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Armstrong PressureFog™

High Pressure Atomizer Installation and Operation Manual

IB-93A-EN

For Digital Copy

Warning: This bulletin should be used by experienced personnel as a guide to the installation and maintenance of the Armstrong PressureFog™. Selection or installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact Armstrong or your local representative if further information is required.

©2014 Armstrong International, Inc. Designs, materials, weights and performance ratings are approximate and subject to change without notice. Visit armstronginternational.com for up-to-date information.

Attention! Pressure Fog humidifier is an advanced product with operation that utilizes a high level of technology. It requires certain setup and configuration to be able to operate in the best manner for the specific application. Without the proper setup and configuration, which are required/explained in this installation and operations manual, the humidifier may malfunction and cause safety hazards. Armstrong International denies liability in such cases. The customer (end user of product) accepts all liability and risk relating to the use of the Pressure Fog humidifier in order to meet expected results of final installation and operation. In addition to adhering to the installation and operation manual, the following warnings must be taken into account:

DANGER OF ELECTRIC SHOCKThe humidifier contains live electrical components. Disconnect the main power supply before accessing/servicing inside parts or during maintenance and installation. Wait at least 3 minutes after removing electrical power.

DANGER OF HIGH PRESSURE WATER LEAKSThe humidifier constantly outputs high pressurized water 1,000-1,200 psig (69-83 bar). Ensure all water connections, both inside and outside the humidifier, are free of defects and imperfections. Ensure all water lines are appropriate and adequate for the high pressure.• The environmental and power supply conditions must conform to the values specified on the humidifier

nameplate.• Only qualified personnel who are aware of the necessary warnings and cautions are able to access/service the

humidifier during installation and operation.• Operate the humidifier at temperatures higher than freezing.• Only demineralized water with a pH level of 5.0 or higher is to be used with the humidifier.• A droplet separator (mist eliminator) must be installed for AHU/duct applications.• Do not attempt to open the humidifier in ways other than those specified in this manual.• Observe the safety standards of the surrounding environment in which the humidifier is installed.• Be sure to remove objects around humidifier that may be damaged by water. Armstrong International denies all

liability for water damage to surrounding objects caused by water leaks from the humidifier.• Do not use corrosive chemicals, solvents, or aggressive detergents to clean the inside and outside parts of the

humidifier, unless specifically indicated in this manual.• Do not drop, hit, or shake the humidifier, as this may cause damage to internal components.• Drain and replace the oil supply of the plunger pump after the first 50 hours of use, and then after every 500

hours of use. Drain and replace the oil supply of the plunger pump if it has not been used for more than a year. New oil may be obtained through your Armstrong representative.

• The output water must be distributed to a special dispersion manifold specified by Armstrong International.• Once dispersion manifold and piping are installed, flush and clean all water lines with DI or RO water prior to

running unit.• Minimum spacing requirements: 3 ft (914 mm) on all four sides, 2 ft (610 mm) on top.• Only use pipe tape (Teflon tape) on all NPT threads. Do NOT use pipe dope!• All humidifier operations must be done in accordance to this installation and operations manual in order to

maintain product warranty.

PressureFog™ Overview .........................4

Components ......................................5

Nozzle Dispersion Manifold ....................6

Physical Data Diagrams ........................7

Control Cabinet Diagrams ......................8

Piping Connections ............................. 10

Operation ......................................... 12

Dispersion Systems ............................ 15

Human-Machine Interface (HMI) ............. 17

Maintenance ..................................... 19

Troubleshooting ................................. 21

Wiring Schematic ............................... 22

Wiring Schematic Notes ....................... 25

Warranty .......................................... 26

PressureFog™ Overview1. Purpose and ApplicationPressureFog™ is a high pressure atomizing humidifier that produces a rich fog which raises the relative humidity. PressureFog™ is an efficient humidifying system that is ideal for applications that require high water volume with minimum energy use. It boosts reverse osmosis or deionized water to 1,000-1,200 psi (69-83 bar) using a plunger pump, which transmits the pressurized water to atomizing nozzles. The nozzles then nebulize the water into an array of super fine particles, 10 microns in diameter. These minutely sized particles create a fog that allow for quick evaporation and cooling by absorbing heat from the surrounding ambient air. This adiabatic process of evaporative cooling decreases the temperature of the air being humidified; it follows a line of constant wet-bulb temperature on the psychrometric chart.

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1.2 Configurations• Pressure Fog humidifiers are available in the followings capacities: 250, 500, 1000, 1500, 2000, 3000 lbs/hr (113, 227, 454,

680, 907, 1361 kg/hr). Power supply voltages available: 240, 480, or 600 VAC, all 3-phase, and 4-wire ground.

1.3 Before Installation • Before removing the packaging and protective material, move the humidifier to the desired site by means of the legs

underneath the unit, keeping it vertical at all times.• Humidifier should be intact upon delivery. Notify the carrier of any damage due to improper shipping.

1.4 Specifications

Attention! PressureFog™ must use deionized or reverse osmosis water!

Electrical Specifications Model PF250 PF500 PF1000 PF1500 PF2000 PF3000

Voltage(AC)

240 3- phase, 50/60 Hz 6.5 A 6.5 A 12.0 A 12.0 A 17.5 A 17.5 A

380-480, 3- phase, 50/60 Hz 4.5 A 4.5 A 7.0 A 7.0 A 10.0 A 10.0 A

600, 3- phase, 60 Hz 4.0 A 4.0 A 6.25 A 6.25 A 8.5 A 8.5 A

Model SpecificationsModel PF250 PF500 PF1000 PF1500 PF2000 PF3000

Capacity lbs/hr (kg/hr) 250 (113) 500 (227) 1000 (454) 1500 (680) 2000 (907) 3000 (1361)

Pump Flow Rate GPM (L/M) 0.5 (1.9) 1 (3.8) 2 (7.6) 3 (11.4) 4 (15.1) 6 (22.7)

Main Unit Weight lbs (kg) 200 (91) 220 (100) 270 (122) 270 (122) 290 (132) 290 (132)

Unit Shipping Weight lbs (kg) 250 (113) 270 (122) 320 (145) 340 (154)

Motor Power HP (kW) 1 (.75) 3 (2.2) 5 (3.7)

Motor Speed (RPM) 1750

Water Filter Housing Dimension in (mm) 5 OD x 12.5 H (127 OD x 318 H)

5-Micron Water Filter Dimensions in (mm) 2.5 OD x 9.75 H (64 OD x 247.7 H)

Inlet Water Pressure 40 to 100 psig (2.8 to 6.9 bar)

Outlet Water Pressure 1000-1200 psig (69-83 bar)

Unit Dimensions LxWxH in (mm) 17x31.5x52 (432x800x1321)

Sound Level (dB) 70 - 85

PressureFog™ Components2. PressureFog™ Components: • Control unit that has a comprehensive human-machine interface (HMI), houses the plunger pump and motor, and contains

the electrical cabinet.• Dispersion manifold that contains the atomizing nozzles and control solenoid valves.• Droplet separator to trap water droplets that have not evaporated (only in AHU/duct installation).• PRV (Pressure Relief Valve) to prevent pressure spikes within water piping.• Water treatment system (supplied by customer).

2.1 Control Cabinet

• E-stop (emergency stop) and on/off switch are on the top door of the control cabinet. These are the two physical controls of the unit.

• Touch-screen HMI allows for complete control of unit and displays system operation. It shows the overall status of the unit as all parameters can be viewed. These parameters are motor speed, motor on/off, inlet and outlet pressures, state of solenoid valves, and percent demand. When the unit shuts down due to an error in the system, the HMI will also show the corresponding alert notifying the error shutdown. See section 6, HMI Layout, on page 17 and 18 for a complete look at how to control PressureFog™ through the HMI.

• Positive displacement, reciprocating plunger pump driven by an inverter duty motor delivers demineralized water at 1,000-1,200 psi (69-83 bar). The pump is able to maintain a constant pressure to supply water to multiple AHUs/ducts or rooms.

• Programmable logic controller (PLC) and variable frequency drive (VFD) control the pump’s motor to adjust the speed of the pump so that pressure and output of the nozzles are precisely modulated according to the demand. Control can be stand alone using humidity sensors, or the system can be manually controlled.

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PressureFog™ Nozzle Dispersion Manifold2.2 Nozzle Dispersion ManifoldThe dispersion manifold contains the atomizing nozzles and control solenoid valves.

• Stainless steel, nozzle risers are welded uniformly onto the tubing of the manifold. The atomizing nozzles are then screwed into the risers (hand-tightened). The nozzles do not require adjustment, and have an anti-drip body which closes the orifice to avoid dripping and prevent any ambient contamination when the nozzle is off.

• Control solenoid valves are used to modulate which groups of nozzles are to be utilized. They are all stainless steel and are controlled automatically or manually through the PLC. They are normally closed, so if power is ever lost to the unit, then they will automatically shutoff the supply to the nozzles.

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2.3 Droplet Separator

The droplet separator (mist eliminator) prevents objects downstream in the AHU/duct from getting wet by trapping fog particles that have not completely evaporated. The droplet separator is made of stainless steel and built to cover the complete cross-section of the AHU/duct. Any trapped water will be efficiently drained so that the AHU/duct stays dry.

2.4 Water Treatment System

The water treatment system should supply deionized or reverse osmosis water at a minimum pressure of 40 psig (2.8 bar) to the pump. The pH level of the demineralized water must be 5.0 or higher.

Nozzles

Nozzle (Part Number) Orifice (in, mm) Threads

Capacity (lbs/hr, kg/hr)

1,000 psi (69 bar) 1,100 psi (76 bar) 1,200 psi (83 bar)

D17983 0.006 (0.15)10-24 UNC/2A

6.6 (3.0) 6.9 (3.1) 7.3 (3.3)

D17984 0.008 (0.2) 9.6 (4.4) 10.2 (4.6) 10.7 (4.9)

D17985 0.012 (0.3) 14.4 (6.5) 15.3 (6.9) 16.6 (7.5)

PressureFog™ Physical Data

Physical Data

Item Inches Millimeters

B - Bottom Door Height 23.7 602

C - Top Door Height 15.8 401D - Cabinet Depth 16.9 429E - Electrical Supply 5.3 135

F - Door Width 28.4 721

H - Cabinet Height 52.0 1321I - Water Inlet 31.2 792O - Water Outlet 12.2 309S - Solenoid Valves Port 12.3 313V - VFD Vent 11.3 288W - Cabinet Width 31.5 800

Unit Dimensions 16x31.5x52 432x800x1321

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PressureFog™ Control Cabinet Diagram

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E-STOP

ON/OFFSWITCH

HMI

TOP DOORHANDLE

BOTTOMDOORHANDLE

®

PressureFog™ Control Cabinet Diagram

MOTOR

PLC

LINEREACTOR

VFD

WATER FILTER

3/4" NPT INLETCONNECTION

3/8" OR 1/2" NPTOUTLET CONNECTION

DRAIN

PLUNGERPUMP

PRESSURETRANSDUCERS

24 VDCPOWER SUPPLY

MAINPOWERINLET

TERMINALBLOCKS& FUSES

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Piping Connections3. Piping ConnectionsPrimary Water connections: • Water inlet hose• Water outlet hose• Drain

Attention! An inlet manual valve must be installed immediately on the unit before connecting the water supply and water inlet hose. The valve should be resistant to demineralized water (stainless steel) and withstand pressures up to 100 psig (6.9 bar).

3.1 Piping Installation

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2

3

Step

Step

Step

Connect the water inlet hose.• The water inlet hose has a connection fitting of 3/4 inches NPT.• The water supply hose is to have an inner diameter (ID) of 5/8 inches (16 mm) or greater. • Connect piping from the water treatment system to the water supply hose.

Connect the drain to the waste water.• The drain may be open to atmosphere.• The drain hose is to have an inner diameter of 3/8 inches (10 mm) or greater.• Connect the drain hose to the drain connection underneath the cabinet using a hose clamp.

4Step

Replace oil cap on pump• Replace black oil cap (used for transport) with the yellow oil cap (used for operation).• Maintain black oil cap for future transport.

Connect the water outlet hose.• PF250, PF500 and PF1000: Piping on the outlet side of the unit must have an ID of at least 3/8

inches (10 mm).• PF1500, PF2000 and PF3000: Piping on the outlet side of the unit must have an ID of at least

5/8 inches (16 mm). • Connect the water outlet hose to the manifold.

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3.2 Piping Specifications

Piping SpecificationsModel PF250 PF500 PF1000 PF1500 PF2000 PF3000

Flow Rate gpm (l/m) 0.5 (1.9) 1 (3.8) 2 (7.6) 3 (11.4) 4 (15.1) 6 (22.7)

Load lbs/hr (kg/hr) 250 (113) 500 (227) 1000 (454) 1500 (680) 2000 (907) 3000 (1361)

Outlet Connection 3/8’’ NPT 1/2’’ NPT

Inlet Pressure 40 to 100 psig (2.8 to 6.9 bar)

Temperature 35°F to 110°F (2°C to 43°C)

Inlet Connection 3/4’’ NPT

Drain Connection 1/2’’ ID, 3/4’’ OD Silicon Tubing

Piping Connections, Continued 3.3 Demineralized WaterPressureFog™ must use deionized or reverse osmosis water to ensure: • No blockage of the nozzle orifices.• No dust from fog evaporation (fog should not leave minerals behind when evaporating).• Better hygiene and low maintenance.

3.4 Check the Piping Connections:

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Unit is vertical and level using stainless steel for external joints and piping.

Distance between unit and dispersion manifold is no greater than 150 ft (46 m)

Water supply pressure is between 40 and 100 psig (2.8 and 6.9 bar)

Drain connected to waste water.

The pH level of the demineralized water is 5.0 or higher.

Pump has yellow oil cap.

All pipe and compression fittings are tight.

Operation4. Modes

PressureFog™ can operate in two modes with a pressure control option:

Auto Mode:• PressureFog™ will modulate its load output based on the RH in the AHU/duct measured by a humidistat.• When the RH is below the humidistat setpoint, the unit demand will automatically increase. This will open more control

solenoid valves on the dispersion manifold so that different groups of nozzles can be utilized to raise the RH. Consequently, the pump output increases in order to meet the demand and maintain the atomization pressure of 1,000-1,200 psi (69-83 bar).

• The unit demand will stay high until the RH meets the humidistat setpoint. • If the RH is above the setpoint, the demand will automatically decrease. The unit will close some control solenoid valves and,

thus, fewer nozzles will be used. The pump output will also be decreased. • Each control solenoid valve has a different combination of nozzles to allow for continuous modulation across a wide range.

Pressure Fog will modulate the control solenoid valves accordingly in order to maintain the desired RH. Each set of control solenoid valves consists of a stage; Pressure Fog can modulate up to 42 stages.

• The unit can read a 0-10 VDC or 4-20 mA demand signal from the humidistat. • The unit can provide power for a 24 VAC humidistat, whose signal is 0-10 VDC.• The supply voltage for a 4-20 mA humidistat must be 24 VDC; it must be 2 wires – supply and output. Refer to the Wiring

Schematics for 240, 480 and 600 VAC on pages 23 through 25.• Ensure the unit reads humidistat signal (voltage and current) through a shielded cable with ground.

Manual Mode (Auto Mode Off):• Contrary to auto mode, the user can tell PressureFog™ which control solenoid valves on the dispersion manifold to open or

close while keeping a continuous flow rate across the nozzles. • Using the control on the HMI, the user can select which valves to be open/closed. The unit will adjust the pump output in

order to maintain a constant atomization pressure (user adjustable). Auto Mode can be turned on or off under the Mode screen.

Pressure Control:• In either mode, the pump can be controlled by the speed of the motor (Set RPM) or by holding a constant atomization

pressure (Set Prs), regardless of how many control solenoid valves are being used.

• By setting the motor speed (Prs Ctrl Off), the unit will always hold a constant speed which means the output pressure can vary depending on how many solenoid valves are open.

• It is best to have Pressure Control On so that the unit will automatically adjust the motor speed to maintain a constant pressure. The atomization pressure (Set Prs) can be set under the mode screen when Pressure Control is on. The motor speed (Set RPM) can be set under the Mode screen when Pressure Control is off.

Warning! Do not set the atomization pressure (Set Prs) greater than 1,200 psi (83 bar)!

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Attention! It is highly recommended that PressureFog™ is run using pressure control mode!

4.1 Pressure Fog Operation

Warning! Please adhere to the following operation steps before starting the unit.

• After turning power on, allow the unit to load the program; this takes about 1 minute. The HMI is operated using complete touch-screen control as it does not contain any physical buttons.

• After the program loads, you will be directed to the Main screen which has access to the Run, Mode, Valves, Conf, Alarm History, and the Logout button (see section 6 HMI Layout on pages 17 and 18 for complete screen navigation).

Operation, ContinuedMode Screen• Ensure the proper modes are selected for the application – auto mode ON/OFF and pressure control (Prs Ctrl) ON/OFF. For

both modes, simply toggle the ON/OFF control by touching the desired mode on the screen.• Prs Ctrl ON: Enter running pressure (psi) for Set Prs (psi), ideally between 1,000 and 1,200 psi (69-83 bar).• Prs Ctrl OFF: Enter motor speed (RPM) for Set RPM. Maximum speed is 1,750 RPM.• Both entries for Set Prs and Set RPM are numeric that is accessed by touching the desired input (Set Prs or Set RPM) on the

screen. Once you enter the pressure or speed, press the enter key on the touchpad to confirm entry.

Air Flow and High Humidity Switches• Under the Switches screen, accessed through the Mode screen, an air flow switch (AHU/duct application only) and a high

humidity switch can be enabled or disabled. For both switches, toggle the Enabled/Disabled control by touching the desired switch on the screen.

• Air Flow Switch Enabled: Normally open switch that does not allow the unit to run unless there is air flow in the AHU/duct. The switch closes when sensing air flow in AHU/duct allowing the unit to run. If air flow is ever lost while running, then the switch will shutdown the unit and triggers an alarm.

• Air Flow Switch Disabled: Unit ignores air flow switch, regardless if it’s connected or not.• High Humidity Switch Enabled: Normally closed switch that does not allow the unit to run unless the % RH is below its

setpoint. The switch opens when the % RH reaches setpoint forcing the unit to temporarily stop and triggering an alarm. The unit will resume running if the % RH drops below setpoint.

• High Humidity Switch Disabled: Unit ignores high humidity switch, regardless if it’s connected or not.

Valves Screen• Manual Mode ON (Auto Mode OFF): Control solenoid valves on the dispersion manifold can be opened and closed manually

by touching the desired valve (up to 6 valves) on the screen to toggle the respective valve’s open/close control.• A valve is open when its toggle control is shaded black on the screen.• Example: Solenoid Valve #1 is Open:

Solenoid Valve #1 is Closed: SV1 Clsd.

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SV1 Opnd

Alarm History Screen• Use the Alarm History screen to view a list of alarms that have occurred since the unit has been powered on. There are up/

down arrows to scroll through the different alarms that have occurred. The most recent alarm that happened is at the top of the scroll list. Use the “CLEAR ALL” touch button on the screen to clear the alarm history.

• To acknowledge any alarm and return to unit operation, simply hit OK on the screen for the respective alarm.

Alarm Descriptions

“No Air Flow” alarm Air flow in the AHU/duct has been lost as read by an air flow switch.

“High Humidity Reached” alarm The % RH has reached its setpoint as read by a high humidity switch.

“Inlet Pressure Too Low” alarm Water inlet pressure has dropped below 40 psi (2.8 bar).*

“Inlet Pressure Too High” alarm Water inlet pressure has gone above 100 psi (6.9 bar).*

“Outlet Pressure Too Low” alarm Water outlet pressure has dropped below 800 psi (55.2 bar).*

“Outlet Pressure Too High” alarm Water outlet pressure has gone above 1,400 psi (96.5 bar).*

* Note: These values may vary depending on the application. Please consult Armstrong if they need to be changed.

Operation, ContinuedRun Screen • Starting and stopping the unit can be executed on the Run screen. To start or stop the unit from running, simply toggle the

Start/Stop control by touching it on the screen. The Run screen displays the motor speed (RPM), inlet and outlet pressures (psi), and the status of auto mode and pressure control mode (On/Off). When auto mode is on, the Run screen will also show the % demand from the humidistat and the current stage # (1-42) of modulation.

• The Run screen displays the following:• Motor Speed (RPM)• Inlet Pressure (psi)• Outlet Pressure (psi)• Auto Mode (On/Off)• Pressure Control Mode (On/Off)• % Demand from Humidistat (Auto Mode On)• Modulation Stage # (1-42, Auto Mode On)

• If starting Pressure Fog in manual mode (auto mode off) with all the valves closed, the unit automatically open solenoid valve #1 so that flow is permitted when the pump creates pressure.

Configuration Screen• The conf (configuration) screen is locked and can only be accessed with the proper credentials. It contains parameters and

settings that should not be changed. Please consult Armstrong if there is a need to access the conf screen.• The E-stop must be RELEASED and the on/off switch must be in the ON position for the unit to run.

E-Stop and ON/OFF Control

E-Stop Twist to release, push to engage operator button

E-Stop released Unit is permitted to run, control solenoid valves are operational, and drain valve is closed.

E-Stop engaged Unit stops running/is not permitted to run, all valves (including drain) are open.

On/Off switch is ON when turned to counter-clockwise position Unit is permitted to run, control solenoid valves are operational, and drain valve is closed.

On/Off switch is OFF when turned to vertical position Unit stops running/is not permitted to run, control solenoid valves are operational, drain valve is closed.

On/Off switch is DRAIN when turned to clockwise position Unit is not permitted to run, control solenoid valves are operational, drain valve is open.

*The E-stop must be RELEASED and the on/off switch must be in the ON position for the unit to run.

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4.2 Filling

Before operating PressureFog™, the piping and dispersion manifold must be filled with water and vented of air. This ensures correct pressurization of the water lines and minimizes the possibility of drastic pressure changes caused by trapped air. With the unit on and the pump off, simply open the inlet manual valve to allow for the demineralized supply water to flow through the water lines, unit, and dispersion manifold. Ensure the E-stop is released and the ON/OFF switch is turned to the OFF position. In manual mode (auto mode off), open each control solenoid valve on the manifold by using the Valves screen on the HMI to allow the water to fill the tubing which houses the nozzles.

Warning: Be sure to close each valve after filling!

E-Stop and On/OFF Switch

Dispersion Systems5. Dispersion SystemsPressure Fog’s dispersion manifolds can be installed in two ways: Air Handling Unit/Duct or Direct Area Discharge

5.1 Air Handling Unit/Duct SystemThe dispersion manifold is installed inside an AHU or duct with a droplet separator where the fog is to be evaporated. The dispersion manifold is made to fit the cross-section of the AHU/duct and consists of stainless steel, high pressure tubing. Each tube has the atomization nozzles precisely welded onto them, along with the control solenoid valves. Each manifold is also equipped with a main drain solenoid valve installed at the lowest point of the piping that connects the rack to the pumping unit. The manifold has the proper number of atomizing nozzles located in specific positions on the manifold to maximize evaporation efficiency within the AHU/duct. This number is calculated during the system configuration phase.

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AHU/Duct Checklist• Do not directly obstruct the dispersion manifold.• AHU/Duct inner walls are to be made on stainless steel to prevent corrosion against demineralized water.• Nozzles are to be pointed in the same direction as the air flow.• Air velocity is to be 500 ft/min (152 m/min) or less.• Downstream air temperature to be determined during system configuration.• Locate the mist eliminator as far as possible downstream of the dispersion manifold.• Ensure the mist eliminator covers complete cross-sectional area of AHU/Duct.

5.2 Direct Area Discharge SystemThe dispersion manifold is installed in a room or some area of space, typically around the perimeter and towards the ceiling, so that the area can be humidified and cooled directly. Each tube of the manifold has nozzles spaced out accordingly and welded onto them. It is crucial that the manifold is installed high enough so that the fog completely evaporates before coming into contact with people, objects, etc. in the area. The number of nozzles, nozzle spacing, and manifold height is determined during the system configuration phase.

Direct Area Discharge Checklist• Do not locate over electrical equipment or equipment that may be damaged by water.• Typically, dispersion manifold is at least 13 feet (4m) from the floor.

Dispersion Systems, Continued

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Dispersion Systems, Continued Human-Machine Interface (HMI) Layout6. Human-Machine Interface (HMI) Layout The Allen-Bradley PanelView C300 HMI is used to control and operate Pressure Fog through its touch-screen access. When Pressure Fog is first turned on, it will take the user to the main screen which has Pressure Fog across the top of it.

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Screen Displayed Items Description

Main

Run Access to Run screen for operation status of unit.

Mode Access to Mode screen to view modes/parameters.

Valves Access to Valves screen to manually control solenoid valves.

Conf Access to Conf (Configuration) screen to adjust system parameters.

Alarm History Access to Alarm History screen to view which alarms have been triggered.

Logout Logout of the current user.

Run

RPM Indicator - displays speed (RPM) of motor.

Auto On/Off Indicator - displays whether Auto Mode is on or off.

Prs Ctrl On/Off Indicator - displays whether Pressure Control is on or off.

Start/Stop Control - Start/Stop toggle to turn pump on and off.

Inlet Prs Indicator - displays current inlet pressure to pump.

Outlet Prs Indicator - displays current outlet pressure to pump.

%D Indicator - displays current demand from humidistat. (%D is only displayed when Auto Mode is on.)

Stage # Indicator - displays current stage of modulation (up to 42 stages). (Stage # is only displayed when Auto Mode is on.)

Main Access to Main screen.

Mode

Auto Mode On/Off Control - On/Off toggle to turn Auto Mode on and off.

Prs Ctr On/Off Control - On/Off toggle to turn Pressure Control on and off.

Set RPM Control - numeric entry to set motor speed (0-1750 RPM). (Set RPM is only displayed when Pressure Control is off.)

Set Prs Control - numeric entry to set run pressure (0-1500 psi). (Set Prs is only displayed when Pressure Control is on.)

Switches Access to Switches screen to enable/disable what switches are to be used.


Switches

Air Flow Switch Control - Enabled/Disabled toggle for the use of an air flow switch.

High Humidity Switch Control - Enabled/Disabled toggle for the use of a high humidity switch.

Mode Access to Mode screen.

Valves

SV1 Opnd/Clsd Control - Open/Close toggle to open or close control solenoid valve #1 manually.







Warning: DO NOT access C300 Setup Screen. Doing so could result in changes to programming!

Main Screen Run Screen

Human-Machine Interface (HMI) Layout

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Screen Displayed Items Description

Conf(Password Protected)

PID Setup Access to PID Setup screen to adjust PID values.

Staging Access to Staging screen to define valve staging.

H-Stat Scale Access to H-Stat Scale screen to set humidistat parameters.

Inlet Prs Access to Inlet Prs screen to set inlet pressure safety switch values.

Outlet Prs Access to Outlet Prs screen to set outlet pressure safety switch values.

System Setup Access to System Setup screen for system parameters and options.


PID Setup

Gain Control - numeric entry to set PID gain used for Pressure Control (0-10).

Integral Control - numeric entry to set PID integral used for Pressure Control (0-10).

Derivative Control - numeric entry to set PID derivative used for Pressure Control (0-10).

Conf Access to Conf screen.

Staging

# of Stages Control - Up/Down arrows to set number of stages for modulation (1-42).

Stage # Control - Up/Down arrows to set what valves will open on corresponding stage (1-42).

V1 On/Off Control - On/Off toggle to turn valve #1 on or off for respective stage.






Main Access to Main Screen

H-Stat Scale

Stop Delay Control - numeric entry to set motor stop time between stages (0-1000 sec).

Scale Min. Control - numeric entry to set h-stat low end at which unit will not run (0-100%).

Scale Max. Control - numeric entry to set h-stat high end at which unit will not run (0-100%).


Inlet Prs

Inlet Min. Control - numeric entry to set minimum inlet prs safety switch (0-100 psi).

Inlet Max. Control - numeric entry to set maximum inlet prs safety switch (0-200 psi).

Delay Control - numeric entry to set delay for inlet prs safety switch values (0-999 sec).


Outlet Prs

Out Min. Control - numeric entry to set minimum outlet prs safety switch (100-1200 psi).

Out Max. Control - numeric entry to set maximum outlet prs safety switch (800-2000 psi).

Min. Delay Control - numeric entry to set delay for min. inlet prs safety switch value (0-999 sec).

Max. Delay Control - numeric entry to set delay for max inlet prs safety switch value (0-999 sec).


System Setup

Disable Security Control - Enable/Disable toggle for turning on or off configuration security.

Change Password Access to Change Password screen to change credentials for system security.

C300 Setup Access to C300 Setup screen for PanelView C300 parameters and options.


LV/HV Drive Control - LV/HV DRIVE toggle to set VFD voltage: 240/380/480 (LV) or 600 (HV)

0-10/4-20 H-Stat Control - 0-10/4-20 toggle to set H-Stat type: 0-10 VDC (0-10) or 4-20 mA (4-20)


Change Password

Old Password Control - arrow keypad to enter current password (A-Z).

New password Control - arrow keypad to enter new password (A-Z).

Confirm Password Control - arrow keypad to confirm new password (A-Z).

C300 WARNING! DO NOT ACCESS C300 SETUP SCREEN. DOING SO COULD RESULT IN CHANGES TO PROGRAMMING!

PressureFog™ Maintenance 7. Water Filter CartridgeThe water filter houses a 5-micron cartridge that must be changed replaced every five (5) months or whenever there is a noticeable pressure drop on the inlet water caused by dirt. A dirty water filter cartridge can restrict water flow to the pump; be sure to check the condition of the cartridge regularly and replace it when dirty. Only use demineralized water with the unit to ensure longevity of the cartridge and pump. Only use water filter cartridges provided by Armstrong. Water filter cartridges are provided by your Armstrong representative.

To replace the water filter cartridge:1. Remove power to the unit.2. Turn off the water supply to the unit. (Close the water supply valve if installed - see section 3.1, Piping Installation on page 9)3. Relieve any pressure by pressing the red button on the water filter.4. Turn the water filter housing (clear) in the clockwise direction (looking at the filter from the top) to loosen and remove it from

the unit.5. Remove the old cartridge and install a new one.6. Replace water filter housing with new cartridge installed back to the unit. Ensure housing is clean.7. Turn on the water supply to the unit. (Open the water supply valve if installed).8. Relieve air gaps by pressing the red button on the water filter.9. Unit is ready to run with new water filter cartridge.

7.1 PumpThe unit has a positive displacement, reciprocating, plunger pump that is all stainless steel. The pump oil must be changed after the first 50 hours of operation, and then every 500 hours or four (4) months, whichever happens first, thereafter. Pump oil is provided by your Armstrong representative.

To drain and replace the pump oil:1. Remove power from the unit.2. Turn off the water supply to the unit. (Close the water supply valve if installed - see section 3.1, Piping Installation on page 9)3. Drain the oil completely into a drain pan by removing the oil plug located below the oil site glass.4. Replace the oil plug after complete drain.5. Remove the yellow oil cap (dipstick) on the oil fill port; add new oil to the fill port until oil level has reached central point of

the oil site glass. DO NOT OVERFILL. Oil capacity is approximately 15 oz (0.44 L).6. Replace yellow oil cap.7. Unit is ready to run with new pump oil.

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YELLOW OIL CAP

OIL SITE GLASS

OIL PLUG

Attention! The pump oil must be changed after the first 50 hours of operation, and then every 500 hours or four (4) months, whichever happens first.

Notes:• If the unit has not been in operation for more than a year, drain and replace the oil before running.• Weekly check the oil level in the oil reservoir by visual inspection. Oil level should be at the central point of the oil site glass.• Annually check the validity of the low pressure switch by turning off the water supply to the unit while running - the unit

should shut down on a low pressure alarm. It should also not be able to start if there is insufficient pressure. Ideally, the inlet water pressure should be at least 40 psi (2.8 bar) seen at the unit.

PressureFog™ Maintenance, Continued

7.2 Piping ConnectionsDue to the high pressure water supplied by the unit, ensure all piping, fittings, and joints are watertight every four months.

7.3 NozzlesNozzles are virtually maintenance free when used with properly treated, demineralized water. Nozzles are to be hand-tightened into the nozzle risers. Never use tools to tighten nozzles. Ensure all nozzle components are free of any dust, dirt, oil, etc. when installing them. If nozzles are faulty, replacement nozzles are available through your Armstrong representative.

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PressureFog™ TroubleshootingIssue Corrective Action

The unit does not start.

Check supply voltage.

Check circuit breakers.

Verify there is inlet waster to the unit at a pressure of 40-100 psig (2.8-6.9 bar)

Verify water filter cartridge is clean.

Clear all alarms.

Check for control and power fuses located inside the electrical cabinet.

Check the 24 VDC power supply.

Check for damaged or unconnected wires in the electrical cabinet.

Verify actual percentage of relative humidity is lower than percentage of relative humidity setpoint.

Verify a humidity demand signal is present

Verify airflow in the duct.

Verify E-Stop is Off and On/Off switch is On.

The unit turns on, but then turns off after a certain time

period.

Verify the inlet water pressure is maintained at 40-100 psig (2.8-6.9 bar).

Verify there are no leaks in the piping system.

Clear all alarms.

Verify pump oil level is sufficient and there is clean oil.

Ensure nozzles are spraying.

Restart unit by terminating power and turning it on again.

Plunger pump excessively vibrates and makes a

clattering noise.

Verify the inlet water pressure is maintained at 40 - 100 psig (2.8 - 6.9 bar).

Verify there is an adequate flow rate to the water inlet

Verify pump and motor are not exceeding their rated speed.

Verify water filter cartridge is clean.

Check water inlet line for debris. Avoid unnecessary bends in the line.

Verify all inlet water lines have an ID of at least 5/8” (16 mm).

Verify motor and pump are properly coupled.

The unit runs, but there is little or no pressure.

Ensure setpoint pressure for operation is at atomization pressure of 1,000-1,200 psi (69-83 bar)

Check for water leaks on the outlet side of the stainless steel piping.

Verify the inlet water pressure is maintained at 40-100 psig (2.8-6.9 bar).

Verify there is no air trapped on the outlet side of the stainless steel piping.

Atomizing nozzles spray very little or do not spray at all.

Ensure nozzles are clean and their orifices are not clogged.

Check for water leaks on the outlet side of the stainless steel piping.

Ensure the pump is producing the proper atomization pressure of 1,000-1,200 psi (69-83 bar).

Verify the control solenoid valves on the nozzle manifolds are opening and not clogged.

Ensure nothing is impeding the flow on the outlet side of the stainless steel piping.

PF250, PF500 and PF1000: Verify all outlet water lines have an ID of at least 3/8” (10 mm).

PF1500, PF2000 and PF3000: Verify all outlet water lines have an ID of at least 5/8” (16 mm).

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Wiring Schematic

22

240 & 480 VAC Non-CE Models

Wiring Schematic

23

380/480 VAC Models

Wiring Schematic

24

600 VAC Models

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Wiring Schematic NotesWiring Schematic Notes

1. Wires A & B are in shielded cable with ground wire G6.

2. Red terminal blocks are connected using 6-pole jumper.

3. Black (blk) terminal blocks are connected using 6-pole jumper.

4. Terminal blocks are to be in same orientation when next to each other - plastic side of one borders metal side of another.

5. Serial port & analog input module are part of PLC. The AI module must be to the right of the serial port when positioned on PLC.

6. PLC RS-232 comm port connects to HMI RS-232 port via RS-232 cable.

7. RS-485 drive card is part of VFD.*

8. Two contact blocks are part of the on/off switch.

9. Position of contact blocks on the on/off switch must be followed as viewed when looking at rear of top cabinet door.

10. Wires S1 thru S6 and N1 thru N6 are for external 24 VDC solenoid valves. The number of valves varies (up to 6) depending on the application.

11. Pressure transducer wires are in 4-wire with ground shielded DIN cable.

*For 240 & 480 VAC models only.

For 600 VAC Models:

• RJ-45 terminal adapter connects to RS-485 port on the VFD for communication between PLC and VFD.

1. The transformer, h-stat trans, can be used to power a 24 VAC, 0-10 VDC signal humidistat. Wires X1 & X3 are used to power it.

2. Wires 40(-) & 41(+) read a 0-10 VDC humidistat signal for a 24 VAC humidistat.

3. Wires 70 (supply VDC+) and 71 (output+) read a 4-20 mA humidistat signal for a 24 VDC humidistat.

4. Wires 40 and 41 or 70 and 71 are in shielded cable with ground wire G7.

5. Wire 50 connects to air flow switch common.

6. Wire 51 connects to air flow switch normally open.

7. Wire 60 connects to high humidity switch common.

8. Wire 61 connects to high humidity switch normally closed.

If using a humidistat, air flow switch, or high humidity switch:

PressureFog™ WarrantyArmstrong International

Limited Warranty and Remedy

Armstrong International, Inc. ( Armstrong ) warrants to the original user of those products supplied by it and used in the service and in the manner for which they are intended, that such products shall be free from defects in material and workmanship for a period of one (1) year from the date of installation, but not longer than 15 months from the date of shipment from the factory, [unless a Special Warranty Period applies, as listed below]. This warranty does not extend to any product that has been subject to misuse, neglect or alteration after shipment from the Armstrong factory. Except as may be expressly provided in a written agreement between Armstrong and the user, which is signed by both parties, Armstrong DOES NOT MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF MERCHANTABILITY OR ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

The sole and exclusive remedy with respect to the above limited warranty or with respect to any other claim relating to the products or to defects or any condition or use of the products supplied by Armstrong, however caused, and whether such claim is based upon warranty, contract, negligence, strict liability, or any other basis or theory, is limited to Armstrong s repair or replacement of the part or product, excluding any labor or any other cost to remove or install said part or product, or at Armstrong’s option, to repayment of the purchase price. As a condition of enforcing any rights or remedies relating to Armstrong products, notice of any warranty or other claim relating to the products must be given in writing to Armstrong: (i) within 30 days of last day of the applicable warranty period, or (ii) within 30 days of the date of the manifestation of the condition or occurrence giving rise to the claim, whichever is earlier. IN NO EVENT SHALL ARMSTRONG BE LIABLE FOR SPECIAL, DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR PROFITS OR INTERRUPTION OF BUSINESS. The Limited Warranty and Remedy terms herein apply notwithstanding any contrary terms in any purchase order or form submitted or issued by any user, purchaser, or third party and all such contrary terms shall be deemed rejected by Armstrong.

Special Warranty Periods are as follows:

PressureFog™ Series PF250, PF500, PF1000, PF1500, PF2000, and PF3000: Two (2) years after installation, but not longer than 27 months after shipment from Armstrong’s factory.

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IB-93A-ENPrinted in U.S.A. - 4/16

© 2016 Armstrong International, Inc.

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