Bulletin 539-C HumidiClean™ Series HC- 6100/6300/6500/6700 Humidifiers Installation, Operation and Maintenance Instructions Table of Contents Page Warning Labels 2-3 Description of Model Number 4 Installation 5-12 Display Menu 13-16 Start-Up Procedure and Operation 16-17 Maintenance 18-22 Troubleshooting 22-27 Typical Wiring Schematic 28-37 PID Control 38-42 Repair Parts 38-42 Software Update 45-48 Communication 48-53 Dimen
The Armstrong HumidiClean humidifier converts ordinary tap water or purified water to steam for distribution to raise the relative humidity level. To allow HumidiClean to function to its full capability, be certain to install in accordance with Armstrong recommendations. DANGER: ELECTRICAL SHOCK HAZARD HIGH VOLTAGES EXIST INSIDE THE HUMIDIFIER TO PROTECT YOURSELF AND OTHERS FROM ACCIDENTAL SHOCKS: 1.
Warning: Do not operate the supplied humidifier in combustible or explosive surroundings. Warning: Do not operate the supplied humidifier if there is any damage to the cabinet or any components in humidifier are damaged. Warning: The main switch should be a connection breaker which has over current and leakage current protecting functions per code EN60947-3 or EN60947-2 if point gap required by EN60947-3 can be fulfilled. 4.
• The disconnecting switch should have a breaking capacity sufficient to interrupt the largest normal running current of loads. The breaking capacity required should be selected according to the table, 7-1, 7-2, 7-3 and 7-4 located on page 7. Model Description HC - XXXX (DI) - XXX X Series HumidiClean™ Humidifiers Type number 6100 6300 6500 6700 Quality of Water Blank: Tap water DI: Deionized or reverse osmosis Rated Power In KW. The minimum is 3 KW, and the maximum is 96KW.
Figure 5-1 HC-6100/6300 Installation Pitch Min. 1” Per 12” Back to Unit Hose Clamp Steam Hose or Copper See Detail “A” Full Size Tee Hose 2” Insulated Copper “P” Trap Drain Every 20’ of Piping or at Bottom of Vertical Run 2” Copper Tee Soldered Joints Reducer 1/2” or 3/8” Copper Tube UP Detail “A” Pitch Min. 1” Per 12” Back to Unit 6” Min.
Installation HC-6100/6300 Mounting The HumidiClean models HC-6100/6300 are designed to be wall mounted. A wall mounting bracket and lag screws are provided for mounting on 410 mm (16”) centers. The operating weight of the unit is 106 kg (233 lbs). A clearance of 600 mm (23”) on the front and sides of the cabinet is required for servicing. 1. Position wall mounting bracket level on wall and mark hole pattern. Make sure holes line up with studs or other sturdy structure. 2.
Table 7-1. Recommended Branch Circuits Rating Amp Wire 1-12 13-15 16-20 21-24 25-32 33-40 41-48 49-64 68-80 81-100 101-120 121-140 141-60 (AWG) 14 12 10 10 8 8 6 4 3 1 0 0 0 (mm2) 3 4 6 6 10 10 16 25 35 50 50 70 95 15 20 25 30 40 50 60 80 100 125 150 175 200 Circuit Breaker Table 7-2. Steam Capacities and Rating Amperages HC6100/HC6100DI 3 KW Unit Nominal Amperage Rating Volts (Vac) Three 208 13.3 7.7 240 12.9 7.5 200 - 4.7 480 - 3.
Duct Steam Distribution 1. The dispersion tube should be proper length. Verify correct size from Table 8-1. 2. Install dispersion tube(s) horizontally in duct so holes face upward. Air flow must be vertical up or horizontal. Do not restrict duct with a height of 200 mm (8”) or less. Installations over 10 m/s (1800 FPM) air velocity are not recommended. Consult factory if air flow is vertical down or air velocity is over 10 m/s (1800 FPM).
Area Steam Distribution The EHF-3 fan package (minimum of 2 required for HC-6500/6700) is designed to be hung on a wall to operate as a remote mounted, direct area discharge option. It incorporates a blower rated at 120v1.28 amps. CFM rating is 463 @ 1600 RPM. The fan package requires a separate 120 volt power supply (optional step down transformer available). Consult Armstrong Installation Bulletin IB-95 for more information.
Figure 10-1 Standard Humidistat H200-XX-XX-XX H270-XX-XX-XX Supply Main Stat/Sensor In Modulating High Limit Sensor Outdoor Temperature Sensor A18609 or A18610 0-10 Vdc Stat (Standard) Ground Class 2 Alarm A8581 High Limit Humidistat High Limit/ Air Flow Switch Ground A9023 Pressure Switch To Set Up: 1) S1-1, 3 Off, S1-2 On 2) S3-1 On, S3-2, 3, 4 Off 3) S2-1, 2, 3 Off 4) Select 0-10vdc “Signal Type” in the Operational Setup Menu. 5) Select Humidistat Sensor Select in the Operational Setup Menu.
Figure 11-1 0-10 Vdc or 4-20mA Control Signal Supply Main Stat/Sensor In Modulating High Limit Sensor Control Signal Outdoor Temperature Sensor Ground S5079a,b,c 4-20ma Setup 10 vdc Setup 1) S3-1 On, 3-2, 3, 4 Off (Default) 2) S1-2 On, S1-1, 3 Off (Default) 3) S2-1, 2, 3 On if 4-20ma S2-1, 2, 3 All Off If 0-10vdc 4) Select Corresponding Control Signal Type In Operation Setup Menu.
High Limit Humidistat Remove the jumper tab from ground and in of high limit/pressure switch connections and wire the high limit stat between these terminals. Refer to Figure10-1 (the overall wiring diagram) for more inform ation. A duct mounted high limit humidistat is recommended to prevent over-saturation of the duct air. Use an on-off controller that opens on fault (high humidity). Humidistat should be set for a maximum of 90% RH.
Display Menu The menu can be accessed via the keypad below the LCD, on the front of electric cabinet. Use the UP or DOWN to change the menu in current level; press ESC to previous menu level; press ENTER to access the current menu. Pressing ENTER will activate selection cursor, press UP(DOWN) to increase (decrease) the value, press ENTER to confirm the change or ESC to cancel.
Operation Setup Enter Password 0000 (Default) Desired RH (This menu is displayed when RH sensor is selected.) Desired RH: XX% Default: 50% Current RH: XX% LT RT move the cursor UP DN to increase/decrease value Steam Generation Steam Gen (Default) Manual Drain (Status 2 will include Drain Drain.) Manual Fill (Status 2 will include Fill Fill.
2000 2250 2500 2750 3000 No Beds Operation Setup - Continued Drain Frequency 6 Default: 12 hours 12 (Default) 24 48 96 Real Time Time Settings 24 Hour Clock Drain Time 1 5 (Default) 10 Load Default Reset all to Default? Confirm Cancel Signal Type 0-10 Vdc (Default) 0-5VDC 1.9V - 3.
Unit Configuration Enter Password ARMH Run Mode Run (Default) Test Contactor Count 1 2 3 4 Control Type PWM (Default) On/Off Power Settings 1000 W 3000 W 5000 W 6650 W 8000 W EOL Reset Clear Ionic Time Confirm Cancel Failure Record Clear Clear Failure List Confirm Cancel User Password Reset User Password Reset Confirm Cancel Temperature Compensation Water Compensation Heater Compensation Factory Use Only Start-Up Proc
Principle of Operation The HumidiClean humidifier converts ordinary tap water or purified water to steam for distribution to raise the relative humidity level. The demand for humidity is sensed by a humidistat or sensor which sends a control signal to the HumidiClean. The HumidiClean is connected to the power supply (208, 220/240, 380/400, 480 or 600 Vac) through a separate circuit breaker supplied by the customer.
Maintenance When 90% of the setting service time has accumulated, the “STATE” LED on the control panel will blink in yellow. (Refer to EOL settings, for bed life duration settings). If the HumidiClean is not serviced at this time; the unit will continue to operate for the remaining 10% of the service life setting. When 100% of the bed life setting has been reached, the “STATE” LED will be on in red. The unit will drain the tank and not respond to a call for demand.
5. Restoring the Unit to Operation a. Turn power on at breaker. b. Unit should begin to fill. Maximum fill time is approximately 30-45 minutes before contactor(s) will be closed. c. Go into the Operation Setup menu and verify that the unit is in “Steam Gen”. d. See the Unit Configuration menu (Password ARMH) to go to the “EOL (end of life) Reset”. This must be done to reset the timer. 6. Modifying the Bed Life Setting 1.
Figure 20-1 HC-6100/6300 6WHDP 2XWOHW (TXDOL]LQJ &RQQHFWLRQ WR 7RS RI /HYHO &DQLVWHU &RYHU /RFDWLQJ 3LQV ,RQLF %HGV (TXDOL]LQJ &RQQHFWLRQ WR %RWWRP RI /HYHO &DQLVWHU +HDWLQJ (OHPHQWV 'UDLQ 2XOHW &RQQHFWLRQ 0RXQWLQJ %ROW /RFDWLRQV Figure 20-2 HC-6500/6700 6WHDP 2XWHW (TXDOL]LQJ &RQQHFWLRQ WR 7RS RI &DQLVWHU &RYHU ,RQLF %HGV (TXDOL]LQJ &RQQHFWLRQ WR %RWWRP RI /HYHO &DQLVWHU +HDWLQJ (OHPHQWV 'UDLQ 2XWOHW &RQQHFWLRQ 0RXQWLQJ %ROW /RFDWLRQV 20 /RFDWLQJ 3LQV
9. Operate the unit configuration menu “EOL Reset”, to reset the ionic bed life. All the accumulated ionic bed time has been reset to zero. The unit should now be heard filling. NOTE: The accumulated ionic bed time can be reset to zero at anytime. However, the unit should not be reset without first inspecting the ionic beds. 10. After the unit has heated up and started making steam, turn main power off and double check tank access panel gasket for steam leakage.
Removing the Tank 1. Operate menu to “MANUAL DRAIN” and allow unit to complete a deep drain. (Caution: Tank will still be quite warm). 2. Turn off circuit breaker. 3. Unlock and open front and side doors. Remove left side panel and top panel. 4. Disconnect 3 hoses from front of tank; rubber hose cuff at steam outlet; heating element leads at contactor, fuses, or power module; and thermocouple and aquastat wires. 5. Loosen and remove 4 mounting bolts at the bottom of tank.
8. If drain valve and fill valve are both energized and water is below the 1/3 full level in the electrode canister (float canister for DI units), make sure the status of Steam Generation in Operation Setup menu is “STEAM GEN.”. Perform continuity check to be sure. 9. If drain valve only is energized and water level is below the 2/3 full level in electrode canister (float canister for DI units), there may be excessive debris in electrode canister (float canister for DI units).
4. If fuses are OK, check voltage to contactor coil. (a) If voltage is 24-28VAC at contactor coil, check coil resistance. It should be 8W with wires disconnected. If resistance is OK, check voltage drops across the contactor. (b) If no voltage to contactor coil, check continuity of wires from PC board to contactor. If continuity is OK, PC board is likely defective. 5. Check voltage signal to power module.
Humidifier runs continuously, %RH is well under set-point. 1. Verify humidistat/RH sensor is wired correctly and dip switches (S2 & S3, See Fig. 10-1, 11-1 and 11-1) on the PC board are set correctly for the humidistat signal. 2. Check humidistat demand signal at low voltage terminal strip. It should be close or at 100%. 3. If humidifier is a three phase model, verify all three phases of power are present and equal. 4. Check amperage draw on all high voltage power lines with a clamp on amp meter.
Dispersion tube spits water or water is present in duct Hint: It is very helpful to cut a small observation window in the duct and cover it with Plexiglas so the steam discharge from the manifold can be observed. This way the problem can be narrowed down to piping/steam quality (steps 1 and 2) or a condensation problem (steps 3 and 4). 1. Check distribution piping for proper pitch and size. Make sure there are no loops, dips or sags where pockets of water can collect.
2 WATER LEVEL DROPPED BELOW LOW LEVEL DURING NORMAL RUN - - The low level switch has not closed after 5 minutes of fill valve on time. This is only after initial start-up fill and boil-down sequence. Check: debris in water switch canister, defective fill valve, no water flow or low water pressure, drain valve stuck open, defective low water level switch (electrodes need to be cleaned).
HC6100-Wye Wiring Layout (380V, 400V, 480V, 600V) 28
HC6100-Delta Three Phase Wiring Layout (208V, 220V, 240V) 29
HC6100-PAR Single Phase Delta Wiring Layout (208V, 220V, 240V) 30
HC6300-Wye Wiring Layout (380V, 400V, 480V, 600V) 31
HC6300-Delta Wiring Layout (208V, 220V, 240V) 32
HC6500-Wye Wiring Layout (380V, 400V, 480V, 600V) 33
HC6500-Delta Wiring Layout (208V, 220V, 240V) 34
HC6500-WYE (2 contactors) Wiring Layout (380V, 400V, 480V, 600V) 35
HC6500-Delta (2 contactors) Wiring Layout (208V, 220V, 240V) 36
HC6700-WYE Wiring Layout (380V, 400V, 480V, 600V) 37
HC6100/6300 Repair Parts Item No. 31 16 1 32a 32b 14 12 11 6 7 5 13 13 13 13 8 8 8 8 8 3 3 4 4 Electrical Compartment and Front Panel Label Front Panel With Keypad Emergency Stop Button (2 N.O.) Main PCB For HC-6000 Wire Harness For HC-6100 Wire Harness For HC-6300 LCD Display For HC-6000 Display Driver Board Fan DC24 (Sanyo 9A0924H4D03) With 2 Cover Part No.
Heating Elements 6100/6300 TC= Thermocouple HC-6100 3kW Voltage Without TC 2PCS/Unit 3kW DI With TC 1PCS/Unit Without TC 2PCS/Unit With TC 1PCS/Unit 208 B5808-1 B5809-1 B5810-1 B5811-1 240 B5808-2 B5809-2 B5810-2 B5811-2 380 B5808-1 B5809-1 B5810-1 B5811-1 480 B5808-3 B5809-3 B5810-3 B5811-3 600 B5808-4 B5809-4 B5810-4 B5811-4 HC-6100 9kW Voltage Without TC 2PCS/Unit 15kW With TC 1PCS/Unit Without TC 2PCS/Unit With TC 1PCS/Unit 208 B5047-1 B5048-1 B5043-1 B5044-1 240
HC6500/6700 Repair Parts Item No.
Heating Elements 6500/6700 TC= Thermocouple HC6500/HC6700 30kW 33.5kW 40kW 45kW Voltage Without TC 5PCS/Unit With TC 1PCS/Unit Without TC 5PCS/Unit With TC 1PCS/Unit Without TC 5PCS/Unit With TC 1PCS/Unit Without TC 8PCS/Unit With TC 1PCS/Unit 208 B5433-1 B5434-1 - - - - B5433-1 B5434-1 240 - - - - B5433-1 B5434-1 - - 380 - - B5433-1 B5434-1 - - - - 480 - - - - - - - - 600 - - - - - - - - HC6500/HC6700 48kW 50.
Resistance Values of Components Resistance Value of 6100/6300 Components Component Resistance Value of 6500/6700 Components Voltage Resistance Component Voltage Resistance Fill Valve 24Vac 18Ω Fill Valve 24Vac 8.8Ω Drain Valve 24Vac 10Ω Drain Valve 24Vac 4.1Ω Contractor 24Vac 7-9Ω Thermocouple in Heating Elements - 0.51Ω Thermocouple in Heating Elements - 0.51Ω Heating Elements 208, 240, 380V, 30/33, 5/40/45/50, 3/60kW 240Vac 7.4-9.
PID Control PID control is essential on the HumidiClean series for maintaining the desired relative humidity (RH) by adjusting the humidifiers output. Please note that the PID control is only used when a RH sensor is supplying the demand in place of a humidistat (configured in Operation Setup Menu). The PID Settings will control how the demand is adjusted according to the error between the current RH and the desired RH set point.
- Has an unstable demand (contactor pulling in and out), decrease your proportional band (PB) value or increase your derivative gain (DG) value. Decreasing your PB value will help reach a stable demand, but it will increase the time it takes to reach the desired RH. Another solution to fixing an unstable demand is to increase the DG value. However, if you have any noise in your demand signal, increasing the DG value will only make your unit demand act worse.
Procedure of HC6000 Version 7 Software Update This section is used for HC6000 software reprogramming only. Please follow the instructions carefully, or pc board could become un-functional. 1. Install the driver program for Atmel MCU, SAM-BA on your computer first. The link for the Atmel program AT91-ISP.exe and the latest version of can be found at the following location: www.armstronginternational.com/hc6000refresh 2. Before refreshing the code, the old code in CPU must be erased: a.
Fig. 46-1 Code Download Window d. Click the “open folder” button on the right of textbox “Send File Name” to open the latest code, please see figure 46-2 below. You will then have to locate the .bin file that you downloaded from the website and then hit open. Fig.
e. Click the button “Send File” to send the latest code into board. You will be asked to unlock the involved lock regions (0 to 7), click the button “Yes” to begin send code into board. Please see figure 47-1 below. Fig. 47-1 Message Unlock Involved Lock Regions Window f. When sending was finished, you will be asked to lock all locks that you have opened just now, click the button “Yes” to lock these locks.
g. When operation has finished, close the “SAM-BA” window first, and then click the icon “remove the USB hardware” to disconnect the link between computer and board. After reminder by system, disconnect the power supply from breaker and pull out the USB cable. h. The soft refresh of HC-6000 is complete, restart the unit. Introduction to Communications Modbus Protocol Setup 1. Wire to the RS-485 port, following Figure 48-1. 2.
be extracted from the protocessor using RUInet. (see Obtaining .xif File using RUInet) 7. A few minutes after the unit is powered on the Initialization LED should light. The protocessor will not communicate until this LED is illuminated. 8. When the Lon device is commissioned the Lon LED on the protocessor will stop blinking and will be on solid. 9. The device should be communicating, when using your BMS to modify points the Network Setup has to be set to “Enable” before any other values can be changed.
7. The device should be communicating, when using your BMS to modify points the Network Setup has to be set to “Enable” before any other values can be changed. This can be found on the variable list under “Network Enable”. Controlling the Humidifier through Communication Port If you are planning on sending a percent output via communication port follow these instructions.
Table 51-1 Modbus Variable Lists Modbus Variants list address description 10001 Fill valve status 10002 Drain valve status 10003 contactor 1 status 10004 contactor 2 status 10005 contactor 3 status 10006 contactor 4 status 10008 Network control 1 comm type 2 Sensor select 3 High limit sensor select 4 Outside temperature 5 Network enable 6 Modulating Fill enable 30001 Desired RH / Demand 30002 Steam Output 30003 Water level 30004 Run status 30005 30006 30007 30008 30009 30010 30011 30012 30013 30014 30015
Table 52-1.
Table 53-1.
Physical Data and Dimensional Drawings Figure 54-1. Models HC-6100 and HC-6300 D K 1” Drain E Electrical Supply G M Knock-Out for Humidistat H A L Knock-Out for Humidistat C H F B R J Table 54-1.
Physical Data, Capacities and Dimensional Drawings Figure 55-1. M odels HC-6500 and HC-6700 — Front, Side, Top Views / 0 (OHFWULFDO 6XSSO\ 8QGHU &DELQHW :DWHU 6XSSO\ 3RUW 8QGHU &DELQHW 4 * ´ 'UDLQ 8QGHU &DELQHW ( . ' $ + & ) .QRFN 2XW IRU +XPLGLVWDW % .
Start-Up Check Lists Armstrong HC6000 Series Pre Start Up Checklist Humidifier model: ______________ Serial #: _______________ Voltage: __________ ph: ______ KW : __________ Steam Capacity: ____________ lbs/hr.
Start-Up Check Lists Steam Dispersion type: □ Humidipack □ Expresspack □ Fan package (EHF) □ Dispersion Tube □ Dispersion Tube with Drain □ Other ____________________________________________ Plumbing: Inlet Water: □ Inlet water pressure between 25-120 psig Drain Lines: Size: ________ □ Air gap located within 3’ of humidifier □ Line pitched 1” per 12” away from humidifier □ Temp-R-Drain (condensate cooler) □ Other condensate cooler ______________________________ Wiring: □ All wires connected securely □
Start-Up Procedure Armstrong HC6000 Series Start Up Checklist Humidifier model: ______________ Serial # : _______________ Voltage: __________ ph: ______ KW : __________ Steam Capacity: ____________ lbs/hr. Unit Tag:_______________ Job name: ________________________________ Unit Tag: _______________ □ Completed Start up Checklist If checklist was not completed, complete before proceeding with start up. □ Check and recheck proper incoming high voltage and high voltage terminals. ex.
Notes 59
Armstrong International, Inc. Limited Warranty and Remedy Armstrong International, Inc. (“Armstrong”) warrants to the original user of those products supplied by it and used in the service and in the manner for which they are intended, that such products shall be free from defects in material and workmanship for a period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the factory, [unless a Special Warranty Period applies, as listed below].
