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.

11
1.5 Cylinder Electrical demand loads
Model Ref. LEC05 LE09
Nominal Output Kg/hr 5 5 5 5 5 5 9 9 9 9 9 9
Voltage V 200 230 380 400 415 440 200 230 380 400 415 440
Power input rating per cylinder Kw 3.73 3.71 3.78 3.81 3.78 3.83 6.71 6.76 6.77 6.79 6.7 6.74
Electrical Supply Ph's Ph+N or
2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph Ph+N or 2Ph
No. of electrodes 2 2 2 2 2 2 2 2 2 2 2 2
Full load Current per cylinder A 22.5 19.5 12 11.5 11 10.5 40.5 35.5 21.5 20.5 19.5 18.5
Maximum overcurrent per cylinder A 33.75 29.25 18 17.25 16.5 15.75 60.75 53.25 32.25 30.75 29.25 27.75
Number of cylinders & supply 2 2 2 2 2 2 2 2 2 2 2 2
2 Supplies @ Fuse Rating/phase A 32 32 16 16 16 16 63 50 32 32 32 25
Supply cable terminals mm2 4 4 4 4 4 4 10 10 10 10 10 10
Wiring diagram A4-LZD-559 cyl 1 and A4-LZD-595 cyl 2 A4-LZD-559 cyl 1 and A4-LZD-595 cyl 2
Cabinet size 4 4
Model Ref. LEC18 LEC30
Nominal Output Kg/hr 18 18 18 18 18 18 30 30 30 30 30 30
Voltage V 200 230 380 400 415 440 200 230 380 400 415 440
Power input rating Kw 13.34 13.36 13.35 13.48 13.39 13.57 22.38 22.43 22.35 22.38 22.32 22.41
Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph
No. of electrodes 3 3 3 3 3 3 6 6 3 3 3 3
Full load Current per cylinder A 46.5 40.5 24.5 23.5 22.5 21.5 78 68 41 39 37.5 35.5
Maximum overcurrent per cylinder A 53.475 46.575 28.175 27.025 25.875 24.725 89.7 78.2 47.15 44.85 43.125 40.825
Number of cylinders & supply 2 2 2 2 2 2 2 2 2 2 2 2
2 Supplies @ Fuse Rating/phase A 50 50 32 32 32 32 100 80 50 50 50 50
Supply cable terminals mm2 10 10 10 10 10 10 35 35 35 35 35 35
Wiring diagram A4-LZD-559 cyl 1 and A4-LZD-595 cyl 2 A4-LZD-561 & A4-
LZD-596 A4-LZD-559 cyl 1 and A4-LZD-595 cyl 2
Cabinet size 4 4
Model Ref. LEC45
Nominal Output Kg/hr 45 45 45 45 45 45
Voltage V 200 230 380 400 415 440
Power input rating Kw 33.57 33.65 33.79 33.85 33.93 33.45
Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph
No. of electrodes 6 6 6 6 6 6
Full load Current per cylinder A 117 102 62 59 57 53
Maximum overcurrent per cylinder A 134.55 117.3 71.3 67.85 65.55 60.95
Number of cylinders & supply 2 2 2 2 2 2
2 Supplies @ Fuse Rating/phase A 160 125 80 80 80 80
Supply cable terminals mm2 35 35 35 35 35 35
Wiring diagram A4-LZD-561 cyl 1 and A4-LZD-596 cly 2
Cabinet size 4
The LEC units have two cylinders the table
refers to the maximum operating current of
each cylinder.
Each LEC unit requires two power suppliers, one
to each of the cylinder at the table rating above.
Both supplies should be routed through a six pole
switch fuse isolator within 1 meter of unit .

12
1 2 4 5 6 7 8 9
10 11 12
HYGROSTAT WITH VOLT FREE CONTACTS (max.
RESISTANCE OF EXTERNAL CONNECTION 100
Ohms.
1.6 Control Circuit Connections
1.6.1 Control Circuit Wiring
Use a dedicated, earthed metal conduit for both the
control signal cable and the security circuit cables,
sharing the same conduit if practicable.
Use screened cable for all control and security circuit
connections to minimise risk of electrical interference.
The screen should be grounded at the VAPANET end
only. See detail on page 7. NB. The control signal
should be connected to ground at the PCB by
connecting either terminal 5 or 6 to terminal 7 –
Important note if the controller output is
referenced to ground, then the “leg” which is
ground must be the one linked to terminal 7.
1.6.2 Proportional Control
The VAPANET Electrode Boiler (LExxP) models can
all be operated by either a potentiometric signal, a
lonworks network signal or by one of 6 standard
proprietary DC analogue signals.
Input signal:
Potentiometric control
0-5V
0-10V
0-20V
(Actually 0-18V – not phase cut)
2-10V
1-18V
4-20mA (Ensure jumper J1 is in place)
Network (Slave unit – demand generated by
Master)
Response:
8-100%
1.6.3 Control Signal Selection
Selection of the control signals is done a part of the
initial set-up procedure using the keypad display. For
confirmation that the signal has been selected, view
the information window.
1.6.4 On/Off Control
Vapanet models can be operated by a single
step humidistat which has Volt-free contacts –
select control option Pot.
DC 0 - 20 4 – 20 Ma POTENTIOMETRIC
VOLTAGE CURRENT CONTROL
CONTROL CONTROL min. 135 Ohms
Max. 10,000 Ohms
NOTE :- FOR CURRENT INPUT ONLY JUMPER J1 ON THE
1150630 CONTROL BOARD MUST BE LINKED.
Jumper J1
should be
fitted if
control
signal is
4 – 20 mA
Vapac PART No. 1150630
16
CR6 1
NetCR7
J6
CR5 1
6 6
10
CR3
16
J1
J2
J3
1
F2
CR1
1
F1 CR2
J4
18 CR4
1
16
J5
CR2
configuration
resistor
CSP

13
1.6.5 Sensing Head
The units are designed to operate using a sensing
head, supplied by Vapac Humidity Control Ltd. which
should be connected as shown below. Other
propriety sensing heads which give a DC signal
may also be used, providing the control signal is
connected to control terminals 5 & 6, and the
sensing head is powered externally from the unit.
If “Frost Protection” is required do not connect
the thermistor input from the sensing head to
control terminals 1 & 2, which should be used to
connect the “frost protection thermistor” (part
number 1220275) instead. Frost protection is
selected via the display – Set the frost demand
above the minimum cylinder demand (LE units
>20%; LE(P) & LE(C) units >8%)
Note:
Use of the 24V supply of the VAPANET unit
to power other items of equipment will
invalidate the Vapac warranty.
1.6.6 Security Circuit / E.P.O. Shutdown
As standard units are shipped such that terminals 9 &
10 are provided for connection of an E.P.O.
(Emergency Power Off) switch or fire shutdown
facility. Other control interlocks, such as high limit
humidistat, airflow switch and/or fan interlock and time
switches etc. should be connected to terminals 11 &
12. Please note that if a display is connected to
the unit “DI1 Control Option” must be set to
“Shutdown”.
NB breaking terminals 9 & 10 will prevent any unit
operation including frost protection.
1.6.7 Load Shed Option
This can only be evoked via a display, either “hard
wired” or hand held. When this option is selected,
making the connection between terminals 11 & 12 will
activate the “load shed” software routine, which will
inhibit the operation of either the unit or in the case of
twin cylinder units unit or just the 2nd cylinder. This will
limit the power used during peak supply periods. If
this option is selected, the fan interlock, airflow switch
and/or high limit hygrostat should be wired into
terminals 9 & 10 with the EPO switch if fitted (as per
the drawing on the far right). It should be noted that
selection of this option will mean that frost protection
cannot be utilized.
Please note that if a display is connected to the
unit “DI1 Control Option” must be set to the
following:
Single cylinder units: “Load shed”.
Twin cylinder units: either “Load Shed Cyl 2” or
“Load Shed Both”.
Vapac’s accessory kit part numbers for sensors are
Remote Room mounted sensing head FVKIT-107
And
Remote Duct mounted sensing head FVKIT-108
1 2 4 5 6 7 8 9
10 11 12
Vapac
HUMIDITY
SENSOR
9 VOLT
POWER SUPPLY
TEMPERATURE
AND
HUMIDITY
SENSOR
Thermistor Thermistor +9 Volt 0 Volt Ref. RH Output
11 10 12
8 7 6 1 2 4 5 9
Load Shed
Standard Operation Load Shed Operation
9 5 4 2 1 6 7 8
12 10 11
E.P.O.
Fire Stop
Fan
Air Flow
High Limit
Interlock
Switch
Hygrostat Hygrostat
Switch
Interlock
High Limit
Air Flow
Fan
Fire Stop
E.P.O.

14
1.6.8 Master/Slave System
For larger duties, VAPANET “Electrode boiler” units can be interconnected and arranged to operate from one proportional signal as a
Master/Slave system. The system allows up to 4 LEC units (of equal duty) to be linked in this way. The slave units will all be given a
demand signal from the master unit. The master unit, to which the proportional signal is connected, will be a “proportional” unit.
To “configure” a system, ensure that the control signal is zero [disconnect the control signal, or switch the units off at the front panel switch].
From the display select set up then network and confirm that you want to attach slaves the LEDs will flash red/amber/green, if not repeat the
procedure. Then press the service pin (network button) on each of the slave control PCB’s in the order that they are required to operate, the
slave user LED1 will flash Green/amber until it is configured, once the light goes out [or flashes red/off], proceed to the next slave. Once
this process is complete, check the screen shows the correct number of slave units then confirm the fact by pressing the OK button on the
on the master display
NB. The total cable length of the network (using the cable recommended by V.H.C.L. – Our part number 8040251) is 500 m and it
should be assumed that there is 1 m of cable in each unit of the “system” (including the “master”).
Ö
xxxxxx xxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxx
xxxxxxxxxxxxxxxxxxxxxxxxx
Õ
Esc Ø
×
Vapac
J2
Vapac part no 1150631
CR1
Net J1
Vapac PART No. 1150630
16
CR6 1
NetCR7
J6
J5
CR5 1
6 6
10
CR3
16
J1
J2
J3
1
F2
CR1
1
F1 CR2
J4
18 CR4
1
16
Vapac PART No. 1150630
16
CR6 1
NetCR7
J6
CR5 1
6 6
10
CR3
16
J1
J2
J3
1
F2
CR1
1
F1 CR2
J4
18 CR4
1
16
J2
40K 48K
J5
V0V
CR2
CR2 CR2
AB AB
located on low voltage rail
Customers terminals within unit
PCB for "Master" or
"Slave" unit with display.
J1 see section 1.9.1
Link if control
signal is mA
current only.
Network Coms,
LED
configuration
UCP1
resistor
Button
Network
9V ac Supply
slave unit.slave unit.
"Slave 9" units.
PCB for "Slave 1" to
J1 see section 1.9.1
Not required forNot required for
J1 see section 1.9.1
Remote Indications
as Volt-free contacts:
CR6 gives the following remote indications
Terminal 547 - Unit Run (normally open)
Terminal 546 - Unit Run (normally closed)
Terminal 545 - Unit Run (Common)
Terminal 544 - Unit Alarm (normally open)
Terminal 543 - Unit Alarm (normally closed)
Terminal 542 - Unit Alarm (Common)
Display if fitted Connection to
Network Expansion to
slave units 2 to 9 or
other network
components.
FRONT VIEW OF 1150630 BOARD
resistor
UCP1
configuration
If unit is not fitted
with a display then
UCP1 configuration
resistor is fitted on
configuration board
1150634 which is
plugged into CR4
on the master unit.
Display & Keypad
(Optional)
Network LED
USER LED 1
Network Button
USER LED 2

15
2.0 Start-Up / Operation
2.0.1 Start-up check list
a) Water supply and Drain Connections:
these should be connected as indicated
under Plumbing and in accordance with the
relevant local regulations. An isolation valve
should be adjacent to the unit. The
connecting metal plumbing must be
grounded close to the unit.
b) Steam Line: This must be connected
according to the installation instructions with
adequate slope and support.
c) Power supply: Wiring to the Vapanet unit
Should be by a qualified electrician and
comply with the relevant regulations using
appropriately sized cable and cable glands,
with disconnect and fuses to suit the
maximum fuse rating of the unit at the supply
Voltage. The disconnect/fuses should be
adjacent to the unit or within easy reach and
readily accessible.
d) Control Connections: Ensure the control
signal and security circuit are
correctly connected according to the relevant
instructions/diagrams.
e) VAPANET 24v / 9V Control Circuit
Transformer: The standard 24V
transformer used in the units has primary
winding for 200V, 220/240V, 380V, 415V, &
440v 50/60Hz connection derived from the
local electrical supply.
Note: 60Hz connection must be specified
with order as 230V 60Hz pump is required.
f) The maximum output & kW rating of the unit
is determined by a Current Set Plug. It is
therefore possible to down rate units to any
output, down to approximately 50% of the full
rated output.
g) Unit Configuration Plug (U.C.P.). Sets the
maximum current level for the unit. It is fitted
directly onto the control P.C.B. If a display is
fitted, it is the only resistor required to be
fitted to the control P.C.B.. However if no
display is present additional resistors need to
be fitted, to provide the microprocessor with
information relating to the control signal etc.
For ease these are fitted to a small PCB
fitted to CR4 of the PCB, and resistor
selection is via shorting links, see control
signal selection on page 13. If insufficient
information is available the unit will remain in
the “not_config” state (see “Used LED” on
page 19) until the information is supplied.
This additional information is provided via
the keypad – when the display is fitted.
2.0.2 Start-Up Instructions
First check:
a) That the transformer connection matches
supply Voltage.
b) That the security circuit is closed for unit
operation.
Close the electrical access panel.
Turn on the water supply to the unit.
Close disconnect/circuit breaker feeding supply to the
unit.
Close the On/Off switch.
The display (if fitted) will now show the Set-Up
procedure.
Follow the procedure by:
- selecting: the preferred language,
- Attaching the control PCB to the Display.
- nominating: the type/quality of the supply
water.
- nominating: the control signal (or Vapac sensor
when being used).
When the control signal has been nominated, the Set-
Up will be entered into the memory. The Set-Up can
then be checked by reading the information menu. If
an error has been made, it will be necessary to go
back to the Set-up menu. If no display is fitted the
information is set using the jumpers on the small
resistor PCB 1150634, fitted to CR4 of the control
PCB.
2.0.3 Commissioning/Start-Up
Once the Set-Up procedure has been completed, the
unit is available to operate according to the
requirements of the control signal.
When starting with an empty cylinder, the VAPANET
programme switches in the contactor and feeds water
in until the water reaches the electrodes, and current
starts to flow. Thereafter the VAPANET system will
continuously monitor and control the conductivity by
adjusting the amount of water drained and fed into the
cylinder.
With no demand the LEC unit has the right hand light
will flash red the left hand light will be off. When the
demand increases or the unit is switched on the two
led will flashing green Amber at rate depending on the
demand input and the actual current drawn, the actual
run current of each cylinder is monitored and until the
actual current has two feed above 90 % the LED will
flash green amber when the current is above 95% for
two consecutive feed the light will flash red one
cylinder may come up to duty before the other but not
until both lights are flashing red is full LEC control
working.
2.0.4 Features of VAPANET Electode
Boiler Unit
The VAPANET system of control is designed to adjust
the function to keep the unit operating in the face of
changing water quality in the cylinder and changing
electrode condition even if, in an adverse operational
circumstance, this results in some reduction in output
while the situation exists.
Foaming protection *
In particular, the VAPANET is designed to prevent the
onset of foaming and to introduce corrective drainage
to keep the unit working.
Automatic switch-off
The VAPANET PCB will stop operating in response to
extreme fault conditions identified as:
Drain Fault STOP (no drain function)
Feed Fault STOP (water not reaching cylinder)
In each case, the display will show the STOP
condition and a Help Message, the User LED’s on the
fascia will indicate the condition see table on page 16.
A warning signal will be available for remote
indication. The STOP condition of a VAPANET PCB
will be cleared via the key pad if a display is fitted or
by pressing the reset button on the fascia – then
switching the unit off and on. THIS ACTION SHOULD

16
1
2
3
Full Pin
ONLY BE TAKEN ONCE THE CAUSE OF THE PROBLEM
HAS BEEN ASCERTAINED AND RECTIFIED.
2.1 Service Advice
The water hardness and the humidity demand at site will
determine the effective life of a steam cylinder. Units located
in areas with naturally soft waters will experience the longer
cylinder life, possibly upwards of 12 months in calendar
terms. With hard waters, a more frequent cylinder exchange
must be expected and cylinder exchange 2 or 3 times a year
can be the average situation. The normal scaling up of the
Vapac steam cylinder is outside the Vapac warranty.
2.1.1 Procedure for cylinder Exchange.
1. With the power connected to the unit, manually drain
the unit, by depressing (and holding) the Run/Off/Drain
Switch to the lower momentary drain position.
2. Disconnect the Vapac from the incoming electrical
supply by means of the external isolator (disconnect
switch). This should be “locked off” to prevent
accidental operation.
3. Unlock the access panel, and swing open to gain
access to the steam cylinder.
4. Carefully ease off (lever) the electrode caps (1& 2). If
the cylinder is to be replaced, care should be taken not
to twist the electrode caps while removing the black
power caps. As the electrodes can rotate in the
cylinder bosses (if the plastic cylinder is hot) and lead to
unbalanced electrical loads.
5. Loosen the hose clip (1) and disconnect the steam
hose (4) from the top of the cylinder.
6. Using a twisting movement, lift the cylinder clear of its
seating in the feed/drain manifold and carefully remove
the used cylinder from the unit.
7. Inspect the feed/drain manifold to ensure to ensure this
is clear of sediment.
8. The drain pump can be removed for inspection and
cleaning, by following the instructions below.
9. With the pump back in position, insert the cylinder into
the feed/drain manifold, pushing it down firmly to
ensure it is seated correctly.
10. Reconnect the steam hose.
11. Replace the electrode caps – ensure that the are
replaced in the same sequence as when removed. With
the cylinder full pin towards the front of the unit,
electrode number 1 will be to the left of the white
cylinder full electrode. Electrodes 2, 3, 4 etc will be
sequentially connected clockwise around the cylinder
(from number 1), when viewed from above. The cables
carry colour-coded sleeves to indicate the phase and
when connected correctly should follow the following
sequence. Red/Yellow/Blue/Red/Yellow/Blue when
viewed clockwise from the top. (NB The colour
sequence for two electrode cylinders will be Red/Blue.
12. The connections to the cylinder should be routed in as
close as possible to their original route.
2.1.2 Typical Cylinder / Electrode Layouts
See technical data for cylinder size fitted to your unit
Fig 1
Full Pin
1
2
1
Full Pin
2
3
1
Full Pin
3
5
2
4
6
Size 1 / 2 (2 electrode)
Size 3
(
3 electrode
)
Size 4 (3 electrode)
Size 4 (6 electrode)
Component Identification

17
Other Maintenance:
•Should only be carried out by a qualified
electrician.
•The steam cylinder should be drained prior to
carrying out any maintenance in the steam
section – This must be done prior to isolating
the electrical supply, i.e. before removing the
front access panel.
•The unit should be isolated from the electrical
supply before any cover or access panel is
removed.
2.2 Service and Maintenance
As the operation of the Vapac is entirely automatic, it
normally requires no attention on a day-to-day basis.
General cleaning and maintenance of the component parts
of the Vapac are recommended at intervals of about one
year, but this is largely dependent upon the frequency of its
use and the quality of the water supply. Where the Vapac is
part of an air-conditioning system being serviced regularly,
the Vapac should be inspected at the same time.
2.2.1 Feed Valve with Strainer
The nylon bodied solenoid valve incorporates a small nylon
strainer which is a push fit in the 3/4" inlet of the valve. With
a new plumbing installation, residual loose solid material in
the pipework could partially block the strainer after start-up.
If for this or any other reason a restriction of the water flow is
suspected (outside of supply pressure considerations), it
would be possible to clean the strainer as follows:-
Turn off the water supply to the Unit.
Undo the nylon nut connecting
the flexible connection to the
valve inlet .
The strainer can be removed
using ‘long-nosed’ pliers to grip
the centre flange provided on
the strainer for this purpose.
Withdraw the strainer.
Wash and replace it.
Reconnect and turn on water
supply.
Reconnect electrical supply to
allow unit to operate.
Note: Always replace the
strainer after cleaning as it is
required to prevent material
lodging in the valve seat or
blocking the small flow control
restrictor which is fitted in the
valve.
2.2.2 Drain Pump
1) Place a bucket below the
pump, to catch any water
remaining in the housing
or pipework.
2) Remove the two screws
holding the pump cover &
lift clear.
3) Undo the three screws
holding the pump body to the
feed & drain manifold, and
remove it - any water trapped
in the pump will be released at
this point.
4) Fit the replacement pump by
following the above steps in
reverse order. Ensuring that the
O-ring surrounding the impeller
Housing is correctly seated, and
That it mates correctly with the
Feed / drain manifold.
Valve with flow
restrictor
3/4 Nylon nut with washer as
part of flexible connector
The pump is a sealed unit and should
not be dismantled. Instructions for
removal / replacement are as follows:
Steam and Condensate Hoses
The hoses used with and in the Vapac should be inspected at the normal service visits as part of normal maintenance. At the first signs
of deterioration, a hose should be removed and replaced.
Strainer

18
3.0 Indicators
3.1 User LED
1. User LEDs provide an indication of the condition of the humidifier.
2. During the initialisation process the User LEDs can be in one of the following states,
User LED State Description
RED Flashing
2 second period Unit initialising. If remains in this state, then unit does not a valid UCP1 fitted.
RED/AMBER Flashing
2 second period UCP1 valid. For units fitted with a display, the unit requires factory set-up (Number of
Electrodes and Number of Turns)
For units fitted with a configuration board, the UCP2 and/or UCP3 are not being
detected.
RED/GREEN Flashing
2 second period UCP1 valid. For units fitted with a display, the unit requires site set-up.
This state does not occur if the unit is fitted with a configuration board.
User LED 1 -
RED/AMBER/GREEN
User LED 2 – OFF
Unit in configuration set-up mode, as instructed from the attached display node.
User LED 1 & LED 2 -
RED/AMBER/GREEN
Invalid configuration. The combination of UCP1 and the number of turns is not
valid.
3. Once initialisation has completed User LED 1 refers to cylinder 1, while User LED 2 refers to Cylinder 2. For combinations of
LED 1 and LED 2 being off, RED or RED Flashing refer to following table.
User LED 1 User LED 2 Description
OFF OFF Cylinder 1 and Cylinder 2 in shutdown.
Or
Cylinder 1 in standby and Cylinder 2 in shutdown.
OFF RED Flashing
1 second
period
Cylinder 1 and Cylinder 2 in standby
Green Amber
Flashing
Red Flashing
Both red and
green/Amber
LED flash at
Variable
Period or on
as per table
Green Amber
Flashing
Red Flashing
Both red and
green/Amber
LED flash at
Variable
Period or on
as per table
Cylinder 1 Startup. Cylinder 2 Startup.
Cylinder 1 Online. Cylinder 2 Online. ( LEC mode OPERATING)
The variable period is determined by the demand signal for cylinder 1 as follows,
Cylinder 1 demand LED ON LED OFF
<12.5% 0.5 seconds 3.5 seconds
<25% 1.0 seconds 3.0 seconds
<37.5% 1.5 seconds 2.5 seconds
<50% 2.0 seconds 2.0 seconds
<62.5% 2.5 seconds 1.5 seconds
<75% 3.0 seconds 1.0 seconds
<87.5% 3.5 seconds 0.5 seconds
>=87.5% ON RED Continually
4. For all other LED sequences refer to the following table,
User LED State Description
AMBER Drain Fault
AMBER Flashing
1 second period Over current Fault
AMBER Flashing
2 second period Feed Fault
GREEN Flashing
1 second period Service Interval expired or low output.
GREEN Flashing
2 second period Periodic Flush/Periodic Drain/Manual Drain/Auto Flush in progress
GREEN Periodic Drain/Periodic Flush/Manual Drain completed.
RED/AMBER
1 second period Constant Output Active/Full Output via UCP3 (Master cylinder only)
AMBER/OFF/AMBER/OFF/GREEN/OFF No Voltage input

19
3.2 Fascia Label symbols
3.3 Other Options
All selectable via a display (either Hard Wired or Hand held)
Feed With Drain
Used to lower the temperature of the drain water.
Frost Protectiion
When this is activated the unit will operate, at a preset demand level, if the temperature surrounding the unit falls
below a preset level, to prevent the pipework from freezing.
It is enabled by setting “frost demand” (via keypad/display) to >0 (it I disabled by setting “frost demand” to 0).
However the unit will not operate unless “frost demand” is set above the unit minimum demand level. Minimum
demand level for LE units is 21% and for LEP units it is 10%.
Frost demand is fully adjustable between 0 & 50%.
Timed Drain down.
Used to drain all the water from the cylinder if the unit remains on standby for longer than a preset (but adjustable)
time period.
For information on setting these options please see the display manual.
1 2
Network LED
(Red)
User LED2
Red/Amber/Green
Network Button
(Service Pin)
User LED1
Red/Green/Amber
Unit Off
Over
Service Interval
Service Routine/Manual
Service Routine/Manual
Constant Output Active/
On-line
Standby
Drain Fault
Feed Fault
Current
Expired
/periodic Drain/Flush in progress
Periodic Drain/Flush completed
Full Output via UCP3 (master
cylinder only).
Expired
Service Interval
cylinder only).
Full Output via UCP3 (master
Constant Output Active/
Periodic Drain/Flush completed
Service Routine/Manual
/
periodic Drain/Flush in progres
s
Service Routine/Manual
Standby
Feed Fault
Drain Fault
On-line
Unit Off
Current
Over
Cylinder 2
(If fitted)
Cylinder 1

20
4.0 Trouble-shooting Check List
- Use manual drain option to check pump operation
Check/Cause/Remedy
- Check main power is connected and switched on.
-Check power supply fuses.
Preliminary
Symptom
Power-On Neon – Off
Symbol-LED – Off
Display - Blank
Power-On Neon – On
Symbol-LED – On
Display - Blank
- Check if security circuit is open circuit
-Check 24V 6.3A fuse mounted at top of Microvap controller PCB 1150630
Automatic STOP – Feed Fault indicated on the Display.
Possibilities
Water is not connected
Water connected but not
reaching cylinder.
Water in cylinder and
overflowing.
Checks
-Check water stop valve is open
-Check internal Vapac hose connections for a leak.
-Check float switch operation
Unit On-Line but inadequate or no steam production.
Possibilities
Contactor not made
MCB’s tripped
SSR’s not switching
Checks
-Contactor coil, Float switches, Control PCB.
-Cylinder Inspection, inspect elements, and float switch operation.
-SSR Check as described below,
Important
Equipment needed
Procedure
SSR Replacement
Automatic Stop – Drain Fault indicated on the display.
Specialised check of the Solid State Relay
The following check should be carried out by a competent electrician
-An AC Voltmeter, multi-meter set to full AC line voltage or suitable voltage test
instrument.
-Remove access panels from both the steam cylinder and electrical compartments
-Ensure that the humidifier has an operational level of water in the cylinder. Switch
unit on and check that the display indicates “Vapac on line”.
-Apply the voltmeter, set to the ful line Voltage, across the output terminals of the
SSR being tested (i.e. the two terminals carrying the cabling to the elements).
Correct Voltmeter Response – oscillating between full and near zero Voltage.
If Voltmeter reads a constant near zero Volts, Check:
a) That the unit is not feeding water – if it is, wait until the feed valve closes and then
re-check. (reason the SSR will hold closed while the feed valve is open).
b) That the control PCB is giving the correct pulsed D.C. signal (approx 5V D.C.) to the
SSR control input terminals.
A faulty SSR should be replaced with an SSR of the same (or higher) Voltage and
amperage rating. Disconnect the unit from the electrical supply. Disconnect the
SSR and undo the mounting screws. The SSR is bedded in thermal compound
to assist heat transfer – it is important that this is cleaned off, and a layer fresh
compound placed under the replacement SSR. When it is secured in position.
Reconnect the SSR, reconnect the electrical supply and check the SSR
function as above before replacing the access panels.
Note:
U
se
p
ro
p
rietar
y
thread lockin
g
com
p
ound on the line volta
g
e
Possibilities
Drain pump function impaired
Float switch failure
Cylinder O/Let Blocked
Checks
-If pump will not function, empty cylinder by disconnecting at the tundish fill-cup the
water supply hose to the cylinder and draining the water into a bucket. Remove,
dismantle and clean pump.
-Check float switch operation
-Check & unblock