Vapac VapaNet Series User manual

These instructions contain operating information and should be left with the unit.
Electrode Boiler Units
LE
Installation & Operation Manual
Edition 3.2.2
(For use with Software version 7.1 & subsequent issues)
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.
ailure 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
Important Installation Points .................................................................................................................... 3
1.0 Installation..................................................................................................................................... 4
1.1 Vapac LE unit dimensions......................................................................................................... 4
1.1.1 LE weights ............................................................................................................................. 8
1.2 Positioning the steam pipes ...................................................................................................... 8
1.2.1 General .................................................................................................................................. 8
1.2.2 Steam Hose Connection........................................................................................................ 8
1.3 Plumbing Considerations. ......................................................................................................... 9
1.4 Electrical Connections............................................................................................................. 10
1.4.1 Important E.M.C. Considerations ....................................................................................... 10
1.4.2 Power Supply Connection ................................................................................................... 11
1.4.2.1 Volt free alarm outputs ........................................................................................................ 11
1.4.2.2 Unit control terminals........................................................................................................... 11
1.4.3 Electrical Connections ......................................................................................................... 12
1.4.4 Cable Entry Provision .......................................................................................................... 12
1.4.5 Vapac Control Circuit Transformer...................................................................................... 12
1.4.6 RDU Connection.................................................................................................................. 12
1.5 Cylinder Electrical demand loads............................................................................................ 14
1.5.1 LExx Units............................................................................................................................ 14
1.5.2 LExxP Units ......................................................................................................................... 17
1.6 Control Circuit Connections .................................................................................................... 19
1.6.1 Control Circuit Wiring........................................................................................................... 19
1.6.2 Proportional Control............................................................................................................. 19
1.6.3 Control Signal Selection ...................................................................................................... 19
1.6.4 On/Off Control ..................................................................................................................... 19
1.6.5 Sensing Head ...................................................................................................................... 20
1.6.6 Security Circuit / E.P.O. Shutdown...................................................................................... 20
1.6.7 Load Shed Option................................................................................................................ 20
1.6.8 Master/Slave System........................................................................................................... 21
2.0 Start-Up / Operation.................................................................................................................... 22
2.0.1 Start-up check list ................................................................................................................ 22
2.0.2 Start-Up Instructions............................................................................................................ 22
2.0.3 Commissioning/Start-Up...................................................................................................... 22
2.0.4 Features of VAPANET Electode Boiler Unit........................................................................ 22
2.1 Service Advice......................................................................................................................... 23
2.1.1 Procedure for cylinder Exchange. ....................................................................................... 23
2.1.2 Typical Cylinder / Electrode Layouts ................................................................................... 23
2.2.1 Feed Valve with Strainer ..................................................................................................... 24
2.2.2 Drain Pump.......................................................................................................................... 24
3.0 Location of Indicators and Controls ............................................................................................ 25
3.1 Positioning of Indicators and controls on Vapac ® Vapanet ® LE Units. ............................... 25
3.2 Initial Set-up ............................................................................................................................ 26
3.3 Normal Run / Standby / Start-up – No User Intervention Required ........................................ 27
3.4 Fault / Service Indications – Requiring Operator Intervention. ............................................... 28
3.4.1 To Postpone the Sevice: ..................................................................................................... 28
3.4.2 To Service the unit:.............................................................................................................. 29
3.5 Fascia Label symbols.............................................................................................................. 30
3.6 Other Options .......................................................................................................................... 30
4.0 Trouble-shooting Check List ....................................................................................................... 31
5.0 Wiring diagram............................................................................................................................ 32
Appendix 1............................................................................................................................................. 43
A Guide to Positioning Steam Pipes:................................................................................................. 43
Appendix 2............................................................................................................................................. 45
A Guide to Positioning Multipipes: ..................................................................................................... 45

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. * If below 5º C Frost protection kit required.
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
Control cabling should be run in screened cables and kept separate from any mains carrying
cables (see page 10).
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.
Do not mount the 'LR' unit close to a source of strong electromagnetic emissions, such as a
variable speed motor drive, Kva transformer, or 'UPS' unit.
A minimum gap of 2 meters must be maintained between the unit and such devices.
Larger output devices may require an increased gap distance, depending on the nature of
screening / filtration measures fitted to the device.
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
675.0
430.0
6.0265.055.0 6.0
140.0
285.0
74.0444.0
172.0203.0
204.0
70.0
203.0172.0
F
D
120.0
62.0
50.0
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.
Do mount units with RDU’s so that steam pipe discharge is
above head height.
Do leave minimum gap between the top of an RDU and
the ceiling as per table in fig 2.
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 (Unless frost protection
kit fitted).
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.
Don’t position an RDU to discharge directly over
expensive equipment, desks or stored materials .
1.1 Vapac LE unit dimensions
Cabinet Size 1.
Covering model references:
LE05 – All
LE09 – All
LE18
–
All
Left:
Top view of unit
showing steam outlet
position (35 mm spigot)
Below:
Rear view of unit
showing wall mounting
points.
Right:
View from beneath unit
showing the electrical gland
plate (approx 120mm x
120mm) with an entry hole
(approx 105mm x 90mm)
Left:
View from beneath unit showing:
‘F’ (Feed) 19mm BSP male
connection for connection for
flexible hose provided with unit.
‘D’ (Drain) connection for 35 mm
pipe.
For clearance around the unit for ventilation & access please see page 7

5
186
360
520
810
DF
Steam Outlet 54 mm
Gland Plate
120 X 120
305
330
6 6
55
305
52
90
62
299
73555
165
165
70
For clearance around the unit for ventilation and access and for units with RDU’s see page 7
Cabinet Size 2.
Covering model references:
LE30 – All
LE45 – All
LE55
-
All
Left:
View from beneath unit
showing-
‘F’ (Feed) ¾ “ BSP male
connection for connection
for flexible hose provided
with unit.
‘D’ (Drain) connection for
35 mm pipe.
Right:
View from beneath unit
showing the electrical gland
plate
(approx 120 mm x 120 mm)
with an entry hole
(approx 105 mm x 90 mm)
Left:
Top view of unit showing
steam outlet position
(54 mm spigot)
Below:
Rear view of unit showing
wall mounting points.

6
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
F F
D
Steam Outlets
54 mm
Gland Plate
120 X 120
Gland Plate
120 X 120
For clearance around the unit for ventilation and access see page 7
Cabinet Size 4.
Covering model references:
LE60 – All
LE90 – All
LE110 – All
Left:
Top view of unit showing
steam outlet positions
(54 mm spigots)
Below:
Rear view of unit showing
wall mounting points.
Left:
View from beneath unit
showing-
‘F’ (Feed) ¾ “ BSP male
connection for connection
for flexible hose provided
with unit.
‘D’ (Drain) connection for
35 mm pipe.
Right:
View from beneath unit showing
the electrical gland plate
(approx 120 mm x 120 mm)
with an entry hole
(approx 105 mm x 90 mm)

7
Cabinet Sz 1 with RDU
Dimensions
L L
2
1
Cabinet
size 2 with
RDU
Dimensions
RDU 30 kg/h
A = 602mm
B = 205mm
RDU 45 kg/h
A = 842mm
B = 360mm
Clearance around LE Units
Unit L H
min
H1
min
H2
min
LE05 All
(No RDU) 85 1000 500 -
LE05 All
(With RDU) 85 1000 - 200
LE09 All
(No RDU) 85 1000 500 -
LE09 All
(With RDU) 85 1000 - 250
LE18 All
(No RDU) 85 1000 500 -
LE18 All
(With RDU) 85 1000 - 500
LE30 All
(No RDU) 85 1000 500 -
LE30 All
(With RDU) 100 1000 - 750
LE45/LE55
(No RDU) 85 1000 500 -
LE45/55
(With RDU) 200 1000 - 775
LE60 - 110 All (Twin
Cylinder No RDU) 85 1000 500 -
A minimum clear space of 1 m is required in
front of the unit for maintenance access

8
1.1.1 LE 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 . The RDU
weight must be added to the unit weight if fitted
on top of the Electrode Boiler unit.
Vapanet model Dry Kg Wet Kg RDU
Kg
LE05 and LE05P 23.5 29 6
LE09 and LE09P 24 31 10
LE18 and LE18P 24.5 36 12
LE30 and LE30P 34 62 14
LE45,LE45P & LE55 34 62 16
LE60 and LE60P 52 106 NA
LE90, LE90P & LE110 52 106 NA
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 90
o
elbows in the
steam line.
Steam Distribution Pipe requirement
Electrode
Boiler Unit
Model
LE05(P)
LE09(P)
LE18(P)
LE30(P)
LE45(P)
LE55
LE60(P)
LE90(P)
LE110
35mm
∅
Pipe No.
54mm ∅.
Pipe No.
1
-
-
1
-
2
Duct
Pressure
Pa.
+2000
-600
+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.

9
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
1.20 l/min
1.20 l/min
1.20 l/min
2.50 l/min
2.50 l/min
5.00 l/min
5.00 l/min
LE05
LE09
LE18
LE30
LE45/LE55
LE60
LE90/LE110
LE05P
LE09P
LE18P
LE30P
LE45P
LE60P
LE90P
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.
(Max.pump flow rate
at Power supply frequency)
l/min Hz
16.8
17.2
50
60.
Do’s
Do use copper or plastic pipe rated for 110
o
C.
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
Single Cylinder Units 30-55 kg/h
Twin Cylinder units 60-110 kg/h
Fig 7
A
B
C
D
F
K
L
M
N
H
G S V

10
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 BROWN 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 -
And RDU.
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