Vapac LR10 User manual

These instructions contain operating information and should be left with the unit.
Resistance Heater Units
Installation & Operation Manual
Edition 6
(For use with Software version 8.0 and 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.
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.

CONTENTS
1.0 Installation................................................................................................................................. 4
1.1 Positioning the Vapac LR unit................................................................................................... 4
1.1.1 Vapac LR unit dimension layout............................................................................................ 4
1.1.2 LR weights............................................................................................................................. 7
1.2 Positioning the steam pipes...................................................................................................... 7
1.2.1 General.................................................................................................................................. 7
1.2.2 Steam Hose Connection ....................................................................................................... 7
1.3 Plumbing Considerations.......................................................................................................... 8
1.4 Electrical Connections .............................................................................................................. 9
1.4.1 Important E.M.C. Considerations......................................................................................... 9
1.4.2 Power Supply Connection................................................................................................... 10
1.4.2.1 Volt free alarm outputs........................................................................................................ 10
1.4.2.2 Unit control terminals........................................................................................................... 10
1.4.3 Electrical Connections......................................................................................................... 11
1.4.4 Cable Entry Provision.......................................................................................................... 11
1.4.5 Vapac Control Circuit Transformer...................................................................................... 11
1.4.6 RDU Connection.................................................................................................................. 11
1.4.7 Cylinder Electrical demand loads........................................................................................ 12
1.5 Control Circuit Connections.................................................................................................... 13
1.5.1 Control Circuit Wiring .......................................................................................................... 13
1.5.2 Proportional Control ............................................................................................................ 13
1.5.3 Control Signal Selection...................................................................................................... 13
1.5.4 On/Off Control ..................................................................................................................... 13
1.5.6 Security Circuit / E.P.O. Shutdown...................................................................................... 14
1.5.7 Load Shed Option................................................................................................................ 14
1.5.8 Master/Slave System .......................................................................................................... 15
2.0 Start-Up / Operation................................................................................................................ 16
2.0.1 Start-up check list................................................................................................................ 16
2.0.2 Start-Up Instructions............................................................................................................ 17
2.0.3 Commissioning/Start-Up ..................................................................................................... 17
2.0.4 Features of VAPANET Resistance Heater Unit .................................................................. 17
2.1 Service Advice ........................................................................................................................ 18
2.1.1 Cylinder Inspection.............................................................................................................. 18
2.2.1 Feed Valve with Strainer ..................................................................................................... 19
2.2.2 Drain Pump.......................................................................................................................... 19
3.0 Location of Indicators and Controls ....................................................................................... 20
3.1 Positioning of Indicators and controls on Vapac ® Vapanet ® LR Units................................ 20
3.2 Initial Set-up............................................................................................................................ 21
3.3 Normal Run / Standby / Start-up – No User Intervention Required........................................ 22
3.4 Fault / Service Indications – Requiring Operator Intervention................................................ 23
3.4.1 To Postpone the Sevice: ..................................................................................................... 24
3.4.2 To Service the unit: ............................................................................................................. 24
3.5 Other Options.......................................................................................................................... 25
3.6 Use with LRO unit................................................................................................................ 25
4.0 Trouble-shooting Check List ................................................................................................... 26
5.0 Wiring Diagram ....................................................................................................................... 27
Appendix 1.
A Guide to Positioning Steam Pipes:................................................................................................. 41
Appendix 2.
A Guide to Positioning Multipipes:..................................................................................................... 43

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 of the cabinet.
Do not locate the cabinet where the ambient temperature around the unit could exceed 35ºC or fall
below 5ºC e.g., an unventilated roof mounted enclosure – see minimum space / ventilation
requirements page 5.
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.
It is important to select the correct water type, see table on page 8, your water supply company
should be able to provide the required information free of charge.
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 9.
Use a high-limit humidistat to ensure positive interruption of unit operation when over-
humidification is detected (see p14).
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.

1.0 Installation.
1.1 Positioning the Vapac LR unit
1.1.1 Vapac LR unit dimension layout
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 3.
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.
Don’t position an RDU to discharge directly over
expensive equipment, desks or stored materials.
305
330
6 6
55
305
52 90
62
299
73555
165
165
70
186
360
520
810
DF
Wall mounting
fixing centres
D = Drain discharge 35mm pipe.
F = Water feed ¾” BSP male
connection
Fig 1 LR5 & LR5P to LR 30 &
LR30P units with or without
RDU fitted.
Steam Outlet
Gland Plate
120 x 120
NB Entry hole for
Gland Plates approx
105 x 90

LR UNIT A B L H min H1 H2
LR5 & LR5P 377 205 80 1000 500 200
LR10 & LR10P 377 205 80 1000 500 250
LR20 & LR20P 435 205 80 1000 500 500
LR30 & LR30P 602 205 80 1000 500 750
Within the area of H1 or H2 above the unit nothing must protrude out from the
wall, as this will effect the natural ventilation path of the Unit.
Fig 3 Clearances around LR units.
Fig 2 LR5 & LR5P to LR 30 & LR30P RDU

Fig 4 LR40 & LR40P to LR 60 & LR60P
LR40, LR40P, LR50, LR50P, LR60, and LR60P units
have the same minimum recommended dimension as
follows:
L 100
H 1000
H1 600
Note:
L, H & H1 refer to dimensions shown in Fig 3 on page 5.
176 6
360
6
152 343
343
70 850
62
237
190
610
810
322
346
190
610
73555
FF
D
55 990
360
20.5"(520) 468
31.1"(790)
55
505
Wall mounting
fixing centres
Steam outlet pipes position.
Gland Plate
120 x 120
NB Entry hole for
Gland Plates approx
105 x 90
Gland Plate
120 x 120
NB Entry hole for
Gland Plates approx
105 x 90
D = Drain discharge
35mm pipe.
F = Two water feed ¾”
BSP male connection
Note:- RDU units
cannot be fitted to LR40 &
LR40P to LR60 and
LR60P units

7
1.1.2 LR 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 Resistive unit.
Resistive model Dry Kg Wet Kg RDU Kg
LR5 and LR5P 34 48 6
LR10 and LR10P 35.5 49.5 10
LR20 and LR20P 39 65.5 12
LR30 and LR30P 40 66.5 14
LR40 and LR40P 72.5 125.5 NA
LR50 and LR50P 73.5 126,5 NA
LR60 and LR60P 74.5 127.5 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
figure 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 requiring rotation of pipe in its
socket before installation.
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
Resistance Heater
Unit Model LR05 LR10
LR05P
LR10P
LR20
LR30
LR20P
LR30P
LR40
LR50
LR60
LR40P
LR50P
LR60P
35mm
∅
Pipe No.
54mm ∅. Pipe No. 1
- - 1 - 2
* Duct Pressure Pa. +2000
-600 +2000 -600
* For systems with a duct pressure over +1000 Pa. It may
be necessary to fit a suitably sized trap in the water feed
line between the Vapac tundish and the feed drain
manifold to ensure water can enter the cylinder when it is
empty.
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)
For guidance on positioning of steam pipes see
Appendix 1.
For guidance on use of Multipipes see Appendix
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

8
1.3 Plumbing Considerations.
1.3.1 Cold water supply.
General
The Resistance Heater range of units is capable of
operating with a range of water quality raw mains or
de-mineralised/de-ionised. The water supply should
be within the following limits:-
Conductivity 0 – 1000µS
PH 7.3 – 8.0
Silica 0
Pressure of between 1 - 8 bar.
Maximum chloride level 170 ppm
Water Supply rates
1.70 l/min
1.70 l/min
2.00 l/min
2.50 l/min
4.00 l/min
4.50 l/min
5.00 l/min
LR05
LR10
LR20
LR30
LR40
LR50
LR60
LR05P
LR10P
LR20P
LR30P
LR40P
LR50P
LR60P
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
Water type Selected Conductivity
range µS Max. Chlorine level ppm
De-mineralised < 50
De-ionised 50 – 100 < 80
Softened 100 – 200 80 – 100
Potable (Low conductivity) 200 – 300 100 – 150
Potable (Med. conductivity) 300 – 500 > 150
Potable High conductivity > 500
Generally the water type will be selected by the
conductivity levels, however they should be
modified as shown, e.g. conductivity of 75µS and
chlorine level of 85 ppm the correct setting is
Softened”.
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 100 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
Twin Cylinder units 40-60kg/h
Fi
g
7
Single Cylinder Units 5-30kg/h
A
B
C
D
F
K
L
M
N
H
G S V

9
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 -
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

10
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 1.5 the terminal layout is shown.

11
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 1, 2 and 3 are
for the power supply connections as indicated in the
diagrams below.
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.
1.4.6 RDU Connection
Vapac terminals 25 & 26 are included to provide a
230Vac electrical supply for the fan motor in the
RDU (Room Distribution Unit) .
Note: The 230Vac at terminals is derived from the
incoming electrical supply to the Vapac. If the local
supply cannot provide 230Vac (example 400V No
Neutral supply) it will be necessary for a transformer
to be fitted in the RDU as indicated below.
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.
TRANSFORMER
PRIMARY
380 – 440 V
SECONDARY
210 – 250 V
FOR FULL ELECTRO-MAGNETIC COMPATIBILITY A NEUTRAL CONNECTION IS REQUIRED FOR ALL
PROPORTIONAL UNITS AS INDICATED IN THE CONNECTION DIAGRAMS ON THE FOLLOWING PAGES.
RDU Connection
The three type’s of RDU are for various voltages and phase without neutrals connections that can be made to the Microvap unit. Please refer
to the Microvap connection diagram on the following three pages as to which type of unit is required. On twin cylinder units two fan circuits as
shown below one for each cylinder will be in the RDU unit.
RDU electrical load
Model RDU05LR RDU09LR RDU20LR RDU30L
Number of fans 2 3 3 5
Fan voltage 230 v 230 v 230 v 230v
Each fan current 50Hz (60 Hz) 115 mA (105 mA) 115 mA (105 mA) 115 mA (105 mA) 115 mA (105 mA)
RDU total load current 50Hz (60 Hz) 225 mA (210 mA) 345 mA (315 mA) 345 mA (315 mA) 575 mA (525 mA)
200 – 250 V 1Ph. N + earth 200 – 250 V 2Ph. + earth 380 – 440 V 2Ph + earth

12
1.4.7 Cylinder Electrical demand loads
Resistive unit model reference LR5 and LR5P LR10 & LR10P LR20 & LR20P LR30 & LR30P LR40 & LR40P LR50 & LR50P LR60 & LR60P
Cylinder 1 Size Left hand power feed 5 10 20 30 20 30 30
Cylinder 2 Size Right hand power feed None None None None 20 20 30
Number of Power supplies to unit 1 1 1 1 2 2 2
Note :- Cylinder 1 power supply equals Cylinder load from table above plus 1amp for control (feed valves and drain pumps ) plus RDU load from 1.4.5 on page 8 if fitted.
Voltage V 200 230 250 200 230 200 230 380 415 440
Nominal cylinder size Kg/hr 5 5 5 10 10 10 10 10 10 10
Electrical Supply Ph+N Ph+N Ph+N Ph+N Ph+N 3Ph 3Ph 3Ph 3Ph 3Ph
No.ofelements 1113333333
Element Resistance ohms 13.7 13.7 13.7 20.9 20.9 20.9 20.9 20.9 20.9 20.9
Element connection direct direct direct Par/star Par/star DELTA DELTA STAR STAR STAR
Element Matrial Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800
Full load Current A 14.6 16.8 18.2 28.7 33.0 16.6 19.1 10.5 11.5 12.2
Power rating Kw 2.92 3.861 4.562 5.742 7.593 5.742 7.593 6.909 8.240 9.263
Max. Output Kg/hr 3.96 5.24 6.19 7.79 10.3 7.79 10.3 9.37 11.17 12.56
FuseRating/phase A20202032402025202020
Supply cable terminals mm24 4 4 16161616101010
Voltage V 200 230 380 415 440 200 230 380 415 440
Nominal cylinder size Kg/hr 20 20 20 20 20 30 30 30 30 30
Electrical Supply 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph
No.ofelements 6666666666
Element Resistance ohms 20.9 20.9 20.9 20.9 20.9 13.7 13.7 13.7 13.7 13.7
Element connection DELTA DELTA STAR STAR STAR DELTA DELTA STAR STAR STAR
Element Matrial Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800 Incoloy 800
Full load Current A 33.1 38.1 21.0 22.9 24.3 50.6 58.2 32.0 35.0 37.1
Power rating Kw 11.483 15.187 13.818 16.481 18.526 17.518 23.168 21.080 25.142 28.263
Max. Output Kg/hr 15.57 20.59 18.74 22.35 25.12 23.75 31.41 28.58 34.09 38.32
FuseRating/phase A40403232326363404040
Su
pp
l
y
cable terminals mm216 16 10 10 10 16 16 10 10 10
5 K
g
/hr C
y
linder 10 K
g
/hr C
y
linde
r
20 K
g
/hr C
y
linder 30 K
g
/hr C
y
linde
r

13
1 2 4 5 6 7 8 9
10 11 12
HYGROSTAT WITH VOLT FREE CONTACTS (max.
RESISTANCE OF EXTERNAL CONNECTION 100
Ohms.
1.5 Control Circuit Connections
1.5.1 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.
1.5.2 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%
1.5.3 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. If the unit has not got a
keypad then this is done on the configuration board
1150634 mounted on the main control board 1150630
using the jumpers provided. The appropriate right
hand link should be made to select the site feed water
type and the appropriate left hand link representing
the actual site control signal should be linked using
the jumper plugs provided.
1.5.4 On/Off Control
Vapanet models can be operated by a single
step humidistat which has Volt-free contacts –
select control option Pot.
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
UCP
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
CR2
J1
Vapac part no. 1150634
Electro
boiler
Pot high
Pot medium
Pot low
Softened
De-iron
De-min
0-5v
0-10v
2-10v
1-18v
0-20v
4-20mA
pot
Full o/p
or slave
Network
J2
UCP1

14
1.5.5 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.
1.5.6 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.
1.5.7 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.
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”).

15
1.5.8 Master/Slave System
For larger duties, VAPANET “Resistive heater” units can be interconnected and arranged to operate from one proportional signal as a
Master/Slave system. The system allows up to 10 cylinders to be linked in this way. The slave units will all be “on / off” units. The master
unit, to which the proportional signal is connected, can be “on / off” but will preferably 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].
Press and hold the service pin on the master control PCB, until the user LED’s flash amber, release and check that the LEDs flash
red/amber/green, if not repeat the procedure. Then press the service pin 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. If units of different capacity are used, ensure that the master is equal to or greater than the capacity of the slaves, and that
the largest capacity slaves come on before the smaller capacity units]. Once this process is complete, confirm the fact by pressing the
service pin on the master PCB until user LED2 goes green [this step is not necessary if all nine slave cylinders are configured].
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

16
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
winging 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 the number and electrical
rating of the heater elements fitted in the
cylinder. It is not possible to “de-rate” the
unit.
g) Unit Configuration Plug (U.C.P.). Provides
the Vapanet control PCB with information
regarding the “system hardware” i.e. the size
of the cylinder and whether the unit is an
“On/Off” (“LR”) or “Proportional” (“LRP”)
model. It is fitted directly onto the control
P.C.B. If a display is fitted only one resistor
is fitted to the UCP, but if no display is
present additional resistors need to be
present to provide sufficient information for
the unit to operate. If insufficient information
is available the unit will remain in the
“not_config” state until the information is
supplied. This additional information is
provided via the keypad – when the display
is fitted.
A brass earth stud is fitted behind the transformer
cover to enable this to be easily completed.
See Page 7 / Appendix 1.
See Page 10/11.
See Page 13.
This is fitted below the stainless steel drain tray. To
gain access, open the front access door, remove the
two M4 screws and remove the transformer cover by
sliding it forward.
Above: UCP1 fitted to Control PCB as if a display is
fitted to the unit.
Right: UCP’s fitted to Configuration PCB Part number 1150634,
as if a display is not fitted to the unit.
Thermistor input from control terminals 1 & 2 (Not shown) are
connected to Configuration PCB CR1.
The Jumper plugs (J1) should be used to select the site demand
signal type (from the following options: 0-5V; 0-10V; 2-10V; 1-18V;
0-20V; 4-20mA [jumper J1 on main PCB should also be made – see
page 13] Pot.; Full O/P; Network or Slave.) and (J2) the site water
quality (from the following options: De-min; De-ion; softened, Pot.
Low; Pot. Medium; Pot. High).

17
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.
Replace 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
feeds water in until the water reaches the bottom float switch, when
the contactor(s) switch on powering the elements. Thereafter the
VAPANET system will continuously monitor and control the
conductivity by adjusting the amount of water drained and fed into
the cylinder.
2.0.4 Features of VAPANET Resistance Heater 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.
Overtemperature protection.
Should the water supply and the float switch fail, an over
temperature cut-out is fitted to the top of the cylinder. If this
operates, the contactor will open, removing the power to the
elements. This cut out must be manually re-set, by pressing the
small button between the electrical connections. THIS SHOULD ONLY
BE DONE ONCE THE CYLINDER HAS BEEN INSPECTED AND THE
FAULT(S) RECTIFIED.
Foaming protection *
In particular, the VAPANET is designed to prevent the onset of
foaming and to introduce corrective drainage to keep the unit
working.
*Not applicable to units fed with de-ionised/de-mineralised water.
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 – the unit should first
be powered down completely (while the reason for the condition is
diagnosed and rectified). THIS ACTION SHOULD ONLY BE TAKEN
ONCE THE CAUSE OF THE PROBLEM HAS BEEN ASCERTAINED AND
RECTIFIED.
The transformer is fitted below the stainless steel drain
tray and is accessible by removing the two M4 machine
screws and sliding the cover forwards.
If no security circuit is fitted (i.e. no airflow switch or
high humidity override hygrostat is required) terminals 9
& 10 must be linked.
If no display is fitted, the selections are made by fitting
jumper plugs to the “Configuration PCB” (Part number
1150634). See page 13.
If no display is fitted the “User LED’s” will be the only
indication of a “Fault Condition”. LED 1 (Left hand)
represents cylinder 1 (Left hand when viewed from the
front) and LED 2 (Right hand) represents cylinder 2, if
fitted.
If a fault condition exists, the LED representing the
cylinder which has the fault will glow “Amber” (constant
for drain fault / flashing for feed fault). The unit should
be powered down at the main Isolator once the reason
has been diagnosed, and the problem rectified. When
the power is re-applied, the unit will once again display
a fault indication. To reset the alarm condition the “fault
reset” button should now be pressed (or the “OK” button
on the display keypad should be pressed if a display is
fitted).

18
2.1 Service Advice
After a pre-determined time an alarm warning –
together with an alpha-numeric message – will be
displayed, warning that the cylinder should be
inspected an cleaned as necessary.
Once this signal has occurred, the following service
routine should be undertaken as soon as possible. On
completion of the service, the service interval timer
will be reset, and there will be an opportunity to adjust
the service interval, if the service reveals that the
interval was inappropriate for the operating
conditions.
Service Advice Routine
2.1.1 Cylinder Inspection.
(See figs 1 - 4)
1 ENSURE THAT THE UNIT IS ISOLATED FROM
THE POWER SUPPLY. Then remove the power
supply plug from the fixed socket.
2Lift cylinder until the bottom (ø 22 mm) spigot is
clear of the feed/drain manifold.NB it may be
necessary to remove the steam hose from the
cylinder, (top) steam outlet spigot, to achieve this.
3Bring the base of the cylinder forward then allow the
cylinder to rest on the cylinder support ring, then
remove the cylinder.
4Undo the securing latches, remove the clamping
ring and lower cylinder casing.
5Empty any loose scale from the lower casing, and
clean as necessary.
6Inspect the elements, for excessive scale build-up
or damage, and clean/ replace as required -
Should it be necessary to replace elements,
ensure that they are replaced with the same type
and power. Please also ensure that the integral
cables are re-connected exactly as the original.
When disconnecting an element, please note
the points of disconnection.
7With the lower cylinder casing removed, and access
to the float chamber improved remove the float
chamber by unclipping it from the back panel and
open the housing by removing the two plastic clips
(use a screwdriver to lever these off) & pulling it
apart (see fig 4).
8Inspect the float switches, and clean/de-scale as
necessary. A build up of scale can prevent correct
operation of the switches, which - in turn - will lead
to operational problems with the unit.
9 Re-assemble cylinder by repeating the above steps
in reverse. To ensure that the cylinder seals
correctly, ensure that the first four clamps that are
tightened, are those at the four quadrants. I.e.
tighten one clamp then tighten the one
diametrically opposite. Then tighten one at
approximately 90oto them and then tighten the
one diametrically opposite. Finally, tighten any
remaining clamps.
Fig 1
Fig 2
Fig 3
Fig 4

19
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.
Valve with flow
restrictor
3/4 Nylon nut with washer as
part of flexible connector
Strainer
The pump 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.

20
3.0 Location of Indicators and Controls
3.1 Positioning of Indicators and controls on Vapac ® Vapanet ® LR Units.
1 2
0
I
Esc
Vapac
Reset Button
Cylinder 1 On/Off/Drain Switch
Cylinder 2 On/Off/Drain Switch
Network LED (Red)
Network Button
(Service Pin)
User LED's
Power Available Neon
Cylinder 2 On/Off/Drain Switch
Cylinder 1 On/Off/Drain Switch
Alpha-Numeric
Display
Network LED (Red)
Network Button
(Service Pin)
Power Available Neon
User LED's
Vapac
1 2
0
I