Installation, User & Maintenance Guide

GH SeriesGas-fired Humidifier

Installation, User &

Maintenance Guide

FOR YOUR SAFETY:Do not store or use gasoline or other flammable vapors and liquids in the vicinity of thisor 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 firedepartment.

WARNING:Improper installation, adjustment, alteration, service or maintenance can cause injury orproperty damage. Refer to this manual. For assistance or additional information consulta qualified installer, service agency, or the gas supplier.

WARNING:If the information in this manual is not followed exactly, a fire or explosion may resultcausing property damage, personal injury or loss of life.

IMPORTANT: Read and save this guide for futurereference. This guide to be left with equipment owner.

Form #01-272 Rev. 1 150-3230 rev.A

Table Of Contents

GENERAL 1

- WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

- RECEIVING & UNPACKING EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

- GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

- MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION 1

- LOCATING AND MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

- GAS PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

- AIR MANIFOLD/CONNECTOR HOSE INSTALLATION FOR DIRECT VENT . . . . . . . . . . . . . . 5

- PROCEDURE:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

- INTAKE AIR DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

- TERMINAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

- VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

- STANDARD UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

- DIRECT VENT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

- ADDITIONAL REQUIREMENTS WHEN VENTING THROUGH A SIDEWALL . . . . . . . . . . . 8

- ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

- PRIMARY WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

- LOW VOLTAGE CONTROL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

- CONTROL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

- OUTDOOR ENCLOSURE HEATER SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- BLOWER PACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

- STEAM DISTRIBUTORS FOR DUCTED APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . 10

- PLUMBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

- WATER SUPPLY LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

- DRAIN LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

- DRAIN WATER COOLER SUPPLY LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- STEAM LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

- WATER TRAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

- CONDENSATE RETURN LINES FOR STEAM DISTRIBUTORS . . . . . . . . . . . . . . . . . 14

OPERATION 15

- WATER LEVEL CONTROL . . . . . . . . . . . . . . . . . . . 15

- B AND P MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

- MC MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

- DRAIN WATER COOLER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

- SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

- BLOWDOWN CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

- DRAIN RATE AND BLOWDOWN VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- MANUAL STEAM OUTPUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- B MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- GHMC DISPLAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- START UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- FILLING THE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- TESTING THE IGNITION SAFETY SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . 17

- SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

MAINTENANCE 18

- DRAINING THE TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

- CLEANING THE STAINLESS STEEL TANK & FLOAT CHAMBER . . . . . . . . . . . . . . . . . . 18

- COMBUSTION BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

- BURNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

- BURNER REMOVAL/INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

- ADJUSTMENTS/REPLACEMENTS OF COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . 19

- GAS VALVE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

- HOT SURFACE IGNITER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

- IGNITION MODULE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

- TRANSFORMER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

- AIR SWITCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- DRAIN PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- COMBUSTION AIR BLOWER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 20

- TANK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

- HEAT EXCHANGER REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

- SERVICING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- FAULT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- B AND P MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- MC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- SERVICE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- FLAME SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- IGNITER CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- GAS VALVE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

- TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

- MANDATORY MAINTENANCE SCHEDULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

- START-UP AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

- VENTING MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

- EXTERNAL CONTROLS WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 28

- GH B/P WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

- GH STAND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

- GH ENCLOSURE PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

- GH ENCLOSURE HEATER INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . 32

- REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33-36

- GH DIRECT VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

GENERAL

WARNING

� Improper installation, adjustment, alteration,service, maintenance, or use can cause carbonmonoxide poisoning, an explosion, fire, electricalshock, or other conditions which may causepersonal injury or property damage. Consult aqualified installer, service agency, local gassupplier, or your distributor or branch forinformation or assistance. The qualified installeror agency must use only factory authorized andlisted kits or accessories when modifying thisproduct. A failure to follow this warning cancause electrical shock, fire, personal injury, ordeath.

� Should overheating occur, or the gas fail to shutoff, shut off the manual gas valve to the appliancebefore shutting off the electrical supply.

� Do not use this appliance if any part has beenunder water. Immediately call a qualified servicetechnician to inspect the appliance and to replaceany part of the control system and any gascontrol which has been under water.

This installation guide has been designed toprovide assistance when installing, mounting, andsizing a GH Series humidifier. Actual on siteapplication may vary. Consult Technical Services oryour local NORTEC representative.

RECEIVING & UNPACKING EQUIPMENT

1. Check packing slip to ensure ALL material hasbeen delivered.

2. All material shortages are to be reported toNORTEC within 48 hours from receipt ofgoods. NORTEC assumes no responsibilityfor any material shortages beyond this period.

3. Inspect shipping boxes for damage and noteon shipping waybill accordingly.

4. After unpacking, inspect equipment fordamage and if damage is found, notify theshipper promptly.

5. All NORTEC products are shipped on anF.O.B. factory basis. Any and all damage,breakage or loss claims are to be madedirectly to the shipping company.

GENERAL SPECIFICATIONS

The NORTEC GH Series humidifier is acompletely new patented design based on leadingedge technology. The GH is designed to provideclean steam humidification at an economical price.

All GH models are available for normal altitude(0-2000 ft elevation) or for high altitude (2000-4500 ftelevation) applications.

GHMC models are also available with enclosurefor mounting outside when space is not available. Theunit will ship completely installed inside the outdoorenclosure ready for field connection. The enclosurewill protect the unit from wind, sun and precipitation.

INSTALLATION

1. The installation must conform with localbuilding codes or, in the absence of localcodes, with the ANSI Z223.1, National FuelGas Code, and/or CAN/CGA B149 InstallationCodes. Refer to the Gas Piping section of thismanual.

2. The humidifier shall not be connected to achimney flue serving any other appliances.

3. Provide for adequate combustion andventilation air in accordance with Sections 7.2,7.3 or 7.4, Air for Combustion and Ventilation,of the National Fuel Gas Code, ANSI Z223.1,or Section 5.3 of CAN/CGA B149 Installation

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MODEL DESIGNATION

The unit specification label indicates the model ofgas humidifier according to the following chart:

GH 100 N DI

PRODUCT LINE(Gas Fired Humidifier)

STEAM OUTPUT(lbs/hr) Normal Altitude

FUEL

N= NATURAL GASP= PROPANE GAS

DE-IONIZED WATER OPTION

DIRECT VENT OPTION

CONTROLS

B = BASIC (ON/OFF)P = MODULATINGMC = DIGITAL CONTROLLER

c/w KEYPAD

HA DVMC

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MODEL GH 200 SPECIFICATIONS

FUEL BLOWERSPEED

(MODEL)

INPUT (BTUH)* ORIFICESIZE

(DRILLSIZE)

STEAM CAPACITY(LBS/HR)

MANIFOLD PRESS. INW.C.

AIRORIFICE

DIAMETER

SHIPPINGWEIGHT

(LBS)

OPERATING WEIGHT

(LBS)

STD DV STD DV STD DV

NATURAL MAX 238,000 238,000 E 200 200 -0.2 0.00 1.062”350 660

MIN (B,P) 119,000 170,000 E 100 140 -0.2 0.00 1.062”

GAS MIN (MC) 65,000 85,000 E 50 70 -0.2 0.00 1.062”

PROPANE MAX 238,000 119,000 9 200 200 -0.2 0.00 1.062”350 660

MIN (B,P) 119,000 170,000 9 100 140 -0.2 0.00 1.062”

(LP GAS) MIN (MC) 65,000 85,000 9 50 70 -0.2 0.00 1.062”


FUEL BLOWERSPEED

(MODEL)


(DRILLSIZE)



AIRORIFICE

DIAMETER

SHIPPINGWEIGHT

(LBS)

OPERATING WEIGHT

(LBS)


NATURAL MAX 357,000 357,000 E 300 300 -0.2 0.00 1.062”800 1200

MIN (B,P) 178,000 255,000 E 150 210 -0.2 0.00 1.062”

GAS MIN (MC) 65,000 85,000 E 50 70 -0.2 0.00 1.062”

PROPANE MAX 357,000 357,000 9 300 300 -0.2 0.00 1.062”800 1200

MIN (B,P) 178,000 255,000 9 150 210 -0.2 0.00 1.062”

(LP GAS) MIN (MC) 65,000 85,000 9 50 70 -0.2 0.00 1.062”


FUEL BLOWERSPEED

(MODEL)


(DRILLSIZE)



AIRORIFICE

DIAMETER

SHIPPINGWEIGHT

(LBS)

OPERATING WEIGHT

(LBS)


NATURAL MAX 476,000 476,000 E 400 400 -0.2 0.00 1.062”800 1200

MIN (B,P) 238,000 340,000 E 200 280 -0.2 0.00 1.062”

GAS MIN (MC) 65,000 85,000 E 50 70 -0.2 0.00 1.062”

PROPANE MAX 476,000 476,000 9 400 400 -0.2 0.00 1.062”800 1200

MIN (B,P) 238,000 340,000 9 200 280 -0.2 0.00 1.062”

(LP GAS) MIN (MC) 65,000 85,000 9 50 70 -0.2 0.00 1.062”


FUEL BLOWERSPEED

INPUT (BTUH)* ORIFICE SIZE(DRILL SIZE)



AIRORIFICE

DIAMETER

SHIPPINGWEIGHT

(LBS)

OPERATING WEIGHT

(LBS)


NATURAL MAX 119,000 119,000 E 100 100 -0.2 0.00 1.062”300 500

GAS MIN 65,000 85,000 E 50 70 -0.2 0.00 1.062”

PROPANE MAX 119,000 119,000 9 100 100 -0.2 0.00 1.062”300 500

(LP GAS) MIN 65,000 85,000 9 50 70 -0.2 0.00 1.062”

* For high altitude units (2000-4500 ft) the input and steam capacities are de-rated by 10%. STD: Standard Gas Unit DV: Direct Vent Unit




Codes, or applicable provisions of the localbuilding codes.

4. The required free area of supply air openingis:11 in. sq. (7,000 mm

2), for GH 100

20 in. sq. (13,000 mm2), for GH 200

30 in. Sq. (19,500 mm2), for GH 300

40 in. Sq. (26,000 mm2), for GH 400

NOTE FOR DIRECT VENT OPTION:

The combustion supply air opening is notrequired to the room where the appliance isinstalled since the combustion airrequirements will be provided through the inletair duct (see installation section). To keepelectronic components cooled, it is required tokeep the environment around the unit at roomtemperature.

NOTE FOR OUTDOOR ENCLOSURE:Required free area of supply air is providedthrough the bottom of the unit. Front louversensure good air circulation in the summer.These louvers should be blocked for winteroperation.

5. Cabinet back and bottom contain air openingsto provide combustion air to the forced draftblower. Either the back or bottom set ofopenings must have at least 2" (50 mm)clearance to allow for adequate combustionair. For example, if the humidifier is floormounted, 2" clearance must be maintained tothe unit's back surface.

6. Excessive exposure to contaminatedcombustion air will result in safety andperformance related problems. Knowncontaminates include halogens, ammonia, andchlorides, excessive dust, lime or dirt.Excessive exposure of electronics to thecontaminants will also result in performancerelated problems. Contact NORTEC TechnicalServices if you have any questions. Ifcontaminants exist, it is recommended to usethe outdoor enclosure option to isolate theunit.

7. All surfaces are zero clearance to combustibleconstruction.

NOTES:

The leveling legs must be left in place whenfloor mounted on combustible material.

The humidifier shall not be installed directly oncarpeting, tile or other combustiblematerial other than wood flooring.

8. For recommended clearances for servicingrefer to Figure #2.

9. During installation cover the humidifier toprevent any dust or other contaminants fromentering the cabinet when activities such asdrilling are taking place.

NOTE: Some insulating materials may becombustible. Prior to installing this applianceexamine the area for insulating material. Ifthis appliance is installed in an insulatedspace, it must be kept free and clear ofinsulating materials. If insulation is addedafter the appliance is installed, it will benecessary to examine the area again.

LOCATING AND MOUNTING

GH Series humidifiers are designed to mount on asuitable wall (GH 100 only), GH Stand, or floor. Theclearance dimensions shown in this manual are forreference only and are the minimum required formaintenance of the humidifier. Local and NationalCodes should be consulted prior to final location andinstallation of the humidifier. NORTEC cannot acceptresponsibility for installation code violations.

1. Figure #1 shows the locations of all requiredconnections to the Gas Humidifier. Careful

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Drain

Gas Input

Line

DWC Water Input

Line*

Power And

Control WiringSteam

Outlet(s)

EXHAUST VENT COMES

OUT FROM THE TOP

Fill Water Input

Line

*DWC = Drain Water Cooler

Figure #1

Wall

Min 36" Side

Clearance for

standard unit.

Min 41” side

clearance for

Direct Vent

option

Min. 36" Of Space

For Frontal Clearance

Top ViewWith Direct

Vent Option

Top clearance of24” required.

Figure #2

consideration should be given to all of theseconnections when choosing a location for thehumidifier.

2. For front and side clearance requirements (foraccess during installation, maintenance andtroubleshooting), see Figure #2.

3. Location of the steam distributor should beminimum of 36” above the humidifier.

4. DO NOT locate humidifier any further thanabsolutely necessary from steam distributorlocation. Net output will be reduced as a resultof heat loss through steam hose (seeEngineering Manual, Form # -163D). Also,increased static pressure (over 7" W.C.) willresult in hot water leaking down the drain.Consult factory if this situation occurs.

5. Where possible, mount humidifier at a heightconvenient for servicing.

6. Wall mounting brackets (provided with GH100) should be securely attached open edgeupwards, horizontal, using field-suppliedfasteners (minimum of four 3/8" diameterfasteners in each bracket). Attach to avertical, solid surface. Put a security boltthrough the hole provided in the back of the

cabinet so that the unit cannot be bumped offthe wall bracket. See Figure #3.

7. Make sure humidifier is mounted level. If floormounted adjust using leveling legs.

All GH models are equipped with adjustableleveling legs which have a maximum travel of1.5”.

- These legs may be used to allow mounting ofan optional stand.

- These legs may be removed and replaced bylonger legs. Factory approval is needed.

- Removal or adjustment of legs requires a1 1/8” wrench.

8. Optional stands are available for all GH Serieshumidifiers. Refer to Shop Drawing Package,Form # 273 for details and part numbers.

9. Clearances around the unit should also bemaintained for good access to the gashumidifier. 3 feet clearance is needed on theright side of the cabinet for GH100/200, 4 feetis needed on the right side of the cabinet forthe GH300/400. The front requires 3 feetclearance for all capacities.

10. DO NOT mount humidifier on hot surfaces.

11. DO NOT mount humidifiers in an area wherefreezing may occur.

12. If humidifiers are mounted on roof, a properlyventilated, temperature controlled, (abovefreezing), weatherproof enclosure must beused. Consult your local representative formore information on Nortec’s enclosure.

13. DO NOT mount humidifiers on vibratingsurface. Consult factory.

14. In earthquake prone areas do not wall mount.Use the existing wall mount brackets to fastenunit to the wall with it sitting on the floor.Maintain spacing for air openings. (See“Installation” item 8).

NOTE FOR OUTDOOR ENCLOSURE:

1. Optional outdoor enclosure can also be used;unit is factory mounted inside the enclosure.

2. The enclosure should be installed at a securedistance from any air or exhaust system. (alsosee local code).

3. The enclosure should be bolted down orsecured if it is to be exposed to high winds.

4. If lifting the enclosure on the roof using aforklift, lift under the unit at cross members forstability. (Strapping belts can also be used.)

5. Clearances around the unit should also bemaintained for good access to the gashumidifier. 3 feet clearance is needed on theright side of the cabinet for GH100/200, 4 feetis needed on the right side of the cabinet for

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4.95"

29.0" Wall

Bracket Hole

Centerlines

Security Bolt

Figure #3

the 300 400. he front re uires 3 feetclearance for all capacities.

GAS PIPING

Installation of piping must be in accordance withlocal codes, and ANSI Z233.1, “National Fuel GasCode,” in the United States or CAN/CGA-B149Installation Codes in Canada.

The following table indicates the maximum andminimum allowable gas pressures for the GasHumidifier.

The gas inlet pipe size to the appliance is:½” NPT for GH 1003/4” NPT for GH 2001” NPT for GH300/ 400

Provide an adequate size gas supply line.

When black iron gas pipe is used, a sediment trapmust be located ahead of the humidifier gas controls.In all installations, a manual shut off valve, locatedoutside the cabinet, must be installed. See Figure #4.

Leak test all gas connections using a commercialsoap solution made to detect leaks. Bubbles indicategas leakage. Seal all leaks before placing thehumidifier in operation.

WARNING: Never use an open flame to check forgas leaks. If a leak does exist, a fire or explosioncould occur, resulting in damage, injury or death.

The appliance must be isolated from the gassupply piping system by closing its individual manualshut-off valve during any pressure testing of the gas

supply piping system at test pressures equal to orgreater than 14” w.c. (3.5 kPa).

Dissipate test pressure from the gas supply linebefore re-opening the manual shut off valve to theappliance.

NOTES:

1. Failure to follow this procedure may damagethe gas valve. Over pressured gas valves arenot covered by warranty.

2. DO NOT use Teflon tape on gas line pipethreads. A flexible sealant suitable for usewith Natural Gas and Propane Gas isrecommended.

3. Plan gas supply piping so it will not interferewith removal of gas valves or blowerassemblies and front or side service doors.

The gas valve is provided with pressure taps tomeasure gas pressure upstream and downstream,(manifold pressure). The minimum gas pressureshown is for the purpose of input adjustment.

A 1/8" NPT plugged tapping, accessible for testgage connection, must be installed immediatelyupstream of the gas supply connection to theappliance.

NOTE FOR OUTDOOR ENCLOSURE: Gas linesshould be routed through the bottom of the enclosure.

NOTE FOR DIRECT VENT UNITS: Thecombustion supply air opening is not required to theroom where the appliance is installed since thecombustion air will be provided through the inlet airduct (see installation notes below). Ventilation isrequired for cooling of the electronic components

AIR MANIFOLD/CONNECTOR HOSE

INSTALLATION FOR DIRECT VENT

All direct vent units are shipped with the airmanifold and connector hoses packaged separately.The connector hoses and air manifold must beinstalled by a qualified installer prior to commissioningthe unit.

Procedure:

1. Apply a ring of silicone around the outside ofeach of the blower adapter connector.

2. Mount a flexible connector hose over the hoseconnection on each blower adapter andsecure using a gear clamp provided with the

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ONO

FF

To Gas Line

Sediment Trap

Gas Valve

Gas Shut

Off Valve

Figure #4

INCHES W.C.

GAS MIN. MAX.

Natural 4.5 14.0

Propane 9.0 14.0

3. Carefully bend the flexible hose(s) to give the“S” shape as shown in the diagram.

4. Mount the air intake manifold to the cabinetbase using the mounting bracket located onthe bottom of the air manifold (refer to Figure6). DO NOT PUNCTURE OR ADD ANYHOLES TO THE AIR MANIFOLD.

5. Apply a ring of silicone to the outside of eachhose connection on the air manifold.

6. Mount the corresponding flexible connectorhose over each hose connection on the airmanifold and secure using a gear clampprovided with the unit.

INTAKE AIR DUCT

All direct vent units require an intake air duct toprovide fresh outside air for combustion.

Each air intake manifold has a single 4-inch(100mm) diameter inlet to which the supply air ductmust be connected.

Intake material must be UL or ULC listed 4-inchdiameter (I.D.) corrugated 2-Ply aluminum ducting. The following table lists several suppliers of approvedintake material.

Sup plier Prod uct

Z-Flex Z-Flex Alu mi num Chim -ney Liner

Flex-L In ter na tional Inc. Flexi-Liner

MICH I GAN CHIM-FLEX CHIM-FLEX Alu mi numLiner

Chim Cap Corp. Flex-All Alu mi num Liner

The following table details the allowable ductlength that can be connected to the direct vent option. Each 90 degree elbow equals 10ft and each 45 degree elbow equals 5ft. If flexible vent material is used, allbends should be smooth and have as large a radius as possible to avoid restricting the combustion air supply.

Al low able Equiv a lent In take Lengths

Max i mum Min i mum

70 ft (21m) 7ft (2.1 m)

All joints must be positively sealed with a siliconesealant to ensure that there are no leaks in the duct.

When installed, the intake duct and exhaust ventshould be the same equivalent length.

Condensate may form on the outside of the intakeduct, particularly in colder climates. It isrecommended to insulate the intake duct to preventcondensation from occurring.

To connect the intake duct to the air manifold:

1. Apply silicone around the outside of theconnector on the top of the air manifold. SeeFigure #6.

2. Mount the intake duct over the connector andsecure with an appropriate clamp to ensure aproper seal has been achieved.

TERMINAL LOCATION

The intake duct must terminate at an outsidelocation with the supplied vent terminal.

- 6 -

Moun tAir Manifoldt ocabi netbas e

A ir Ma nifolds hould be ti ghta gainst rearp anel

Figure #6

Gear Clamp

Hose connection (apply silicone)

Flexible Connector Hose

Figure #5

The intake and vent terminals must be installed as shown in Figure 7.

When locating the intake terminal, a minimumdistance must be maintained from the exhaust ventterminal to prevent re-circulation of exhaust gases. Figure 7 shows the proper location of intake andexhaust terminals on an outside wall.

Periodic cleaning of the screens in the terminal isrequired for proper operation.

Location of intake & vent terminal must complywith all local and national codes.

VENTING

CAUTION: The humidifier shall not be connectedto a chimney flue serving any other appliances. Allventing must be installed in accordance with local andnational codes.

NOTE: These requirements apply to bothstandard, direct vent units and units with outdoorenclosure.

NOTE FOR OUTDOOR ENCLOSURE: It isrecommended to vent the gas unit through thesidewalls of the gas enclosure to eliminate possibleleakage through the enclosure roof.

The vent pipe must be the same diameter as thevent connector. The supplied vent termination at thehumidifier is a MALE CONNECTION. Standard venting hook ups require a female to male path. It is highlyrecommended that a female to female adapter beassembled directly onto the humidifier. This willestablish the proper vent sequencing. Consult withventing contractor/supplier for proper hook up orconsult manufacturer listing, see page 37. ContactNORTEC for additional information.

GH100 exhaust manifold terminates with 3”O.D.Stainless Steel Tubing. GH200, 300 and 400 exhaustmanifolds terminate with 4”O.D. Stainless SteelTubing.

The maximum flue gas temperature at thehumidifier vent connector will not exceed 480°F. Useonly special gas vents listed for use with Category IIIor IV gas burning appliances, such as those listed inthe venting system chart, see page 37. (Listed to ULStandard 1738 in the USA and ULC-S636 in Canada.)

All venting joints must be positively sealed withhigh temperature RTV silicone sealant rated for atleast 480°F.

When venting a category IV appliance it isnecessary to provide for condensate removal in theventing system. This provision may be met by usingthe special drain tee as listed in the venting systemchart.

When a drain tee is used it is necessary to install a trap in the drain to ensure that flue gases do not ventinto the drain. Install the trap with a 12” minimumheight of standing water column.

Prior to activating the appliance, ensure that thetrap is filled with water and that the drain terminates inaccordance with local plumbing codes.

For any vent lengths over 20 feet long, useinsulated vent.

WARNING: Provide a screen or barrier to preventpersonal injury in areas where inadvertent personnelcontact with vent pipe can occur.

Stan dard Unit

The maximum recommended vent length is 100equivalent feet where each 90° elbow equals 10' andeach 45° elbow equals 5'. For lengths over 100’,consult factory.

Di rect Vent Unit

A maximum exhaust vent length of only 70equivalent feet (21m) is permitted with the direct ventoption, where each 90º elbow equals 10ft and each45º elbow equals 5ft. This maximum cannot beexceeded.

All horizontal runs of the vent pipe shall have aminimum rise of 1/4” per foot (21 mm/m) and shall besupported at maximum intervals of 5' (1.5 m) and ateach point where an elbow is used.

- 7 -

Figure #7

4 ft - 6 ft

Exhaust

Intake

The vent terminal must be installed within thesame atmospheric pressure zone as the combustionair inlet of the humidifier.

Periodic cleaning of the screens in the ventterminal is required for proper operation of thehumidifier.

NOTE OUTDOOR ENCLOSURE: Flue gasesmust be vented out of the enclosure.

ADDITIONAL REQUIREMENTS WHEN VENTINGTHROUGH 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 aboveany forced air inlet located within ten feet; or at leastfour feet below, four feet horizontally from, or one footabove any door, window, or gravity air inlet into anybuilding.

A minimum horizontal clearance of four feet fromelectric meters, gas meters, regulator and reliefequipment is required.

Locate the vent terminal at least seven feet abovegrade when it is adjacent to public walkways.

Locate the bottom of the vent terminal at leasttwelve inches above grade or ground, or normallyexpected snow accumulation level. The snow levelmay be higher on walls exposed to prevailing winds.

Avoid areas where local experience indicates thatcondensate drip may cause problems such as aboveplanters, patios, or over public walkways, or over anarea where condensate or vapor could create anuisance or hazard, or could be detrimental to theoperation of regulators, relief valves, or otherequipment.

Refer to the vent manufacturer's installationinstructions.

ELECTRICAL

PRIMARY WIRING

1. Humidifiers require field wiring to primaryvoltage terminal blocks. Power requirement is 120 Vac, 15A fused circuit, single phase.Wiring is fed through a 7/8" hole on upper right hand side of control compartment. See figure#1.

2. When installed, the appliance must beelectrically grounded in accordance with local

codes or, in the absence of local codes, withthe National Electrical Code, ANSI/NFPA 70,and/or the CSA C22.1 Electrical Code, if anexternal electrical source is utilized.

3. Connect ground wire to cabinet ground clamp.

4. External wiring sizes must be in accordancewith NEC and/or CEC and existing localelectrical codes and by-laws.


- Pri mary power should be routed through the grille atthe bot tom of the unit.

- If backup heater is used, sep a rate 240 V sup ply mustbe pro vided with dis con nect brought to the En clo surefor the heater. (Heater uses 20A – con sult lo cal codesfor wir ing size) See in stal la tion draw ing pro vided withthe heater for in struc tions on page 32. Note: Heatermay be plugged into 3-pronged, 30 am pere, 240 Vout let.

- If units op er ates dur ing the sum mer, wire ex haust fanpro vided with the en clo sure (120V wires sup plied with en clo sure), from in de pend ent sup ply.

LOW VOLTAGE CONTROL WIRING

All GH models require at least one type of inputcontrol signal for unit operation. Refer to the sectionsbelow that detail the types of controls that can be used with each model.

Low voltage control terminal strips are provided inthe electrical compartment. Internal sides are factorywired. External sides are to be field wired. Refer tothe specific control-wiring diagram supplied with eachunit.

Field wiring from humidistat to humidifier andbetween devices should be 18 AWG or heavier andkept as short as possible.

Controls are available from NORTEC asaccessories and can be ordered with the humidifier.Controls by others may also be used as long as theymeet the criteria noted below. The following is a

- 8 -

Figure #8

A

BC

1 2External

Internal3 4 5 6

On/Off Signal Loop(B Models)

24 VACAvailable

7 8 9

DP/MC MODELS

EMC MODELS

summary of the common types of controls that may be used with NORTEC Gas Humidifiers.

A – Wall or Duct Mounted Control On/OffHumidistat: Wired to make on drop in humidity, breakon rise to setpoint. Set to desired RH. Can be amake/break set of contacts from a Building Automation System.

B – Duct Mounted Safety High Limit On/OffHumidistat: Wired to make on drop in humidity, breakon 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.

C – Duct Mounted Safety Air Proving On/OffSwitch: Wired to make when sensing air flow, breakwhen no air flow. Used as a safety to preventsaturation when there is no air flow. Highlyrecommended for ducted applications.

D&E – Wall or Duct Mounted ModulatingHumidistat: Provides a modulating signal to the unitthat represents the output (up to 100%) required fromthe humidifier. Refer to the sections below that detailthe signal ranges that can be used with each model.

NOTE FOR OUTDOOR ENCLOSURE: Controlwiring should be routed through the grill at the bottomof the unit.

GHB MODELS

GHB models will accept on/off controls only (seeA , B & C on figure #8). In general, A is essentialwhereas B and C are optional. On/Off controls are tobe wired in series (only one path for current) acrossterminals 1 and 2 on the low voltage control terminalstrip. All on/off controls used must be of the type thatthe contacts are closed when operation is required and open to shut off the unit. A jumper wire may be placed across these terminals to replace on/off controls andprovide for constant operation.

Caution: Terminal 1 is the “hot” wire from the24Vac control transformer; it will trip the 3A breaker on the transformer if any control field wiring touchesground metal.

GHP MODELS

GHP models accept a single 0-10 VDC or 0-20mA control signal (see D on Figure #8) acrossterminals 4 and 5 on the low voltage terminal strip togenerate a modulating output from the humidifier.Terminals 1 and 3 are 24 Vac and ground respectivelyand may be used to power a remote mountedmodulating humidistat.

An on/off security loop exists across terminals 1and 2 and should be wired as described for GHBmodels.

GHMC MODELS

GHMC models may be configured for either singleor dual channel modulation. Control signals can be0-10 VDC or 0-20 mA (0-5 VDC, 1-5 VDC, 4-20 mAand 2-10 VDC are also available). The unit must beordered from the factory for the desired signal typeand number of channels. When configured for2-channel modulation the humidifier will generatesteam only if both channels indicate a demand (seeD&E on figure #8). If both channels are demandingsteam the humidifier will satisfy the lower demandsignal.

An on/off security loop exists across terminals 1and 2 and should be wired as described for GHBmodels.

CONTROL INSTALLATION

1. Mount any wall humidistat (control or highlimit) over standard electrical box at heightsimilar to typical thermostat. Any wallhumidistat should be in location representative of overall space being humidified and not inpath of blower pack or air supply grille. Do not mount on an outside wall where temperaturefluctuations can affect control response.

2. Mount duct humidistat in locationrepresentative of overall air humidity, usuallyin return duct. Do not mount it directly in frontof steam distributor or in turbulent or mixingzone. Mount humidistat where air's humidityand temperature are uniform andrepresentative of spaces being humidified.

3. Mount duct high limit humidistat downstreamof steam distributors far enough that, undernormal humidity and air flow conditions, steam will have been fully absorbed (typically at least 10 feet). It must be located to sense highhumidity only when uniform and representative air is over-humidified or approachingsaturation.

4. Mount duct air-proving switch so that it is ableto sense air flow or lack of it. Wire it to makewhen air flow is sensed and break when airflow fails.

5. Check operation of all on/off controls beforestarting humidifier.

- 9 -

6. Calibration of controls (on/off or modulation) in the field may be necessary due to shippingand handling. Verify humidistat accuracybefore commissioning system.

OUT DOOR EN CLO SURE HEATERSET TING

Position #1 on the heater will maintain the airaround the heater at around 60ºF. Each incrementchanges the set-point by an additional 16ºF. The offposition can be obtained by turning the knob counterclockwise. The set-point position is at 3 O’clock.

BLOWER PACKS

1. Blower packs are an optional accessory usedto directly distribute steam to localized areas(such as computer rooms) or in structures that do not have a built-in air distribution system.

2. Blower packs are remote mounted only. SeeBlower Pack Manual XX-277 for requirementsand installation instructions.

STEAM DISTRIBUTORS FOR DUCTEDAPPLICATIONS

1. Any humidifier's steam line may be dividedinto multiple branches to feed more than onedistributor. Steam supply line “tees” arecommon copper fittings that are available forthis purpose. Do not install zone valves on any of the steam supply lines.

2. Steam distributor locations are typically asfollows: supply air duct, return air duct, airhandling unit. Proper location shouldconsider: air temperature, relative humiditybefore the distributor, air velocity, dimensionsof the location, amount of steam beingintroduced into the duct, downstreamobstructions, and surfaces vulnerable towetting.

3. When steam distributors are located in a duct,they should be in a straight section of duct atleast 6 feet (2 meters) from any elbow orobstruction. If the duct or plenum conditionsresult in poor absorption distancecharacteristics, please consult your localrepresentative or the factory. (SeeEngineering Manual, Form # -163D forinformation on absorption distances.) SeeFigure #9.

4. Steam distributors should always span the fullwidth of the air stream. Multiple steamdistributors, arranged in a bank, can minimizeabsorption distance.

5. Exercise extreme caution when installing infiberglass or internally lined ducts. Ifnecessary, remove 4-6 feet of the lining where the steam is being introduced.

6. High positive or negative static pressure ductsor plenums have special requirements. Highpositive static pressure ducts may require theunit to be fitted with an extended externalwater trap. Consult factory.

7. Low temperature ducts below 60°F (15°C),shallow ducts, or branch ducts might requirethe use of a field supplied condensate drainpan below the steam distributor. See Figure#10.

8. The steam distributor mounting plate isperpendicular to the steam distributor. Whenthe mounting plate is attached to the side ofthe duct, the distributor is level. An upward ordownward slope to the distributor will result in

- 10 -

6 ft(2m)

Minimum

6ft(2m)

Minimum

NOTE: Multiple Steam DistributorsCan Reduce the Minimum Distance.

Figure #9

Shallow Duct

Drain PanT-Bar Ceiling To Drain

Branch Duct

Drain Pan

Figure #10

poor condensate drainage and “spitting” ofcondensate in duct. See Figure #11.

9. Any distributor longer than 3 feet (1 meter)should be supported at its end with a threaded rod through top or bottom of duct. See Figure#12.

10. Using duct mounting template provided, cut ahole in side of duct just large enough to admitsteam manifold and condensate drain pipeassembly. Use four sheet metal screws toattach mounting plate to side of duct. SeeFigure #13 and #14.

11. It is recommended that single distributors aremounted near the bottom of the duct to ensure the steam is dispersed into the majority of theair flow. See Figure #14.

12. With multiple steam distributors, the top steam distributor should be at least 8" below top ofduct to avoid possible condensation onsurface of duct. The remainder of spacebelow is proportioned accordingly. See Figure #15. For short steam absorption systems seeFigure #16.

- 11 -

Wrong

Support(If Needed)

CorrectAlways Mount Level

Wrong

Figure #11

3/8" Threaded Rod(Field Supplied)

Hex Nut(Factory Supplied)Steam DistributorDuct

Figure #12

1. 2 . 3.

1. Steam Distributor Mounting Plate2. Cut Hole In Duct For Insertion Using Template3. Mount With Four Sheet Metal Screws

Figure #13

A

B

H

2/3 H

1/3 H

H

A

B

H

W/2 W/2

W = 8" min.

S.D.ASDBSDCSD

H min.8"10"14"

A4.125"4.875"8.25"

B3.875"4.125"5.75"

S.D.ASDBSDCSD

H min.6"8"12"

A3.25"5.125"7.625"

B2.75"2.875"4.375"

Fig ure #14

Figure #15

8"Steam Header

Figure #16

PLUMBING

NOTE: All water supply and drain lineconnections should be installed in accordance withlocal plumbing codes.

NOTE FOR OUTDOOR ENCLOSURE: Watersupply should be routed through the bottom grille ofthe enclosure. If freezing conditions may occur, waterlines must be heat traced up to the unit.

FILL WATER SUPPLY LINE

1. The humidifier is intended to operate on coldpotable tap water.

2. DO NOT use a hot water source to supply thehumidifier. Minerals will adhere more easily to surfaces and the fill valve's small flowregulating orifice could become plugged.

3. Consider using a water softener. Longeroperating times between tank cleaning will bereached on softened water.

4. Reverse osmosis (RO) water can provide very long times before cleaning is required since itis cleaner than softened water. However, it isalso more corrosive. Deionized (DI) water may be used with all models. ConsultNORTEC representative for DI water unit.

5. Standard fill valves are sized for waterpressure ranging from 30 to 80 psig (ideally 55 to 60 psig). For other pressures, consultfactory. This pressure should be measured atthe humidifier if the water pressure is suspect.

6. It is recommended to have a faucet installedclose to the inlet water supply to allow quickfilling of the system on initial start up. This can also be very useful for mandatory cleaning ofthe unit. See Figure #17.

7. ALWAYS supply and install a shut off valve inthe water supply line dedicated to thehumidifier to facilitate servicing. Use ½" ODcopper to within 4 feet of the humidifier.Reduce copper to 3/8" OD and connect to thefactory-supplied 3/8" olive compression fittingon the side of the humidifier.

8. NOTE FOR OUTDOOR ENCLOSURE:Manual shut off valve should be provided bothat the unit and inside the building for additional safety if freezing condition may occur.

DRAIN LINE

1. The humidifier is equipped with a 1-3/4" drainoutlet connection on the side of the humidifier.See Figure #18. A field-supplied funnel isrequired for correct operation of the unit’sdrain system. See Figure #19. It will alsoprevent backup due to partially blocked orbadly installed drain lines.

2. The drain line should not end in a sink usedfrequently by personnel, or where plumbingcodes prohibit it. Route to a floor drain orequivalent for safety reasons.. Sump/Condensate pumps are available (refer

- 12 -

Steam outlet

Faucet

Water Source

Shut-off valve

MainFill

3/8”NPT

Faucet allows quick fill of the system on initial start-up using simple a garden hose.The faucetis also useful when cleaning the tank.

Figure #17

Fill Water Connection

Gas Connection

Drain Connection

DWC Water Connection

Figure #18

NOTE: Elbow Should Not Reach Bottom Of The Funnel.

Air Gap

1-3/4" CONNECTION HOSE 90deg Elbow (By Others)

Funnel

Figure #19

to Engineering Manual Form #XX-261) if anappropriate drain is not available.

3. Keep drain lines as short as possible. Keepdrain lines sloped down, not level and not upsince low spots in drain lines will accumulatesediment and cause backup. The drain lineshould be 1-3/4" O.D. or larger. Drain water istempered to be below 60ºC, so any kind ofplumbing tubing may be used. Consult localcodes.


- Hu mid i fier must not be drained on the roof.

- If freez ing con di tion may oc cur, drain linesshould be heat traced.

DRAIN WATER COOLER SUPPLY LINE

1. Drain Water Cooler valves are sized for waterpressure ranging from 30 to 80 psig (ideally 55 to 60 psig). For other pressures, consultfactory. This pressure should be measured atthe humidifier if the water pressure is suspect.

2. ALWAYS supply and install a shut off valve inthe water supply line dedicated to thehumidifier to facilitate servicing. Use ¾” IDpipe with standard ¾” female NPT fitting toconnect to DWC valve on the side of thehumidifier. See Figure #18.

3. For proper operation of DWC, water line mustdeliver at least 8 gal/min (30 l/min) of water atthe temperature of no more than 68ºF (20º C).

STEAM LINE

1. Field-supplied hard copper with ½" thick (min.) insulation is recommended for steam supply,with NORTEC supplied steam hose couplingused to make connection to humidifier. SeeFigure #20.

2. Do not install zone valves on steam lines. Improper adjustment will over-pressurize thegas humidifier

3. NORTEC steam supply hose or field-suppliedpiping should be sloped upwards from thehumidifier to the steam distributors. Slopeshould be at least 2" in 12"(10 degree slope)to promote condensate runback. See Figure#20. If this slope is not possible, condensatemust be removed before the distributor. SeeFigure #22. If downward slope is necessary,slope should be ½” in 12” to promotecondensate to run towards the distributor.Condensate should be removed just beforeentering distributor. See Figure #24.

4. Minimize the length of steam line and keep itas straight as possible, minimizing bends.Avoid using 90° elbows. Wherever possible,use long radius turns (using tube bender onoversized copper or pairs of 45° elbows). This will reduce the condensate generated by heatloss. This will also reduce the back pressureand avoid the need to install an extendedwater trap.

- 13 -

Field Supplied InsulatedHard Copper PipeOr Flexible Steam HoseAvailable From Factory

Clamp To Steam DistributorOr Remote Blower Pack

To Drain

Figure #20

Min. 3’

Min. 10 Degree Slope

Trap

3' min.

To Drain

Figure #21

Condensate To Drain

Figure #22

5. Ensure that the steam hose does not kink orsag. The steam hose becomes more flexiblewhen hot. The hose should be supported toprevent water traps. Only use steam hose forconnections or steam line runs of 5 feet orless. See Figure #23.

6. To ensure odor-free steam, always useNORTEC steam hose. Check steam hoseand hose couplings periodically for cracks,breaks, kinks. Replace as required. DO NOTsubstitute hose. NORTEC is not responsiblefor health effects or damage from substitutehose.

7. Steam lines require 1-5/8" O.D. (nominal1-1/2") copper pipe. For steam runs longerthan 40 feet use insulated nominal 2" copperto ensure the draining of condensate.

8. Do not use steel or plastic pipe for steamdistribution or hose other than NORTECsupplied. Substitution will void warranty.

9. If steam line is routed below steam distributoror if the steam distributor is lower than thehumidifier, a condensate trap “tee” will berequired to remove water at this low point.Run condensate from trap to nearest drainlower than the distributor. See Figure #24.

10. Do not run steam line more than 1 foot perlb/hr output. Example, 10 lbs/hr should nothave a steam run longer than 10 feet. If longruns are unavoidable, the humidifier should be sized larger to compensate for condensatelosses and insulated copper should definitelybe used.

NOTE FOR OUTDOOR ENCLOSURE: It isrecommended to insulate steam lines between the enclosure and the building or air handlingunit specifically if freezing conditions mayoccur.

WATER TRAP

1. The GH Series humidifier produces steam atatmospheric pressure. Pressure head mustdevelop to push steam through supply line and into air duct.

2. Combined resistance of duct positive staticpressure and steam line resistance creates asmall pressure head in water tank. Totalamount of positive static pressure head isreflected directly by water column differentialthat develops in the built in water trap.

3. The built in water trap allows a maximum of 7" W.C. pressure before tank water escapesthrough drain. This pressure should not beexceeded.

4. Static pressure is usually higher whendistributor's steam outlets are faced upstreamin a duct.

CONDENSATE RETURN LINES FOR STEAMDISTRIBUTORS

1. Nortec steam distributors and blower packshave built-in connections for draining offcondensate. These condensate lines must beconnected to the nearest floor drain or to acondensate pump (available from NORTEC).A flexible condensate hose, (available fromNORTEC), may be used for short condensateruns.

2. Always incorporate a trap in routing ofindividual condensate return lines.Condensate that accumulates in trap willprevent possibility of steam escaping. Depthof trap must exceed duct static pressure ininches of water column. See Figure #25.

3. Ensure the trap is 3’ minimum under thesteam distributor and has the trap as close tothe floor drain as possible.

- 14 -

Avoid Water TrapsAvoid Kinks

Proper Slope

Gentle Sweeping Turns

Fig ure #23

Not AcceptableWithout Trap "Tee"

Obstruction

Duct

Condensate "Tee"At Low Point InSteam Hose(Consult Factory)

To Floor Drain

Create A False Low Point To Remove Condensate WheneverThe Steam LineMust Approach The Distributor From Above.

Humidifier

Figure #24

4. Provide a “U” trap in condensate line evenwhen distributor is located in return airplenum. It stops a suction action fromimpeding condensate flow with duct pressures below atmosphere.

OPERATION

WATER LEVEL CONTROL

A float chamber with two floats and a controllerboard maintains water level and controls the fill cyclesthrough a solenoid operated valve. Cold fill water fromone of the fill valve outlets is routed through fill cupand introduced to the bottom of the water tank. Thesecond fill valve outlet is connected to the floatchamber to provide additional cooling. The fill cupincorporates a 1" (25mm) minimum air gap, to meetplumbing codes.

B and P Models

On initial startup, with a call for humidity, thesolenoid operated water fill valve opens and fills thewater tank. When the water level reaches switch “C”,see Figure #26, the firing sequence is initiated. Thewater fill continues until switch “B” is reached. Float“B” will initiate a time delay relay which maintainswater flow for a preset amount of time. When that timeexpires the drain pump is engaged to blow down amanually adjustable amount of water.

During operation, the water level in the tank willlower by evaporation until switch “B” initiates the filland overflow cycle again.

If the water level ever falls below switch “C” theburners will shut down to prevent any damage to theunit.

MC Model

On initial startup, with a call for humidity, thesolenoid operated water fill valve opens and fills thewater tank. When the water level reaches switch “C”,see Figure #26, the firing sequence will be initiated.The water fill continues until switch “B” is reached.While the water level is between switch “A” and “B”the fill valve will be pulsed for intervals proportional tothe demand for humidity. When the water levelreaches switch “A” the fill valve will be disabled. 60seconds after the fill valve is disabled the drain pumpwill be activated (for a period of 0-240 seconds set byprogrammable parameter DRN1). For setting of thisblow down time, refer to the GHMC Display Manual,form #274.

During this time water will be drained from the tank until the timed cycle is complete.

The fill valve is disabled following the abovesequence until water level in the tank drops belowswitch “B” (due to evaporation). At that time the above sequence is repeated. If the water level ever fallsbelow switch “C” the burner(s) will shut down toprevent any damage to the unit.

DRAIN WATER COOLER OPERATION - *NEW*

The unique design for the internal Drain WaterCooler from NORTEC will ensure water tempering atall times of the water going to drain. The fresh fill water coming from the separate fill line to the unit willcompletely mix with incoming water from the tankduring blow down or drain cycles and ensure waterdoes not exit the system at more then 140ºF (60ºC).

- 15 -

FILL CUPDUAL FILL VALVE

FLOAT CHAMBER

STEAM OUTLET(S)

DRAIN PUMP

DRAIN WATER COOLER

DWC FILL

TOATM.

TANK

AB

C

Figure #26

Condensate Trap

Depth Of Trap "Y"Must Be 2" More ThanDuct Static Pressure

min 3’

Figure #25

SEQUENCE OF OPERATION

Provided the necessary power, water, gas andvent connections are completed, the unit is started bythe activation of the on/off switch located on the frontpanel.

When the operating humidistat and safety controlsare closed, the ignition module will energize the igniter.The hot surface igniter then heats up, and after aboutseven seconds, the gas valve is energized. Theburner will then be lit and the igniter will shut off. If theburner flame is not sensed by the flame sensor within4 seconds, the gas valve will shut off and this cycle willbe repeated a maximum of three times. When thehumidity in the space matches the setting of theoperating controller, the burners will shut down and theunit will remain idle until the next call for humidity.

BLOWDOWN CALIBRATION

The gas humidifier will periodically “blowdown”water from the tank to reduce the concentration of totaldissolved solids that accumulate during long termoperation. Gas Humidifiers are shipped factory set atmaximum blowdown (approximately 20% of output).This setting ensures that scale build-up will beminimized for all water conditions. The amount ofblowdown is field adjustable. Two parameters will helpdetermine the proper blowdown setting of the Gas-fired Humidifier

• Water hardness• Silica content

Due to the wide range of water conditions foundthroughout North America it is important that theblowdown is set according to the local waterconditions. By water conditions we are referring to thehardness of the water supplied to the humidifier. Thehardness is measured in grains per gallon. It is alsoimportant to test for silica content. Silicates may causefoaming and contribute to scale buildup in thehumidifier tank and float chamber. When excessivefoaming occurs, an optional foam separator isavailable from NORTEC.

If you are unaware of the hardness or silicacontent of your water supply, there are many “do ityourself” kits which can be purchased, or there areseveral companies that will perform the tests for areasonable price. You can even contact yourmunicipality for your water condition.

It is possible to reduce this setting according toobservation and guidelines in the tables above . Also,when high silica content has been identified, thehumidifier tank and float chamber will requireincreased maintenance and the blowdown settingshould be increased to factory setting. In this casesilica content may determine the appropriateblowdown setting.

- 16 -

GH

Ban

dG

HP

Water Hardness Inspection Interval Blowdown Potentiometer Setting(located on the electrical panel behind the locked door)

All GHB and GHP Models

<4 grains Annual Between low & midpoint

4-10 grains Semi-Annual Between midpoint and maximum

>10 grains Bi-monthly Maximum

GH

MC

WaterHardness

InspectionInterval

Blowdown DRN1 Setting

GHMC 100 GHMC 200 GHMC 300 GHMC 400

<4 grains Annual 2 2 3 8

4-10 grains Semi-Annual 3 4 6 10

>10 grains Bi-monthly 4 6 8 12

*Refer to GHMC instruction manual for programming instructions.

DRAIN RATE AND BLOWDOWN VOLUME

When the drain pump is activated, the tank drainsat a rate of 8 gal/min (30 l/min). If the Drain WaterCooler is in use, the actual drain rate of the unitdoubles. For details on total blowdown volume, referto the chart below.

MANUAL STEAM OUTPUT ADJUSTMENT

B Models

Manual rate adjustment for GHB units isaccomplished by rotating the output adjustmentselector that is located on the switch panel behind thelocked door panel. Rotate the knob labeled “Output”clockwise to increase output and counter clockwise todecrease output. See specifications for output values.

GHMC DISPLAY OPERATION

Refer to the GHMC Display Unit OperatingInstructions, Form XX-274, for information onprogramming and operating the display unit.

START UP PROCEDURE

Also see Startup Sheet on page 25.

Prior to filling the unit, it is necessary to ensurethat no dirt or dust has accumulated in the controlcompartment. If necessary, clean this area to preventcontaminants from being drawn into the combustionblower. All water, gas, electrical and ventingconnections must be properly completed and testedbefore commissioning the unit.

FILLING THE SYSTEM (approximate time to fill: 1hour)

Before the GH unit will initiate combustion it mustbe filled with water to the low level setting of the waterlevel controller. (Refer to water level control). To fillwith water, turn the gas supply off and switch the uniton at the power switch. After turning the unit on, give ita call for humidity to start the fill cycle. The unit will fillautomatically until the low water level is reached andthen trial for ignition will begin. After three tries theignition module(s) will lock-out. Leave the unitswitched on until the fill sequence is complete. Thenswitch off the power and proceed with the ignitionsafety shut-off test.

TESTING THE IGNITION SAFETY SHUT-OFF

The ignition system safety shut-off must be testedby conducting the following method of test:

1. With the gas supply off, turn power on.

2. Blower pre-purges for 30 seconds.NOTE: On multi-blower models, it isnecessary to wait for all blowers to cycle.

3. After seven seconds the gas valve isenergized for four seconds, then de-energized.

After three trials for ignition (complete with

pre-purge) the unit goes into a safety lockout.

4. Manually re-open the gas supply. No gasshould flow to the main burner. End of test.

5. To reset the system, momentarily shut offpower switch, then turn it back on again. Aftera pre-purge the igniter will start to heat up andnormal operating cycle will occur as describedin the IGNITION SEQUENCE.

- 17 -

GH Blowdown Volume - L/hr (gal/hr)

GH 100 GH 200 GH 300 GH 400

WithDWC

WithoutDWC

WithDWC

WithoutDWC

WithDWC

WithoutDWC

WithDWC

WithoutDWC

< 4 grains 8 (2.0) 4 (1.1) 16 (4.0) 8 (2.0) 32 (8.5) 16 (4.0) 64 (16.9) 32 (8.5)

4-10 grains 12 (3.0) 6 (1.6) 24 (6.3) 12 (3.0) 48 (12.7) 24 (6.3) 96 (25.3) 48 (12.7)

> 10 grains 16 (4.0) 8 (2 .0 ) 32 (8.5) 16 (4.0) 64 (16.9) 32 (8.5) 128 (33.8) 64 (16.9)

These values are dependant of the water inlet pressures, gas inlet pressures, and steam output. These setting varyfrom site to site. If your blowdown volume is different then the values given adjust the blowdown setting accordingly.Consult factory for more details.

SAFETY INSTRUCTIONS

Refer to front cover and page 1 of this guide.

MAINTENANCE

Please also refer to Maintenance schedule onpage 24.

DRAINING THE TANK

During extended periods of inactivity such as offseason or periods of very low demand, it is advisableto drain the water from the tank. On all models this isaccomplished by switching the unit to “Drain”.

MC models can also be programmed to drainautomatically after being inactive for a specified time.Refer to the GHMC Display Unit OperatingInstructions, Form #XX-274.

Ensure that power is switched on again duringperiods of demand.

CLEANING THE STAINLESS STEEL TANK& FLOAT CHAMBER

CAUTION: Water and scale may be hot enoughto cause burns. Turn off humidifier and allow it to coolbefore cleaning.

The combustion chamber walls are usually selfcleaning. The mineral buildup flakes off, due to theexpansion and contraction and violent boiling actionduring on/off cycles, and settles to the bottom of thetank. A scale accumulation of up to 2" thick on thebottom of the tank will not affect operation of the GHunit.

It is recommended that the tank and float chamberbe cleaned at least once every season to maintainoptimum operation. It may be necessary to increasethe frequency of cleaning or increase the blowdownsetting in areas of hard water or prolonged annualusage (see the “Blowdown Setting section of thismanual).

To clean tank, remove steam lines and removecabinet lid. Lid is held down by keyed lock at rear lip.Remove tank lid by removing hold down knobs or nutsbeing careful to not damage the insulation or gasket.Do not remove the heat exchangers without consultingNORTEC.

Scoop out loose scale with a small shovel such asthose used for gardening. Once loose scale isremoved, use a scraper such as a plastic windshield

scraper to remove scale adhering to the tank orcombustion chamber walls. DO NOT use a metalscraper that will scratch the stainless steel surfaces ofthe tank. Once all large pieces of scale have beenremoved, vacuum the tank out with a shop vacuum, fillpart way with water, and flush remaining sedimentfrom the tank through the drain.

Due to the presence of polymer gaskets aroundthe heat exchangers, do not use any harsh cleaningchemicals. Please consult NORTEC prior to using anychemicals. Once the lid has been replaced, fill the unitwith water and examine for leaks.

Inspect the drain and fill lines assembly for scalebuild-up and if necessary remove them from thehumidifier for cleaning. If the blowdown assemblybecomes blocked, scale build-up in the tank will beaccelerated and damage to the humidifier could result.The drain pump may be opened and cleaned. ConsultNORTEC for proper procedure.

Reassemble the drain and blowdown if they wereremoved. Re-install tank and cabinet lid making suretank cover gasket is intact. Do not over tighten holddown knobs. If using a torque wrench do not exceed10 ft-lb. Re-connect all steam and condensate lines.

Cleaning the float chamber is accomplished byremoving the hold down screws to access the floatsand using a small brush to gently clean the scale fromthe floats and chamber. Ensure that floats are back inplace and o-ring is properly seated before tighteningscrews on float chamber. Special attention must beused when removing or re-installing the float chamber.The switch board must be replaced into the sameposition as before cleaning and the tie -wrap must beused to hold the float chamber in position. For properinstallation see Fig. #26.

COMBUSTION BLOWER

The combustion air blower motors arepermanently lubricated and require no othermaintenance.

BURNER

The burners are made of ceramic fabric materialand operate in the infrared mode. Depending on theenvironment, the burner(s) may require removal of lintor grease-laden dust periodically. This may beachieved by removing the burner and applyingpressurized air to the external surface of the material.Refer to the Servicing Section related to burnerremoval.

- 18 -

BURNER REMOVAL/INSPECTION

1. Shut off electrical power and gas supply to theappliance.

2. Disconnect wiring to hot surface igniter andflame sensor and remove. See section onremoval of these components.

3. Remove blower. See Blower RemovalSection.

4. Remove (5) burner flange mounting bolts.

5. Gently remove the burner assembly from theappliance being careful not to damage theburner material.

6. To reinstall, reverse above procedure andensure that flange gasket is not damaged anda good seal is maintained. Replace theburner gaskets.

7. Always test for leaks after any service hasbeen performed on the gas train as there is anexplosive gas mixture present downstream ofthe combustion blower.

ADJUSTMENTS/REPLACEMENTS OFCOMPONENTS

CONSULT FACTORY PRIOR TO THEREPLACEMENT OF ANY COMPONENT.

DANGER - SHOCK HAZARD - Make sureelectrical power to the appliance is disconnected toavoid potential serious injury or damage tocomponents.

Gas Valve Replacement


2. Remove front door and right side panel.

3. On units with multiple burners disconnect gassupply line from the Gas Intake Manifold. Onunits with a single burner disconnect gassupply line from the gas valve.

4. Disconnect wiring connections to gas valve.

5. Use (2) pipe wrenches to release the unionconnections between each gas valve and theinlet manifold mounted on the combustionblower inlet.

6. On units with multiple burners remove gassupply manifold with valves attached.Disconnect valve to be replaced from the gassupply manifold.

7. Remove union and nipple assembly fromvalve that is being replaced and install on newvalve.

8. Reverse above procedure to reinstall.

9. Leak test the gas train beforere-commissioning unit.

Hot Surface Igniter Replacement

NOTE: Replacement igniters must be supplied byNORTEC or damage to the unit may occur.


2. Disconnect wiring leads to the igniter.

3. Remove nut holding igniter cylinder to burnerflange and carefully remove igniter.

4. Inspect igniter gasket and replace ifnecessary.

5. Reverse above procedure to re-install.

CAUTION: Silicon carbide igniter is fragileand brittle. Exercise extreme care in handlingthe assembly to avoid damage.

Ignition Module Replacement

1. Shut off electrical power to the appliance.

2. Remove access door.

3. Disconnect wiring connections to the modulelabeling as required.

4. Remove screws (2) holding module.


Transformer Replacement


2. Remove access door.

3. Disconnect wiring connections fromtransformer leads labeling as required.

4. Remove screws (2) holding transformer.

- 19 -


Air Switch Replacement


2. Remove front panel.

3. Remove wiring connections to switch.

4. Remove screws (2) holding the switch.

5. Remove pressure hose(s) from switch notingproper location.


Drain Pump Replacement

1. Drain the unit completely. If the pump isbroken see (4.) below.


3. Remove front and right doors.

4. If the pump is broken detach hose connectingthe pump with fill cup from fill cup and drainwater manually. Make sure water is coldenough not to cause injury.

5. Remove wiring connections to the pump.

6. Remove hoses attached to the pump.

7. Remove the pump from the cabinet bracket.

8. Remove the pump bracket and install it onnew pump.


NOTE: To avoid water spillage (some waterwill be left on the tank bottom after manualdraining) use shop vac to remove left overwater.

Combustion Air Blower Replacement


2. Remove front door and right side panel.

3. Disconnect electrical plug connection toblower motor.

4. Disconnect the pressure hoses from theblower inlet.

5. Use (2) pipe wrenches to release the unionconnection between the gas valve and theinlet manifold mounted on the combustionblower inlet.

6. Remove nuts (4) on discharge outlet ofblower.

7. Remove blower assembly.

8. Remove (3) bolts on air intake assembly.

9. Attach air intake assembly onto newcombustion air blower ensuring that the O-ringis properly seated.

10. Reverse the above procedures to install thenew blower assembly.

11. Leak test the gas train beforere-commissioning unit.

Tank Replacement

1. Drain water from unit. See section “DrainingThe Tank”.

2. Switch off power to the unit and open frontand right door.

3. Disconnect steam and condensate lines.

4. Remove top cabinet panel with lock key andlift the door out of the overlapped edge.

5. Remove tank lid by unscrewing the knobs.

6. Remove left door/panel.

7. Disconnect float chamber by releasing thehose clamps (top and bottom).

8. Disconnect the blowdown -drain assembly byreleasing the hose clamp.

9. Remove gas manifold by disconnecting thecoupling bellow the gas valve.

10. Disconnect high stack unit sensor wires.Remove exhaust manifold.

11. Disconnect the wire harnesses from eachburner, ignition module, air proving switch.

12.12. Remove nuts holding the heat exchanger. Andpull heat exchanger out. Do not remove theburners.

13.13. Remove nuts which hold tank mount brackets

- 20 -

14. Disconnect the left end tank brackets from theframe.

15. Carefully slide tank out the left end of thecasing.

16. Reverse procedure to replace tank. Inspectheat exchanger gasket to ensure it is notdamaged. Tighten the nuts to 75 in lbs.

Heat Exchanger Replacement

1.1. Drain water from unit. See section “Drainingthe Tank”.

2.2. Switch off power to the unit and open front andright doors.

3.3. Shut off gas supply to the unit.

4.4. Remove gas train by breaking gas valveunion.

5.5. Disconnect wire harness at blower, ignitionmodule, air proving.

6.6. Disconnect vent connection to the unit.

7.7. Remove exhaust manifold.

8.8. Remove heat exchanger nuts.

9.9. Slide heat exchanger out.

10.10. Re-assemble in reverse order. Inspect allgaskets to ensure that they are not damaged.(Exhaust manifold gasket and burner gasketmust be replaced; clean surfaces from anyleftovers.)

- 21 -

SERVICING THE UNIT

Caution: Disconnect power before servicing thisappliance.

Caution: Label all wires prior to disconnectionwhen servicing controls. Wiring errors can causeimproper and dangerous operation.

The combustion chamber, heat exchanger andflue baffles are all fabricated from stainless steel anddo not require cleaning.

Should the main burner fail to light, or flame is notdetected during the first trial for ignition period, the gasvalve is de-energized and the control goes through aninterpurge delay before another ignition attempt. Thecontrol will attempt two additional ignition trials beforegoing into lockout. The valve relay will bede-energized immediately, and the combustion blowerwill be turned off.

FAULT CONDITIONS

This appliance is equipped with a self diagnosticignition module which identifies a fault code when itoccurs.

B and P Models

Faults are indicated with a flashing LED on B andP units. The LED’s are located on the switch paneland correspond to their respective ignition modulesfrom left to right looking from the burner entry side.

Counting the number of flashes of the LED’s andreferring to the Fault Conditions given below canidentify most ignition problems. Recovery from lockoutrequires resetting of the humidifier. Momentarily shutoff the power switch, then turn it back on again.

MC MODELS

Faults are indicated with a fault message on thedisplay of MC models. Refer to “GHMC Display UnitOperating Instructions” (Form XX-274) for anexplanation of fault messages. Recovery from lockout

requires resetting of the humidifier. This can beachieved by momentarily shutting off the power switchthen turning it back on, or by pressing the reset buttonon the main MC control board mounted on theElectrical Swing Panel inside the electrical cabinet.

SERVICE CHECKS

Flame Sensor

Flame current is the current which passes throughthe flame from the sensor to ground. The ignitionmodule must detect a minimum flame current of 0.7microamps or a flame proving lockout will occur. Tomeasure flame current, connect an DC micrometer tothe FC- FC+ terminals on the module. Meter shouldread 0.7 uA or higher. If meter reads below “0” onscale, meter leads are reversed. Disconnect powerand reconnect meter leads for proper polarity.

NOTE: Proper polarity of supply voltage to theunit is necessary for flame sensing to occur.

NOTE: Oxidation on flame sensing rod canreduce measured current. The oxidation can becleaned from the sensing rod using steel wool or anemery cloth.

Igniter Check

If the igniter is suspected of being defective thenthe following test may be carried out;

1. Ensure that the power and gas is switched offbefore servicing.

2. To test the igniter, disconnect the igniter leadsfrom their terminal connections, one on theignition module the other is part of the wireharness. Keep note of where they attach.

3. Using a multimeter set the Ohm’s scale andplace one of the meter leads on one of theigniter wire ends and the other meter lead onthe end of the other igniter wire.

4.4. You should obtain a reading between 50 and300 Ohm’s. This indicates the igniter is okay,otherwise it should be replaced.

Gas Valve Setting

The gas valves used in the GH series humidifierare negative-pressure-regulated valves. The valvesetting listed on the product rating plate is shownrelative to atmosphere – this setting will always remainconstant. In the direct vent application, the actualmanifold (outlet) pressure of each gas valve will vary

- 22 -

Error Mode LED Indication

Internal Control Failure Steady on

Air Flow Fault 1 Flash

Flame With No Call For Heat 2 Flashes

Ignition Lockout 3 Flashes

depending on the vent length and on the firing rate.The table below lists the outlet pressure of the gasvalve under different conditions. This table should beused as a guide when servicing/troubleshooting theunit. The actual measured manifold pressure shouldfall within the range shown.

Maximum VentLength(70 ft. 21m)

Minimum Ventlength

Maximum firingrate

-0.62” w.c. -0.40” w.c.

Minimum firingrate

-0.25” w.c. -0.15” w.c.

- 23 -

- 24 -

Symptom Causes / Service Checks

On-off Switch Energized, Humidistat calling foroperation. Unit does not operate.

- No power to appliance. Check circuit breaker. Check disconnect switch.

- Defective Transformer. Check secondary voltage. If no 24 volts, replacetransformer if breaker is not blown.

- Check re-setable stack high limit switch and reset if necessary.

- Low voltage breaker blown. Check breaker (located on bottom of interfacepanel). If breaker blown, reset breaker.

- Fault LED not operating. Loose connection at ignition module. DefectiveLED. Check wiring connections. Check for continuity between FC1 AndFC2 on ignition control module using multimeter.

- Ignition module locked out. Check LED diagnostic light MC display forfailure identification. See Fault Conditions for identification of fault codes.

Unit energized/Ignition module okay. BlowerNOT running.

- Loose wire(s). Check wiring connection(s).

- No call for humidity.

- Defective or loose blower driver board. Check blower driver board for greenLED. Check if properly seated. Replace if properly seated but no LED.

- Defective blower. Replace blower.

- 24VDC power supply defective or fuse blown. Check fuse on power supply.

Power to unit on, humidistat on, indicator lightson except humidity demand.

- Control signal miswired. Check signal.

- Low water level. Check water supply.

- Low float switch stuck or defective. Check continuity of float switch andinspect floats. Clean floats if scaled up; replace if defective.

- Bad control. Check LED for steady on or check MC display.

Pressure switch input okay but no trial forignition after purge delay.

- Miswired. Check PSW terminal voltage.

- Check for change of state when unit is turned down.

- Bad control. Check LED for steady on.

Valve activates. No ignition. LED displays 3flashes.

- Defective hot surface ignitor. Check resistance (see service checks).

- Gas valve off or no gas supply. Turn on gas.

- Mis-wired ignitor. Check wiring.

- Bad control. Replace.

Igniter on. No valve operation. LED displays 3flashes

- Valve wiring not connected. Connect.

- Damaged valve coil. Replace valve.

- Bad control. Check voltage between MV1 & ground. Replace control.

Valve activates. Ignition occurs, LED displays 3flashes.

- Defective flame sensor. Check flame current (see service checks).

- S2 wire not connected or loose. Connect.

- L1 and neutral wires to unit reversed. Correct polarity.

Flame with no call for heat. - Stuck valve. Shut off gas supply. Check LED for 2 flashes. Replace valve.

TROUBLESHOOTING GUIDE

- 25 -

RE

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- 26 -

ON/OFF Red Switch

Gas

ManifoldGas Orifice

Mounted In

The Gas

Manifold

Air Intake

Air Orifice

ON

OFF

START-UP AND INSPECTION

Date:_____________________________________

Reference Order #:__________________________

Job Name:_________________________________

Model:____________________________________

System ID #:_______________________________

Startup procedure:1.Filling system

Manually turn all Gas Valves to the OFF position (red switch on Gas Valve)

Turn unit ON at the main power switch

… Unit will fill automatically until low water float is reached and trial for ignition will begin…

… After 3 tries the ignition module will lockout since gas valve is turned OFF…

Wait until fill sequence is completed

Turn unit OFF at the main power switch

Manually turn all gas valve to the ON position (red switch)

2.Testing the ignition safety Shut-OFF

Manually close Gas Supply to the unit.

Turn unit ON at the main power switch

… Blower will pre-purge for 30 seconds….

… On multiple blower units, wait until all blowers have cycle….

… After 7 seconds the gas valve will energize for 4 seconds, then de-energize….

… After 3 tries, the ignition module will go into a safety lockout….

Manually re-open Gas Supply to the unit.

…. No gas should flow to the main burner….

…. End of test….

3.Normal operation

Reset system by momentarily shutting OFF main power switch and switching

back ON

… Igniter will start to heat up and normal operation cycle will occur…_________________________________

1 Steam line use 3ft above unit before sloping min 10º to distribution system.

2 BH Venting in stainless steel only (class III for GH 100 and class IV for GH 200 & 400). Co-venting with other appliance is prohibited. Vent must be same diameter as the ventconnector. 100-ft equivalent length maximum including elbows.

3 Drain lines must be kept as short as possible and slopped downwards.

Drain

Gas Input

Line

Water Input

Line

Power And

Control Wiring

Steam

Outlet

Vent

DWC

Line

MECHANICAL ELECTRICAL & CONTROLS

Steam Lines installed and sloped properly1

� Primary Voltage (120 VAC) connected, unit grounded �

Venting installed properly2

<100ft equivalent length � Control ON/OFF Security loop installed �

Gas supply line connected and purged of air � Modulating controls connected �

Gas Pressure at Gas Valve � Blower Packs powered by independent supply �

Fill valve installed and has its own shut off valve �

DWC valve installed and has its own shut off valve �

Drain piping installed with AIR GAP and slopedproperly

3�

- 27 -

VENTING MANUFACTURER

• Venting must be listed as Categories III(GH 100) or IV(GH 200/300/400).• BH type venting made of stainless steel must be used.• Follow venting installation instructions recommended by manufacturer.

FLEX-L INTERNATIONAL -

Telephone:(800)561-1980 - US & CanadaFax:(609)768-2385

Female / Female Adapter3” : SRANT6-3 4” : SRANT6-4

Please call to locate the wholesaler closest to you.

HEAT-FAB INC. - www.heat-fab.com/

Telephone:(800)772-0739Fax:(413)863-4803

E-mail: [email protected]

Female / Female Adapter3”:FSA-NOR-3 4”:FSAA4

Please call or see their website to locate thewholesaler closest to you.

FAS N SEAL -www.protechinfo.com/fasnseal.html

Telephone:(800)766-3473Fax:(518)463-5271E-mail: [email protected] / Female Adapter3” : FSAA3 4” : FSAA4


Z-FLEX- www.flexmaster.com/zflex/ -

United StatesTelephone:(603)669-5136Telephone:(800)654-5600Fax:(603)669-0309

CanadaTelephone: (905)731-9411Fax: (905)731-7086Female / Female Adapter3” : 02SVSLBX03 4” : 02SVSLBX04


- 28 -

3 4 65 7 8 9 10 1211EXTERNAL

INTERNAL

EXTERNAL

INTERNAL

GH SERIESEXTERNAL CONTROLS WIRING CONNECTIONS

LOW VOLTAGE TERMINAL STRIP

WARNING: Failure to wire the control lerin accordance with the wir ing diagramsuppl ied with the uni t could permanent lydamage the electronics . Such errors wil lvoid the uni t warranty.

Security Loop24Vac

ModulationSignalInput

"B"(MC Only)

ModulationSignalInput

"A"(GHP/MC)

+5 Vdc Supply

Unit Operation Signal(BMS Interface)

0 - 10Vdc

Peripheral Humidifier Interface0 - 10 Vdc

INPUTS OUTPUTS

NOTE: This is a wiring diagram only. For specific wiring instructions, it is necessary to referto the wiring diagram which is supplied with each unit.

generic

1 2

MC Models Only

On/Off ControlHumidistat

Air ProvingSwitch

High LimitHumidistat

BlowerPack

Other On / OffDevice

NOTE: If no On/Off Controlis used then a field jumpermust be connected acrossterminals 1 and 2 in orderfor the humidifier to operate.

GH SERIESEXTERNAL CONTROLS WIRING CONNECTIONSLOW VOLTAGE TERMINAL STRIPDiagram number GHX3001 Rev. B January 2, 2001

- 29 -

GH B/P Wiring Diagram

1 2 3 4 5 6

ON/OFF Controlsin series

Field wiring for GHB ON/OFF By others

1 2 3 4 5 6

ON/OFF Controlsin series

Field wiring for GHP 0-10 Vdc Modulation By Others

0-10 Vdc Modulating Humidistat By OthersWall Or Duct

-

-

+

+

- 30 -

GH

STA

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SA

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30

.0(7

7)

30

.0(7

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30

.0(7

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W

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26

.4(6

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23

.8(6

1)

23

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1)

L

in(c

m)

12

.6(3

2)

20

.3(5

2)

36

.7(9

4)

GH

10

0

GH

20

0

GH

30

0/

40

0

MO

DE

LD

IME

NS

ION

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STA

ND

SS

HO

PD

RA

WIN

G

- 31 -

5S

Q6

Su

gg

este

dve

nt

insta

llatio

ns

(by

oth

ers

)

61

25

81

/26

3/4

Fro

nt

Vie

w

Su

gg

este

dro

utin

go

fd

rain

,fill,

an

dg

as

co

nn

ectio

ns

(by

oth

ers

)

14

1/2

82

72

A

Exh

au

st

Fa

nH

oo

dS

ug

ge

ste

dve

nt

insta

llatio

ns

(by

oth

ers

)

GH

EN

CL

OS

UR

E

Physic

alD

ata

Novem

ber

13th

,2000

NO

TE

S:

1.S

ee

suggeste

dm

ounting

location

ofvent,

fill,

dra

in,and

gas

lines

on

dra

win

g.C

onnections

and

mate

rials

for

connections

tobe

made

by

oth

ers

at

site

(refe

rto

the

GH

insta

llation

manual).

2.120V

connection

for

exhaustfa

nto

be

made

atsite

by

oth

ers

.3.S

ee

GH

Shop

Dra

win

gs

for

dim

ensio

ns

locating

vent,

fill,dra

in,ste

am

,and

gas

connections.

4.A

sa

sta

ndard

the

GH

unit

isfa

cto

rym

ounte

din

sid

eth

eenclo

sure

.5.S

team

lines

should

be

route

dth

rough

the

back

or

sid

es

ofth

eenclo

sure

.6.In

sula

teand

min

imze

ste

am

run

length

tore

duce

ste

am

losses.

7.If

freezin

gconditio

ns

occur ,

enclo

sure

should

be

used

inconju

nction

with

freeze

pro

ction

featu

reand

back

up

heate

r .A

lllines

should

als

obe

heat

traced

up

toth

eunit.

PA

RT

NO

.D

ES

CR

IPT

ION

DIM

AW

EIG

HT

15

02

024

Enclo

sure

-G

H30

0/40

04

6.2

532

0L

B

15

02

025

Enclo

sure

-G

H200

27.2

528

0L

B

15

02

026

Enclo

sure

-G

H100

27.2

528

0L

B

Fro

nta

lC

lea

ran

ce

(min

36

”(9

2cm

))

Sid

eC

lea

ran

ce

(min

42

”(1

07

cm

))

- 32 -

OP

TIO

NA

L

HE

AT

ER

INS

TA

LL

AT

ION

MO

UN

TIN

GS

TU

DIS

LO

CA

TE

DO

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EN

CLO

SU

RE

'SM

AIN

BE

AM

INS

ER

TR

UB

BE

RG

AS

KE

TP

RO

VID

ED

ON

TO

MO

UN

TIN

GS

TU

DT

HE

NIN

STA

LL

TH

EH

EA

TE

RT

HR

OU

GH

TH

EH

OLE

INT

HE

HA

ND

LE

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LA

CE

TH

EW

AS

HE

RA

ND

SE

CU

RE

INS

TA

LLA

TIO

NW

ITH

TH

EN

UT.

MO

UN

TIN

GS

TU

D

HE

AT

ER

MO

UN

TIN

GH

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BB

ER

GA

SK

ET

DE

TA

ILA

GH

EC

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SU

RE

He

ate

rIn

sta

llatio

nin

str

uctio

ns

DW

G.

#1

50

23

03

.

A

12

34

56

8

11 12

13

16

17

18

22

23

24

25

26

28

27

31

32

33

34

35

36

21

19

30

37

910

14

7

15

20

29

32a

Inclu

des:

32

-26

-27

-28

-31

-34

RE

PL

AC

EM

EN

TP

AR

TS

GH

Se

rie

s

-33

-

- 33 -

- 34 -

GH SERIES REPLACEMENT PARTS

Item # Description Model Type GH 100 GH 200 GH 300 GH 400

1 Knob, Tank lid -Hold down all models 170-8828 170-8828 170-8828 170-8828

2 Tank Lid all models 170-5010 170-5012 170-5014 170-5014

3 Gasket, Tank Lid all models 170-8201 170-8210 170-8214 170-8214

4 Gasket, Exhaust manifold all models 170-8215 150-1653 150-1654 150-1654

5 Exhaust Assembly all models 170-5038 170-5044 170-5048 170-5048

6 Sensor, Stack Hi-Limit Manual Reset all models 170-3202 170-3202 170-3202 170-3202

7 Fill Cup - to - Fill Valve Hose all models 150-3052 150-3052 150-3052 150-3052

8 Fill Cup NHDI all models 150-2694 150-2694 150-2694 150-2694

9 Float Chamber - to - Tank Hose all models 150-3033 150-3033 150-3033 150-3033

10 Float Chamber - to - Fill Valve Hose all models 150-3035 150-3035 150-3035 150-3035

11 Dual Fill Valve all models 170-4231 170-4232 150-1357 170-4234

12 Float Chamber Dual Fill all models 150-3031 150-3031 150-3031 150-3031

13 Float Chamber Bracket all models 150-2647 150-2647 150-2647 150-2647

14 Fill Cup - to - DWC Hose all models 150-3051 150-3051 150-3051 150-3051

15 Pump - to - Fill Cup Hose all models 150-3050 150-3050 150-3050 150-3050

16 Float Chamber Board all models 150-3032 150-3032 150-3032 150-3032

17 Drain Water Cooler Valve Assembly all models 150-3100 150-3100 150-3100 150-3100

18 Drain Water Cooler Body Assembly all models 150-3089 150-3089 150-3089 150-3089

19 Ignition Module, Main (Burner A only) GHB, GHP 170-2501 170-2501 170-2501 170-2501

(all Burners) GHMC 170-2502 170-2502 170-2502 170-2502

Ignition Module, Auxiliary (Burners B, C, D) GHB, GHP n/a 170-2502 170-2502 170-2502

20 Float Chamber -to - Tank Hose all models 150-3033 150-3033 150-3033 150-3033

21 Pump, Drain 24V 60Hz all models 150-2644 150-2644 150-2644 150-2644

22 Manifold, Gas Intake all models 150-3029 170-1292 150-2017 170-1293

23 Valve, Gas Negative-Regulated (-0.2"w.c.) all models 170-2201 170-2201 170-2201 170-2201

24 Blower 24V dc all models 170-2104 170-2104 170-2104 170-2104

25 Gasket, Burner/Blower all models 170-8208 170-8208 170-8208 170-8208

26 Sight Glass Replacement Kit all models 170-9607 170-9607 170-9607 170-9607

27 Igniter, Hot Surface Shielded with gasket all models 170-9601 170-9601 170-9601 170-9601

28 Sensor, Flame Proving with gasket all models 150-3886 150-3886 150-3886 150-3886

not shown Flame sensor / igniter kit all models 150-3884 150-3884 150-3884 150-3884

29 Pump - to - Tank Hose all models 150-3049 150-3049 150-3049 150-3049

30 Bracket, Ignition Control all models 170-5861 170-5861 170-5861 170-5861

31 Gasket, Igniter (Shielded) all models 170-8219 170-8219 170-8219 170-8219

32 Burner Assembly all models 170-5083 170-5083 170-5083 170-5083

32a Burner Assembly complete all models 150-3885 150-3885 150-3885 150-3885

33 Switch, Air Proving single can all models 170-3702 170-3702 170-3702 170-3702

34 Gasket, Burner plate all models 170-8206 170-8206 170-8206 170-8206

35 Removeable Heat Exchanger all models 170-5015 170-5015 170-5015 170-5015

35a Seal Plate for GH 300 only (not shown) all models n/a n/a 150-2002 n/a

36 Gasket, Heat Exchanger all models 170-8220 170-8220 170-8220 170-8220

37 Tank Weld Assembly with insulation all models 150-3881 150-3882 150-3883 150-3883

RE

PL

AC

EM

EN

TP

AR

TS

GH

Series

12

3

45

46

47

48

49

10

11

12

13

14

15

16

17

18

22

20

23

24

30

27

28

31

32

3

19

21

2625

34

33

29

-35

-

- 35 -

- 36 -

GH SERIES REPLACEMENT PARTS

Item # Description Model Type GH 100 GH 200 GH 300 GH 400

1 Cabinet top door all models 150-2551 170-7222 170-7422 170-7422

2 Top, Control Cabinet all models 150-2546 170-7204 170-7404 170-7404

3 Lock, c/w Keys all models 185-3104 185-3104 185-3104 185-3104

4 Cabinet front panel all models 170-7101 170-7101 170-7101 170-7101

5 Cabinet front door all models 150-2552 150-2552 150-2552 150-2552

6a Relay DPDT 24V GHB, GHP 145-3020 145-3020 145-3020 145-3020

6b Relay 4PDT 24V latch GHB, GHP n/a n/a 149-3005 149-3005

7 Bracket,Terminal Mounting, GH all models 150-2543 150-2543 150-2543 150-2543

8 Cabinet left door all models 150-2550 170-7221 170-7421 170-7421

9 Frame left front all models 170-7141 170-7141 170-7141 170-7141

10 Frame left rear all models 170-7143 170-7143 170-7143 170-7143

11 Frame right front all models 150-2544 170-7242 170-7442 170-7442

12 Cabinet left rear panel all models 170-7102 170-7102 170-7102 170-7102

13 Door, Control Cabinet, Right all models 150-2549 150-3080 150-3083 150-3083

14a Bracket, Stiffening/Mounting all models 170-7133 170-7233 170-7233 170-7233

14b Bracket, Wall (not shown) all models 170-7134 n/a n/a n/a

15 Panel, Control Cabinet, Rear all models 150-2548 150-2548 150-2548 150-2548

16 Panel, Direct Vent all models 150-2560 150-3081 150-3082 150-3082

17 Frame right rear all models 170-7144 170-7144 170-7144 170-7144

18 Cabinet right base all models 150-2545 170-7206 170-7406 170-7406

19 Cabinet left base all models 150-2553 170-7203 170-7403 170-7403

20 Hex Head Cap Screw all models 170-8890 150-1703 150-1703 150-1703

21 Terminal Strip all models 1453952 1453952 1453952 1453952

22 Transformer 120/24 75VA all models 170-3121 170-3121 170-3121 170-3121

23 Ground CLamp all models 1323020 1323020 1323020 1323020

24 Terminal Block 2 Pole all models 1473002 1473002 1473002 1473002

25 Power Supply 24VDC all models 150-3609 150-3609 150-3610 150-3610

26 Electrical Component panel all models 150-2559 150-2559 150-2559 150-2559

27 Potentiometer 10.0 K ohm (for Output) GHB 170-3952 170-3952 170-3952 170-3952

28 Potentiometer 1.0 M ohm (for Blowdown) GHB, GHP 170-3950 170-3950 170-3950 170-3950

29a Controller Base GHB, GHP 170-3041 170-3056 170-3081 170-3081

29b Controller Base GHMC 170-3600 170-3600 170-3600 170-3600

30 Blower Driver all models 170-3604 170-3604 170-3604 170-3604

31a Timer 0.5-10 min D.on break GHB, GHP 170-3102 170-3102 170-3102 170-3102

31b Timer 0.5-10 sec D.on break GHB, GHP 170-3102 170-3102 170-3102 170-3102

32a PCB Keypad/Display GHMC 170-3606 170-3606 170-3606 170-3606

32b Diagnostic Display GHB, GHP 150-3105 150-3104 150-3103 150-3104

33 Switch On/Off/Drain all models 145-3001 145-3001 145-3001 145-3001

34a Lamp green all models 132-3096 132-3096 132-3096 132-3096

34b Lamp amber all models 132-3098 132-3098 132-3098 132-3098

34c Lamp - Red GHMC 145-3095 145-3095 145-3095 145-3095

not shown Switch, Lockout/Run GHMC 147-3010 147-3010 147-3010 147-3010

- 37 -

Item # De scrip tion Nortec P/N

GH100 GH200 GH300 GH400

1 Adapter, Blower intake 150-1635 150-1635 150-1635 150-1635

2 Gas ket, adapter 150-2164 150-2164 150-2164 150-2164

3 Hose, Flex i ble Connector 150-2148 150-2148 150-2148 150-2148

4 Air Manifold 150-3519 150-3520 150-3521 150-3522

5 Clamp, Gear 132-5009 132-5009 132-5009 132-5009

1

2

5

4

3

DIRECT VENT

LIM ITED WAR RANTY

NORTEC IN DUS TRIES IN COR PO RATED and/or NORTEC AIR CON DI TION ING IN DUS TRIESLIM ITED (here in af ter col lec tively re ferred to as THE COM PANY), war rant for a pe ri od of two years fromdate of ship ment, that THE COM PANY's manu fac tured and as sem bled prod ucts, not oth er wise ex presslywar ranted, are free from de fects in ma te rial and work man ship. No war ranty is made against cor ro sion,de te rio ra tion, or suit abil ity of sub sti tuted ma te ri als used as a re sult of com pli ance with gov ern mentregu la tions.

THE COM PANY's ob li ga tions and li abili ties un der this war ranty are lim ited to fur nish ing re place mentparts to the cus tomer, F.O.B. THE COM PANY's fac tory, pro vid ing the de fec tive part(s) is re t urned freightpre paid by the cus tomer. Parts used for re pairs are war ranted for the bal ance of the term of the war rantyon the origi nal hu midi fier or 90 days, which ever is longer.

The war ran ties set forth herein are in lieu of all other war ran ties ex pressed or im plied by law. Noli abil ity what so ever shall be at tached to THE COM PANY un til said prod ucts have been paid for in full andthen said li abil ity shall be lim ited to the origi nal pur chase price for the prod uct. Any fur ther war ranty mustbe in writ ing, signed by an of fi cer of THE COM PANY.

THE COM PANY's lim ited war ranty on ac ces so ries, not of NORTEC's manu fac ture, such as con trols,hu midis tats, pumps, etc. is lim ited to the war ranty of the origi nal equip ment manu fac turer from date oforigi nal ship ment of hu midi fier.

THE COM PANY makes no war ranty and as sumes no li abil ity un less the equip ment is in stalled instrict ac cor dance with a copy of the cata log and in stal la tion man ual in ef fect at the date of pur chase andby a con trac tor ap proved by THE COM PANY to in stall such equip ment.

THE COM PANY makes no war ranty and as sumes no li abil ity what so ever for con se quen tial dam a geor dam age re sult ing di rectly from mis ap pli ca tion, in cor rect siz ing or lack of proper main te nance of theequip ment.

THE COM PANY re tains the right to change the de sign, speci fi ca tion and per form ance cri te ria of itsprod ucts with out no tice or ob li ga tion.

NORTEC INDUSTRIES INC.P.O. Box 698

826 Proctor AvenueOgdensburg, NY 13669

Website: www.humidity.com

NORTEC AIR CONDITIONINGINDUSTRIES LTD.2740 Fenton Road

Ottawa, ON K1T 3T7

E-mail: [email protected]

A WMH COMPANY

Installation, User & Maintenance Guide

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