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Nortec Industries GS Series User's Manual

1. BYOTHERS ACTUAL Ground Wire O Ground Ground Leg 600V 3 p h 0 Step down Dedicated 2 Pole Transformer Circuit Terminal 12 600V 208V Breaker Block byothers Or O Disconnect L3 Note 600V 3 Phase Supply E 1 Neutral 600V 1ph between any two hot leg x N 347 V 1ph between hot and neutral T T T Ground Wire O Ground L1 Ground z Leg Step down Dedicated O 2 Pole 460V 3 p h Transformer en Terminal L2 460V 208V boss Block by others Disconnect L3 Note E I Neutral 460V 3 Phase Supply 460V 1ph between any two hotleg T T 277V 1ph between hot and neutral Ground Wire Ground Ground Leg Li Dedicated O 2 Pole 380V 3 h Circuit Terminal p L2 Block Disconnect L3 Note 380V 3 Phase Supply Neutral 380V 1 phase between two hot legs E 1 220 1 phase between hot and neutral xN T T 1 Ground Wire Ground Lei on 208V 3 h Dedicated 12 Circuit 3 Pole Breaker Terminal Or Block ES Disconnect C Note Neutral 208V 3 Phase Supply 208V 1 phase between two hot legs E I 120V 1 phase between hot and neutral x N T 1 Ground Wire 120V 1ph I LR p Ground x Leg O 120V 1
2. Figure 16 Roof Curb Dimensions Roof Curb Dimensions Model Dimension A Curb Height Shipping Weight Operating Weight GSTC Outdoor 100 8 63 27 91cm 15 38 1cm Min 400 Ibs 181 kg 556 Ibs 252 kg GSTC Outdoor 200 15 06 38 25cm 15 500 Ibs 227 kg 744 Ibs 338 kg GSTC Outdoor 300 GSTC Outdoor 400 GSTC Outdoor 500 46 25 117 5cm 15 38 1cm Min 15 38 1cm Min 745 Ibs 339 kg 800 Ibs 363 kg 1210 Ibs 550 kg 1505 Ibs 684 kg GSTC Outdoor 600 46 25 117 5cm 15 38 1cm Min 844 Ibs 384 kg 1525 Ibs 693 kg Roof Curb by Others SECTION A A 3 3 4 9 5cm ELECTRICAL SIDI 6 0 15 24cmj BASE FRAME BURNER SIDE ELEMENT CURB e The integral base of the GS Outdoor model is e Gas lines are to be routed to the outside designed to mount on a curb The curb must be connection on the right side near the back of the built to structurally support the entire weight of unit The installation of a sediment trap and a the humidifier when in operation Required curb certified manual shut off valve are required dimensions are given in Figure 16 outside of the unit The gas piping must not block access to or prevent opening of the
3. Natural Gas 1507713 1 2 3 4 5 6 Propane 1507714 1 2 3 4 5 6 132 Elbow Assembly for Air Intake 1504204 1 2 3 4 5 6 133 Burner Blower Gasket 1708208 1 2 3 4 5 6 Not Bracket Fan Board Mount 1505899 1 1 2 2 3 3 Shown Not Board 1505689 1 1 2 2 3 3 Shown Not lgniter Jump Start Module 1506793 1 2 3 4 5 6 Shown Not Replacement Kit 1507696 1 1 1 1 1 1 Shown Not Flexible hose for Direct Vent 1502148 1 2 3 4 5 6 Shown ent Tube for Air Proving per inch 1605227 Order by foot as Required own 65 Exploded view of item 211 0 0 Q E O p Q U uo 0 N O Exploded View April 2008 www humidity com Nortec GS Series Indoor Cabinetry Spare Parts Number Description Part GS 100 GS 200 GS 300 GS 400 GS 500 GS 600 201 Service Door Assembly Mini 2524439 1 Single 2524440 1 Double 2524441 1 1 Triple 2524458 1 1 202 Fron Door Assembly 2528421 1 1 1 1 1 1 203 Recessed Handle 2523444 1 1 1 1 2 2 204 Transformer 24 16V 15VA 50 60 hz 1505760 1 1 1 1 1 1 205 Logic Control Board 1505762 1 1 1 1 1 1 206 Board 1504760 1 1 1 1 1 1 207 Primary Transformer 110 120 V Models 1504859 1 1 1 1 1 1 208 240V Models 15067619 1 1 1 1 1 1 F
4. a eee de Bed ee 38 SOFTWARE FLOW CHART 39 FAULT AND WARNING 57 60 EXPLODED VIEW INTERNAL COMPONENTS SPARE PARTS 63 EXPLODED VIEW INDOOR CABINETRY 5 5 66 EXPLODED VIEW OUTDOOR CABINETRY 5 5 68 GS QUICK REFERENCE iii i ved eee ae 72 GENERAL This installation guide has been designed to provide assistance when installing mounting and commissioning GS Series humidifier Actual on site application may vary Consult Technical Services or your local NORTEC representative WARNING e Improper installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning an explosion fire electrical shock or other conditions which may cause personal injury or property damage Consult a qualified installer service agency local gas supplier or your distributor or branch for information or assistance The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product A failure to follow this warning can cause electrical shock fire personal injury or death Should overheating occur or the gas fail to shut off shut off the manual gas valve to the appliance before shutting off the electrical supply D
5. 1808133 1 1807884 1 1 180881 1 23 fRainCap 1508130 1 Pp 806 18080229 1 Double 1807889 1 1 1 Triple 150788 1 1 Aa k gt k Ai 25 FanHood 1 1807811 1 26 Cover Plate Top Panel 11508109 1 27 Gasket Steamline 100 1508105 1 400 500 600 1507871 28 Cover Plate Steam Line 100 150816 1 200 300 1807870 400500600 1507810 29 Step up transformer 120 240V option 1508167 1 30 Mounting bracket step up transformer 1507759 1 31 Mid Cross Member Mini 1506958 1 1506978 Double 1506983 Triple 1506972 O Singef 1506979 Double 1506981 Triple 1506971 gle 1908087 Double 1807862 180780 __ 39 Access Door Side 1507801 1 __ 1 _ 40 Base Assembly 1508123 1 fJ 1932 1508017 _ 1508016 __ 41 Lifinglug 1 1807901 4 42 Pump House Heater 500 watts 1808089 1 43 Mounting Bar Pump House Heater 1508
6. amp jou seu 0 u uA sejddiu Yue 1no JEU 2949 palinbel ueuw w umop 1sn py mow sjeoj eunsu3 32014 SMOY 1 pue YMS 590 1 e uoee Jauanq 34 4 1 S 3 ILON 1 uing seo episjno pue yun eu OOM 15 SU JOSUSS ueejo Josues owe Josues juBrens SI JOSUSS JEU euiej pue eoeuns JOY 42949 tone i JONVNILNIVIN FALLNI 3ONVN31NIVN YVINDIY dn ueys OL SQ33N LVHM SAVG 6 ATNGAHOS IJONVNALNIVIN AHO LVONVIN 29 e Ensure that power is switched on again during periods of demand e The GSTC model of the Gas Steam humidifier includes a pre cleaning sequence feature When activated through the keypad the unit will flush the humidifier refill with cold water and flush again reducing the scale accumulated at the bottom of the tank CLEANING THE STEEL TANK CAUTION Water and scale may be hot enough to cause burns Turn off humidifier and allow it to cool before cleaning It is recommended that the tank be
7. 25 SCALE MANAGEMENT Sr SEG 27 0000090900 e 27 FAULT CONDITIONS s s As x GA ME BORSA RU Ld Ge 28 2 DRAINING THE TANK xo S y QU Gere JG Ge BR AE ideer W 28 MANDATORY MAINTENANCE 5 29 CLEANING THE TANK ve k ox e OI EE er aar de W 30 SSERVIGING THE UNIT Pr FE SEG Se pA Te Ge e oe ate 31 31 COMPONENTS REPLACEMENT 32 Hot Surface Igniter and Flame Sensor Replacement 32 Burner Removal and 32 Removal and Installation of the Combustion 33 Gas Valve Replacement 33 Air Switch Replacement ease sr Sars Ro deck Boi GE ACE 0 34 Float Chamber Replacement 34 Transformer 35 Fill Valve Replacement 35 Drain Pump 36 Fill Box Replacement km kom w e a a we 36 Removal of the Heat Exch nger MUR S boe 37 DIP SWITCH SETTINGS oo uuo EE hw
8. BURNERS SHORT CYCLE DELAY Nortec www humidity com SERVICE INTERVAL XXX HOURS 1 VERTICAL ARROW INDICATES ADDITIONAL SERVICE INTERVAL SELECTIONS AVAILABLE BY SCROLLING SERVICE HISTORY X Y STEAM HOURS XXXX DATE TIME FAULT HISTORY X Y TYPE OF FAULT DATE TIME THIS WILL DRAIN CONTENTS OF TANK lt SERVICE INTERVAL lt irta SERVICE HR NDER CHANGE VALUE XXX 2 USE UP DOWN ARROWS TO XXX HOURS CHANGE HOURS PRESSING ENTER CLEARS CLEAR REMAINDER THE REMINDER 1 DISPLAYS THE LAST 10 SERVICE PERIODS 2 DISPLAYS THE NUMBER OF STEAM HOURS WHEN SERVICE WAS PERFORMED 3 DISPLAYS THE DATE THE SERVICE WAS PERFORMED 1 DISPLAYS THE LAST 54 FAULTS 2 GIVES A DESCRIPTION OF THE FAULT TYPE 3 DISPLAYS THE DATE THE FAULT OCCURRED THIS WILL DRAIN CONTENTS OF TANK 1 CONTINUE 1 PRESSING ENTER STARTS THE TANK DRAIN PROCEEDURE Keypad Display Menu Structure Service Level 1 of 2 SERVICE LEVEL 2 of 2 MAIN MENU SYSTEM STAS THIS WILL DRAIN THIS WILL DRAIN SERVICE LEVEL CONTENTS OF TANK lt CONTENTS OE TANK FAULT HISTORY 1 USER SETTINGS TANK DRAIN CONTINUE gt SHORT CYCLE DELAY 1 PRESSING ENTER STARTS THE TANK DRAIN PROCEDURE 1 VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE CLEAN BURNERS SERVICE INTERVAL SERVICE HISTORY
9. N BH type double wall with double wall connectors required Note These are guidelines only Follow the local and or national codes in your respective area STe Figure 7 Vertical Venting Application Using B or BH Venting UL Listed Cap Required Flashing B or BH type vent using double wall vent with double wall connectors is required Reference local and or national codes before installation of the vent ET Horizontal run 4 minimum air 1 4 rise per ft space required Exhaust venting Condensate tee outlet required type double wall vent with double wall connectors required Steam Outlet 2FTMin for category appliances n 3 Min Limitations on horizontal S E distance when venting with B vent BH type double wall vent with double wall connectors required and all joints are to be air and water tight BH vent is a category Ill appliances Condensate tee and trap must be installed Take the condensate to a floor drain or a condensate pump Figure 1t 8 Side Wall Venting Application Using BH Type Only Wall BH type vent using double wall vent Hangers Strap 5 with joints being air and water tight PA Pa 2 Reference local and or national 8 8 NE Nortec vent terminal codes before installing vent Exhaust venting outl
10. setting for the humidifiers service reminder in steam hours Remaining This field displays the amount of time steam hours remaining before the next service is to be performed Start Date This field displays the date this service interval began SCREEN 5 SECURITY LOOP 0 1 SAFETY SENSORS 0 1 TANK SENSORS 0 1 Security loop This field displays the status of the security loop terminals 1 and 2 on LV terminal strip If itis open the display will indicate if it is closed the display will indicate I Safety sensors This field displays the status of the safety sensors input If it is open the display will indicate O if it is closed the display will indicate 1 There are two safety sensors on the GSTC One for tank over temperature and one for stack over temperature Both sensors are wired in series Tank sensor This field displays the status of the tank sensor input If it is open the display will indicate O if it is 51 closed the display will indicate 1 Closed indicates that the tank temperature is above 160 F 70 This input is used for the keep warm feature and for activating the fill valve during blowdown cycles SCREEN 6 3 DAY DRAIN 1 KEEP WARM 0 XX BLOWDOWN RATE FT BLOWDOWN 1 3 day drain This field indicates if the feature has been selected 0 no 1 yes Keep warm This field indicates if the feature has
11. FAULT HISTORY TANK PRE CLEAN BURNERS SHORT CYCLE DELAY BURNER 1 ENABLED BURNER 2 ENABLED BURNER 3 ENABLED SHORT CYCLE DELAY SECONDS XX BURNER 1 ENABLED BURNER 2 ENABLED BURNER 3 ENABLED BURNER 4 ENABLED BURNER 5 ENABLED BURNER 6 ENABLED SHORT CYCLE DELAY lt CHANGE VALUE XX BURNER 1 ENABLED DISABLED Keypad Display Menu Structure gt Nortec www humidity com Service Level 2 of 2 USER SETTINGS 1 of 3 SYSTEM STATUS DATETIMEUNTS lt TIME HH MM SERVICE EVE LANGUAGE CONTROLS DATE MM DD YY USER SETTINGS CAPACITY LIMIT i UNITS LB HR CALIBRATE 1 VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING CHANGE TIME XX XX CHANGE DATE MM DD YY SELECT UNITS PRESS ENTER TO LB HR SELECT UNITS KG HR DATE TIME UNITS SELECT LANGUAGE SELECT LANGUAGE LANGUAGE CONTROLS lt ENGLISH WATER MANAGEMENT FRENCH GERMAN CAPACITY LIMIT CALIBRATE PRESS ENTER TO SELECT LANGUAGE PRA Nortec Keypad Display Menu Structure pod User Setting 1 of 3 www humidity com USER SETTINGS 2 of 3 FTBD HOURS CHANGE HOURS XXX FTBD HOUR CHANGE HOUR XX BLOWDOWN RATE CHANGE VALUE XX STEAM OUTPUT MAIN MENU SYSTEM STATUS DATE TIME UNITS 8D HOURS XXX BD HOUR XX SERVICE LEVEL LANGUAGE CONTROLS LOWDOWN RATE XX USER SETTINGS LOAT CHECK CHANGE VALUE HH MM LL CORRCTN CAPACITY LIMIT DRAIN CORRCIN XX CALIBRATE DRAIN COOL SMART 1 VERTICAL A
12. The actual date and time will be displayed MAIN MENU The main menu lists the available sub menus where system adjustments can be made Some of the menus are password and jumper protected to SYSTEM STATUS SERVICE LEVEL USER SETTINGS DIAGNOSTICS block access by unauthorized personnel System status Displays various system parameters as the user scrolls through the lists For further details see specific section below Service Level password protected This section is specific to all service related activity For further details see specific section below 49 User Settings password protected This section allows the user to set parameters specific to their requirements For further details see specific section below Diagnostics safety loop protected Allows the user to activate and monitor various system operations Service checklist not available for first release Troubleshooting not available for first release SYSTEM STATUS SCREEN 1 STATUS LOCKOUT DEMAND CHANNEL 1 0 DEMAND CHANNEL 2 0 CAPACITY LIMIT 0 Status Displays the present status of the system Depending on system activity at the time the field could display lockout security loop open active unit generating steam or standby security loop closed but no modulation demand signal Demand channel 1 This field will display the modulation demand input on that channel Demand channel 2 Field o
13. 1 10 Thermostat On Of 80F 1508042 1 1 1 1 1 11 Electrical Cabinet 1506989 1 1 1 1 1 12 FrontPanel 11507783 1 1 1 1 1 1 13 Access Door Electronics 1507801 1 1 1 1 1 14 Access Door Tank 11807800 1 1 1 1 1 15 Left Panel 1508096 1 single 150808 1 J Double 1807601 1 1 J _ 150784 1 1 1 16 Top Assembly _ 1508100 1 T Single 180809 1 Pp Double 1807868 1 1 180806 __ 1 Female to Female Coupling _ 3 Dia 1508136 1 i __ ao oss a S o _ 180886 1 1 1807880 1 Vent Pipe 24 Long 3 Dia 1508132 1 1808031 1 J _ 15088 1 1 10882 PJ 1 Chimney Flashing for3 ventpipe 1508138 1 for 4 vent pipe 1508137 for vent pipe 150785 J 1 1 J for6 ventpipel 1508150 1 21 Stom Colla for 3 vent pipe 1508140 1 for 4 vent pipe 1508139 1 T T fer amp wntppe 1507890 1 1 for 6 vent pipe 1507884 1 1 1 40 Vent Pipe 12 Long 3 Dia 1508134 1
14. Periodic cleaning of the screens in the vent terminal where applicable is recommended NOTE Use only NORTEC original parts to replace damaged or defective components Failure to do so may cause improper operation of the humidifier and will void warranty DRAINING THE TANK e During extended periods of inactivity such as off season or periods of very low demand it is advisable to drain the water from the tank On all models this is accomplished by switching the unit to Drain e Do not remove the front clean out port on the tank until the unit has completely drained On GS 300 600 units do not remove the top clean out ports on the tank unless the water has cooled or the unit has completely drained jsneuxe y joies AG pue SI JOSUSS JEU ENSIA X 3995 TH SI PUI sxee JO 20090 quan PIG eq pinoys anj4 sde 0007 096 sMO paonpold 6uguan seg sxeo JO 12edsu pue Jeajo SI deo Jequieuo pue dno y sYea 10 12edsu s ur sye 12edsu seu uy Bun2euuoo pue eop woy ejeos peuinbeJ YUE eJeos u sejddiu
15. Two electrical conduits are provided for routing the primary wiring to the disconnect switch and then back inside the enclosure to the main power terminal strip See Figure 20 for details Figure 20 Electrical Box Disconnect box By others Primary wiring By others FILL WATER SUPPLY LINE Figure 22 77 KG Drain Connection e Each unit is supplied with a 72 NPT male connection to the fill valve Refer to Figure 21 for connection details A minimum fill rate of 10 l min 2 6 gal min is required for all unit sizes Allowable pressure range is 30 80 psig e Always install a manual shut off within the gr A vo building to allow isolation of the water to the unit Freeze 1 Outlet i i Wi 1 protection amp union must be installed on the fill line prior to standard 3 camps the fill valve to allow for servicing 2 supplied e Heat trace fill line piping above rooftop from the pipe chase up to the fill valve Figure 21 Fill Water Connection AUXILIARY DRAIN e Standard GS Outdoor units come with capped Check Valve NPT auxiliary drain connection at the bottom of If required the tank It is recommended to install a manual shut off valve on this connection and route to drain provide an air gap Drain Line Connection e GS Outdoor units standard with freeze protection have a normally open drain valve mounted at the auxiliary drain connec
16. TANK DRAIN ENABLED ENABLED BURNER 6 ENABLED BURNER 1 DISABLED SHORT CYCLE DELAY After entering the user code 0335 the individual burner can be highlighted Once ENTER is pressed the burner can be enabled or disabled Short Cycle Delay The short cycle delay feature can be used to reduce the amount of ON OFF cycles during operation The feature will cause a delay between cycles by forcing the system to wait a pre set period seconds before responding to a demand signal SERVICE INTERVAL SERVICE HISTORY SHORT CYCLE DELAY SHORT CYCLE DELAY lt FAULT HISTORY SECONDS XX CHANGE VALUE XX TANK DRAIN TANK PRE CLEAN BURNERS SHORT CYCLE DELAY The delay can be set from 1 to 1000 seconds The default shall be 1 second since any larger value can result in a less dynamic response of the system as a whole This feature should only be used once a short cycle condition has been identified 54 User Settings DATE TIME UNITS lt LANGUAGE CONTROLS WATER MANAGEMENT CONTROL TYPE CAPACITY CALIBRATE When parameter requires change press the two arrow keys and enter the password 0335 As long as you remain in this section you will not need to enter the password more than once Date Time Units This field is used for modifying the Date time and the units of measurement The date and time are important parameters when features such as full tank blowdown are enabled CHANGE TIME
17. by others _ Hose Coupling _ by others Air Intake Connection Figure 5 Direct Vent Side Wall Requirements Exhaust terminal with opening vertical Intake terminal with opening vertical is 4 ft 6 ft 1 2 1 83 m Keep 6 15 2 away from sidewall Location of air intake and flue gas terminal must comply with all local and national regulations EXHAUST VENTING The GSTC and GSP classed category and III fan assisted gas appliances This allows two methods of venting Listed below are instructions for both venting systems followed by specific requirements for each system Review the requirements for both category I and III installations and select the venting method best suited for the installation Category class must be used in direct vent applications GENERAL REQUIREMENTS e The vent systems shall be listed to UL or UL CSA standard and meet the installation requirements of the National Fuel code in the USA ANSI Z223 1 and the Canadian Standards CAN CGA B149 Installation Codes Any local jurisdictions reflecting changes to the above codes should be observed In applying the codes reference should be given to the venting manufactures instructions the serving gas supplier regulations and the specific instructions provided in this manual This appliance must be installed to comply with national regulations and codes A qualified technician comp
18. e Atthe completion of the test the float chamber will indicate middle float position green LED and the unit will go into standby mode until demand signal is received e Proceed to the safety shut off test TESTING THE IGNITION SAFETY SHUT OFF Test the ignition system safety shut off in the following method e Close the shut off valve in the gas supply line e Setthe demand signal to the humidifier to 10096 e Ensure all external controls connected to the security loop are closed e Switch the humidifier on At the completion of the float test the humidifier will begin the combustion sequence by energizing the combustion blowers All blowers will run at full output for 30 seconds to pre purge the combustion chamber During this time the controller will monitor that all air proving switches closed to prove air flow The igniter s will be energized for 15 seconds allowing it time to heat to the appropriate ignition temperature and the gas valve will be energized After 4 seconds both the gas valve s and the igniter will be de energized After three trials for ignition complete with pre purge the red LED on the ignition control module will begin blinking to indicate a safety lockout and fault message will be displayed on the humidifier display NOTE On multiple burner models each burner tries to ignite in sequence It is necessary to wait for all burners to cycle to complete the test Manually re open the gas suppl
19. gt suma ker ANE OE ac Ge Ek Va de ee E qo M TE EO ae ee Wee 1 DELIVERY a oe 3 ER m x OP ewe 8 2k Sa ER EG 1 RECEIVING amp UNPACKING EQUIPMENT 1 GENERAL SPECIFICATIONS 1 MODEL DESIGNATION o S 2 E 8 SUR ge FORA WR a 1 MODEL SPECIFICATION GS INDOOR INSTALLATION LOCATING AND MOUNTING 2 4 GAO PIPING s 5 um GA Ea de BOR 5 8 5 COMBUSTION AIR REQUIREMENTS 6 DIRECT VENT GUIDELINES 6 EXHAUST VENTING dk nex E ADDITIONAL REQUIREMENTS WHEN VENTING THROUGH SIDEWALL 11 ELECTRICAL o s kat wee aoe awe a er w ok er en Ba dr VOS 12 sPRIMARY WIRING sex dcx 2 ase ene s GR ST Bs Saks GE I rer 13 LOW VOLTAGE CONTROL WIRING tea nada raaua 14 CONTROL INSTALLATION 15 PLUMBING 2 s ae s soue 2408 Sete e bib 4 ee 15 FIEL SUPPLY LINE o gt g x ben dnm b ek RE eg Aer W 15 SDRAINLINE amp sce 2 fe o EEE S Q Ua s DEOR M BE EO lg We Po ee ee 15 AUXDRAIN PORT csser red
20. 1 1 112 Exhaust Manifold Gasket Single 1505973 1 Dual 1505942 1 2 2 3 3 113 Exhaust Manifold GS 100 1505875 1 GS 200 1505861 1 GS 300 400 1505843 1 1 GS 500 600 1505828 1 1 114 Flexible Gas Hose with fittings 1505960 1 2 3 4 5 6 115 Auxillary Drain Plug 1507043 1 1 1 1 1 1 116 Auxillary Drain Termination 1506925 1 1 1 1 1 1 117 Drain Pump 24v 60 hz 1502644 1 1 1 1 1 1 118 Tank Thermal Sensor 1506026 1 1 1 1 1 1 119 Float Chamber 1115933 1 1 1 1 1 1 120 Float Chamber Mounting Bracket 1113777 1 1 1 1 1 1 121 Float Board 2521137 1 1 1 1 1 1 122 Lower Mixing Box 1506749 1 1 1 1 1 1 123 Replacement Burner Ass y 110 120V Models 2528416 1 2 3 4 5 6 208 240V Models 1507669 1 2 3 4 5 6 124 Burner Plate Gasket 1505936 1 2 3 4 5 6 125 Sight Port Replacement Kit 2528417 1 2 3 4 5 6 GS Series Internal Components Spare Parts continued Number Description Part GS 100 GS 200 GS 300 GS 400 GS 500 GS 600 126 lgniter flame sensor gasket 1506892 1 2 3 4 5 6 127 Hot Surface Igniter Replacement kit 110 120V Models 2528418 1 208 240V Models 1507695 1 128 Flame Sensor Replacement Kit 1507694 1 2 3 Igniter flame Sensor Replacement Kit 110 120V Models 2528420 1 208 240V Models 1507712 1 2 3 129 Combustion Blower 110 120V Models 2524360 1 2 3 208 240V Models 1502289 1 130 Air Proving Switch 1504175 1 2 3 4 5 6 131 Gas Valve Assembly
21. 3 TOGGLES BETWEEN ON AND OFF 4 DISPLAYS USER SETTING ON OFF OR SMART Keypad Display Menu Structure Nortec www humidity com System Status 1 of 2 42 MAIN MENU SYSTEM STATUS SERVICE LEVEL USER SETTINGS Nortec www humidity com SYSTEM STATUS 2 of 2 gt SERVICE INTERVAL XXX HOURS REMAINING XXX HOURS START DATE MM DD W SECURITY LOOP 0 1 SAFETY SENSORS 0 1 TANK SENSORS 0 1 3 DAY DRAIN KEEP WARM BLOWDOWN RATE 25 FT BLOWDOWN ON LOOP BACK 1 DISPLAYS THE USER SELECTABLE MAINTENANCE INTERVAL 2 DISPLAYS THE TIME LEFT BEFORE MAINTENANCE IS DUE 3 DISPLAYS THE START DATE OF THE CURRENT SERVICE INTERVAL 1 DISPLAYS STATUS OF THE SECURITY LOOP OPEN CLOSED 2 DISPLAYS STATUS OF THE SAFETY SENSORS 3 DISPLAYS STATUS OF THE TANK SENSOR 1 DISPLAYS IF FEATURE IS SELECTED 2 DISPLAYS IF FEATURE IS SELECTED 3 DISPLAYS PRESENT BLOWDOWN RATE 4 DISPLAYS IF FEATURE IS SELECTED Keypad Display Menu Structure System Status 2 of 2 SYSTEM STATUS SERVICE LEVEL USER SETTINGS SERVICE LEVEL 1 of 2 MAIN MENU SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE CLEAN BURNERS SHORT CYCLE DELAY SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK PRE CLEAN BURNERS SHORT CYCLE DELAY RVICE INTERVAL RVICE HISTORY FAULT HISTORY RNERS ORT CYCLE DELAY RVICE INTERVAL RVICE HISTORY ULT HISTORY
22. 70 feet for direct vent models L Proper pipe diameter used L Condensate tee installed STEAM LINES L Slope up 2 per 12 L Sloped back to drain Ll Slope down 77 per 12 L Trapped 2 more than static duct pressure L Traps Size L Insulated L Length Size 90deg Elbows qty 45deg Elbows L Can condensate be trapped anywhere in the steam line yes L no 0 CONDENSATE LINES L Sloped back to drain L Trap is greater than 2 duct static pressure Ll Size of trap 25 SUPPLY WATER LINE Nortec supplied adapter installed on fill valve 7 gt Manual shut off valve and union installed Verified pressure 30 80 psig Water source of 10 l min 2 6 gpm Leak tested 1 2 dia At max 4ft of the unit gogogo DRAIN LINES 1 Air gap located within 3ft of the unit Minimum drain line size of 1 in dia Downward slope Tundish funnel installed to provide air gap Temperature rating of piping Hose connections tightened Auxiliary drain piped with shut off valve to tundish WATER QUALITY Well water L City water L Softened water RO DI water 0 Conductivity mhmos Hardness _GPG Silica ppm Chlorides ppm pH NOTE Failure due to chloride corrosion is not covred under Nortec s standard warranty Consult factory for more information ELECTRICAL INSTALLATION Comply with local regulations Proper supply voltage must match rating plate and breaker size Electrical disconnect swi
23. IN W C NATURAL GAS MAX 280 000 210 0 05 MIN 45 000 25 0 05 PROPANE MAX 280 000 210 0 35 MIN 50 000 25 0 35 MODEL GS 300 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS IN W C NATURAL GAS MAX 420 000 315 0 05 MIN 45 000 25 0 05 PROPANE MAX 420 000 315 0 35 MIN 50 000 25 0 35 MODEL GS 400 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS IN W C NATURAL GAS MAX 560 000 420 0 05 MIN 45 000 25 0 05 PROPANE MAX 560 000 420 0 35 MIN 50 000 25 0 35 MODEL GS 500 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS IN W C NATURAL GAS MAX 700 000 525 0 05 MIN 45 000 25 0 05 PROPANE MAX 700 000 525 0 35 MIN 50 000 25 0 35 MODEL GS 600 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS IN W C NATURAL GAS MAX 840 000 630 0 05 MIN 45 000 25 0 05 PROPANE MAX 840 000 630 0 35 MIN 50 000 25 0 35 HIGH ALTITUDE derate in input exists for installations at higher altitudes For Canadian models an automatic 10 derate applies to installations from 2000 4500 feet For U S Models refer to the chart below for high altitude derate information FOR U S MODELS ONLY Altitude Derate Feet Meters 0 2000 0 610 0 2001 3000 610 915 8 3001 4000 915 1220 12 4001 4500 1220 1370
24. OFF erating an error Unit will display warning but continues to operate Factory set ON FULL TANK BLOWDOWN FULL TANK BLOWDOWN FUNCTION SW5 8 Disabled OFF Enabled Factory set ON 40 NORTEC TC CONTROLLER Menu Structure INTRODUCTORY SCREEN MAIN MENU UP DOWN NORTEC GSTC 4 LL ORTEC GSTC 400 SYSTEM STATUS oi VERSION X XX POINTER TO SERVICE LEVEL SELECTA SYSTEM LOCKOUT MENU ITEM TO OPEN THE diel ale el SELECTION PRESS THE ENTER BUTTON NOTES Go To System Status page 22 Service Level page 24 User Setting page 26 Nortec Keypad Display Menu Structure As GENERAL www humidity com SYSTEM STATUS SERVICE LEVEL USER SETTINGS SYSTEM STATUS 1 of 2 STATUS LOCKOUT DEMAND CHANNEL 1 0 DEMAND CHANNEL 2 0 CAPACITY LIMIT 0 SYSTEM DEMAND XXX BURNERS X X OUTPUT BURNER XXXLB TOTAL OUTPUT 08 WATER LEVEL x FILL VALVE DRAIN VALVE OFF DRAIN COOLING SMART 4 1 DISPLAY TOGGLES BETWEEN LOCKOUT ACTIVE AND STANDBY DEPENDING ON SYSTEM DEMAND 2 ONLY VIEWED IF UNIT IS CONFIGURED FOR DUAL CHANNEL 1 DISPLAY WILL SHOW NUMBER OF BURNERS AND DISPLAYS THE NUMBER OF ACTIVE BURNERS 2 DISPLAYS THE OUTPUT PER BURNER IN POUNDS PER HOUR OR KG HR 3 DISPLAY OF TOTAL SYSTEM OUTPUT IN LBS HR KG HR 1 DEPENDING ON WATER LEVEL WILL DISPLAY 0 5 2 TOGGLES BETWEEN ON OFF AND PULSED
25. build up The unit also includes an internal 1 air gap and a vacuum breaker to prevent siphoning effect On initial start up the solenoid operated fill valve fills the tank The water level reaches the backup float first and then the main float If the backup and main floats do not read the same water level during the operation of the unit the unit will shut down on a fault The unit will continue to fill the unit to the top green position The drain pump will then be energized to drain the water level down to just below the bottom red position and then the fill valve will energize again to fill the unit to the middle yellow position During this time the software is performing a test on the fill valve and drain pump If a demand signal is present the unit will then begin the combustion sequence As the unit operates the fill valve with be pulsed to maintain the water level between the yellow and green positions During steam production the unit will also check if the floats and drain pump are operational by activating a drain sequence every 24 hours adjustable to time of day START UP PROCEDURE Figure 24 Plumbing Connections Fill Chamber Vacuum Break Presure Equalizer _ Main Fill to System Dual Fill Valve _ Drain Outlet Internal Trap Drain Pump _ Drain Float Chamber START UP CHECKLIST Before the GS humidifier is operated for the first time a complete inspect
26. minimum of 12 above any installed it MUST consist of 2 devices in series surface where snow or ice could accumulate In A pressure regulator plus one other device Both areas where normal snow accumulation is these devices must be able to work on their own higher mount the unit accordingly without damaging any downstream piping or appliance and the only way the downstream e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of the humidifier Figure 17 Gas Piping e The humidifier may be installed directly on combustible flooring or in the U S on wood flooring or Class A Class B or Class C roof covering materials Inlet coupling supplied GAS PIPING Shut off Gas Valve e Installation of piping must be in accordance with by others local codes and the National Fuel Gas Code ANSI Z223 1 in the United States or CAN CGA B149 Installation Codes in Canada e Referto the indoor gas piping installation guidelines for gas line sizes pressures leak testing procedures and safety instructions y Ae y Vip Union by others Sediment Trap by others Figure 18 GasPiping Main Gas Supply Line Over Pressure Regulator Device l x 6 6 Gas Connection Gas Unit system can be damaged is by the failure of both devices EXHAUST VENTING OUTDOOR UNITS e All required exhaust venting is provided with ea
27. right side e Ensure that the humidifier is mounted level service door Refer to Figure 17 for details e The pan in the bottom of all outdoor models has e Nortec recommends that each Gas Fired a pipe chase for routing of services into the Humidifier has it s own regulator installed in line to humidifier from below the unit Th operating Natural Gas pressure supplied for the GS units must be in the range of e Itis not necessary to make the hole in the roof 5 9 of Water Column and propane version the same size as the curb The curb drawing 10 14 of Water Column shows the location and size of the pipe chase required The pipe chase should be sealed when e Over pressure protection devices shall be the installation is complete to ensure positive or provided to prevent the pressure in the piping negative pressure from the building system from exceeding that value that would cause unsafe operation of any connected and e The panels of the outdoor model have louvers to properly adjusted Gas utilization equipment See provide ventilation for the electronics and air for Figure 18 the combustion process Locate the unit so that louvered panels are a minimum of 10 ft from any e fthe system has a pressure that is higher than mechanical exhaust outlet the max working pressure of our humidifier then an Over pressure protection system is required If e When mounted on the curb the lowest air intake there is an Over pressure protection device louvers must be a
28. setpoint Set to desired RH Can be a make break set of contacts from a Building Automation System Duct Mounted Safety High Limit On Off Humidistat Wired to make on drop in humidity break on rise to safety setpoint Set to approximately 85 RH as a safety to prevent saturation and wetting in the duct Highly recommended for ducted applications Duct Mounted Safety Air Proving On Off Switch Wired to make when sensing air flow break when no air flow Used as a safety to prevent saturation when there is no air flow Highly recommended for ducted applications Wall or Duct Mounted Modulating Humidistat Provides a modulating signal to the unit that represents the output up to 10096 required from the humidifier Signal type can be changed in the field via dip switch settings on the logic control board All GS models may be configured for either single or dual channel modulation Control signals can be 0 10 VDC or 0 20 mA 0 5 1 5 VDC 4 20 mA and 2 10 VDC are also available The unit must be ordered from the factory for the desired signal type and number of channels When configured for 2 channel modulation the humidifier will generate steam only if both channels indicate a demand If both channels are demanding steam the humidifier will satisfy the lower demand signal PRIMARY 208 240V 1 phase line voltage wiring to unit VOLTAGE
29. to the building drainage system e The drain line should not end in a sink used frequently by personnel or where plumbing codes prohibit it Route to a floor drain or equivalent for safety reasons Internal drain water tempering will ensure maximum of 1409F 60 exiting water temperature e Never install PVC piping as a drain line material Always use material suitable for with standing 140 F 60 e Keep lines as short as possible Keep drain lines sloped down not level and not up since low spots in drain lines will accumulate sediment and cause backup The drain line should be 1 1 5 O D or larger Consult local codes e When the drain pump is activated the tank drains at a rate of 7 8 gal min 18 20 l min AUX DRAIN PORT e An auxiliary drain port is also provided on the side of the humidifier It can be used to manually drain the unit if required The unit is shipped with this connection plugged It is recommended to install a shut off valve on this line see Figure 11 e The auxiliary drain port is used with the standard freeze protection Install a shut off valve on this line and pipe to the drain funnel see Figure 11 The manual shut off valve must always be in the open position when the unit is operating but can be closed for servicing of the unit STEAM LINES AND CONDENSATE LINE e Steam hoses and clamps are provided with the GS humidifier for connection to the steam lines Refer to Fi
30. 113 2 Em p Ooo op 1 1508111 Tiplef 1508164 Strapping Pump House 1508110 3 3 70 wo ec 1 uise zs 007 97 90 000 SUoNDNJJSU pugs S9 VAR WIO9 L PIUINY MMM 29 10N 88860656 35 59 SNOILONALSNI 1 dNVIS 0073 OVZAZHO 00 37H9 01 uev 601 uev 00959 00959 uuo 26 UL 9E 09 L3ZHO 0 LIZHO 00759 00E59 reg us tz 0837H9 007S9 77 Ov3cHO 00189 V NOISNSNIA wo 9 00 ui v V 325 UNN 9 9 Iss ONN 91 8 nN G uz V 9c 95 9c GLE Q IQUSOM 4901 9c 91 8 2 8 4 JAS 8 38 50 ONVIS 3OV lg 4 4 TALS 8 AS SO ONVIS 14 NOWIAOO FOVUI S 5 JAS 8 3S S 3 OO HH 3lV1d 9 9 TIALS 8 35 59 ONVIS 30013 931 009 0088 00250 uoyduoseq AS S3IV1d 1806005 931 JHL NI S31OH JHL VIA 0013 JHL OL Q3N3IS V ATNYNINRIId 38 AVIA QNVIS JHL OL UIIQIIARH IHL dO JONVIVE RINSNA OL AIVSSIDIN 38 AVN SONVIS JHL JO 931 IHL MOTH8 lOO IHL ONIAIWIHS 6 FT VIS SI LI ANY 0073 OL ATIN
31. 16 4501 higher 1370 higher Contact Factory Figure 1 Typical Installation Indoor Steamline B or BH Venting Type Snap on Installation Control Wiring Steam Outlet Optional Direct Vent Gas Line Connection Main Power Disconnect Shut Off Clean Out Access Door 117 Fresh Water Fill Line 3 4 min 30 80 psi Exhaust Outlet gt Air with Funnel Optional Stand Auxiliary Drain Service Access Door Mechanical Service Access To Drain Door Electrical Figure 2 Clearance Requirements Side Clearance Front Clearance 4 10 2 cm to vent pipe Minimum 36 91 5 cm Minimum 36 91 5 cm i torti 5 30 76 2 cm Required only for Po GSTC GSP Right 500 600 30 76 2 cm Farr AK _ Optional stand INDOOR INSTALLATION e Ambient temperature location for humidifier 41 F 104 F 5 C 40 The installation must conform with local building codes or in the absence of local codes with the ANSI e Relative humidity location for humidifiers 7223 1 National Fuel Gas Code and or CAN CGA 5 rh 80 rh B149 Installation Codes Refer to the Gas Piping section of this manual e All GS humidifiers are rated for the clearance to shown in Figure 2 LOCATING AND MOUNTING e Location of the steam dist
32. 5 EXTERNAL TT r1 1 2 3 4 5 6 7 8 9 101112 1314151617 118 INTERNAL i n INTERNAL NOTE If no On Off Control is used then a field jumper must be connected across terminals 1 and 2 in order for the humidifier to operate Low Voltage Terminal Strip 1 amp 2 Wire all on off controls and safeties between these two terminals If not used jumper 1 amp 2 for the unit to operate 4 Modulating input to humidifier A 5 Modulating input to humidifier B 6 10 Vdc output 8 When 24 Vac input received the unit will initialize a full tank blowdown 9 Safety interrupt 24 Vac 10 amp 11 Remote indication connection for humidifier on status indication 12 amp 13 Remote indication connection for humidifier active status 14 amp 15 Remote indication connection for service required indication 16 amp 17 amp 18 Remote indication connection for fault indication 14 CONTROL INSTALLATION Mount any wall humidistat control or high limit over standard electrical box at height similar to typical thermostat Any wall humidistat should be in location representative of overall space being humidified and not in path of blower pack or air supply grille Do not mount on an outside wall where temperature fluctuations can affect control response Mount duct humidistat in location representative of overall air humidity usually in return duct Do not mount it directly in front of s
33. 6 Removal of Heat Exchanger 1 2 10 11 12 Take the humidifier out of operation Disconnect the gas supply pipe from the connection on the humidifier and close off the pipe Unlock and remove the right side panel s On Direct Vent units only Remove hoses from air intake manifold and air inlet elbows Dismount flue gas pipe at the flue gas outlet connection On Direct Vent units only Dismount air supply pipe at the air supply connection Unlock and remove the left and the right top panels Free all cable connections to the components combustion blower ignition module air pressure switch etc of the respective heat exchanger IMPORTANT Note the connector assignment Undo the coupling of the respective flexible gas pipe and remove the flexible gas pipe Dismount the burner with the air blower and the gas pressure regulating valve of the respective heat exchanger Unscrew the nuts and remove the flue gas manifold from the tank Unscrew the nuts on the heat exchanger and pull out the heat exchanger from the tank Re installation is carried out in the reverse sequence Replace all seals with new ones S87 Figure 38 Heat Exchange Assembly DIP Switch Settings 1 2 3 LA GSTC GSP 2 Nortec Logic Control Board www humidity com 3 DAY DRAIN 3 DAY DRAIN FUNCTION SW3 7 Function Disabl
34. GE er W boo 16 STEAM LINES AND CONDENSATE LINE 16 GS OUTDOOR INSTALLATION 16 MOUNTING 24 2 pun bas ER 4 AR PUR 6 958 Rok Xe de Me BD ike d P s 16 TYPICAL GSTC OUTDOOR INSTALLATION 17 ROOF CURB DIMENSIONS sos i x s Q y w Q RR e yb W 18 EGA PIPING S Z Z I QS Pa a PN TE 19 EXHAUST sa sk i k k ALAS Udo DR de s 8 W 20 ELECTRICAL INSTALLATION 20 FILE WATER SUPPLY LINE gt s auk be RA Yea eee ee GR QUQ Rex Cur Er Q 21 xPDOUDIB cT 21 AUXILIARY DRAIN 5 a 5 sa ROGA ROS ae s E x s me CR Ja TR 21 SS TEAM LINES Gar ies Po Gre Eu n dp e BAR um Red wee Xo dou re W 22 PRINCIPLE OF OPERATION 22 COMBUSTION uetus EE me BG ree 22 WATER MANAGEMENT 22 START UP PROCEDURE 23 sFILEING THE SYSTEM gt sre ee ee b S X 23 TESTING THE IGNITION SAFETY SHUT OFF sia S a n w SUR lt 23 STARTING THE HUMIDIFIER 2 2 2 240064 9E a AR 24 TAKING OUT OF OPERATION 24 INSTALLATION CHECKLIST
35. GS 500 600 Provide an adequate size gas supply line In all installations a certified manual shut off valve located outside the cabinet must be installed When black iron gas pipe is used a sediment trap must be located ahead of the humidifier gas controls See Figure 3 Leak test all gas connections external to the humidifier using a commercial soap solution made to detect leaks Bubbles indicate gas leakage Seal all leaks before placing the humidifier in operation WARNING Never use an open flame to check for gas leaks If a leak does exist a fire or explosion could occur resulting in damage injury or death The appliance must be isolated from the gas supply piping system by closing its individual manual shut off valve during any pressure testing of the gas supply piping system at test pressures equal to or greater than 14 w c 3 5 kPa Dissipate test pressure from the gas supply line before re opening the manual shut off valve to the appliance NOTES See pg 19 for additional Gas Piping information e Failure to follow this procedure may damage the gas valve Over pressured gas valves are not covered by warranty e DO NOT use Teflon tape on gas line pipe threads A flexible sealant suitable for use with Natural Gas and Propane Gas is recommended e Plan gas supply piping so it will not interfere with removal of gas valves or blower assemblies and front or side service doors e All gas piping should b
36. ISSV JUNI UIMOT 8 guno3s YO 2 ET NI 00 OL Selivd ANY INN N3IHOIL Z SINN ANY StIBHHSVWOIOO1 SNOJ IHL ONISN YAHIGINNH OL ANVIS NILSVA 9 IS38N3N HIIM OL ONVIS 3AOSV W L UISIGINNH YIMOT S ONVIS NI STIOH 3SV8 USHIGIANH JHL NI 370H IvHL OS ONVIS ANY 83 HIGINNH N I1V IIOIADH IHL SO 931 MOTHS ANVIS NOLLISOd Y NIN 8 6 L8 NI ZE WAWININ V SOOT IHL 3AO8V dn YAISIGINNH LSIOH NINO 5108 N3IHOIL dNVH 1 133HS NO NMOHS OL ONVIS 31gIN3SSV CIOVINVONN ANY INISIRId RIV 530919 TIV ANY ANVIS HOVANN SNOIONULSNI AT8IA3SSV 00 00 03 ANVIS IHL NMOHS 009 00SS9 ANY 00v 00 S9 03 AINO GISN SI NOILO3S 31QGIWN V GS Quick Reference Propane min Propane max Min free air opening in cm Input BTU s 45 000 60 000 BH Vent B Vent BH Exhaust Piping in cm 588 266 954 432 974 441 1340 607 1360616 354 160 485 217 529 239 659 298 703 318 0335 mw pp _ TT T_T j mm gt To tank Gallons litres 2 64 10 pp pense 1 TTT T_T TTT volts a c Transformer Required 120 LIMITED WARRANTY Walter Meier Inc and or Walter Meier Ltd hereinafter collectively referred to as THE COMPANY warrant for a period of two years from date of shipment that THE COMPA
37. MAN CAPACITY LIMIT CALIBRATE This field allows the user to select the menu language of choice English French German Here the user can select the language of choice for the menu displays To set the language highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to select the choice English French German Pressing enter saves the setting and returns the user to the previous menu DATE TIME UNITS FTBD HOURS LANGUAGE CONTROLS FTBD HOUR FTBD HOURS BLOWDOWN RATE WATER MANAGEMENT FLOAT CHECK CHANGE HOURS XXX CONTROL TYPE FILL CORRCTN CAPACITY LIMIT DRAIN CORRCTN CALIBRATE DRAIN COOL SMART NOTE ONLY ENGLISH AVAILABLE AS OF 05 03 Water Management This section allows the user to set time based parameters and adjust water control parameters FTBD Hours This section allows the user to set the frequency of full tank blowdowns FTBD FTBD s drains and re fills the entire contents of the humidifier after a preset accumulated operating time Run time is measured in steam hours weighted run time hours and can be adjusted from 0 hours feature off to 400 hours in 25 hour increments Once the FTBD time has expired the controller will wait until the FTBD hour to initiate the cycle This prevents random drains at times when they would be inconvenient DATE TIME UNITS FTBD HOURS LANGUAGE CONTROLS FTBD HOUR FTBD HOUR BLOWDOWN RATE WATER MANAGEMENT lt FLOAT CHECK CHANGE HO
38. NY s manufactured and assembled products not otherwise expressly warranted are free from defects in material and workmanship No warranty is made against corrosion deterioration or suitability of substituted materials used as result of compliance with government regulations THE COMPANY s obligations and liabilities under this warranty are limited to furnishing replacement parts to the customer F O B THE COMPANY S factory providing the defective part s is returned freight prepaid by the customer Parts used for repairs are warranted for the balance of the term of the warranty on the original humidifier or 90 days whichever is longer The warranties set forth herein are in lieu of all other warranties expressed or implied by law No liability whatsoever shall be attached to THE COMPANY until said products have been paid for in full and then said liability shall be limited to the original purchase price for the product Any further warranty must be in writing signed by an officer of THE COMPANY THE COMPANY s limited warranty on accessories not of Walter Meier s manufacture such as controls humidistats pumps etc is limited to the warranty of the original equipment manufacturer from date of original shipment of humidifier THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict accordance with a copy of the catalog and installation manual in effect at the date of purchase and by a contractor a
39. Potable 0 1500 0 12 0 14 6 5 7 5 0 25 Treated 0 100 0 1 0 1 7 7 5 0 25 e NORTEC recommends performing semi annual water analysis to ensure optimal performance e The humidifier is intended to operate on cold potable tap water e DO NOT use a hot water source to supply the humidifier Minerals will adhere more easily to surfaces and the fill valve s small flow regulating orifice could become plugged e Consider using a water softener Longer operating times between tank cleaning will be reached on softened water e Reverse osmosis RO water can provide very long times before cleaning is required since it is cleaner than softened water Deionized DI water may be used with all models Consult your NORTEC representative for quote on a water treatment system SAFETY INSTRUCTIONS Refer to front cover and page 1 of this guide FAULT CONDITIONS This appliance is equipped with a self diagnostic ignition module which identifies a fault code when it occurs Refer to the fault amp warning list on pg 60 GSTC MODELS Faults are indicated with a fault message on the display of GSTC models Recovery from lockout requires resetting of the humidifier This can be achieved by momentarily shutting off the power switch then turning it back on or by pressing the reset button on the logic control board mounted inside the electrical cabinet 28 A history of all faults is stored in memo
40. RROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING FLOAT CHECK FILL CORRCTN CHANGE VALUE XXX DRAIN CORRCTN CHANGE VALUE XXX DRAIN COOL ON OFF SMART ili Nortec Keypad Display Menu Structure AE User Setting 2 of 3 www humidity com USER SETTINGS 3 of 3 MAIN MENU SYSTEM STATUS DATE TIME UNITS CONTROL TYPE CONTROL TYPE PRESS LANGUAGE CONTROLS ENTER TO SERVICE LEVEL MENU IS WATER MANAGEMENT CONTROL INPUT CONTROL INPUT lt SELECT USER SETTINGS ENTER CONTROL TYPE CONTROL TRANSDUCER INPUT TRANSDUCER INPUT CAPACITY LIMIT CALIBRATE 1 VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING USE SET MAXIMUM SET MAXIMUM lt UP DOWN CAPACITY XXX CAPACITY XXX ARROWS WATER MANAGEMENT TO SET CONTROL TYPE MAXIMUM CAPACITY LIMIT CAPACITY DATE TIME UNITS CALIBRATE CALIBRATE LANGUAGE CONTROLS SIGNAL SIGNAL lt PRESS WATER MANAGEMENT CALIBRATE 4957 CONTROL TYPE SIGNAL CAPACITY LIMIT CALIBRATE ERE Nortec Keypad Display Menu Structure 1 User Setting 3 of 3 www humidity com CONTROLLER INTRODUCTORY SCREEN NORTEC GSTC 400 VERSION X XX SYSTEM LOCKOUT 06 07 03 9 30 Product name NORTEC GSTC 100 600 Version The display will indicate the revision level of the control software System Depending on system activity the display will toggle between LOCKOUT ACTIVE or STANDBY Date Time
41. The controller shuts OPEN WITH down and retries There are no limits to the amount of times BLOWERS ACTIVE this warning is generated WARNING AOW X On startup if the AP switch does not close within the proving SEE FAULT LIST AIR PROVING SWITCH X period After 3 tries a fault will be generated OPEN WITH BLOWERS ACTIVE WARNING BHW X Ifa blower RPM is above the RPM tolerance limit this SEE FAULT LIST BLOWER X warning is generated If it is above the RPM tolerance limit RPM HIGH for more than 10 seconds a fault will be generated WARNING BLW X If a blower RPM is below the RPM tolerance limit this SEE FAULT LIST BLOWER X warning is generated If it is below the RPM tolerance limit RPM LOW for more than 10 seconds a fault will be generated WARNING HMW In the user menu the user sets the maintenance time Once SEE FAULT LIST MAINTENANCE TIME this time expires this warning is displayed The maintenance HAS ELAPSED time is measured in weighted operational hours With switch 5 44 activated this warning will remain until the warning is reset in the User level WARNING UNW 6 Low water level has not been reached within expected time SEE FAULT LIST Too LONG TO FILL interval during initial fill sequence Unit will continue filling while warning is displayed A Water Fill Fail fault will be generated if the low water level is not reached after an additional length of time WARNING UNW C Keep warm feature has initiated combustion sequence at Warning message KEEP
42. Transformer Replacement 1 2 Shut off electrical power to the appliance Remove front access door Disconnect wiring connections from transformer leads labeling as required Remove screws 2 holding transformer Reverse above procedure to re install Figure 34 Transformer Assembly Fill Valve Replacement 1 Shut off electrical power and water supply to the humidifier 2 Remove the right side service access door 3 Remove all wiring connections to the fill valve 4 Remove the hose clamps on the fill valve outlets and remove hoses note the correct hose assignment 5 Remove the 2 screws securing the fill valve to the cabinet and remove the valve 6 Reverse the above sequence to install the new module 7 Leak test all water connections before re commissioning the humidifier Figure 35 Fill Valve Replacement Drain Pump Replacement 1 Drain the unit completely If the pump is broken use the auxiliary drain out port Shut off electrical power to the appliance Remove front and right doors Remove wiring connections to the pump Remove hoses attached to the pump Reverse above procedure to re install NOTE To avoid water spillage some water will be left on the tank bottom after manual draining use shop vac to remove left over water Figure 36 Drain Pump Assembly Fill Box Replacement Leak test all water connections before re commissioning the humidifier 558
43. UR CONTROL TYPE FILL CORRCTN CAPACITY LIMIT DRAIN CORRCTN CALIBRATE DRAIN COOL 56 FTBD Hour Works in conjunction with FTBD hours DATE TIME UNITS FTBD HOURS LANGUAGE CONTROLS FTBD HOUR BLOWDOWN RATE BLOWDOWN RATE CHANGE VALUE XX FLOAT CHECK STEAM OUTPUT Ai Y FILL CORRCTN CAPACITY LIMIT DRAIN CORRCTN CALIBRATE DRAIN COOL WATER MANAGEMENT lt Here the user sets the time of day 24 hour format when they want the FTBD to execute The time can be set to trigger the cycle during off hours when the humidity requirements are minimal The time is adjusted in one hour increments Blowdown Rate This parameter adjusts the frequency of blowdown cycles DATE TIME UNITS FTBD HOURS LANGUAGE CONTROLS FTBD HOUR FLOAT CHECK BLOWDOWN RATE CHANGE VALUE HH MM WATER MANAGEMENT lt FLOAT CHECK CONTROL TYPE Y FILL CORRCTN CAPACITY LIMIT DRAIN CORRCTN CALIBRATE DRAIN COOL Depending on water quality the blowdown rate can be adjusted from 5 to 50 The percentage is based on the steam production rate i e a 1096 BD rate will drain 10 kg of water for every 100 kg of steam produced The higher the mineral content of the water the higher the BD rate should be set Float Check This parameter sets the time of day the controller will force a float check Float checks are important to ensure the water level detection system is operating correctly The float check also tests the fill and drain system
44. WARM ACTIVE 75 output This occurs when keep warm feature has been will stop being SYSTEM DEMAND activated via dip switch settings the system demand is displayed once tank ACTIVATED AT 75 below minimum and the tank temperature sensor is temperature sensor registering cold open contacts indicates water is warm Keep warm feature can be disabled using dip switch settings 62 MMM 8002 lud sjueuoduiJo BUJSJU 1 5 55 ett ott GS Series Internal Components Spare Parts Number Description Part GS 100 GS 200 GS 300 GS 400 GS 500 GS 600 101 Cover Plate Clean Out Port 2523457 1 1 2 2 3 3 102 Gasket Tank Cover Plate 2524361 1 1 2 2 3 3 103 Secondary Safety Switch 1504832 1 1 1 1 1 1 104 Fill Box 2526152 1 1 1 1 1 1 105 Vacuum Break Valve 72 npt 1505959 1 1 1 1 1 1 106 P Trap 2526521 107 Dual Fill Valve 10 0 l min amp 0 35 l min 1505759 1 1 1 1 1 1 108 Heat Exchanger Gasket Single 2524405 1 Dual 2524403 1 2 2 3 3 109 Direct Vent Air Manifold GS 100 1506140 1 GS 200 1506141 1 GS 300 400 1506142 1 1 GS 500 600 1506143 1 1 110 Heat Exchanger Replacement Kit Mini 2528422 1 Single 2528423 1 1 Dual 2528424 1 1 2 2 3 111 Stack High Limit Switch 1506745 1 1 1 1
45. XX XX DATE TIME UNITS gt HH MM CHANGE DATE LANGUAGE CONTROLS WATER MANAGEMENT MM DD YY CONTROL TYPE MM DD YY CAPACITY LIMIT LB HR CALIBRATE SELECT UNITS LB HR KG HR Time of day To set the time of day highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to adjust the hours 24 hour format Pressing enter saves the setting and indexes the display to minutes Use the UP DOWN arrows to adjust the minutes Pressing enter saves the setting and returns the user to the previous menu Date To set the date highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to select the month Pressing enter saves the setting and indexes the display to number of the month Use the UP DOWN arrows to adjust the number Pressing enter saves the setting and indexes the display to year Use the UP DOWN arrows to adjust the year Pressing enter saves the setting and returns the user to the previous menu Units Here the user can select the unit of steam production rate To set the units highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to select the units LB HR or KG HR Pressing enter saves the setting and returns the user to the previous menu 55 Language Controls DATE TIME UNITS SELECT LANGUAGE SELECT LANGUAGE LANGUAGE CONTROLS lt ENGLISH ENGLISH lt WATER MANAGEMENT FRENCH FRENCH CONTROL TYPE Y GERMAN GER
46. XXX TANK DRAIN ENTER TANK PRE CLEAN DATE TIME BURNERS SHORT CYCLE DELAY In this area the customer can view the history of service maintenance performed on the humidifier SERVICE HISTORY X Y The service history stores the last 10 service periods X 7 service occurrence where 1 is the most recent 52 Y total number of recorded services up to 10 maximum STEAM HOURS XXX DATE TIME This field displays the steam hours and the date and time when the specific service X was performed SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE CLEAN DATE TIME BURNERS SHORT CYCLE DELAY TYPE OF FAULT Fault history In this area the customer can view the history of recorded faults for the humidifier FAULT HISTORY X Y The fault history stores the last 54 system faults X fault occurrence where 1 is the most recent Y total number of recorded faults up to 54 maximum type of fault and date time A description of the fault type is displayed along with a date and time stamp when the fault occurred SERVICE INTERVAL SERVICE HISTORY THIS WILL DRAIN THIS WILL DRAIN FAULT HISTORY CONTENTS OF TANK lt CONTENTS OF TANK TANK DRAIN CONTINUE lt TANK PRE CLEAN BURNERS SHORT CYCLE DELAY Tank Drain The tank drain feature when activated will activate the drain valve for a fixed period of time depending on unit size To drain the tank press enter
47. and will report any problems detected To set the time of day highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to adjust the hours 24 hour format Pressing enter saves the setting and indexes the display to minutes Use the UP DOWN arrows to adjust the minutes Pressing enter saves the setting and returns the user to the previous menu DATE TIME UNITS FTBD HOURS LANGUAGE CONTROLS FTBD HOUR DRAIN COOL BLOWDOWN RATE XX WATER MANAGEMENT lt FLOAT CHECK CONTROL TYPE Y FILL CORRCTN CAPACITY LIMIT DRAIN CORRCTN CALIBRATE DRAIN COOL 57 Fill CORRCTN correction Used for adjusting the fill rate Adjustments to be made under factory direction only Drain CORRCTN correction Used for adjusting the drain rate Adjustments to be made under factory direction only Drain Cool The customer can select the type of drain water tempering they require depending on local plumbing codes The customer can select ON OFF or SMART ON whenever the drain valve is activated through software the fill valve will automatically activate This is the factory default setting but is the most wasteful of water since it will activate even if the drain water is cool OFF The drain water is never tempered This can be used where plumbing codes permit Some process waters are very expensive so the customer may choose to temper the drain water through other means SMART The humidifier has a tan
48. ave any questions If contaminants exist isolate the unit from the contaminated space DIRECT VENT GUIDELINES Installation of the combustion air supply line must be carried out by adequately qualified personnel All local regulations relating to the provision of air supply systems must be observed and adhered to The maximum pipe length for the air supply line and exhaust is equivalent to 70 21m The vent pipe diameter must be maintained over the overall length of the vent All air piping must be listed type for direct vent application with sealed joints and seams such as Z flex The air supply line should be approximately as long as the flue gas venting and must be supported at every 5 ft 1 5 m and additionally at every pipe bend The air supply line must be installed with air supply terminals provided At low temperatures water condensation can form on the outside of the pipe To prevent this it is recommended that the supply air line is insulated and an in line heat is added Consult factory Attach the air supply line to the manifold using a hose clamp or hose coupling if required See Figure 4 WARNING Air supply line should not obstruct any services going to the humidifier front and right side cabinet panels WARNING BH Type venting must be used in a direct vent application The air intake terminal and the flue gas terminal must end at an outside location See Figure 5 Air Piping Insulated
49. been selected 0 no 1 yes Blowdown rate This field displays the selected blowdown rate Full tank blowdown This field indicates if the feature has been selected 0 no 1 yes SERVICE LEVEL SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE CLEAN BURNERS SHORT CYCLE DELAY The service level area is where service related tasks are performed Below is description of each field and what can be performed in them When parameter requires a change press the two arrow keys and enter the password 0335 As long as you remain in this section you will not need to enter the password more than once SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE CLEAN BURNERS SHORT CYCLE DELAY Service interval MAINTENANCE TIME SERVICE INTERVAL XXX HOURS XXX HOURS lt MAINTENANCE DUE XXX HOURS CLEAR REMAINDER In this area the customer can set service interval for humidifier MAINTENANCE MAINTENANCE TIME XXX HOURS This field displays the user selected MAINTENANCE time To change the time selected enter the user code and adjust the time in SET MAINT TIME 0 3000 hours 0 disabled MAINTENANCE DUE XXX HOURS This field displays the time remaining until the next service interval To reset the MAINTENANCE due time enter the user code and select CLEAR REMINDER Service history SERVICE INTERVAL SERVICE HISTORY SERVICE HISTORY X Y FAULT HISTORY STEAM HOURS X
50. carefully remove the burner assembly Handle the burner only by the metal surfaces Do not grip the ceramic matting as grease dust or dirt can affect the performance of the burner Reverse the sequence above to re install the burner after cleaning or if necessary replace Figure 28 Burner Assembly Hold Burner only on metal pipe S e Ceramic Matting DO NOT TOUCH with new burner Inspect and replace any gaskets that may be damaged Tighten the 4 brass nuts of burner mounting plate to torque of 95 in Ib Leak test the gas train before re commissioning the humidifier Removal and Installation of the Combustion Blower 1 Shut off electrical power and gas supply to the humidifier Remove the right side service access door Disconnect all wiring to the combustion blower gas valve and air proving switch note the connector assignment Undo the coupling on the flexible gas hose and disconnect the gas hose from the gas valve Undo the 2 screws that mount the gas valve air inlet assembly to the blower and remove the assembly Undo the 2 screws of the fan board mounting bracket if present and remove bracket leaving electronic board and igniter jump start module s attached Undo the 4 nuts on the blower outlet and remove blower Reverse the sequence above to install the new combustion blower Inspect and replace Figure 29 Combustion Blower Replacement any gaskets that ma
51. ch GS Outdoor model by Nortec including rain cap and storm collar All venting components external to the unit are shipped with the unit and must be installed on site Refer to Figure 19 for venting components Figure 19 Exhaust Outdoor Units Rain Cap All Venting provided lt by Nortec lt gt Extension Pipe Storm Collar e Each vent length and the rain cap have a built in mechanical locking band and gasket Simply push together each component to the stop bead which provides an air amp water tight seal Then tighten the integrated locking band on each component to complete the installation of the exhaust venting e The rain cap must extend at least 2 feet above any ridge within 10 feet of the unit The exhaust venting can be extended using additional vent lengths purchased from Nortec ELECTRICAL INSTALLATION e Power and control wiring is to be routed into the humidifier through the pipe chase in the base pan of the outdoor models located in the burner area e Installation details for primary and low voltage control wiring are the same as for indoor units e Afield supplied NEMA rated weatherproof disconnect switch must be mounted external to the GS Outdoor unit to allow for power interruption during servicing and or maintenance A mounting plate located on the front of each outdoor model above the electrical access door is available for mounting of the disconnect switch
52. cleaned at least once every season to maintain optimum operation It may be necessary to increase the frequency of cleaning or increase the blowdown setting in areas of hard water or prolonged annual usage see the Blowdown Setting section of this manual Cleaning of the humidifier is mandatory and must be performed on a regular basis To reduce cleaning time use the pre cleaning sequence on the GSTC model to help evacuate mineral debris from the unit Check the controller operation to activate this feature The combustion chamber walls are usually self cleaning The mineral buildup flakes off due to the expansion and contraction and violent boiling action during on off cycles and settles to the bottom of the tank The combustion end block will have scale build up as will the heat transfer tubes These surfaces must be cleaned at regular intervals Frontal port cleaning will be done through the front door of the unit Remove cabinet door on the left of the LCD display using a Philips screwdriver Remove the side tank port opening by removing the 3 16 nuts key or socket is needed Additional clean out ports are available on the top of the 300 400 and 500 600 Ib h tanks To access these ports remove the top cabinet panel using a Phillips screwdriver Remove the top clean out ports my removing the nuts Removal of the heat exchanger s is not necessary to clean the inside of the tank Scoop out loose scale with a small
53. ds Avoid areas where local experience indicates that condensate drip may cause problems such as above planters patios or over public walkways or over an area where condensate or vapor could create nuisance or hazard or could be detrimental to the operation of regulators relief valves or other equipment Refer to the vent manufacturer s installation instructions The vent terminal must be installed in the same atmospheric pressure zone as the combustion air inlet of the humidifier If this is not possible as in cases of positive or negative room pressures the humidifier should be installed with the direct vent option ELECTRICAL PRIMARY WIRING All work concerning the electrical installation must be performed by qualified personnel WARNING The electrical parts inside the humidifier are very sensitive to electrostatic discharge Appropriate measures against electrostatic discharge ESD protection must be taken when carrying out installation work e The humidifier should only be connected to primary power mains power after all installation work has been completed e An external disconnect switch must be installed close to the unit to allow for power interruption during servicing and or maintenance e Humidifiers require field wiring to primary voltage terminal blocks Power requirement must be 120V or 208 240 Vac 15A separately fused circuit single phase Use only copper wire with a minimum 70 C 158 F tem
54. e This venting category cannot be used in direct vent applications Installation as a Category Appliance e This venting system can be installed horizontally or vertically and can terminate on a rooftop or sidewall provided the NFGC Nation Fuel Gas Code and CAN CGA B149 codes are followed The venting manufacturer instructions must also be followed See Figure 6 77 amp 8 e This venting must be used in all direct vent applications e This category installation may not be common vented with any other natural draft gas appliance or power assist appliance The humidifier cannot share a chimney flue servicing an appliance designed to burn solid fuel e Venting must be UL or UL CSA listed tested to ULC 5636 Standard Venting may be BH or L vent Special gas vent shall be listed and installed in accordance with the terms of the special gas vent listing and the manufacture s instructions The special instructions listed below should be followed as well e All joints must be sealed using high temperature RTV silicone BH Vent Manufacturers 1 Flex L International 2 Fas N Seal 3 Heat Fab Inc 4 Z Flex e The gas humidifier is supplied with the following exhaust outlets GS 100 3 GS 200 4 GS 300 400 5 GS 500 600 6 e The venting must remain the same diameter throughout the installation 41 WARNING Provide screen or barrier to prevent personal injury in areas where inadvertent personnel con
55. e adequately supported to prevent any strain on inlet piping The gas valve is provided with pressure taps to measure gas pressure upstream and downstream manifold pressure The minimum gas pressure shown is for the purpose of input adjustment A 1 8 NPT plugged tapping accessible for test gage connection must be installed immediately upstream of the gas supply connection to the appliance COMBUSTION AIR REQUIREMENTS Provide for adequate combustion and ventilation air in accordance with Sections 8 3 Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 1 or Sections 7 2 7 3 7 4 of CAN CGA B149 Installation Codes or applicable provisions of the local building codes The required free area of supply air opening is 13 in sq 8 387 mm for GS 100 23 in sq 14 839 for GS 200 35 in Sq 22 581 mm for GS 300 47 in Sq 30 323 mm for GS 400 59 in Sq 38 064 mm for GS 500 71 in Sq 45 806 mm for GS 600 Cabinet top and bottom contain air openings to provide combustion air to the forced draft blower DO NOT BLOCK THESE OPENINGS Excessive exposure to contaminated combustion air will result in safety and performance related problems Known contaminates include halogens ammonia and chlorides excessive dust lime or dirt Excessive exposure of electronics to the contaminants will also result in performance related problems Contact NORTEC Technical Services if you h
56. e fill FLOAT CHECK powered and in an operating or standby valve and drain valve via the condition the controller will test the water diagnostics screen level detection circuit If the test fails this fault Float board is defective is displayed Consult factory FAULT WLF If the controller detects two or more float level Miswired float board ILLEGAL FLOAT readings which are not expected ex Switch 1 Defective float board COMBINATION and 3 ON or switch 1 2 and 3 ON this fault Consult factory will be recorded FAULT FDF The controller monitors the water level as it Float board defective FILL VAVLE ON fills and drains It expects to see the levels Contact agent for replacement float DETECTION increase logically 1 2 3 4 5 If the water level board INCONSISTENT increases and jumps a step 1 2 4 5 this fault will be generated The same holds for water level decreasing FAULT KWF During a keep warn cycle if the tank Ensure that the tank temperature KEEP WARM TIME temperature sensor does not open within a sensor is connected OUT certain time window this fault is generated Defective tank temperature switch TOO LONG TO Contact agent for replacement switch HEAT FAULT OTF If input TBS 4 on the logic board goes low Do not operate and consult the factory STACK OVER no 24 Vac detected this fault will be TEMP generated This could indicate either the tank SWITCH TRIPPED over temperature switch has opened or the stack over tempera
57. e humidifier will go into standby mode until the next call for humidity demand rises above minimum 96 at which time the unit will again begin the combustion sequence TAKING OUT OF OPERATION If it is required that the humidifier be taken out of operation e g for service or end of season shut down proceed as follows e Ifthe unit is firing remove the demand signal open the security loop allowing the burners to shut off and the blowers to perform a post purge of the heat exchangers before shutting off e Switch the main power switch from On to Off and then to the Drain position The drain pump will be energized and the tank will begin to drain e Once the tank has completely emptied shut off the drain switch e Close the shut off valve in the gas supply line GS INSPECTION CHECK LIST HUMIDIFIER MOUNTING L Verify proper clearances around the unit L Humidifier mounted level L Humidifier properly secured to stand and stand bolted to floor LI All service doors accessible L Roof curb sized correctly Outdoor Model Only GAS PIPING L Correct gas line size installed L Certified manual shut off valve and union installed L Sediment trap installed L Gas piping leak tested L Air purged from lines L Proper gas supply pressure L Regulator dedicated for each gas unit EXHAUST GAS VENTING L Comply with local regulations L Proper venting materials used B or BH refer to gas codes L Maximum vent length of 100 feet
58. e site e Hardness Measured in gpg grains per gallon Follow the instructions on each individually wrapped test strip and use the colour chart provided The recommended operating range for hardness is 0 gpg to 12 gpg Note High hardness along with high silica may increase the service intervals of the system Consult the factory if this condition exists at the site e pH Follow the directions on the test strip bottle The recommended operating range for pH is 6 5 to 7 5 on the colour scale Consult the factory if outside these parameters e Chlorides Measured in ppm parts per million Follow the directions on the test strip bottle The recommended level for chlorides is not to exceed 25 ppm NOTE Failure due to chloride corrosion is not covred under Nortec s standard warranty Consult factory for more information e High levels of chlorides will attack stainless steel Consult the factory for additional information if your water contain high levels of chlorides e Conductivity Measured in micromhos Follow the directions for the conductivity pen found inside the box Multiply the digital reading by 1 5 The recommended operating range for conductivity is 0 1500 micromhos Consult the factory is you measure outside these parameters Tech Water Water Hard Silica Alkalin Chlor nology Type Cond ness Range Range Range Range Range Gas GPG PPM pH PPM Fired hos
59. ed OFF Function Enabled Factory set ON KEEP WARM 3 DAY DRAIN FUNCTION SW5 7 Function Enabled ON Function Disabled Factory set 3 day drain OFF MAINTENANCE GSP MAINTENANCE INTERVAL GSP SW3 8 500 hour Factory set OFF 1000 hour ON ANALOG CHANNEL 1 Input Range SW1 SW4 1 SW 4 2 0 10V input OFF OFF OFF 0 5V input OFF ON OFF 2 10V input OFF OFF ON 1 5V input OFF ON ON 0 20mA input ON OFF OFF 0 10mA input ON ON OFF 4 20mA input ON OFF ON 2 10mA input ON ON ON ANALOG CHANNEL 2 Input Range SW1 2 SW4 3 SW 4 4 0 10V input OFF OFF OFF 0 5V input OFF ON OFF 2 10V input OFF OFF ON 1 5V input OFF ON ON 0 20mA input ON OFF OFF 0 10mA input ON ON OFF 4 20mA input ON OFF ON 2 10mA input ON ON ON 39 INPUT CHANNEL DUAL CHANNEL FUNCTION SW4 5 One Channel Input OFF Dual Channel Inputs ON TIME PROPORTIONING TIME PROPORTIONING SW4 7 Disabled Factory set OFF Enabled ON BLOWDOWN GSP BLOWDOWN SW5 1 SW 5 2 SW5 3 596 ON OFF OFF 1096 OFF ON OFF 1596 ON ON OFF 2096 OFF OFF ON 25 Factory set ON OFF ON 30 OFF ON ON 35 ON ON ON MAINTENANCE SHUTDOWN MAINTENANCE SHUTDOWN FUNCTION SW5 4 Unit will shutdown 72 hours after service time expired by gen
60. ed to an air handler on the roof or pipe chased external to the unit through the rooftop to enter the building e All steam lines must be insulated to reduce losses e For steam line installation guidelines consult the distribution system installation manual Steam Distributor Installation Manual Form 231 and SAM e Short Absorption Manifold Form 249 Figure 23 Steam Connection BH Venting Supplied Cuff hose and clamps provided ary Steam line Insulation recommended 222 PRINCIPLES OF OPERATION Combustion The combustion system is based on a fully modulating forced draft combustion air blower s a negative pressure regulated gas valve and a 10096 premix burner On a call for humidity the combustion air blower s starts and creates a negative pressure s across an orifice located at the air inlet The blower is energized to purge the system then the hot surface ignitor is activated During this time the electronic ignition module does a diagnostic check of safety systems including the air proving switch which senses the negative pressure at the air inlet orifice After the function of the safety systems has been verified the gas valve s will open and the gas air mixture is ignited by the hot surface ignitor If a flame is sensed by the flame sensor the gas valve s remains open and combustion continues If a flame is not sensed the above sequence is repeated to a maximum of
61. em of the GS humidifier Some local plumbing codes may still require the installation of a double check valve on the fill line to the humidifier to prevent contamination of the supply water system Verify with local codes and install if necessary Figure 11 Plumbing Connections 1 2 NPT Water Supply Nortec Union by others Check Val o Valves by others if required Manual Shut off by others 3 4 O D Drain Hose clamp by Nortec Manual Shut off by others Union by others Funnel with Air Gap by others connections should be installed in accordance with local plumbing codes 1 2 NPT Female Auxiliary Drain FILL WATER SUPPLY LINE e Each unit is supplied with an adapter for the fill valve Fill rate 10 l min all unit sizes Size of piping is a minimum 72 copper recommend 27 up to within 4 feet of unit DRAIN LINE e The humidifier is equipped with a 4 O D Unthread ed drain outlet connection on the side Standard fill valves are sized for water pressure ranging from 30 to 80 psig ideally 55 to 60 psig For other pressures consult factory This pressure should be measured at the humidifier if the water pressure is suspect 15 of the humidifier vacuum break valve is installed internal to the unit on the drain line The drain water line must be piped to drain funnel to provide an air gap before connection
62. ere freezing may occur e f humidifiers are mounted on a roof a properly ventilated temperature controlled above freezing weatherproof enclosure must be used e DO NOT mount humidifiers on vibrating surface Consult factory e The humidifier shall not be installed directly on carpeting tile or other combustible material other than wood flooring e Some insulating materials may be combustible Prior to installing this appliance examine the area for insulating material If this appliance is installed in an insulated space it must be kept free and clear of insulating materials If insulation is added after the appliance is installed it will be necessary to examine the area again GAS PIPING Installation of piping must be in accordance with local codes and ANSI Z233 1 National Fuel Gas Code in the United States or CAN CGA B 149 Installation Codes in Canada The following table indicates the maximum and minimum allowable gas pressures for the Gas Humidifier INCHES W C GAS MIN MAX Natural 4 5 9 0 Propane 9 0 13 0 Figure 3 Gas Connection Inlet coupling supplied Shut off Gas Valve A by others e s a I vi P AS M cal 4 lt Q 6 AN Union by others Sediment Trap by others The gas inlet pipe size to the appliance is 1 2 NPT for GS 100 3 2 NPT for GS 200 1 NPT for GS 300 400 1 1 2 for
63. et Condensate N ee Trap 2 ft Min N 3 Min Steam Outlet il a il enes tee and trap nil must be installed Take the condensate to a floor drain or a condensate pump BH type double wall vent with double wall connectors is required for category Ill appliances Note These are guidelines only follow the local and or national codes in your respective area Figure 9 Co venting Application Using B Vent Only UL Listed Cap Required Y B type double wall ven with double wall connectors is required for category I serving two more gas appliances Exhaust venting outlet de p x Condensate Tee Steam Outlet Condensate tee and trap must be installed Take the condensate to floor drain or a condensate pump Category gas appliance uses B type venting Follow local and or national codes for venting installation Note These are guidelines only Follow local and or national codes in your respective area e For any vent lengths over 20 feet long insulate the vent pipe to reduce the amount of condensate that could form in the flue gases e When the venting passes through a cold area or location that has large amounts of air passing
64. etent with these codes and the local requirements of the jurisdiction must carry out the installation Proper removal of combustion gases must be assured and building materials must be protected from degradation by flue gases Never mix venting types B to BH or visa versa Never use two different manufacturer s equipment for the same chimney All vent runs should be as direct as possible with no more than 6 elbows in the system Maintain an upward slope of per ft on all horizontal vent pipe runs This gas humidifier may not be used in conjunction with a power venter or draft inducer Figure 6 Horizontal Venting Using a Direct Vent Application Using BH Type Only Wall N BH type vent using double wall vent 3 P Hangers with all joints being air and water tight 2 3 Reference local and or national codes e before installation of the vent m Condensate Exhaust venting must Tee 2 ft be min 4 ft max 6 ft Condensate tee and trap must to floor drain or condensate pump es Terminations in distance apart from unit for direct venting Trap Mi lied with be installed Take the condensate P 3 Min d the fresh air intake M IS WA 7 Exhaust venting outlet b Direct vent Steam Inlet Outlet al al lo
65. g on the environment the burner s may require removal of lint or grease laden dust periodically This may be achieved by removing the burner and applying pressurized air to the external surface of the material Refer to the Servicing Section related to burner removal Flame Sensor Flame current is the current which passes through the flame from the sensor to ground The ignition module must detect minimum flame current of 0 7 microamps or flame proving lockout will occur To measure flame current connect an DC micrometer to the FC FC terminals on the module Meter should read 0 7 uA or higher If meter reads below 0 on scale meter leads are reversed Disconnect power and reconnect meter leads for proper polarity 81 NOTE Proper polarity of supply voltage to the unit is necessary for flame sensing to occur Oxidation on flame sensing rod can reduce measured current The oxidation can be cleaned from the sensing rod using steel wool or an emery cloth Igniter Check If the igniter is suspected of being defective then the following test may be carried out 1 Ensure that the power and gas is switched off before servicing 2 Totest the igniter disconnect the igniter leads from their terminal connections 3 Using a multimeter set the Ohm s scale and place one of the meter leads on one of the igniter wire ends and the other meter lead on the end of the other igniter wire Gas Valve Settin The gas val
66. gn based on leading edge technology The GS is designed to provide clean steam humidification at an economical price The GS Series humidifiers are designed exclusively for humidification in ventilation systems or direct room humidification Any other type of application without the written consent of Nortec or your Nortec agent is considered as not conforming with the intended purposes The manufacturer supplier can not be made liable for any damages resulting from improper use MODEL DESIGNATION The unit specification label indicates the model of gas humidifier according to the following chart GS TC 100 N DV OC PRODUCT LINE Gas Steam Humidifier Total Controller c w KEYPAD Economical Humidifier size Ibs hr 200 300 400 500 600 FUEL N NATURAL GAS PROPANE GAS DIRECT VENT lt OPTION OUTDOOR MODEL MODEL SPECIFICATION MODEL GS 100 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS IN W C NATURAL GAS MAX 140 000 105 0 05 MIN 45 000 25 0 05 PROPANE MAX 140 000 105 0 35 MIN 50 000 25 0 35 MODEL GS 200 SPECIFICATIONS FUEL BLOWER SPEED INPUT BTUH STEAM CAPACITY LBS HR MANIFOLD PRESS
67. gure 12 for connection details e For steam line installation between the humidifier and distribution system consult the distribution System installation manual Steam Distributor Installation Manual Form ZXX 231 and SAM e Short Absorption Manifold Form 249 e The GS series of Gas Steam humidifiers can develop steam pressures up to 12 w c to overcome duct and steam line pressures An enclosed trap on the drain line prevents steam from going to drain Duct pressures above 12 will cause steam to exits through the drain line Consult factory 16 Figure 12 Steam Line Connection Steam Line Snap on Insulation e Hose cuffs amp clamps supplied 7 aos GS Outdoor Installation GS Outdoor units are CSA certified for outdoor installation and come complete with exhaust venting and internal ventilation cooling for the electronics Heaters for freeze protection are standard with outdoor units All installations must conform with local building codes or in the absence of local codes with the National Fuel Gas Code ANSI 7223 1 in the United States or CAN CGA B149 Installation codes in Canada NORTEC can not accept responsibility for installation code violations MOUNTING e Typical rooftop installations are shown in Figure 13 amp 14 e The GS Outdoor unit comes standard with cutouts in the base to allow for lifting by a forklift When lifting by this method ensure that the forks extend ac
68. if the AP switch does Check that blue hoses on the Air AIR PROVING not close within the proving period this fault Proving switch have not come loose SWITCH X OPEN will be generated Check that wires on the Air Proving WITH switch are on the N O contacts BLOWERS ACTIVE If available swap Air Proving switch with another and see if the fault follows the air proving switch if so replace switch Consult factory FAULT ACF X On initial startup if any of the A P switches are Ensure that wiring on the air proving AIR PROVING closed this fault will be generated switch is on the N O contacts SWITCH X Ensure that there is no continuity CLOSED WITH between the switch with the wires off BLOWERS if so replace switch INACTIVE Ensure that there is not a strong positive pressure in the room holding the switch closed Consult factory FAULT BHF X If the blower RPM is above the RPM tolerance Check wiring to lead blower and BLOWER X for more than 10 seconds this fault is ensure a good connection RPM HIGH generated and the humidifier stops Check lead blower for any restrictions by testing it in the diagnostics screen Consult factory FAULT BLF X If the blower RPM is below the RPM tolerance Check wiring to blower X and ensure BLOWER X for more than 10 seconds this fault is a good connection RPM LOW generated and the humidifier stops Check blower X for any restrictions by testing it in the diagnostics screen Consult factory FAULT BNF X On sta
69. ing manufacturer for proper hook up Vent connectors shall not be connected into any portion of a mechanical draft system operating under positive pressure Use only double wall aluminum inner wall B vent Single wall venting can not be used due to the increased wet time in the lining If the vent connector attaches to a lined masonry chimney the chimney must be sized and installed according to the provisions of the National Fuel Gas Code or Canadian CAN CGA B149 standards An approved venting manufacturers termination cap for the stack outlet must be used The maximum flue temperature is 400 degrees F Normal operating range is 360 to 380 degrees F When the category installation is selected it may be commonly vented with other listed gas fire appliances Total input rates of all appliances will determine the vent size the chimney must be sized and installed according to the provisions of the National Fuel Gas Code or Canadian CAN CGA B149 standards maximum of 4 gas appliances may be common vented on the same floor Multiple story common venting is not recommended Refer to the vent manufacturers instructions for proper clearances to combustibles Figure 10 Exhaust Connection Female to Female Adapter by others e This appliance should not be connected to chimney flue servicing a separate appliance designed to burn solid fuel Never connect this humidifier to a chimney servicing a fireplace
70. ion must be performed to ensure that the installation and all water gas steam electrical and venting connections to the humidifier conform to the guidelines in this manual Complete the checklist on pages 25 amp 26 before commissioning the unit 23 Qualified personnel must correct any deficiencies with the installation before commissioning takes place Prior to starting the humidifier it is necessary to ensure that no dirt or dust has accumulated in the electronics compartment or the burner area A build up of dust on the electronics can cause overheating and early failure of the components If necessary clean the area around thehumidifier to prevent contaminants from being drawn into the combustion blowers FILLING THE SYSTEM Before the GS unit will initiate combustion it must be filled with water and the internal controller must have completed a self test to verify that the water fill System level controller and drain pump are functioning correctly e Close the shut off valve in the gas supply line e Remove any demand signal to the unit e Open the shut off valve in the water supply line e Switch the humidifier on e The fill valve will energize and the tank will begin to fill fill time is approximately 10 to 30 minutes depending on unit size Once the float chamber has registered low water level the unit will perform an internal test of the fill and drain system as described in the Water Management section
71. k sensor that communicates the water temperature to the controller If the water is hot during drain cycles the fill valve will be activated This is the most water smart of the settings DATE TIME UNITS CONTROL TYPE LANGUAGE CONTROLS CONTROL INPUT CONTROL TYPE TRANSDUCER INPUT CONTROL INPUT gt WATER MANAGEMENT TRANSDUCER INPUT CONTROL TYPE Y CAPACITY LIMIT CALIBRATE Control Input This section is used for configuring the controller for a controller input or a transducer input To select control input highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to select control input The controllers dip switches then determine the type 0 10 Vdc 0 20 mA etc of control signal to process PROPORIN CHI 6000 range 0 65535 INTEGRAL CHI 4000 range 0 65535 DERIVATIV CH 2000 range 0 65535 PID BAND CH 1 30 range 0 100 DATE TIME UNITS CONTROL TYPE 2 range 0 65535 LANGUAGE CONTROLS PID CONSIANIS CH1 PROPORIN CH2 6000 range 0 65535 WATER MANAGEMENT CONTROL INPUT PID CONSTANTS CH2 INTEGRAL CH2 4000 rus DERIVATIV CH2 2000 1 range 0 l CONTROLIVPE lt V TRANSDUCER INPUT PD LEARN PID BAND 2 3096 range 0 10096 CAPACITY LIMIT CALIBRATE PID LEARN 1 Activates self test algorithm 58 Transducer Input This section is used to configure the controller for transducer signals In this section you can adjust the proporti
72. ment 11 Leak test the gas train before re commissioning the humidifier Air Switch Replacement 1 2 Shut off electrical power to the appliance Remove right side service panel Remove wiring connections to switch Remove pressure hose s from switch noting proper location Figure 31 Air Switch Replacement 5 Remove screws 2 holding the switch 6 Reverse above procedure to re install Float Chamber Replacement 1 Drain the contents of the tank and then shut off electrical power and water supply to the humidifier 2 Remove the left front service access door 3 Remove the cable connection to the float board 4 Remove the hose clamps on the float chamber and remove all hoses note the correct hose assignment 5 Squeeze both sides of the mounting bracket to release it from the slots in the support bracket behind the float chamber 6 Reverse the above sequence to install the new module 7 Leak test all water connections before re commissioning the humidifier Figure 32 Float Chamber Replacement Ignition Module Replacement 1 2 Shut off electrical power to the humidifier Remove the front electrical access door Disconnect all wiring connections to the ignition module labeling as required Remove the 2 screws securing the ignition module and remove Reverse the above sequence to install the new module Figure 33 Ignition Module Assembly
73. nly visible if the unit is configured for dual modulation This field will display the modulation demand input on that channel Capacity limit This field displays the user adjusted capacity limit set for the humidifier SCREEN 2 SYSTEM DEMAND XXX BURNERS ACTIVE X X XXXLB XXXLB OUTPUT BURNER TOTAL OUTPUT System demand This field displays the total system demand as a percentage Burners active This field displays the number of active burners and the number of available burners 50 Output Burner This field will display the actual output of steam generated by each burner kg hr or Ibs hr Total output This field will display the total system steam output kg hr or Ibs hr SCREEN 3 WATER LEVEL X FILL VALVE ON OFF DRAIN VALVE DRAIN COOLING SMART Water level This field displays the present water level detected by the float system Fill valve This field displays status of fill valve on off or pulsed Drain valve This field displays status of drain pump on or off Drain cooling This field displays the user or factory default setting OFF fill will not activate when drain is activated ON fill will activate whenever the drain activates SMART fill will activate only when drain water is hot SCREEN 4 SERVICE INTERVAL XXX HOURS REMAINING XXX HOURS START DATE MM DD YY Service interval This field displays the user or factory default
74. o not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water DELIVERY The standard delivery includes e Gas Steam humidifier equipped with desired options e n a bag you will find Manuals Adapter fittings for water connection Steamhose for steam outlet with clamps Hose and clamps for drain connection e The GS Indoor Series offers an optional telescopic stand mounted inside the unit legs Stand cross bracing are shipped with the unit e The GS Outdoor Series comes with all required venting to be installed on site e Desired accessories ordered RECEIVING amp UNPACKING EQUIPMENT e Check packing slip to ensure ALL material has been delivered e All material shortages are to be reported to NORTEC within 48 hours from receipt of goods NORTEC assumes no responsibility for any material shortages beyond this period e Inspect shipping boxes for damage and note on shipping waybill accordingly e After unpacking inspect equipment for damage and if damage is found notify the shipper promptly e All NORTEC products are shipped on an F O B factory basis Any and all damage breakage or loss claims are to be made directly to the shipping company GENERAL SPECIFICATIONS The NORTEC GS Series humidifier is a completely new patented desi
75. onal integral and derivative constants There is also PID learn algorithm which will tune the various PID constants for optimal performance Capacity Limit In this section the customer can adjust the maximum output of the humidifier between 25 100 To adjust the maximum capacity highlight the selection then enter the user code 0335 Press enter Use the UP DOWN arrows to adjust the output between 25 and 100 DATE TIME UNITS SET MAXIMUM LANGUAGE CONTROLS CAPACITY XXX SET MAXIMUM CAPACITY XXX WATER MANAGEMENT CONTROL TYPE CAPCITY LIMIT Calibrate This selection is used to fine tune the operating range of the controller Some modulation signals are not precisely as stated e g a 0 10 controller could actually modulate over a 0 11 volt range This selection should only be used by factory trained individuals 59 FAULT LIST GSTC fault GSP fault code Description of fault Troubleshooting displayed displayed FAULT NBF Once the GS controller detects an ignition Check red LED s on all modules for NO BURNERS module fail it will index to the next available flashing fault code AVAILIBLE ignition module If all ignition modules have Ensure there is gas supply to the failed or there are none available in the case of humidifier a 100 unit this fault will be generated Ensure that the burners have not been disabled in the software Consult factory FAULT AOF X On startup after 3 tries
76. over the venting it should be insulated to prevent condensation from forming inside the venting e Vent pipe passing through walls floors and ceilings must be installed with the proper clearances from combustible materials and venting manufactures fire stop equipment e The venting shall not pass through any circulation air duct or plenum WARNING Provide a screen or barrier to prevent personal injury in areas where personnel may come into contact with hot vent pipes e A drip T or flue box condensate port should be used for condensate removal When a condensate drain is used it will be necessary to install a trap to prevent flue gases from escaping Install a trap with a minimum 12 standing water column Prior to activating the appliance ensure that the trap is filled with water and that the drain terminates in accordance with local plumbing codes Never vent into a unlined masonry or concrete chimney Chimney or vent should extend at least 3 1 m above a roof and at least 2 6 m above any ridge within 10 3 m of the chimney Local codes apply Install venting so as to prevent accumulation of condensate and have a means for condensate removal Plastic PVC CPVC and HTPV special gas vents are not approved for use with this appliance The vent must terminate at a sufficient height above the roof to prevent blockage by expected snowfall e Vent pipe must be secured with hangers or pipe s
77. perature rating Wiring can be fed through 7 8 hole on the bottom or the top of the control compartment See Figure H1 e When installed the appliance must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 and or the CSA C22 1 Electrical Code if an external electrical source is utilized e External wiring sizes must be in accordance with NEC and or CEC and existing local electrical codes and by laws LOW VOLTAGE CONTROL WIRING All GS models require at least one type of input control signal for unit operation Refer to the sections below that detail the types of controls that can be used with each model Low voltage control terminal strips are provided in the electrical compartment Internal sides are factory wired External sides are to be field wired Refer to the specific control wiring diagram supplied with each unit 12 Field wiring from humidistat to humidifier and between devices should be shielded 18 AWG or heavier and kept as short as possible Controls are available from NORTEC as accessories and can be ordered with the humidifier Controls by others may also be used as long as they meet the criteria noted below The following is a summary of the common types of controls that may be used with NORTEC Gas Humidifiers Wall or Duct Mounted Control On Off Humidistat Wired to make on drop in humidity break on rise to
78. ph Dedicated p L2 Circuit Terminal Neutral Or Block Disconnect O Note 120V 1 phase Supply 120V 1phase between hot and neutral E 240V 1phase between two 120V 1ph supply x N T T 1 Ground Wire 1 Ground Ground x Leg 1 20 1 ph ti Stepup Dedicated O Transformer Circuit Neutral 120V 240V Breaker 3 Pole min 2kVa A or O Terminal by others Disconnect Block Note NOTE Voltage At Terminal Block Must Be In Accordance With Spec Label 120V 1 phase Supply 120V 1phase between hot and neutral 240V 1phase between two 120V 1ph supply si All Wiring To Be InAccordance With Existing National And Local Electrical Codes 13 GS SERIES EXTERNAL CONTROLS WIRING CONNECTIONS LOW VOLTAGE TERMINAL STRIP NOTE This is generic wiring diagram only For specific wiring instructions it is necessary to refer to the wiring diagram which is supplied with each unit WARNING Failuretowirethe controllerinaccordancewiththewiringdiagram thatwas supplied with the unit could permanently damage GSTC GSP board Such errors will void the unit warranty Security Loop lt in 8 E g L 8i D e eg gt gt gt E 4 B gi 5 i 3 Y Bo gi P x S 3 28 2 8 HD 2 3 2 E P F Ei 2 gi doi 2 p 1 B 38 gig 938
79. pp GS Series y 7 Nor tec Gas Steam Humidifier www humidity com Installation User amp Maintenance Guide IMPORTANT Read and save this guide for future reference This guide to be left with equipment owner 1506222 D FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s telephone Follow the gas supplier s instructions If you can not reach your gas supplier call the fire department UNIT OPERATING RANGES Max Ambient Temperature 104 F 40 Min Ambient Temperature 41 F 5 C Max Relative Humidity RH non condensing 95 RH Min Relative Humidity RH non condensing WARNING Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life IMPORTANT Read and save this guide for future reference This guide to be left with equipment owner Table Of Contents GENERAL di WARNING
80. pproved by THE COMPANY to install such equipment THE COMPANY makes no warranty and assumes no liability whatsoever for consequential damage or damage resulting directly from misapplication incorrect sizing or lack of proper MAINTENANCE of the equipment THE COMPANY retains the right to change the design specification and performance criteria of its products without notice or obligation Walter Meier Climate USA Inc 826 Proctor Avenue Ogdensburg New York 13669 Walter Meier Climate Canada Ltd 2740 Fenton Road Ottawa Ontario K1T3T7 Tel 866 NORTEC 1 Fax 613 822 7964 northamerica climate Qwaltermeier com www humidity com walter Meier PRINTED IN CANADA tod
81. ributor should be XT minimum of 36 above the humidifier GS Series humidifiers are designed for floor mounting or on GS Stand optional The clearance dimensions shown in this manual are for reference only and are the minimum required for maintenance of the humidifier Local and National Codes should be consulted prior to final location and installation of the humidifier NORTEC cannot accept responsibility for installation code violations e DO NOT locate humidifier any further than absolutely necessary from steam distributor location Net output will be reduced as a result of heat loss through steam line Also increased static pressure over 12 W C will result in hot water going down the drain Consult factory if this situation occurs Figure 1 shows typical installation with all required connections to the GS Humidifier Careful consideration should be given to all of these connections when choosing a location for the e Where possible mount humidifier at height convenient for servicing e Make sure the humidifier is mounted level humidifier WARNING During installation cover the e DO NOT mount humidifier on hot surfaces humidifier to prevent any dust or other o contaminants from entering the cabinets when The humidifier must be installed so that all activities such as drilling are taking place electrical components are protected from exposure to water e DO NOT mount humidifiers in an area wh
82. rienced and trained personnel Only use original NORTEC spare parts to replace defective components Damage caused by non approved parts is not covered under NORTEC s standard warranty Hot Surface Igniter and Flame Sensor Replacement 1 Shut off electrical power and gas supply to the humidifier Remove the right side service access door Disconnect all wiring to the igniter and flame sensor Unscrew the fixing nuts for the igniter and flame sensor Carefully remove the igniter and flame sensor Reverse the sequence above to install the new igniter and flame sensor Always install a new Figure 27 Flame Sensor and Ignitor Assembly 1 gasket when replacing the flame sensor and igniter CAUTION The silicon carbide igniter is breakable Handle with great care to avoid damage Burner Removal and Installation Shut off electrical power and gas supply to the humidifier Remove the right side service access door Disconnect all wiring to the combustion blower gas valve air proving switch igniter and flame sensor note the connector assignment Undo the union on the flexible gas hose and disconnect the gas hose from the gas valve Undo the 4 nuts on the blower outlet and remove blower leaving the gas valve air inlet assembly and the fan board mounting bracket if present mounted to the blower Undo the 4 large nuts that secure the burner mounting plate to the face of the heat exchanger and
83. ross the entire base to prevent tipping or damage to the unit e The enclosure also comes complete with four 4 removable lifting lugs fastened to the base All four lugs must be utilized if moving the unit in this manner Protect the cabinet from damage from the lifting cables chains during lifting The lifting lugs should be removed from the base once the unit has been correctly positioned on the curb mounting e See Figure 15 for clearance details Figure 13 GSTC Outdoor Typical Installation Rooftop BH Vent Insulated Steam Line By others Electrical Disconnect By others i Roof Curb ai i Gas Line with Manual Shut off By 5 Drain mn 7 Funnel With Air Gap Manual Shut off Figure 14 GS Outdoor Typical Installation Rooftop BH Vent By Norte i Steam Line Electrical A By athers Disconnect FE y 4 we By others Ps d Roof Curb By others Figure 15 GSTC Outdoor Clearance Minimum Required Clearances Model Left Right GSTC Outdoor 100 0 40 101 6 cm GSTC Outdoor 200 0 40 101 6 GSTC Outdoor 300 76cm 40 101 6 cm GSTC Outdoor 400 76cm 40 101 6 cm GSTC Outdoor 500 76cm 40 101 6 cm GSTC Outdoor 600 76cm 40 101 6 cm Back 15 25 cm 15 25 cm 15 25 cm 15 25 cm 15 25 cm 15 25 cm
84. rtup if the blower RPM does not exceed Ensure there is power to the blower BLOWER X 500 RPM within 5 seconds or if during and that all wires are making a proper NOT OPERATIONAL operation the RPM drops below 500 RPM for connection more than 5 seconds this fault is generated Consult factory FAULT GVF X Ifthe controller detects that a gas valve has Ensure that the ignition module is not ILLEGAL GAS activated at a time it should not this fault is miswired or that the module is not VALVE Generated faulty by swapping it with a known BURNER X good one If the problem follows the ignition module replace the module Consult factory 60 FAULT LIST FAULT GIF X Following an ignition module fault if the Ensure that the ignition module is not GAS RE IGNITION modules gas valve activates this fault will be miswired or that the module is not BURNER X generated faulty by swapping it with known good one If the problem follows the ignition module replace the module Consult factory FAULT DBF There are many time windows in the GS Ensure that pump is being energized DRAIN NOT software If during a drain cycle the time Check for blockage in all aspects of WORKING window for the water level to drop is exceeded the drain system DRAIN IS BLOCKED this fault is generated Float board defective Consult factory FAULT FCF Once every 24 hours provided the unit is Ensure the proper operation of th
85. ry of the software and can be viewed through the service level on the display Refer to the keypad display menu structure at the end of the manual GSP MODELS Faults are indicated on GSP models with a fault code on the small display screen attached to the logic control board The display can be viewed by removing the front electrical door Check the display for the fault code before shutting off power to the unit Resetting the humidifier clears the fault This can be achieved by shutting off the power switch then turning it back on or by pressing the reset button on the logic control board A list of all fault codes and the type of fault they represent is located near the back of the manual MAINTENANCE To ensure proper performance and long operating life of the GS humidifier it is recommended that the appliance and installation be inspected at least once a year by a qualified service person A proper maintenance schedule should be followed Since the amount and type of maintenance required is generally as a result of how much the humidifier operates all GS humidifiers monitor the amount of steam produced over time and will indicate when service is required All units come factory set with a service interval of 500 hours This service interval can be adjusted through software GSTC models or by dip switch settings GSP models on the logic control board All maintenance work must be performed by experienced and trained personnel
86. shovel such as those used for gardening Once loose scale is removed use a scraper such as a plastic windshield scraper to remove scale adhering to the tank or heat exchanger walls DO NOT use a metal scraper that will scratch the stainless steel surfaces of the tank Once all large pieces of scale have been removed vacuum the tank out with a shop vacuum fill part way with water and flush remaining sediment from the tank through the drain Due to the presence of polymer gaskets around the heat exchanger do not use any harsh cleaning chemicals Please consult NORTEC prior to using any chemicals Once the lid has been replaced fill the unit with water and examine for leaks Inspect the drain and fill lines assembly for scale build up and if necessary remove them from the humidifier for cleaning If the blowdown assembly becomes blocked scale build up in the tank will be accelerated and damage to the humidifier could result The drain pump may be opened and cleaned Consult NORTEC for proper procedure Reassemble the drain and blowdown if they were removed Re install tank top and side lids making sure tank cover gasket is intact Do not over tighten hold down nuts If using a torque wrench do not exceed 50 in lIb 5ft Ib Re seal all cabinet lids Cleaning the float chamber is accomplished by removing the hold down screws to access the floats and using a small brush to gently clean the scale from the floats and chamber Ensure
87. specific amount of operating time and can also be triggered by a signal sent to the humidifier from a building management system WATER QUALITY Due to the wide range of water conditions found throughout North America it is important that the blowdown is set according to the local water conditions By water conditions we are referring to the hardness of the water supplied to the humidifier The hardness is measured in grains per gallon It is also important to test for silica content Silicates may cause foaming and contribute to scale buildup in the humidifier tank and float chamber If you are unaware of the hardness or silica content of your water supply there are many do it yourself kits which can be purchased or there are several companies that will perform the tests for a reasonable price You can even contact your municipality for your water condition or order the NORTEC water test kit 227 Figure 25 Site Water Test Kit P N 1507214 Note Water quality conditions resulting in component failures are not covered under NORTEC s standard warranty e Silica Test Measured in ppm parts per million Follow the directions with the kit A high reading will decrease the performance of your system The recommended operating range for silica is 0 ppm to 14 ppm Note A high silica content along with a high hardness content may increase the service intervals of the system Consult the factory if this condition exists at th
88. tact with vent pipe can occur e A minimum equivalent vent length of 7 feet must be connected to the humidifier Vent lengths must not exceed 100 30 m Each 90 elbow is equivalent to 10 and each 45 elbow equals 5 The vent run should be as direct as possible with no more than 6 elbows in the system e Diret vent applications length of vent should not exceed 70 in equivalent length ADDITIONAL REQUIREMENTS WHEN VENTING THROUGH A SIDEWALL For sidewall venting locate the humidifier as close as possible to the wall being used Locate the vent terminal at least three feet above any forced air inlet located within ten feet or at least four feet below four feet horizontally from or one foot above any door window or gravity air inlet into any building A minimum horizontal clearance of four feet from electric meters gas meters regulator and relief equipment is required For sidewall vent terminations the humidifier must be installed with the certified vent terminal that can be purchased from Nortec GS 100 3 Nortec P N 1502321 GS 200 4 Nortec P N 1502322 GS 300 400 5 Nortec P N 1507320 GS 500 600 6 Nortec P N 1507321 Locate the vent terminal at least seven feet above grade when it is adjacent to public walkways Locate the bottom of the vent terminal at least twelve inches above grade or ground or normally expected snow accumulation level The snow level may be higher on walls exposed to prevailing win
89. tch close to humidifier Cables properly affixed Low voltage wiring amp control signal s wired to correct terminals Humidifier configured for correct control signal s gogogo TYPE OF CONTROLS INSTALLED LOCATION WIRING SETTING O High Limit Air Proving Modulation Control L On Off Control L Controls by Nortec Controls by Others 26 e Close the shut off valve in the water supply line e solate the humidifier from the electrical power supply at the main disconnect switch SCALE MANAGEMENT The gas humidifier will periodically blowdown water from the tank to reduce the concentration of total dissolved solids that accumulate during long term operation Gas Humidifiers are shipped factory set with a blowdown of 25 This setting ensures that scale build up will be minimized for all water conditions Once the water conditions are known the blowdown rate can be adjusted by software GSTC models or by using dip switches on the logic control board GSP models Another effective means of controlling the amount of scale in the tank is with the use of the Full Tank Blowdown FTBD built into the software When this feature is activated the drain pump will be energized to drain the entire contents of the tank and then the tank will be refilled with fresh water thus keeping the amount of total dissolved solids to a minimum The feature can be programmed in the software to occur after a
90. team distributor or in turbulent or mixing zone Mount humidistat where air s humidity and temperature are uniform and representative of spaces being humidified Mount duct high limit humidistat downstream of steam distributors far enough that under normal humidity and air flow conditions steam will have been fully absorbed typically at least 10 feet It must be located to sense high humidity only when uniform and representative air is over humidified or approaching saturation Mount duct air proving switch so that it is able to sense air flow or lack of it Wire it to make when air flow is sensed and break when air flow fails Check operation of all on off controls before starting humidifier Calibration of controls on off or modulation in the field may be necessary due to shipping and handling Verify humidistat accuracy before commissioning system PLUMBING NOTE All water supply and drain line e tis recommended to have a faucet installed close to the humidifier to allow quick filling of the system on initial start up This can also be very useful for mandatory cleaning of the unit e ALWAYS supply and install a shut off valve and union in the water supply line dedicated to the humidifier to facilitate servicing e f water hammer occurs install a shock arrester on the fill water line just before the inlet to the fill valve Water hammer will damage the fill valve e A 1 air gap is designed into the fill syst
91. that floats are back in place and o ring is properly seated before tightening screws on float chamber Special attention must be used when removing or re installing the float chamber Figure 26 Cleaning Tank Access Torque 50 in LB 5 7 NM The switch board must be replaced into the same position as before cleaning and the tie wrap must be used to hold the float chamber in position SERVICING THE UNIT Caution Disconnect power before servicing this appliance Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation The combustion chamber heat exchanger and flue baffles are all fabricated from stainless steel and do not require internal cleaning Should the main burner fail to light or flame is not detected during the first trial for ignition period the gas valve is de energized and the control goes through an interpurge delay before another ignition attempt The control will attempt two additional ignition trials before going into lockout The valve relay will be de energized immediately and the combustion blower will be turned off SERVICE CHECKS COMBUSTION BLOWER The combustion air blower motors are permanently lubricated and do not require lubrication Clean out any dust that has accumulated in the blower housing using an air gun BURNER The burners are made of ceramic fabric material and operate in the infrared mode Dependin
92. three times after which the ignition module will lock out The gas valve s maintains a constant ratio air to gas independent of blower speed or external conditions This air and fuel is thoroughly mixed in the blower s and then forced through the burner ports where ignition occurs Hot products of combustion are forced through a baffle inside the heat exchanger and then vented outside The heat exchanger has a large flat surface to minimize scale build up and promote scale shedding to the bottom of the tank This self cleaning action helps to maintain the efficiency of the heat exchanger while the smooth surfaces allow for easy cleaning when necessary The GS 100 has a single removable combustion chamber heat exchanger The combustion system is duplicated on larger units with multiple chambers inside a common tank WATER MANAGEMENT The GS Series of humidifiers is equipped with a unique float chamber water level monitoring device Two magnetic floats one is a backup measure 5 different water levels in the humidifier for proper operation The float chamber and board are located away from the boiling action to increase reading accuracy and reduce mineral build up since it is not in the boiling water The float chamber is connected to the tank under the water level and above the water level to ensure equalization of pressure between the tank and float chamber In addition cooling water is introduced in the float chamber to reduce scale
93. tion and piping that terminates at the pipe chase in the base pan This valve opens and will drain the contents of the tank in the event of a power failure See Figure 222 Install a manual shut off valve on this line and pipe to the drain funnel This valve must always be left in the open position when in DRAIN LINE operation but can be closed for servicing of the unit e GS Outdoor units have an integrated 12 w c trap and vacuum break valve on the drain line A e Drain pipe should be capable of withstanding drain hose connected to the outlet of the internal 200 F temperatures trap terminates at the pipe chase in the burner section e Route the drain hose to a drain funnel in the building to provide an air gap before entering main building drain sewage system e When the drain pump is activated the tank drains at a rate of 18 20 l min 7 8 gal min e Internal drain water tempering will ensure a maximum of 140 F 60 during normal operation 21 STEAM LINES e The steam outlet connection is located at the back of the GS Outdoor unit Steam hose s and clamps are supplied with the unit and are intended to provide a flexible coupling outside of the unit to the building steam lines See Figure 23 e GS Outdoor models can develop steam pressures up to 12 w c to overcome duct and steam line pressures Pressures above 12 w c will cause steam to exit through the drain line e Steam lines can be rout
94. traps e All horizontal runs must be adequately supported with hangers or straps to prevent sagging Installation as a Category I Appliance e The GS series humidifiers have a fan assisted combustion which operates with a non positive vent static pressure when installed with the appropriate vent diameter e Category appliances must be vented vertically or nearly vertical See Figure 7 amp 9 e This category appliance is restricted to vertical venting installations with limits placed on horizontal lengths and vent diameters Refer to the tables in local and or national codes No sidewall termination is accepted e Vent piping must be UL or UL CSA listed type B or B W Recommended B Venting Manufacturers 1 Simpson Dura Vent 2 Selkirk Canada Corporation 3 American Metal Products 4 Metal Fab Inc e The vent pipe exiting the humidifier is sized for Category Ill installations A field supplied adapter is required to increase the pipe immediately at the exit of the humidifier The vent pipe must be expanded to the minimum sizes listed below for each model increasing as code requires GS 100 i 4 minimum diameter GS 200 5 7 8 GS 300 400 GS 500 600 i e The termination at the humidifier is a MALE connection Standard venting hook ups require a female path It is highly recommended that a female to female adapter be assembled onto the humidifier to establish the proper venting sequence Consult with the vent
95. ture switch has opened FAULT HMF In the user menu the user sets the maintenance Perform tank cleaning and all other MAINTENANCE time Once this time expires a warning is maintenance requirements outlined in TIME displayed 72 hours later the warning changes the manual HAS ELAPSED to this fault The maintenance time is measured in weighted operational hours With switch 5 4 deactivated this fault is enabled FAULT FTF Fill time out fault during fill process The GS Verify water supply is open WATER FILL FAIL software monitors the changes in water level Verify adequate water supply to unit during filling sequence If ware level changes do not occur within an expected time interval this fault will be generated 30 80psi 10L min minimum dia Line size Verify wire harness and connection between float chamber and I O board TB 61 WARNING LIST GSTC Warning GSP warning Description of warning Troubleshooting displayed displayed WARNING IMW X Once the controller activates an ignition module it will SEE FAULT LIST IGNITION MODULE X allow 4 minutes for the gas valve to activate After the trial FAIL period if the gas valve has not activated a fault will be generated The module will be locked out and the next burner will be indexed WARNING APW X Should the air proving switch open while the unit is SEE FAULT LIST AIR PROVING SWITCH X operating this warning is generated
96. use for Primary transformer 6 25 1505020 1 1 1 1 1 1 208 gnition Control Module 110 120V Models 2525914 1 2 3 4 5 6 208 240V Models 1505987 1 2 3 4 5 6 209 Relay Mount Socket 1703250 1 1 1 1 1 1 210 Blower Relay 1453020 1 1 1 1 1 1 Not Slotted wire duct 1506041 Order by Length Required Shown 211a LCD Display Assembly 1507741 1 1 1 1 1 1 211b LCD Mounting Bracket 1506951 1 1 1 1 1 1 211c On Off Drain Switch 1453001 1 1 1 1 1 1 67 L PIUUNY MMM pepojdx3 2 Joopino seues SH Eee Description Part 68 100 GS 200 GS 300 GS 400 GS 500 GS 600 1 Transformer 24 16V 15VA 1505760 1 1 2 Transformer 208 24Vac 250VA 1506719 1 1 1 1 1 Fuse 6 25 Amp for 208V transformer 1505020 1 1 1 1 1 1 LOD Display Assembly 1507741 1 1 1 1 1 1 3b LCD Mounting Bracket 1506951 1 1 1 1 1 3c On Of Drain Switch 1453000 1 1 1 1 1 1 4 Logic Control Board 1505762 1 1 1 1 1 5 VoBoad 01 180476 1 1 1 1 1 6 ignition Control Module 1505987 1 2 3 4 5 6 8 Relay Mount Socket 1703250 1 1 1 1 9 flower Relay 11488000 1 1 1 1
97. ves used in the GS series humidifier are negative pressure regulated valves The valve setting listed on the product rating plate is shown relative to atmosphere this setting will always remain constant The valves come preset from the factory for the correct gas type If an adjustment is required use the following steps 1 Remove the screw from the pressure port marked out on the back side of the gas valve 2 Connect a hose from a digital manometer or an inclined manometer capable of reading below 0 1 to the out pressure port 3 Activate the humidifier and measure the gas valve pressure once the valve is energized and a flame is established in the combustion chamber Verify this pressure to the pressure listed on the unit specification label 4 Ifthe pressure needs adjusting remove the locking cap on the top of the gas valve 5 Below the locking cap is an adjustment screw Increase the pressure by turning the adjustment screw clockwise decrease by turning counter clockwise NOTE The pressure will fluctuate slightly as the unit operates especially with very sensitive measuring devices Use the mean pressure value as the set pressure Once the pressure has been adjusted replace the locking cap Replace the screw in the out pressure port and tighten firmly COMPONENT REPLACEMENT CONSULT FACTORY PRIOR TO THE REPLACEMENT OF ANY COMPONENT All service work must be performed by expe
98. when CONTINUE is selected During the tank drain cycle the display will indicate the tank is draining and the amount of time remaining on the cycle To interrupt the cycle the unit must be switched off then on Must enter service password to activate this function 53 Tank Pre Clean The tank pre clean feature when activated will activate the drain valve for fixed period of time depending on unit size The fill valve will then activate filling the tank partially with cold water At the completion of the fill cycle the tank will once again drain This will help to flush out any accumulated minerals as well as cool the tank for the service personnel e THIS WILL DRAIN THIS WILL DRAIN SERVICE HISTORY CONTENTS OF TANK lt CONTENTS OF TANK FAULT HISTORY TANK DRAIN CONTINUE gt BURNERS SHORT CYCLE DELAY To pre clean the tank press enter when CONTINUE is selected During the tank pre clean cycle the display will indicate the tank is draining and the amount of time remaining on the cycle To interrupt the cycle the unit must be switched off then on Must enter service password to activate this function Burners This field allows the user to enable and disable individual burners for service reasons Depending on the GSTC model only the number of burners installed will be displayed SERVICE INTERVAL ENABLED BURNER 1 ENABLED SERVICE HISTORY ENABLED BURNER 2 ENABLED ENABLED FAULT HISTORY yr BURNER 3 ENABLED ENABLED
99. y be damaged When mounting the gas valve air inlet assembly to the combustion blower ensure that the cork gasket is properly oriented or gas flow through the valve will be impeded Leak test the gas train before re commissioning the humidifier Gas Valve Replacement 1 Shut off electrical power and gas supply to the humidifier Remove the right side service access door Disconnect all wiring to the gas valve and air proving switch note the connector assignment Undo the coupling on the flexible gas hose and disconnect the gas hose from the gas valve Remove the hoses from the air proving switch note the connection layout Undo the 2 screws that mount the gas valve air inlet assembly to the blower and remove the assembly Undo the 4 screws and remove the gas pipe connection from the inlet of the gas pressure regulating valve Undo the 3 screws that hold the air inlet venturi to the gas valve Remove the rubber grommet and brass orifice mounted in the outlet of the gas valve Undo the 3 screws of the pressure switch support bracket and remove the assembly from the gas valve Reverse the sequence above to install the new gas pressure regulating valve Inspect and replace any gaskets that may be damaged When mounting the gas valve air inlet assembly to the combustion blower ensure that the cork gasket is properly oriented or gas flow through the valve will be impeded Figure 30 Gas Valve Replace
100. y to the humidifier No gas should flow to the burner s To reset the humidifier shut off the power switch then turn the power back on STARTING THE HUMIDIFIER Once the tank has been filled and the ignition safety test has been performed as outlined above the humidifier is ready to be put into operation Verify that the inspection checklist has been completed and all deficiencies with the installation have been corrected Open the shut off valve in the gas supply line Open the shut off valve in the water supply line Ensure all external controls connected to the security loop are closed Verify that the building demand signal is connected to the humidifier Install and secure all cabinet service doors Switch the humidifier on 24 e Atthe completion of the float test the humidifier will begin the combustion sequence and each burner will ignite in sequence e Depending on the system demand the combustion blowers will modulate faster or slower to control the burner input e The water in the tank will heat up and begin to boil delivering steam to the distribution system e During the boiling sequence the water fill valve will periodically activate to replenish water that has evaporated from the tank e Once the humidity requirements have been satisfied demand drops below minimum all gas valves will be de energized and the blowers will be shut off after performing a post purge of the combustion chamber e Th

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