Vapac LEC05 User manual

These instructions contain operating information and should be left with the unit.
LEC Electrode Boiler Units
Installation & Operation Manual
Edition 1.1
Installation in countries covered by EC Directives:
This product meets the requirements of the RoHS Directive 2002/95/EEC
This product will meet the requirements of the Low Voltage Safety Directive 2006/95/EEC and the
EMC Directive 2004/108/EEC when installed in accordance with the instructions contained in this
manual.
Failure to comply with these instructions may invalidate the manufacturer's warranty or any
certificate/declaration of conformance requested to be supplied with the unit.

2
CONTENTS
1.0 Installation....................................................................................................................................................4
1.1 Vapac LE unit dimensions .............................................................................................................................4
1.2 Positioning the steam pipes......................................................................................................................6
1.2.1 General.................................................................................................................................................6
1.2.2 Steam Hose Connection .......................................................................................................................6
1.3 Plumbing Considerations. ........................................................................................................................7
1.4 Electrical Connections..............................................................................................................................8
1.4.1 Important E.M.C. Considerations........................................................................................................8
1.4.2 Power Supply Connection....................................................................................................................8
1.4.2 Power Supply Connection....................................................................................................................9
1.4.2.1 Volt free alarm outputs.........................................................................................................................9
1.4.2.2 Unit control terminals...........................................................................................................................9
1.4.3 Electrical Connections........................................................................................................................10
1.4.4 Cable Entry Provision ........................................................................................................................10
1.4.5 Vapac Control Circuit Transformer....................................................................................................10
1.5 Cylinder Electrical demand loads...........................................................................................................11
1.6 Control Circuit Connections...................................................................................................................12
1.6.1 Control Circuit Wiring .......................................................................................................................12
1.6.2 Proportional Control...........................................................................................................................12
1.6.3 Control Signal Selection.....................................................................................................................12
1.6.4 On/Off Control...................................................................................................................................12
1.6.5 Sensing Head......................................................................................................................................13
1.6.6 Security Circuit / E.P.O. Shutdown....................................................................................................13
1.6.7 Load Shed Option...............................................................................................................................13
1.6.8 Master/Slave System..........................................................................................................................14
2.0 Start-Up / Operation...................................................................................................................................14
2.0 Start-Up / Operation...................................................................................................................................15
2.0.1 Start-up check list...............................................................................................................................15
2.0.2 Start-Up Instructions ..........................................................................................................................15
2.0.3 Commissioning/Start-Up....................................................................................................................15
2.0.4 Features of VAPANET Electode Boiler Unit.....................................................................................15
2.1 Service Advice .......................................................................................................................................16
2.1.1 Procedure for cylinder Exchange. ......................................................................................................16
2.1.2 Typical Cylinder / Electrode Layouts.................................................................................................16
2.2.1 Feed Valve with Strainer....................................................................................................................17
2.2.2 Drain Pump ........................................................................................................................................17
3.0 Indicators....................................................................................................................................................18
3.1 User LED ...............................................................................................................................................18
3.2 Fascia Label symbols .............................................................................................................................19
3.3 Other Options.........................................................................................................................................19
4.0 Trouble-shooting Check List......................................................................................................................20
5.0 Wiring diagram ..........................................................................................................................................21
Appendix 1.............................................................................................................................................................28
A Guide to Positioning Steam Pipes: .................................................................................................................28
Appendix 2.............................................................................................................................................................29
Appendix 2.............................................................................................................................................................30
A Guide to Positioning Multipipes:....................................................................................................................30

3
Important Installation Points
The unit must be installed to comply with national regulations and/or codes of practice. A qualified
electrician must carry this out.
Ensure at least 1000 mm clear front access to the electrical and steam sections.
Do not locate the cabinet where the ambient temperature around the unit could exceed 35º C; or
fall below 5º C e.g., an unventilated roof mounted enclosure – see minimum space / ventilation
requirements page 7.
Do not locate the cabinet where a ladder is required for service access as this could make
servicing and cylinder service or exchange hazardous.
Make sure steam line(s) have adequate slope (min 12%) for condensate drainage and use
condensate separators if the pipe is lower than the unit.
Provide adequate support to prevent sags developing in flexible steam lines, which can fill with
water and create a "trap".
Do not locate vented drain directly under the cabinet.
Important Electrical Connection Items
Before commissioning the unit, check that all electrical (power) connections - including those at
the terminals and contactor are tight.
Check that the transformer primary winding connection is correct for the supply voltage at Vapac
terminals A1 & A2.
The Vapac transformer must not be used to power other equipment.
To comply with EMC aspects see recommendations on page 10.
Use a high-limit humidistat to ensure positive interruption of unit operation when over-
humidification is detected (See page 17).
It is important that the control signal connected to terminals 5 & 6 must be referenced to ground at
the control PCB – this can be done by linking either terminal 5 or 6 to terminal 7.
NB if the controller output is referenced to ground, it is important that the “leg” which is
connected to ground at the controller is also connected to ground at the Vapac unit. Grounding
the opposite “leg” will cause damage to the controller and/or the Vapac control PCB.
Important Maintenance Items
Only a qualified electrician should carry out maintenance.
The boiler contains hot water, and must be drained before any maintenance is carried out on the
steam section. This should be done prior to isolating the power, and removing the front access
panel
ESD SENSITIVE DEVICES USED ON PCB. ENSURE ANTI-STATIC PRECAUTIONS ARE TAKEN
WHEN REMOVING OR REPLACING PCB’S.

4
85 85
1000 500
1.0 Installation.
Do’s
Do mount the unit as close to the steam distribution
pipe(s) as possible.
Do mount the unit at a height convenient for reading the
display window.
Do ensure adequate side ventilation (min 80 mm).
Do ensure adequate service access to the front of the unit
(min 1000 mm).
Do ensure adequate service access below the unit (min
1000 mm).
Do ensure that the holes in the rear top panel remain
unobstructed to allow a free flow of air see fig 1.
Do use the marking on the side of the carton as a template
to mark the mounting hole positions.
Do remove the cylinder, if necessary, to access the
mounting holes in the back of the steam section.
Do use M6 projecting type wall bolts or equivalent to
mount the unit in position.
Don’ts
Don’t mount the unit close to sources of strong electro-
magnetic emissions e.g. variable speed lift motor
drives, kVa transformers etc.
Don’t mount the unit in an unventilated enclosure.
Don’t mount in a position requiring ladder access to the
unit.
Don’t mount the unit behind a false ceiling or other
situation where an unusual malfunction (e.g. water
leak) would cause damage.
Don’t mount the unit in an area which will be hosed down.
Don’t install the unit where the ambient temperature can
exceed 35oC; or fall below 5oC.
Don’t mount the unit inside a cold-room or other place
where temperature and humidity conditions can cause
condensation on electrical components.
Don’t mount the unit where the sound of a contactor
opening/closing and water flow in a pipe would be
unacceptable e.g. libraries, private apartments, etc.
1.1 Vapac LE unit dimensions
Cabinet Sz 4 (5 – 45 kg/h Models) Minimum
Clearances.

5
Cabinet Sz 4 (5 – 45 kg/h Models)
55 990
360
20.5"(520) 468
31.1"(790)
55
505
176 6
360
6
152 343
343
70 850
62
237
190
610
810
322
346
190
610
73555
FF
D
Steam Outlets
54 mm
Gland Plate
120 X 120 Gland Plate
120 X 120
Left:
Top View Showing Steam
O/let position
Below: Rear View
showing wall mounting
points.
Left:
Bottom View Showing
“F” (Feed connection) ¾”
BSP male connection for
flexible hose provided
with unit.
“D” (Drain connection)
35 mm pipe.
NB:
Entry hole for gland
plates is approx.
105 mm x 90 mm
For clearance around the unit for ventilation and access see page 7

6
1.1.1 LEC weights
The unit dry weight is the delivered unit with no
water in unit, the wet weight is the operational
weight when the unit is running .
Vapanet model Dry Kg Wet Kg
LEC05 68 96
LEC09 71 100
LEC18 72 125
LEC30 74 127
LEC45 75 128
1.2 Positioning the steam pipes
1.2.1 General
Steam pipes should be positioned as shown below,
allowing a minimum rate of fall back to the unit of
12% to allow the free flow of condensate back to the
unit. If the above fall is not possible, then
condensate separators must be fitted as shown in
appendix 1.
The position of the steam pipe or multipipe in a air-
conditioning system relative to other items such as
bends, filters, heat exchangers, etc., is critical. The
steam pipe must not be located closer to such item,
than the entrainment distance, and must be decided
by the design engineer responsible for the project.
Do's
Do obtain project engineer's instruction/drawing for
chosen location of pipe
Do obtain project engineer's instruction/drawing for
pipe position relative to the top & bottom of the
duct (or sides if airflow is vertical.
Do check if alternative slope of Ø35mm pipe has
been specified.
Do use bracket/lug on the end of Ø54mm pipes for
extra support.
1.2.2 Steam Hose Connection
Do's
Do use Vapac steam hose or well insulated copper
pipe.
Do keep steam hose as short as possible (under 2m
for max efficiency).
Do arrange to have a vertical rise immediately over
the unit of 300mm.
Do use the full height available between the unit
and steam pipe to provide maximum slope (min
12-20% for condensate to drain back to the
steam cylinder (or down to a condensate
separator). Always provide a continuous slope.
Do provide adequate support to prevent sagging
a) fit pipe clips every 30-50cm
or b) support straight lengths on cable trays
or in heat resistant plastic pipe.
Do ensure radius hose bends are fully supported to
prevent kinks developing when in service.
Do add extra insulation to steam hose for longer
runs (2m-5m) and in cold ambient conditions to
avoid excess condensate and reduction in
delivered output.
Don'ts
Don't allow steam hose to develop kinks or sags.
Don't include horizontal runs or 90oelbows in the
steam line.
Steam Distribution Pipe requirement
Electrode Boiler
Unit Model LEC05 LEC09
LEC18
LEC30
LEC45
35mm
∅
Pipe
No.
54mm ∅.
Pipe No.
2
-
-
2
*Duct Pressure
Pa. +2000 -600
35mm
∅
Pipe Selection 54mm ∅Pipe Selection
Duct width
B mm In-duct Length L mm Duct width B mm In-duct Length L mm
320-470
470-620
620-770
770-920
920-1070
1070-1200
300
450
600
750
900
1050
700-950
950-1450
1450+
(Kg)
650 (1.8)
900 (2.2)
1400 (3.2)
R min for 35
∅
Pipe = 250mm
R min for 54 ∅Pipe = 500mm
Flexible Steam
Pipe.
No Sags!
Distance to first
bend.
VAPAC
HUMIDIFIER
Flexible Steam
Pipe.
Flexible pipe coupling to
connect Steam pipe to Duct
pipe coupling length to allow
for line movement and
expansion. Coupling clamp
with Hose clips each end.
35 or 54 mm
copper or
stainless steel
steam pipe with
Insulation.
Fig 6
For guidance on positioning of steam pipes see Appendix 1.
For guidance on use of Multipipes see Appendix 2.

7
1.3 Plumbing Considerations.
1.3.1 Cold water supply.
General
The Vapanet range of electrode boilers is capable of
operating with a range of “raw mains” water quality. The
water supply should be within the following limits:-
Hardness 50 – 500 ppm
Conductivity 80 – 1000µS
PH 7.3 – 8.0
Silica 0
Pressure of between 1 - 8 bar.
In addition, if stainless steel electrodes are used the chlorine
level must not exceed 170 ppm.
Water Supply rates per cylinder
1.20 l/min
1.20 l/min
1.20 l/min
2.50 l/min
2.50 l/min
LEC05
LEC09
LEC18
LEC30
LEC45
2 Cylinder per unit
2 Cylinder per unit
2 Cylinder per unit
2 Cylinder per unit
2 Cylinder per unit
Do’s
Do install a stop-valve/Shut-off valve and a strainer close to
the unit.
Do provide a water supply with sufficient pressure and pipe
size to ensure an adequate flow rate to all units connected
to the system.
Do use the water connection with nylon nut provided.
ALL Dimensions in mm
Don'ts
Don’t use a wrench or other tool to tighten the water supply
connection - the nylon nut and rubber washer provided,
should only require tightening by hand to effect a seal. If
water seepage occurs, undo the nut to wipe the washer
clean and re-seat it.
1.3.2 Drain connection.
General
Do's
Do ensure metal drain and supply water pipework is
grounded electrically close to the unit (a ground/earth stud
is positioned on the underside of the cabinet.
Drain capacity per cylinder
= pump discharge rate of max 16.8 l/min at 50 Hz.
Power supply 17.2 l/min at 60 Hz.
Do’s
Do use copper or plastic pipe rated for 110 oC.
Do arrange to discharge drain water from the unit into a
trapped and vented drain at a position where flash steam
rising from the drain line vent will not pose a problem for
the Vapac or other equipment.
Do provide adequate fall for the drain pipework to allow free
flow of water drained from each unit.
Do ensure drain line pipe size will accommodate water being
drained at the same time from all the Vapac units which
are connected to it.
KEY: -
A Tundish Fill-cup
B Steam Cylinder
C Feed Drain Manifold
D Drain Pump
F Feed Solenoid Valve
G Water Connection ¾” BSP.
H Flexible hose ¾” BSP.
K 35∅Steam Hose coupling and Hose
Clips.
L 35∅copper or plastic Drain for 110°C
Water with supports.
M Tundish
N U-trap side exit.
S Optional Strainer
V Isolation stop cock
LEC Twin C
y
linder Units 5-45 k
g
/h
A
B
C
D
F
K
L
M
N
K
H
G S V

8
1.4 Electrical Connections
1.4.1 Important E.M.C. Considerations
Use a dedicated, earthed metal conduit for both the control
signal cable and the security circuit cables along their entire
length - they may share the same conduit where practicable.
The earth must be made by "metal-to-metal" contact and
should be a good RF (Radio Frequency) earth.
The control and security circuit connections should be run in
screened cable with the screen grounded at the VAPANET
end (onto the electrical section back panel). The screen
should be maintained as close as possible to the cable ends
and any tail between the screen and the earth point must be
kept short (50 mm maximum).
Control Cable / Security Circuit
Conduit Entry Arrangement
Control Cable / Security Circuit
Screening Arrangement
Tail to be kept short
(less than 50mm)
Cables to control terminals
Screen left intact
Outer insulation
Earthed back panel
Important Power Connection Information
Vapac 24V and 9 V secondary Transformer Primary supply connections:
Vapac units are wired to allow connection to alternative site Voltages.
Make the following simple checks before connecting the power supply:-
Move the RED connection on the VAPANET transformer primary winding circuit to the
position marked with the supply Voltage that is to be connected between VAPANET
power terminals A1 and A2.
The transformer primary circuit terminal positions are clearly marked:- 200V, 230V,
380, 415 & 440V. If the actual (measured) site voltage is 400v the preferred
tapping is 380V. The transformer is fitted below the Drain tray, and is accessible by
removing two screws and the cover, which should be slid it towards you.
Note:
24 V a.c. Control circuit -
9 V a.c. PCB Circuit -
Transformer Primary Circuit -
230V ac Pump Supply. -
6.3 A 20 mm (T – Time Lag) fuse (Pt.No. 1080093) mounted on VAPANET
Echelon PCB (Pt.No.1150630).
2 A 20 mm (F - Quick blow) fuse (Pt No. 1080099) mounted on the VAPANET
Echelon PCB (Pt, No. 1150630).
Two fuses protect the control circuit on Single cylinder units F1 2.0A (slow
blow) (Pt. No. 1080095) mounted in fuse-terminal holder protects Primary
transformer and RDU unit if fitted. F2 500 mA 20 mm (F - Quick blow) fuse (Pt
No. 1080054) mounted in fuse-terminal holder protects Transformer Primary
and Pump or both pumps if two pumps are fitted.
The pump or pumps on twin cylinder units are fed from the main transformer
via a 230 volt auto winding. The pumps are protected by fuse F1 and F2 above
feeding the transformer primary.
All metal surfaces which come
into contact with each other,
must be free of paint, grease,
dirt, etc., thereby ensuring a
good low impedance R.F.
(Radio Frequency) path to
ground.
Electrical section metalwork
Metal conduit

9
1.4.2 Power Supply Connection
The unit requires the following connections as shown in the diagram
below
1.4.2.1 Volt free alarm outputs
The unit has connections for volt free alarm outputs these are on the
three double terminals next to the main power input terminals.
The top terminals are for unit volt free fault alarm as follows:
542 common for fault alarm
543 Normally closed when no fault
544 Normally open when no fault
The bottom terminals are for unit volt free run signal as follows:
545 Common for run signal
546 Normally closed when unit is in standby or fault
(not running)
547 Normally open when unit is in standby or fault
(not running)
If the unit is part of a master slave system or network, the run
& fault outputs can be selected (via keypad & display) as
either network (system) or unit only. This is selectable at
Service Engineers Level, in the Engineering Menu, in the
window “Fault/Run Scope”. The default is “network”. It is
possible to get both alarm & Run indication in all units: Single
cylinder units will give this indication if the service interval has
expired; Twin Cylinder & Networked units will give this
indication if the service interval has expired or if the master
cylinder is operating and any slave cylinder (or cylinders) are
in fault.
1.4.2.2 Unit control terminals
For unit control and network termination see section
1.6 the terminal layout is shown here.

10
1.4.3 Electrical Connections
The wiring to the Vapac should be done by a qualified
electrician. The external overcurrent protection and wiring
should comply with the appropriate Regulations and Codes of
Practice.
Important: Make sure the connection to the primary Voltage
winding of the Vapac transformer matches the supply Voltage
which is to be connected between Vapac terminals A1 & A2.If
the actual (measured) site voltage is 400v the preferred
tapping is 380V.
A fused disconnect/isolator or MCB should be used to
disconnect the supply from all electrodes simultaneously.
This must be sized to suit the total maximum phase/line
current of the unit and should be located adjacent to the
Vapac cabinet or within easy reach and readily accessible.
In Vapac VAPANET units terminals A1, A2 and A3 are for the
power supply connections as indicated in the diagrams below
(twin cylinder units have two supplies A1,A2,A3 & B1,B2,B3).
Twin cylinder units’ have terminals for the connection of two
power supply input circuits. On twin cylinder units’ this allows
individual external protection of each steam cylinder. Fused
disconnect/isolator or MCB provision must be linked to
ensure both 3 phase supply inputs are disconnected
simultaneously.
1.4.4 Cable Entry Provision
Cable glands must be used to ensure cables are held
securely at the entry position. All Vapac cabinets are
equipped with a removable gland-plate. The installing
electrician should remove this and take it to a work-bench to
drill for the required cable gland size.
1.4.5 Vapac Control Circuit Transformer
The internal control circuit of the Vapac unit operates at
24Vac - the transformer secondary is set at 24V.
As standard the Vapac VAPANET includes a transformer with
alternative primary winding options 200V, 230, 380, 415, and
440V and requires on site adjustment to match it to the
Voltage connected to Vapac terminals A1 and A2.
The transformer also has a 9V secondary tapping which
provides power to the VAPANET 1150630 PCB.
Important: The Vapac transformer must NOT be used to
power other equipment or the warranty will be invalidated.
Notes:-
1. All units must have a PE earth connection connected to the units terminal.
2. Unit with N.A. in the following tables means NOT AVAILABLE there is not a unit available to run at the voltage
and phases shown. Please check that the correct model reference is ordered and installed, for the low or high
voltage required, and at the desired steam output.
3. Standard design is for 50 Hz. Supplies. Design for 60 Hz. Also available - 60 Hz. Supply must be specified with
order as the standard pump is only 50Hz.
FOR FULL ELECTRO-MAGNETIC COMPATIBILITY A NEUTRAL CONNECTION IS REQUIRED FOR ALL PROPORTIONAL
UNITS AS INDICATED IN THE CONNECTION DIAGRAMS ON THE FOLLOWING PAGES.