor (e.g. by
the use of a cool rag) within a certain time “Time Range” by more than the set temperature value “Temp
Range”, the steam generator is blocked for a certain time “Lock Time”. If the blocking time has elapsed
the steam generator is enabled again.
Note: temperature monitoring is activate only during steam bath operation and if the door of the steam
bath cabin is closed.
Select “Instab.Temp” in the engineering menu, then press the <Set> key. Select “Instab.Func”, then press
the <Set> key. In the upcoming display activate the monitoring function (On), then press the <Set> key.
Now, determine the desired settings for the temperature sensor monitoring:
• “Temp Range”: Temperature range
Factory setting: 10 °C
Setting range: 1…30 °C
• “Time Range”: Time span for the temperature monitoring
Factory setting: 10 seconds
Setting range: 1…60 seconds
• “Lock Time”: Blocking time for steam production
Factory setting: 120 seconds
Setting range: 1…600 seconds
Instab.Temp.
Instab.Func.:Aus
Esc Set
Instab.Temp.
Temp Range :10°C
Time Range :10s
Lock Time :120s
Instab.Func.:On
Esc Set
Instab.Temp.
Temp Range :10°C
Time Range :10s
Lock Time :120s
Instab.Func.:On
Esc Set
Instab.Temp.
Temp Range :10°C
Time Range :10s
Lock Time :120s
Instab.Func.:On
Esc Set
Instab.Temp.
Temp Range :10°C
Time Range :10s
Lock Time :120s
Instab.Func.:On
Esc Set
Engineering
Stop Mode :Switch
Instab.Temp.:Set
FactoryReset:Set
Min.Request :25/20%
Count Down :Set
Esc Set
Instab.Func.
O
On
On
Esc Set
Temp Range
10 °C
10 °C
Esc Set
Time Range
10 s
10 s
Esc Set
Lock Time
120 s
120 s
Esc Set