Stulz BNB Series User manual

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Technical Manual
STULZ UltraSonic Humidifier
System for direct room humidification BNB
BNB 1000A BNB 4000A
BNB 2000A BNB 5000A
BNB 3000A BNB 8000A
Version 10-2015
Item No. 1000683 EN

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   STULZUltraSonic-SystemforDirectRoomHumidicationBNB-
Dear Customer,
Many thanks for choosing to buy a STULZ product. STULZ has been a purveyor of sophisticated technical solutions for comfort
and precision air conditioning applications since 1947.
Best regards,
STULZ GmbH
Hotline
For general inquiries, please get in touch via our hotline on
[phone] or
[email protected]/en.
Technical Support
In the event of technical problems, please contact our Technical Support on
[phone]
Current updates to technical documentation
Youcanndthelatestdocumentsandbrochuresat:
www.Stulz.de/en/e-stulz
Manufacturer's address
STULZ GmbH
Air Conditioning and Humidifying Systems Division
Holsteiner Chaussee 283
D-22457 Hamburg
Germany

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CONTENTS
1. INFORMATION ON THIS DOCUMENT .................................................5
1.1. Validity......................................................................5
1.2. Target group .................................................................5
1.3. Conventions regarding illustrations................................................5
1.4. Abbreviations ................................................................5
1.5. Formatting...................................................................7
1.6. Nomenclature ................................................................7
1.7. Liability claims for defects .......................................................7
1.8. Exclusion of liability............................................................7
1.9. Copyright....................................................................7
2. SAFETY .........................................................................8
2.1. Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.2. Basic safety instructions ........................................................9
2.3. Qualicationrequirementsforpersonnel ..........................................10
2.4. Compatible products ..........................................................10
2.5. Other applicable documents ....................................................11
2.6. Transport and storage.........................................................11
2.7. Installation..................................................................11
2.8. Spare parts .................................................................11
3. PRODUCT PACKAGE .............................................................12
3.1. Optional accessories..........................................................13
4. PRODUCT DESCRIPTION ..........................................................14
4.1. Sizes ......................................................................14
4.2. Rating plate.................................................................15
4.3. Description of unit ............................................................16
4.4. Operatingprincipleofultrasonichumidication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.5. Technical data ...............................................................18
4.6. Dimensional drawing..........................................................19
4.7. Application limits .............................................................20
4.8. Service life of materials........................................................21
4.9. Water treatment .............................................................22
4.10. Use in conformity with VDI 6022.................................................24
5. DESIGN AND PLANNING...........................................................26
5.1. Humidierdistance ...........................................................27
5.2. Applications.................................................................29
5.2.1. Comfort applications ..................................................29
5.2.2. Equipment room applications ...........................................29
6. OPEN-LOOP AND CLOSED LOOP CONTROL ..........................................30
6.1. Master/slavecontrolcabinetforultrasonichumidier(USM/USScontroller) ...............31
6.2. ON/OFF control module .......................................................32
6.3. Accessorysets(controlledbyon-siteswitchgearcabinet). . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7. INSTALLATION ...................................................................33
7.1. Installation diagram...........................................................35
7.2. Installation clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7.3. Wall-mounted installation ......................................................37
7.3.1. Wall bracket dimensions ...............................................38
7.3.2. Safety tray dimensions ................................................39
7.4. Connectingwatersupplyline(s) .................................................40
7.4.1. Connecting the pipe for the demineralized drinking water......................42
7.4.2. Waste water connection................................................44
7.5. Electrical connection ..........................................................49
7.5.1. Connectingcablesbetweenthehumidierandcontrolcabinet..................49
7.5.2. Cable dimensions ....................................................53
7.5.3. Internal wiring .......................................................55

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8. START-UP.......................................................................57
8.1. ReportsandchecklistsforSTULZUltraSonichumidiers .............................60
9. OPERATION .....................................................................61
9.1. Operation ..................................................................62
9.1.1. Using the USM.......................................................63
9.1.2. Operating the ON/OFF control module ....................................69
9.1.3. Operation when using accessory sets .....................................70
10. DECOMMISSIONING ..............................................................71
10.1. Switching off ................................................................71
11. MAINTENANCE ..................................................................72
11.1. Maintenance cycles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
11.2. Checklist for hygiene checks in line with VDI 6022...................................74
11.3. Visual inspection .............................................................75
11.4. Cleaning ...................................................................76
11.4.1. Cleaning water-bearing parts............................................76
1.1.1. Cleaningtheairlter ..................................................77
11.4.3. Cleaning the water tank, transducers and mist guide tubes ....................78
11.5. Inspect the electrical system....................................................80
11.5.1. Replacing the relay PCB ...............................................82
11.5.2. Replacingthesolenoidvalveandoatswitch ...............................84
11.5.3. Replacing the transducers ..............................................86
11.5.4. Replacing the nebulizer print plate .......................................88
11.5.5. Replacing the fan.....................................................89
12. DISMANTLING AND DISPOSAL .....................................................90
12.1. Dismantling .................................................................90
12.2. Disposal ...................................................................90
13. SPARE PARTS LISTS..............................................................91
14. EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
15. TROUBLESHOOTING .............................................................97
16. CE DECLARATION OF CONFORMITY ................................................98
17. MAINTENANCE CHECKLIST.......................................................102
18. START-UP CHECKLIST ...........................................................104
19. HUMIDIFICATION TEST REPORT ...................................................106

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STULZUltraSonic-SystemforDirectRoomHumidicationBNB-  Informationonthisdocument
1. Information on this document
ThisTechnicalManualcontainsdetailedinformationoninstallation,conguringtheimplementedpro-
grams, and troubleshooting.
The Technical Manual must be kept on site at the location of use and be available at all times.
Make sure that persons responsible for operating the product and working on the product have fully read
and understood this guide. If you have any questions, please call the hotline.
1.1. Validity
ThisTechnicalManualappliestoSTULZUltraSonichumidiersBNB1000A-BNB8000A.
1.2. Target group
Thisdocumentisintendedforqualiedelectriciansandspecialistplanners.Theworkdescribedinthis
documentmayonlybeperformedbypersonswiththerequisitequalications(see"2.3.Qualication
requirements for personnel" on page 10).
1.3. Conventions regarding illustrations
Safety and warning notices are indicated by signal words. The signal words indicate hazard levels with a
risk of injury of varying degrees of severity. The signal word NOTICE indicates a risk of property damage.
Signal word Meaning Consequences of failure to observe
DANGER Immediate threat of danger Death or serious injury through a high-risk hazard
WARNING Immediate threat of danger Death or serious injury through a medium-risk hazard
CAUTION Immediate threat of danger Slight injury through a low-risk hazard
NOTICE Immediate threat of danger Damage to property or the environment
Note Special notes on optimum use of the product
1.4. Abbreviations
Abbreviation Name Explanation
A Ampere SIunit:electricalcurrent
A Cable cross-section in mm2
AC Alternating current ─
BNB Box Nebulizer Version BUltrasonichumidierfordirectroomapplications
CH Relay panel
DC Direct current ─
DIP Dual in-line package Describes small switches with 2 parallel terminal strips

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Abbreviation Name Explanation
FAN ─
FS Float switch ─
GND Ground Ground wire or signal ground
─ ─ ─
HR Auxiliary relay
i Voltage drop in V
I Current in A
kg/h Kilograms per hour Compositeunitformassowrate
K Kelvin SIunit:Temperature
CFU Colony forming unit
Unit used to quantify microorganisms when the number of
viable microorganisms in a material is determined by
culturing.
L Pipe length in m
LED Light-emitting diode ─
l/h Liters per hour Compositeunitforvolumetricowrate
m Meter SIbaseunit:Length
min Minute SIunit:Time
N Neutral wire ─
NB Nebulizer ─
NC Normally closed Relay is closed without current
NO Normally open Relay is open without current
RH Relative humidity in %
s Second SIbaseunit:Time
SV Solenoid valve ─
T Cycle time ─
ti Pulse time ─
TP ─Thermostat
tp Rest time ─
tw Delay time
UpSupply voltage ─
Uout Output voltage ─
Uin Input voltage ─
USM UltraSonic Master ─
USS UltraSonic Slave ─
V Volt SIunit:electricalvoltage
ΩOhm SIunit:electricalresistance

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1.7. Liability claims for defects
Following the assembly and operating instructions in this Technical Manual is a prerequisite for trou-
ble-free operation of the STULZUltraSonicBNBultrasonichumidier and for potential claims for defects.
Read the Technical Manual before working with the product.
1.8. Exclusion of liability
Following the assembly and operating instructions in this Technical Manual is a prerequisite for safe
operationoftheproductandforattainingthespeciedproductcharacteristicsandperformancefeatures.
STULZshallnotbeliableforanyinjuryorpropertydamageoranynanciallossresultingfromnon-
compliance with the assembly and operating instructions. In such cases, all liability for material defects is
excluded.
1.9. Copyright
All brand and product names are trademarks or registered trademarks of the products bearing these
names. UltraSonic® is a registered trademark of STULZ GmbH.
All rights reserved, including in respect of this translation. No part of this document may be reproduced in
anyform(e.g.printing,photocopying,microlm,datatransferorothermethod)orduplicatedorpro-
cessed by electronic means, without the written consent of STULZ GmbH.
Technical data subject to change without notice.
1.5. Formatting
Format Name Example
bold
Operating states
Values that require setting
ON or OFF.
Set the voltage to 7.5 V .
italic References in the document Prerequisite, procedure, result
" XX" Buttons Press the "►" button
1.6. Nomenclature
Full name Name in this document
STULZUltraSonicBNBultrasonichumidier Ultrasonichumidier
STULZ UltraSonic Master USM
STULZ UltraSonic Slave USS
STULZ heat exchanger terminal module FDSX Heat exchanger terminal module FDSX
Table 1: Nomenclature

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2. Safety
The plant operator must ensure that the safety and warning notices in this documentation are observed
and adhered to. The plant operator must furthermore ensure that any persons working on the system
have read and understood the documentation in its entirety. The documentation must always be kept in
the same place as the equipment.
Failure to observe the safety and warning notices may put personnel, the environment and the system at
risk and voids all entitlement to claims for material defects.
Safe operation of the system is only ensured if it is used in accordance with its proper use. The limit
values set out in the technical data must never be exceeded.
If anything is unclear or you require additional information, please call STULZ Technical Support.
2.1. Proper use
TheSTULZUltraSonicBNBmodelseriesisdesignedfordirectroomhumidicationthroughtheultra-
sonic atomization of demineralized drinking water. The STULZ UltraSonic BNB model series is intended
solely for indoor use, and may only be used with compatible products. Any other use besides or beyond
this shall be regarded as improper use. STULZ cannot be held liable for damages resulting from the
above. The risk shall be borne by the plant operator alone.
Use of any other supplied media requires the approval of STULZ.
The system may only be used in accordance with the technical documentation from STULZ and the data
on the rating plate.
Thefollowingusesoftheunitareprohibited:
●Use of the unit outdoors.
●Use of the unit in potentially explosive atmospheres.
●Use of the unit in ventilation systems.
●Useoftheunitwithouttreateddrinkingwaterofthespeciedquality.
●Use of the unit under water.
●Use of the unit with media other than those approved by STULZ.
●Use of the unit outside the application limits.

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STULZUltraSonic-SystemforDirectRoomHumidicationBNB-  Safety
CAUTION
Risk of injury from rotating parts.
Touching rotating parts carries a direct risk of injury due from mechanical forces.
The STULZ UltraSonicBNBultrasonichumidier may only be installed, connected and started up by
specialist engineers.
●Before any repairs and maintenance work, always switch off the power supply to the system and
the unit, and secure so they cannot be switched back on for the duration of the work.
CAUTION
General risks of injury.
• Make sure that all persons and specialist engineers wear the appropriate protective equipment
(gloves,helmet,safetygoggles)fortheirwork.
• Make sure that all transport, storage, installation, start-up, maintenance and disposal work is
performedsolelybyappropriatelyqualiedspecialistpersonnel.Thequalicationrequirementsfor
specialist personnel are listed in section "2.3.Qualicationrequirementsforpersonnel"onpage
10.
• Makesurethattheunitisonlyopenedbyqualiedspecialistpersonnel.
• Make sure that applicable documents are observed during transport, storage, installation, start-up,
maintenance and disposal. Other applicable documents are listed in section "2.5. Other applicable
documents" on page 11.
• Units must be stationary and switched off before any work is carried out. The unit must be discon-
nectedfromthemainspowerforanymaintenanceworkandawarningsignafxedtopreventit
from being inadvertently switched on. Before restarting, the preparatory measures in the Installa-
tion/Start-up section must be carried out.
• TheunitsmayonlybeconvertedormodiedfollowingconsultationwithSTULZGmbH.Genuine
spare parts and parts/accessories approved by STULZ GmbH are a guarantee of safety.
• Never operate the system without the necessary protective covers.
• Before any work on the electrical installation, switch off the power supply to the unit and all con-
nected components and secure so they cannot be switched back on.
• The regulations from professional associations must be complied with.
CAUTION
Danger of death. Electric shock risk.
There is an immediate danger of death from electric shock if live parts are touched.
The STULZ UltraSonicBNBultrasonichumidier may only be installed, connected and started up by
specialist electricians.
●To change the settings of DIP switches or to remove the connections, always switch off the power
supply to the system and the unit, and secure so they cannot be switched back on for the duration
of the work.
WARNING
DANGER
2.2. Basic safety instructions

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CAUTION
Danger due to incorrectly congured components.
Duringinstallationandconguration,itmaybenecessarytoadditionallycongurefurthercomponents
for use with the STULZ UltraSonicBNBultrasonichumidier.
●Beforestart-up,alwayscheckthecurrentcongurationofallaffectedcomponents(referalsotothe
documentationoftherespectivecomponents).
NOTICE
2.3. Qualication requirements for personnel
All electrical work must be performed exclusively by authorized specialist electricians. Specialist person-
nel within the context of this documentation are persons who are familiar with the electrical installation,
start-up,maintenanceandrepairofthesystem,andareinpossessionofthefollowingqualications:
●Successful,certiedcompletionoftraininginelectricalengineering
●Familiarity with the technical documentation
All water installation work must be performed exclusively by authorized and trained specialist personnel.
Specialist personnel within the context of this documentation are persons who are familiar with the elec-
trical installation, start-up, maintenance and repair of the system, and are in possession of the following
qualications:
●Instruction by an expert
●Familiarity with the technical documentation
All work relating to transport, storage and operation must be performed exclusively by persons
who have received instruction in such work.
The plant operator must ensure that all maintenance, inspection and installation work is performed
byauthorizedandqualiedspecialistpersonnelwhohavebeenbriefedbythoroughly
studying the technical documentation.
2.4. Compatible products
The STULZ UltraSonicBNBultrasonichumidieriscompatiblewiththefollowingSTULZproducts:
●STULZ ion exchanger SD 2800
●STULZ UltraWater reverse osmosis system
●STULZ conductivity measuring kit
●STULZ USM control cabinets USM 503, USM 1303, USS 503, USS 1303
●STULZ ON/OFF electronic control module