COMPLETELY READ THESE INSTRUCTIONS BEFORE STARTING TO INSTALL THIS HUMIDIFIER . AN ADDITIONAL OWNER’S MANUAL IS PROVIDED FOR STARTING UP, RUNNING, AND MAINTAINING THE HUMIDIFIER. ALL WORK MUST BE COMPLETED BY QUALIFIED TECHNICIANS ONLY
HUMIDIFIRST ULTRASONIC HUMIDIFIERS
INSTALLATION MANUAL
ULTRASONIC HUMIDIFIER INSTALLATION IN
LIEBERT AIR CONDITIONERS (5-1-12)
VER LR - STD
HUMIDIFIRST
TABLE OF CONTENTS Page Introduction
3
Principles of Ultrasonic humidification
3
General installation overview
4
Bill of materials
5, 6
Important notes – misc.
6
Installation instructions
7 thru 11
Final Check list
12
Ultrasonic humidifier module location
13
Humidifier kit component explosion view
14
Reheat shield location
15
Water and drain connection points
16
Drain connection detail drawing
17
Electrical component location drawing
18
Water line connection kit for humidifier
19
Humidifier dimensions data and weight
20
Transformer physical data
21
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HUMIDIFIRST
INTRODUCTION Congratulations on your purchase of a Humidifirst ultrasonic humidifier – the highest quality and most “User Friendly� commercial/industrial humidifier available today. Your selection of an ultrasonic humidifier provides you with the benefits of this technology, including energy efficiency, minimal maintenance, and healthy, uncontaminated moisture. And Humidifirst humidifiers are 100% American made. This humidifier is made of high-grade stainless steel. This ensures unit longevity, minimal maintenance, and a clean, healthy humidifier.
PRINCIPLES OF ULTRASONIC HUMIDIFIERS Ultrasonic humidifiers vibrate a water mist into the air by using piezoelectric crystals (transducers). The transducers are mounted in a pan of water approximately 1.5 inches deep. Each transducer is approximately the size of a nickel and vibrates at approximately 1.6 megahertz, a speed so fast that the water above the crystal cannot follow the speed of the transducer, causing the water to cavitate. This process emits very small water droplets into the air, approximately one micron in diameter (similar in size to steam droplets). The water droplets are so small that they evaporate almost immediately. The water feeding an ultrasonic humidifier must be pure so that minerals and other contaminates are not vibrated into the air. Such purity is achieved with de-ionized (DI) water filters to remove all minerals and foreign matter from the water. DI water offers additional benefits. It assures a pure, healthy mist for those breathing the air, and it significantly reduces the amount of maintenance required for the humidifier, i.e. no scaling or sludge to be removed from the humidifier pan.
General installation overview (typical) 3
1. The humidifier installer will be removing the existing infrared humidifier and install the Humidifirst ultrasonic humidifier. 2. The existing air conditioner microprocessor will control the new Humidifirst humidifier, therefore the existing humidifier relay and fuses will be used (do not permanently remove). 3. A 560 va transformer is provided by Humidifirst to power the new ultrasonic humidifier. It will step the incoming 120 or 480 volt, one/three phase power down to the Humidifirst requirements (24 volt and 48 volt ac). The transformer is to be located in the existing power section of the air-conditioner. 4. A power interface back plate, with circuit breakers, relays, terminals, etc., is provided to wire all electrical components to. It is to be located in the existing power section of the air conditioner. 5. The Humidifirst drain pan will be piped into the existing air conditioner drain tubing. 6. Humidifirst will provide a push fitting to connect to your water piping. 7. Stainless steel shields are provided to divert mist away from the electric reheat coils 8. The water quality to the new ultrasonic humidifier should 2.5 Parts Per Million (PPM) or cleaner. If water exceeds 10 PPM dust may form in the humidified space.
Bill of Materials
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1.
Humidifirst Ultrasonic humidifier: provided with a stainless steel drain pan/mounting frame (Suggest mounting screws/tapcons 5 - #10 by ½” long ). The humidifier comes pre-wired with 10’ of factory supplied cable.
2.
Transformer:
Primary Voltage Secondary Voltage
= =
110/208/480 24/46/48/50
Sheet metal mounting screws: (4) - #14 by 1/2” long (4) – lock washers 3.
Humidifirst Interface Control Board (HIP): Includes circuit breakers, relays, terminal block, and surge arresters Sheet metal mounting screws: (4) - #10 by 3/4” long (4) – plastic spacers (mount behind HIP)
4.
Stainless steel electric reheat shields. Three shields are provided: (1) – 24” field adjustable, (2) additional fixed shields are provided. Sheet metal screws: (8) - #10 by ½” long
5.
Water line connection kit to include: a.¼” OD plenum rated polyethylene tubing with a stainless steel orifice b. a set of quick disconnect service valves to easily isolate the humidifier when servicing c.One - ¼” OD tube insert union and One - ¼” OD tube insert by ½” nmpt (typically use one or the other)
6.
Drain assembly kit includes: a.an elbow fitting b. 3/4” ID flexible tube c.5/8” ID flexible tube d. stainless steel tube clamps (2)
7.
Wire kit for connecting transformer to the Humidifirst interface control board (HIP), includes: stranded wire (8 - color coded wires, 18 awg, five feet length each, (5) transformer crimp connectors, tie-wraps, and tie-wrap cradles. Two of the wires are to connect the HIP to the existing humidifier contactor/relay.
8.
0.5 cu. ft. mixed bed resin D.I. bottle with flexible hoses. (OPTIONAL)
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9.
Water conductivity sensing probe (OPTIONAL)
IMPORTANT NOTES
Note A:
Most existing air conditioners may already be corroded at the bottom plate and fan deck. To avoid further deterioration, it is recommended to apply corrosion protection paint for added protection.
Note B:
Flush all water tubing completely before connecting to the Humidifirst ultrasonic humidifier
Note C:
For multi-unit retrofits, it will be more efficient to provide D.I. water to all units via a central water treatment station. In this case, no water treatment controls or alarms will be included in individual retrofit kits. Water treatment controls and alarms should be located at the water treatment central station.
Note D:
The water quality to the new ultrasonic humidifier should 2.5 Parts Per Million (PPM) or cleaner. If water exceeds 10 PPM dust may form in the humidified space.
Note E:
When using de-ionization water treatment, ask for “Mixed bed – Nuclear Grade” resin.
“Read Completely Before Starting Work”
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INSTALLATION INSTRUCTIONS A.
Prepare the air-conditioning unit: 1.
Turn off the main power disconnect and disconnect power to the A/C unit.
2.
Shut off the water supply to existing humidifier.
3.
Remove the existing humidifier. Refer to the air-conditioner’s Installation manual if needed. You may need a wet-vac to vacuum water from the humidifier. Use caution when removing the wiring of the existing humidifier. The existing electrical circuit may include the following: a.
Pan Overload Safety (HS3): This can normally be jumped out (System2, System 3 - levels 1,2,3). This must be done to allow the new humidifier to operate. On System 3 Levels 0-10, use this circuit to tie into the optional 10 ppm alarm. (Refer to the drawing sent with the Humidifirst conductivity sensor)
b.
Fill Solenoid Valve: This circuit can be terminated. The ultrasonic humidifier has its own internal fill solenoid.
c.
Alarm Circuit: There are a number of alarm shutdown circuits used with different Liebert microprocessor based systems. These circuits must be reviewed carefully if you wish to use them for external alarms and monitoring. First, refer to the Humidifirst Wiring diagrams provided with your retrofit package. The Humidifirst Interface Control Back Plate (HIP) (pages 22 and 23) can be equipped with an optional water conductivity meter, which monitors water quality via a conductivity probe installed in the water line supplying the humidifier. There are two alarm relays on the conductivity sensor (refer to page 23). The first stage alarm is at 2.5 PPM, indicating the water treatment system (or D.I. bottle) needs serviced. The second
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stage alarm is at 10 PPM alarm, indicating the water quality has denigrated to a point where dust may form in the environment. This alarm can be used to shut the ultrasonic humidifier down. d.
Microprocessor Alarm Points (when the optional conductivity sensor is purchased): System 2, System 3 Levels 01, 02, 03 (See drawing included with conductivity sensor) These microprocessors utilize a 4-prong auto-flush probe. This probe can be used for the 10 PPM shutdown alarm. The 2.5 PPM pre-alarm can be connected to the “local alarm” points (24-50) if not already in use, or to a remote location to indicate this alarm. System 3 Level 0 Electronics: (See drawing included with conductivity sensor) Connect to HS3 (manual reset humidifier safety) located under older existing humidifier pan. This will allow shutdown of the humidifier on a 10 PPM alarm. The 2.5 PPM pre-alarm can be connected to the “local alarm” points (24-50) if not presently used, or to a remote location to indicate this alarm because there will be no visual/audible at the A/C unit. System 3 Level 10 Electronics: (See drawing included with conductivity sensor) Connect to HS3 (manual reset humidifier safety) located under old existing humidifier pan. This will allow shutdown of the humidifier on a 10 PPM alarm. The 2.5 PPM pre-alarm can be connected to the “local alarm” points (24-50, 24-25, 24-55, 24-56) or to a remote location to indicate this alarm. This step is highly recommended on this microprocessor because there will be no visual/audible indication on the 10 PPM shutdown alarm.
System 3 Level 10
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The humidifier float switch circuit has to be jumped to avoid “humidifier fault” alarm light for staying activated. 4.
Applying Protective Paint to air-conditioning unit Scrub the bottom plate with sand paper to remove existing rust flakes. Vacuum and clean dry. Apply a coat of the corrosion protection paint. Let dry and apply another coat if necessary.
B.
Installing the Ultrasonic Humidifier 1.
Power Supply: Check the existing air-conditioner for voltage input. Voltage should be either 208/3/60 or 480/3/60. Remove the power wires to the existing humidifier. The Ultrasonic humidifier comes equipped with a 10’ long power cord. This cord connects to the Humidifirst supplied interface control board. See the Humidifirst wiring diagrams for the correct wiring color code and terminal points.
2.
Controls: Mount the Humidifirst supplied interface control board (HIP) in the space indicated on pages 14 and 18, using the factory supplied (4) self-tapping #10 x ¾” screws and (4) spacers. The spacers should be placed between the control circuit board and the existing unit’s control panel.
3.
Transformer: Mount the transformer in the space indicated on pages 14 and 18 using the (4) #14 x ½” screws provided with the kit.
4.
Reheat shields: Secure the stainless steel electric reheat shield(s) using the enclosed #10 x ½” screws. Three shields are provided. The center shield (adjustable) is used to direct air from the A-coil area towards the humidifier to “balance” the airflow so the mist from the humidifier is directed vertically downwards. The two fixed shield are used to stop mist from touching the reheat coils. Please note that mist is drawn out of the humidifier nozzle by the passing air being drawn down between the air conditioner blowers. (refer to pages 14 and 15 for more details)
5.
Mounting drain pan and Ultrasonic humidifier: Refer to
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pages 13, 14 and 16 for mounting frame installation details. Locate the safety pan so that once the ultrasonic humidifier is set in place, it can be located so that the discharging mist is centered between the blower inlets. Also, locate the pan so that the drain tube can be attached conveniently. Once this safety pan is installed the ultrasonic humidifier can be set in place. First remove the humidifier mist nozzle so that the humidifier inserts easily. The humidifier rests on the drain pan – no attachment required. Once the humidifier is in place the nozzle can be reinserted. The nozzle hold down screws should be reinserted to prevent water from dripping through the holes. The inlet side of the humidifier should be pushed back against the hanger bracket side of the safety pan so that the mist pattern is farther away from the reheat shield(s). 6.
Supply Water: Water connection requirements will vary, depending on whether you are connecting to a central water treatment system or a deionization (DI) bottle. Humidifirst supplies a water line connection kit that incorporates a 1/4” OD tube to provide vibration isolation between the humidifier and the air-conditioner (see pages 16 and 19). This polyethylene tube is plenum rated. We also provide fittings to adapt to your water treatment system (please note that The Home Depot usually stocks various compression fittings if you have special connection requirements). When connecting to a DI bottle: Most existing humidifiers are fed by a ¼” OD copper tubing. When we supply the DI bottle we include in the retrofit a ¼” compression union and 4’ of copper tubing. These parts can be used to extend the water supply to a location within the unit reaching the D.I. bottle inlet connection. With the DI bottle option, we also provide tubing, valve(s) and fitting to interface between the DI bottle, optional conductivity sensor and the ultrasonic humidifier. A drawing is provided with these options when purchased from Humidifirst. When connecting to a central water treatment system: Connect using the Humidifirst supplied fittings (One - ¼” OD tube insert union and One - ¼” OD tube insert by ½” nmpt)
7.
Drain: Connect the safety pan drain tubing. Air conditioner installations vary. Cut tubing to the correct length. (Refer to pages 16 and 17 for details.)
8.
Wiring: Route and connect all required field wiring.
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(Refer to the Humidifirst supplied wiring schematics) a.
Connect the power wire from existing humidifier fuse-block to the Humidifirst Interface Control Panel (HIP).
b.
Connect the primary wires (2-wires) from the Humidifirst supplied transformer to the HIP. Choose the correct voltage taps for the primary (0 & 208 or 0 & 480)
c.
Connect the secondary wires (3-wires) from the Humidifirst supplied transformer to the HIP
d.
Connect the existing humidifier contactor/relay on the air conditioner electrical panel to the HIP. Connect terminal (16) to the far left top input on contactor/relay. Connect terminal (17) to the far left bottom input on contactor/relay. Make sure that the wires that connected the existing humidifier power fuse to this contactor have been removed and abandoned.
e.
Route Humidifirst factory-wired cord of the ultrasonic humidifier to electrical panel through existing wire knock-outs and connect to the HIP. The wires in the cord are color coded. Wire according to the wiring diagrams.
f.
(Optional) Connect the water conductivity sensor for alarm annunciation. Route the conductivity sensor probe cord to electrical panel section through existing wire knock-outs and connect to the HIP. Contact closures are provided at 2.5 PPM and 10 PPM. As indicated previously, over the years the airconditioner has been provided with many versions of microprocessor control. Normally Open and/or Normally Closed contacts are required for alarm annunciation. Additional details are provided with the conductivity sensor. The water conductivity sensor, on some air-conditioner control versions, can be used to shutdown the ultrasonic humidifier.
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FINAL CHECK LIST
1. Tie-wrap all new wires neatly after connecting and tightening wires to terminals. 2. Open water supply shut-off valves and check for leaks. 3. Clean-up any loose debris before closing up unit and starting fan. 4. Make sure that drain hose is sloped in proper direction. 5. Reconnect power to the A/C unit. Turn the A/C main power disconnect switch to the “ON� position. Check the voltage input to transformer to confirm that is either 208 volt or 460 volt and that it is connected to the correct transformer taps. The transducers voltage should be close to 46 volts for best operation. Voltage to the solenoid valve and control circuit should approximately 24 volts. 6. To insure that humidifier is operating properly, a plexiglass panel may be placed temporarily over the right side of the A/C unit. Look through plexiglass panel to monitor performance or to check for any leakages. 7. Recommended setting for microprocessor humidity controls: Room Humidity Set-point: 45-50% Humidity Sensitivity: 3-5%
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13 0.360 0.480
LR-30
POWER (KW)
LR-24
MODEL
30 TON NOMINAL
10-24 TON NOMINAL
FOR LIEBERT SIZE
1. LIEBERT RETROFIT KITS ARE FOR DOWN FLOW AIR CONDITIONER APPLICATIONS
NOTES:
DISCHARGE AIR
CHK'D BY
DBW
REV. DATE
SCALE
10-7-04
12-17-03
NTS
RT - 050 B
LIEBERT ULTRASONIC HUMIDIFIER RETROFIT
ULTRASONIC HUMIDIFIER MODULE
BY-PASS AIR HERE
RETURN AIR
HUMIDIFIER KIT EXPLOSION VIEW
HUMIDIFIRST CIRCUIT BOARD
TRANSFORMER
BY-PASS AIR ELECTRIC REHEAT SHIELD(S)
EXISTING BY-PASS AIR
D. I. BOTTLE (OPTIONAL) ULTRASONIC HUMIDIFIER & MOUNTING SHELF
DRILL AND FASTEN HERE (TWO SCREWS)
14
REHEAT SHIELD PLACEMENT
RETURN AIR
BY-PASS AIR HERE LEFT AND RIGHT REHEAT SHIELD (FIXED)
ELECTRIC REHEAT COIL CENTER REHEAT SHIELD (ADJUSTABLE)
DISCHARGE AIR
▼
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SUGGESTED WATER AND DRAIN CONNECTION POINTS
WATER CONNECTION MAKE 1/2" FEMALE NPT
HUMIDIFIRST DRAIN PAN CONNECTION POINT, 5/8" ID TUBE ULTRASONIC HUMIDIFIER BY - PASS AIR 1/4" OD INSERT FITTING FOR POLYETHYLENE TUBING
12.25"
19" 17"
BLOWERS BLOWER DECK DRAIN CONNECTION - MAKE 3/4" FEMALE NPT (MUST BE AT LEAST 2'' BELOW THE HUMIDIFIRST DRAIN PAN CONNECTION POINT)
16
17
1. THE 5/8" ID TUBE CONNECTS TO THE HUMIDIFIRST SAFETY PAN 2. THE 3/4" ID TUBE CONNECTS TO THE AIR CONDITIONER DRAIN LINE 3. CUT THE RUBBER TUBES TO THE CORRECT LENGTH (8" LENGTH PROVIDED)
NOTES:
3/4" I. D. FLEXIBLE RUBBER TUBE
ELBOW FITTING
5/8" I. D. FLEXIBLE RUBBER TUBE
LIEBERT RETROFIT DRAIN CONNECTION KIT
HOSE CLAMPS
CHK'D BY
DBW
REV DATE
SCALE
12-2-04
NTS
LR-09
LIEBERT RETROFIT DRAIN CONNECTION KIT
HUMIDIFIRST ULTRASONIC HUMIDIFIER
HUMIDIFIRST ULTRASONIC HUMIDIFIER
A
18 TYPICAL EXISTING HUMIDIFIER RELAY LOCATION
TYPICAL EXISTING HUMIDIFIER FUSE LOCATION
HUMIDIFIRST CONTROL PANEL AND TRANSFORMER LOCATED IN THIS AREA
MOUNT THE HUMIDIFIRST CONTROL PANEL AND TRANSFORMER IN THIS AREA. THE TRANSFORMER CAN BE MOUNTED HORIZONTALLY ON BOTTOM PANEL (NEXT TO LATCH) IF AREA IS FULL.
IF BACK PLATE IS TOO FULL MOUNT THE HUMIDIFIRST TRANSFORMER HERE
MICROPROCESSOR AREA
HUMIDIFIRST
BEFORE OPERATING THE HUMIDIFIER 1. Attach the water tube kit (kit includes tube, inline strainer, male and female water quick disconnect fittings, and union fitting). Push the tube end into insert fitting on side of the humidifier until it bottoms out (approx. ½”) – see below. 2. The humidifier must be mounted on a level surface or transducer failure may occur. 3. For initial start-up, remove humidifier lid and pour water into the water pan to a depth of 1”. 4. Read the complete owner’s manual before operating the humidifier. INSERT IN HUMIDIFIER WATER SUPPLY FITTING ¼” UNION OR 1/2'’ MPT
WATER DISCONNECTS
ORIFICE
LIEBERT RETROFIT FRONT VIEW
Indicates field inserted
19
20
12.28"
LR-24 = 52.38" LR-30 = 66.18"
POWER, WATER AND DRAIN PAN CONNECTION THIS SIDE
31 POUNDS 360 WATTS 12
WEIGHT POWER TRANS'R
16
480 WATTS
36 POUNDS
LR-30
CHK'D BY
DBW
REV DATE
SCALE
11-17-04
NTS
LR-08
ULTRASONIC HUMIDIFIER FOR LIBERT A/C
HUMIDIFIRST
8.78"
LR-24
MODEL
A
Transformer: 600 VA, weight 23#
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HUMIDIFIRST ULTRASONIC HUMIDIFIERS
1520 Neptune Dr., Suite A, Boynton Beach, FL 33426 (561) 752-1936 FAX (801) 760-2777 www.humidifirst.com
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