TM READ AND SAVE THESE INSTRUCTIONS INTAC ® Microprocessor Humidifier Controller Installation Instructions ————————————————— Operation and Maintenance Manual % Power 68% Heaters 1 2 3 002 INTAC ® Humidifier Control System NORMAL FILL DRAIN SYSTEM OPERATION FAULT PURE Humidifier Co. ENTER 100 200 300 HOME Our results are comforting PURE HUMIDIFIER® and INTAC® are registered trademarks of PURE Humidifier Co. 1 Form No: INOM-9-15 Table of Contents INTAC® Specifications ………………………………………………………………... 1 INTAC® Keypad Features …………………………………………………………….. 2 INTAC® Menu Overview - How to Navigate ………………………………………… 3 INTAC® Menus - How to Navigate - Home Display ………………………………... 4 INTAC® Menus - How to Navigate - 100 & 200 Menus ……………………………. 5 INTAC® Menus - How to Navigate - 300 Menu …………………………………….. 6 INTAC® Menus - How to Navigate - 500 Menu …………………………………….. 7 Modes of Operation Description - Electric Humidifiers ……………………………. 8-9 Modes of Operation Description - Gas Humidifiers ………………………………... 9 Modes of Operation Description - Steam-to-Steam ……………………………….. 9 Tri-Probe Operation …………………………………………………………………… 10 Automatic Drain Cycle ………………………………………………………………… 10 PID Control Loop Tuning ……………………………………………………………... 11 INTAC® Optional Features ……………………………………………………………. 12-13 INTAC® Terminal Board Connections ……………………………………………….. 14-15 INTAC® Hardware Layout …………………………………………………………….. 16 Modbus Modbus Register Map ………………………………………………………. 17 INTAC® Error Code Summary ……………………………………………………….. 18-21 INTAC® Complete Menu Listing ……………………………………………………... 22-27 Notes ……………………………………………………………………………………. 28 1 INTAC® Specifications Specifications Supply Voltage: 24VAC ± 20% at 50/60 Hz, ± 1HZ, 9.33VA max. Current Input Impedance: 93 Ohms Voltage Input Impedance: 5000 Ohms Minimum Output Voltage Impedance: 1kOhm Maximum Output Current Impedance: 800 Ohm Termination: Removable screw terminal block Screw Termination Wire Size: 16 gauge maximum Maximum wire length to Tri-Probe: 50 feet* Thermocouple Wire for Tank Temp Sensor When Used: Type K Ambient Temperature Range: 32ºF to 130ºF Relative Humidity: 0 to 90% RH, non-condensing. Vibration: 2g., 10 to 150 HZ., applied in any one of three axes. Storage Temperature: -40ºF to 158ºF Limits, Ranges, Accuracy: Calibration accuracy and sensor conformity: ± 1% of Span, ± 1 LSD at 77ºF ±5ºF at rated line voltage ± 10 % *For standard water units only. The Tri-Probe level sensor wiring is susceptible to interference from wire-to-wire capacitance and wire-to-ground capacitance. For remotely mounted panels with less than 20 feet of wire length for the Tri-Probe wires 18 gauge thermostat wire may be sufficient. For distances up to 50 feet it is best to use individual stranded 20 ga THHN wire with a minimum insulation thickness of 0.030 inches run in a nonmetallic conduit. This conduit shall contain the three Tri-Probe wires only. The tank ground wire that terminates on plug J2 terminal #7 and all other low voltage wiring shall be run separate from the Tri-Probe wires. Unshielded TIA Category 6 networking cable may alternately be used, provided that the cable is not run inside a metal conduit or parallel to and within 2 inches of a metal conduit or pipe for more than 10 feet. Furthermore, only one conductor of each twisted pair is used for the probe wiring and the ground wire is also run separate from this wire bundle. The other 5 wires in the bundle shall be cut and taped off on both ends so they do not short to one another or to ground. 1 INTAC® Keypad Features Normal Operation LED (Green Colored): Fill LED: On Display: 2 line x 20 character Indicates normal whenever the vacuum fluorescent display Menu Number Operation fill valve is open Drain LED: On whenever the drain valve is open % Power 68% Heaters 1 2 3 002 INTAC ® Humidifier Control System System Fault LED: indicates when an error or fault has occurred NORMAL FILL DRAIN SYSTEM OPERATION FAULT PURE Humidifier Co. ENTER 100 200 300 HOME Enter Key: Used to toggle/confirm setting once it has been changed and to access the 300 menu “Down” & 200 Menu Key: “Up” & 100 Menu Key: Used to access the 200 menu, Used to access the 100 menu, decrease a value, or scroll increase a value or, scroll down in a menu up in menu 100, 200, 300 KEYS ARE USED TO ACCESS CORRESPONDING MENU DEPRESS 200 & 300 KEYS SIMULTANEOUSLY TO ACCESS THE 500 MENU The Home Display is accessed by depressing the 100 & 200 keys simultaneously (Home=Home Display) 2 INTAC® Menus Overview HOW TO NAVIGATE: Press and simultaneously to exit any menu and reach the home display at any time. Press or to move up or down through the home display or menu screens. To access a menu, press and hold the corresponding numbered menu key for three (3) seconds. To access the 500 Menu, press and hold the 200 300 and simultaneously for three (3) seconds. ENTER Press to activate a menu prompt. The prompt will begin to blink. Press or to change a prompt value. ENTER Press to confirm a prompt value. Notes: > Menus can only be accessed from the home display. Press a nd s i m u l t a neously to exit any menu and reach home display. 100 200 3 INTAC® Menus HOME DISPLAY NORMAL Normal Operation < DISPLAY Safety Circuit Open E01 ERROR AND < ALARM RH Alarm DISPLAYS Low RH A01 Accumulated Run SYSTEM Time 60 Days 012 < OPERATION DISPLAYS Time to Clean 30 Days 011 PRESS TO MOVE Control UP OR DOWN TCM 010 THRU THE HOME DISPLAY Outdoor Air Temp 78°F 009 H2O Actual 212°F 008 H2O Set Pt 45°F 007 HL RH Actual 60% RH 006 HL RH Set Pt 50% RH 005 H2O Level Full 004 Note: Capacity This is a complete listing of all 180 lbs/hr 003 the displays and menu prompts. Not all displays and menu prompts will appear on your 75% Power controller as they are Heaters 1 2 3 4 002 dependent on your configuration number. Prompts shown are RH Set Pt 45% examples only and may not represent your control settings. Actual 40% 001 4 RH Hi Alarm MENU 100 5% RH 104 PRESS AND HOLD FOR RH Lo Alarm 3 SECONDS UNTIL MENU PRESS TO -5% RH 103 APPEARS MOVE UP OR DOWN THRU MENU 100 - CONTROL THE HOME HL RH Set Pt PARAMETERS DISPLAY 80% RH 102 RH Set Pt 45% RH 101 100 INTAC Baud Rate 38400 213 INTAC Address 1 212 Note: This is a complete listing of all Clean Reset the displays and menu prompts. Off 211 Not all displays and menu prompts will appear on your controller as they are Time to Clean dependent on your configuration 30 Days 210 number. Prompts shown are examples only and may not represent your control settings. End of Use Drain 48 Hours 209 H2O Hysteresis PRESS TO 3°F 208 MOVE UP OR DOWN THRU THE HOME H2O Set Pt DISPLAY 45°F 207 Fill Delay 5 Seconds 206 Cool Down Temp 200°F 205 MENU 200 Cool Down Delay 150 Seconds 204 PRESS AND HOLD FOR 3 SECONDS UNTIL MENU Drain Interval APPEARS 40 Hours 203 MENU 200 - WATER & COM PARAMETERS Drain Duration 10 Minutes 202 Operational Mode Normal 201 200 5 RH Input Filter 1 Seconds 310 Duct Derivative 0.00 Minutes 309 Duct Integral 0.00 Minutes per repeat 308 Duct Hysteresis 3% RH 307 PRESS TO MOVE UP OR Duct Prop Band DOWN THRU 25% RH 306 THE HOME DISPLAY Cycle Time 1.0 Seconds 305 Room Derivative 0.00 Minutes 304 Note: Room Integral This is a complete listing of all 5.00 Minutes per repeat 303 the displays and menu prompts. Not all displays and menu prompts will appear on your Room Hysteresis controller as they are 3% RH 302 dependent on your configuration number. Prompts shown are examples only and may not Room Prop Band represent your control settings. 25% RH 301 ENTER 300 MENU 300 PRESS AND HOLD FOR 3 SECONDS UNTIL MENU APPEARS MENU 300 - PID (PROPORTIONAL, INTEGRAL & DERIVATIVE) 6 Menu Access All Menus 525 Unit Capacity Air Process Hi 40 Lbs/Hr 523 20.00 Milliamps 513 Capacity Unit Air Process Lo Lbs/Hr 522 4.00 Milliamps 512 Temperature Unit Air Sensor Fahrenheit 521 Current 511 Dedicated Input HL Process Hi Pnl Lockout 520 10.0 Volts 510 Out Process Hi HL Process Lo 10.00 Volts 519 0.0 Volts 509 Out Process Lo Hi-Limit Sensor 0.00 Volts 518 Voltage 508 Process Output RH Process High Voltage 517 10.00 Volts 506 Air Offset RH Process Lo 0.00 Volts 505 0°F 516 Air Range Hi RH Sensor 130°F 515 Voltage 504 Air Range Lo H2O Sensor -30°F 514 K Type 503 Control Source Transmitter 502 Note: This is a complete listing of all and ENTER the displays and menu prompts. Not all displays and menu prompts will appear on your controller as they are 200 300 dependent on your configuration number. Prompts shown are examples only and may not MENU 500 represent your control settings. PRESS AND HOLD SIMULTANEOUSLY FOR 3 SECONDS UNTIL MENU APPEARS MENU 500 - INSTALLATION 7 MODES OF OPERATION DESCRIPTION The INTAC® controller is preprogrammed at the factory for a specific type of modulation or on/off control. When a modulating mode of operation is selected the INTAC® will use the analog input on plug J2 terminals 1 and 3 for voltage inputs and J2 terminals 2 and 3 for current inputs. When programmed for “transmitter” mode on menu 502 a second modulating high-limit input may also be used on plug J4 terminals 5 and 7 for voltage inputs and J4 terminals 6 and 7 for current inputs. When programmed for “on/off” mode the INTAC® uses plug J1 terminal 1 and 2 where a closed switch between these two terminals will turn the humidifier output on. ELECTRIC HUMIDIFIERS SCR The fastest acting mode of modulation available is SCR control. SCR stands for silicon-controlled rectifier. Two SCR’s are employed back-to back in a device called a solid state relay (SSR). The SSRs are used to switch the power on and off to each heating element on a very short time scale. The INTAC® will send a pulse to each SSR according to the control signal for a percentage of the cycle time of one second (field adjustable). For example at 50% power the SSR will be on for ½ a second and off for ½ a second. This type of modulation is designed to provide extremely accurate control of the humidifier output. For a three phase humidifier, each set of heating elements within the humidifier evaporating chamber will be modulated to provide 0-100% modulating control of the humidifier output (capacity). SCRMod Just like SCR modulation except only one heater set is modulated with SSRs and mechanical contactors are staged on/off on heater sets 2 through 4. For a four heater set unit, the first heater set is controlled by SSRs. As the unit power goes from 0-24% the SCRs for heater set one will fully modulate from zero to 100% in this range. At 25% unit power the second heater set’s contactor will pull in and the SSRs will drop to 0% power on the first heater set. From 25% to 49% unit power the second contactor will remain pulled in while the SSRs modulate heater set one back to 100% power. At 50% unit power the third heater set’s contactor will pull in and the SCRs power will drop to zero. From 50% to 74% unit power the second heater set and third heater set will remain on while the SSRs modulate from 0 to 100%. At 75% unit power the SSRs drop down to 0% power and the fourth heater set contactor pulls in. From 75% to 100% the SSRs will modulate from 0 to 100% power. A 3% hysteresis is built-in so the contactors are not turning on and off quickly. For example if a contactor is turned on at 50% power then it will be turned off at 46% power. TCM (TIME CYCLE MODULATION) Time Cycle Modulation provides 0-100% modulating control of the humidifier output by cycling the mechanical contactors that supply the heating elements. The contactors are energized by the INTAC® controller between 0-100% of the cycle time. The cycle time is adjustable between 30 seconds and 4 minutes, depending on the application and control tolerances desired. With the default 60 second time cycle and at 50% power the contactor will be on for 30 seconds and off for 30 seconds. A feature called Watt-cycle rotates heater usage on multiple heater units to extend heater life. A slower cycle rate extends the contactor life, whereas faster cycle rates improve control response time. 8