Originalinstructions
Usersmanual
MCD100S,MCD120S,MCD140S,MCD155S
Desiccantdehumidifier
withsteamheaterforreactivation
Appliestoallunitsmanufactured
fromweek22,2013
190TEN–1067–J1408 ©MuntersEuropeAB2014
Impo rtan tuserinformation
Intendeduse
Munters dehumidifiers are intended to be used for the
dehumidificationofair.Anyotheruseoftheunit,or
use which is contrary to the instructions given in this
manual, can cause personal injury and damage to the unit
and other proper ty.
No modification of the unit is allowed without prior
approvalby Munters. Attachment or installation
of additional devic es is only allowed after written
agreement by Munters.
Warranty
Thewarrantyp
eriodisvalidfromthedatetheunit
left our f acto
ry, unless otherw ise stated in writing.
Thewarranty
is limited to a free exchange of parts or
components w
hich have failed as a result of defects in
materials o
rworkmanship.
All war ranty claims must include proof that the
fault has occurred within the warranty period an d
that the u n it has been used in accordance with the
specifications. All claims must specify the unit type and
fabrication number. This information is stamped on the
identification plate, see section Marking.
It is a condition of the war ranty that the unit for the full
warranty period is serviced and maintained by a qualified
Munters engineer or Munter s approved engineer.
Access to specific and calibrated test equipmen t is
necessary. The service an d maintenance must be
documented for the warranty to be valid.
Alway s contact Munters for ser vic e or repair. Operating
faults can o ccur if the unit is maintained insufficiently or
incorrectly.
Safety
Information about dangers are in this manual indicated
by the common hazard symbol:
WARNING!
Indicatesapossibledangerthatcanleadtopersonalinjury.
CAUTIO N!
Indicatesapossibledangerthatcanleadtodamagetothe
unitorotherproperty,orc auseenvironmentaldamage.
NOTE!
Highlightssupplementaryinformationforoptimal
useoftheunit.
ConformitywithDirectives
The dehumidifier is in conformity with the essential
safety requirements of the Machinery Directive
2006/42/EC, the Low Voltage Directive 2006/95/EC
and the EMC Directive 2004/108/EC. The
dehumidifier is manufactured by a n ISO 9001:2008
accredited manufacturing org an isation.
Copyright
The contents of this manual can be changed without
prior notice.
NOTE!
Thismanualcontainsinformationwhichis
protectedbycopyrightlaws. Itisnotallowedtoreproduceor
transmitanypartofthismanualwithoutwrittenconsentfrom
Munters.
Please send any co mments regarding this manual to:
Munters Euro pe AB
Technical Documentation
P.O. Box 1150
SE- 164 26 KISTA Sweden
e-mail: t-doc@munters.se
ii
Importantuserinformation
190TEN–1067–J1408
Tableofcon tents
Importantuserinformation ............... ii
Intendeduse ...........................
ii
Warranty ...............................
ii
Safety ..................................
ii
ConformitywithDirectives ............
ii
Copyright ..............................
ii
Tableofcontents ........................... iii
1 Introduction ................................. 1
1.1 General ................................
1
1.2 Aboutthismanual .....................
1
1.3 Unintendeduse ........................
1
1.4 Safetyandcautions ...................
1
1.5 Operationmonitoring .................
3
1.6 Applicationlimitations .................
3
1.7 Faultindications .......................
3
1.8 Steamsupply ..........................
3
1.9 Marking ................................
4
2 Dehumidifierdesign ....................... 5
2.1 Productdescription ...................
5
2.2 Principleofoperation ..................
5
2.3 Maincomponents,explodedview ....
7
2.4 Configurationfeatures ................
8
2.4.1 Insulatedprocessairinlet .....
8
2.4.2 Processfancontrol ............
8
2.4.3 EnergyRecoveryPurge .......
9
3 Installation ................................... 10
3.1 Safety ..................................
10
3.2 General ................................
10
3.3 Inspectionofdelivery ..................
11
3.4 Movingthedehumidifier ..............
11
3.5 Storingthedehumidifier ..............
12
3.6 Siterequirements .....................
12
3.7 Splitunitinstallation ...................
12
3.7.1 Assembly .......................
14
3.7.2 Electricalconnections .........
16
3.8 Scopeofdelivery–steamreactivation
system .................................
18
3.9 Steamregulation ......................
19
3.10 Steamheater–recommendationsfor
installation .............................
19
3.11 Ductinstallation .......................
23
3.11.1Generalrecommendations ...
23
3.11.2Ductforoutdoorairinlet .......
24
3.11.3Ductforwetairoutlet ...........
24
3.11.4Ductconnectiondimensionsfor
inlets ............................ 25
3.11.5Ductconnectiondimensionsfor
fans .............................
26
3.12 Steamconnections ....................
28
3.13 Electricalconnections ................
28
3.14 Externalhumiditytransmitter .........
29
4 Commissioning ............................. 30
4.1 Pre-startchecks .......................
30
4.2 Airflowadjustment ....................
30
4.2.1 General .........................
30
4.2.2 Settingtheratedairflows ......
31
4.2.3 Baseconfigurationsettings ...
31
4.3 Set-upandtestofsteamheater ......
32
5 Operation .................................... 33
5.1 Controlpanel ..........................
33
5.2 General ................................
34
5.3 Quickstop ..............................
34
5.4 Operatingtheunit .....................
35
5.4.1 Initialstart–up,Manualmode
(MAN) ...........................
35
5.4.2 Initalstart-up,Automatic
mode(AUTO)–regulatingto
set-point ........................
35
6 Serviceandmaintenance ................. 36
6.1 Safety ..................................
36
6.2 Regularserviceandmaintenance ...
36
6.3 Serviceoptions ........................
37
6.4 Extendedwarranty ....................
37
6.5 Serviceindicatorlamp ................
37
6.6 Serviceandmaintenanceschedule
(0–24000hours) .......................
38
6.7 Serviceandmaintenanceschedule
(28000–48000hours) .................
39
6.9 Maintenanceofsteamheaterunit ....
40
6.10 Airfilterreplacement ..................
41
6.10.1Preparation .....................
41
190TEN–1067–J1408
Tableofcontents
iii
6.10.2Reactivationairfilter ...........
41
6.10.3Processairfilter ................
42
7 Faulttracing,steamheaterunit ........... 43
8 Technicalspecification .................... 44
8.1 Capacitydiagrams ....................
44
8.2 Noisedata ............................. 45
8.2.1 MCD100E ......................
45
8.2.2 MCD120E ......................
46
8.2.3 MCD140E ......................
47
8.2.4 MCD155E ......................
48
8.3 Dimensionsandservicespace .......
49
8.3.1 Dimensions,MCD100–140S .
49
8.3.2 Dimensions,MCD155S .......
50
8.3.3 Dimensionsforunitswithout
processfan .....................
51
8.3.4 Servicespace ..................
51
8.4 Technicaldata .........................
52
9 Scrapping .................................... 54
10 ContactMunters ............................ 55
iv
Tableofcontents
190TEN–1067–J1408
1 Introduction
1.1 General
Munters manufactures a w ide range of e fficient dehumidifiers designed for different uses and applications.
Contact your nearest Munters office if you have any questions reg a rding the installat ion or the use of your
dehumidifier.
For product data, see section Technical specification.
1.2 Aboutthismanual
This manual contains necessary information for how to install and use the dehumidifier in a safe and
efficient way. Information and guidelines for the operation of the c ontrol system can be found in a
supplementary document, also delivered with the dehumidifier.
NOTE!
Makesuretoreadallrelevantpartsofthismanualbeforeoperatingorperforminganyworkonthe
dehumidifier. Thismanualshouldbestoredinapermanentlocationclosetothedehumidifier.
1.3 U nintendeduse
The following restrictions on use apply:
■
Thedehumidifier is not intended for outdoor installation.
■
Thedehumidifier is not intended f or u se in classified areas where explosion safety compliant equipment
is requi red.
■
Thedehumidifier must not be installed near any heat g enerating devices that can cause damag e to the
equipment.
1.4 Safetyandcautions
Every measure has been taken in the design and manufacture of the dehumidifier to ensure that it meets the
safety requirements of the directives and standar ds listed in the EC Declaration of Conform ity.
The information in this manual shall in no way take precedence over individual responsibilities or local
regulations.
During operation and other work with a machine it is always the responsibility of the individual to consider:
■
Thesafety
of all persons concerned.
■
Thesafety
of the unit and other property.
■
Theprotec
tion of the environment.
The types
of dang ers that are indicated in this manual are described in section Important user information.
190TEN–106 7–J1408
Introduction
1
WARNING!
-Theunitmustnotbesplashedwithorimmersedinwater.
-Donotconnecttheunittoothermainsvoltagethanspecifiedontheidentificationplate.
-Donotinsertfingersoranyotherobjectsintotheairvents.
-Allelectricalinstallationsmustbecarriedoutbyaqualifiedelectricianandinaccordancewithlocalregulations.
-Thedehumidifiercanrestartautomaticallyafterapowercut. Alwayssetandlockthemainpowerswitchinthe
OFFpositionbeforecarryingoutanyservicework.
-Useonlyapprovedlifting
equipmenttopreventpersonalinjuryanddamagetotheequipment.
-AlwayscontactMuntersforserviceorrepair.
WARNING!
Neverliftanassembledunitusingliftingeyeboltsattachedtothetopbox. Liftingeyeboltsmustonlybeusedfor
liftingthetopboxduringinstallationofasplitunit. Failuretoobservethiscancausepersonalinjuryanddamageto
theunit
The safety labels below are attached to the unit. Make s ure that all personnel working with or near the unit
are aware of the meaning of each label.
Figure 1.1 Risk of p ersonal inju ry due to electric shock. Figure 1.2 R isk of personal injury due to hot surfaces.
TextonthesafetylabelinFigure 1.3 :
WARNING
Only lifting of top box permitted.
WARNING
!
Only lifting of top box permitted.
Refer to the user manual before lifting.
Figure 1.3 L ifting of unit not perm itted .
Refer to the user manual before lifting.
2
Introduction
190TEN–106 7–J 1408
1.5 Operationmonitoring
Thedehumidifier is controlled and monitored from the control panel on the front of the unit, see section
5.1, Control panel. The HMI ( Human M achine Interface) is used to display values and parameters, and to
input settings and commands to the control system. The HMI is described in the separate supplement.
1.6 Applicationlimitations
Thedehumidifier conforms to the emission limits of residential, commercial and light-industrial
environments except for the emission limits for harmonics emission (EN 61000–3–12). As the equipment
exceeds the limits for harmonics it may not be used in residential, commercial or light-industrial
environment without taking proper steps regarding the power installation like supplying the equipment
from a dedicated transformer connected to the high or medium voltage network.
Thedehumidifier may only be used in industrial environments (class A) w hen the HMI is equipped with a
touch panel. If the HM I is equipped with a text panel, the dehumidifiermaybeusedinallenvironments
since t he text panel is approved according to class B.
1.7 Faultindications
Any faults are indi
cated by the red light on the control panel. The cause of the alarm is indicated on the
display.
1.8 Steamsupp ly
The quality of water determines the quality of steam produced. It is important that a good quality steam
supply, at the correct temperature and pressure, is available for a reliable operation of t he steam heater.
Disregarding this can lead to degradation of the heater performance and eventually to failure.
The following impurities are common in the feed water:
■
Dissolved solids – which can cause scale to form on equipment. The principal dissolved solids are
carbonate and sulphates of calcium and magnesium.
■
Suspended solids – these can cause sludge to form in the boiler. Suspended solids are usually solid
mineral or org anic particles carried in suspension in the water.
■
Dissolved gases – these can cause corrosion in equipment. The dissolved gases are oxygen and carbon
dioxide.
■
Frothing substances that can c ause contamination and corrosion of the equipment. The frothing
substances creates a foam that usually contains soda in the form of carbonates, chlorides or s ulphates.
Cor rect water treatment is required to remove the impurities in the feed water. If the impurities are not
removed there could be an overflow of boiler water into the steam s yste m .
190TEN–106 7–J1408
Introduction
3
1.9 Marking
Figur e 1.4 Position of identification plat e
MCD155S
0910 170XXX XXXXX
13,2 kW
Max
13,9 kW
Munters Europe AB
Isafjordsgatan 1
164 26 Kista, Sweden
M
STEAM
Made in Sweden
Fabr. No.
Fabr. year 2009
3 ~ 400V 50 Hz
Type
IP33
Figure 1.5 Identification plate, example
Explanation of "Fabr. no" on the identification plate:
09: Year of manufacture
10: Week of manufacture
170XXX: Ar ticle number
XXXXX: Serial number
4
Introduction
190TEN–106 7–J 1408
2 Deh umidifierde sign
2.1 Productdescription
The desiccant dehumidifier has been designed to effectively dehumidify the air in environments requiring
low air humidity.
All functional components are enclosed in a corrosion resistant Aluzink
®
casing (standard) or stainless steel
casing (option) which makes installation and maintenance easy. The unit is constructed on a steel base frame
which allows the use of a fork-lift truck during transportation and installation.
The electrical control system complies with standard EN 60204-1. The electrical components are mounted
on bus bars. The dehumidifier is manufactured according to European standards and the established
requirements for CE-marking.
2.2 Principleofoperation
1
4
2
3
Figure 2.1 R otor principle
1. Process air
2. Dr y air
3. Reactivation air
4. Wet air
The desiccant rotor is the adsorption dehumidifying component in the unit. The rotor structure is
comprised of a large number of small air channels.
The desiccant rotor is made of a composite material that is highly effective in attracting and retaining water
vapour. T he rotor is divided in two zones. The airflow to be dehumidified, p r ocess air, passes through the
largest zone of the rotor and then leaves the rotor as dry air. Since t he rotor rotates slowly, the incoming air
always meets a dry zone on the rotor, thus creating a continuous dehumidification process.
Theairflow tha t is used to dry t he rotor, r e a c tivation air, is heated. T he reactivation air passes through
the rotor in the opposite direction to the process air and leaves the rotor a s wet air (warm, moist air). T h is
principle enables t he dehumidifier to work effectively, even at freezing temperatures.
190TEN–106 7–J1408
Dehumidifierdesign
5
2
1
4
3
Figur e 2.2 Airflow overview
1. Process air
2. Dr y air
3. Reactivation air
4. Wet air
6
Dehumidifierdesign
190TEN–106 7–J 1408
2.3 Maincomponents,explodedview
2
3
4
5
6
7
10
11
13
9
8
12
1
Figure 2.3 Main compo nents
1. Reactivationfan 8. Rotordrivemotor
2. Filter,reactivationair 9. Drivebelt
3. Steamvalveandactuator 10. Rotor
4. Processfan 11. Rotorseal
5. Steamcoil 12. Filterbox,processair
6. Electricalpanel 13. Filterbox,processair(option)
7. Temperaturesensor
190TEN–106 7–J1408
Dehumidifierdesign
7
2.4 Configurationfeatures
This chapter includes infor mation about functions and components that can be added w hen ordering a
MX² dehumidifier. At delivery, each unit is configured according to the configuration sheet supplied with
the user manual.
2.4.1 Insulatedprocessairinlet
All dehumidifier units supplied with pre-cooled process air have insulated process air inlet. The process air
sector in front of the rotor has an internal lining of isolation to prevent condensation on the unit .
2.4.2 Processfancontrol
The process fan is equip
ped with a frequency converter for controlling the fan s peed. T he process fan
control can be configur
ed as fixed speed or variable speed according to below:
Fixed speed
The frequency conve rter for the process fan is pre-set at t he factory and the process fan always runs with a
constant speed that gives the rated process airflow.
Variable speed
The frequency conve
rter for the process fan is controlled either by flow or pressure.
At flow control, a pressure sensor measures the pressure difference over the inlet cone on the process fan. At
pressure control, a pressure sensor measures the air pressure in the dry air duct.
Th e a ctual value from the pressure sensor is calcula ted, tog e the r with the fan coefficient, by the PLC in the
control system. The PLC compares the actual value w ith the set point value and changes the command
signal to the frequency converter if there is a difference b etween the values.
8
Dehumidifierdesign
190TEN–106 7–J 1408
2.4.3 EnergyRecoveryPurge
1
2
3
4
7
6
5
6
Figure 2.4 Principle for Energy Recovery Purge
1. Reactivation air
2. Heated reactivation air
3. Wet air
4. Process air
5. Dry air
6. Purge air
7. Warm purge air
Energy Recovery Purge (ERP) is an energy saving solution that recycles heat from the rotor, after the
reactivation section in the rotational direction of the rotor. A minor part of the reactivation airflow is
bypassed to the warm sector of the r otor, before the airflow enters the r eactivation heater. The airflow
is heated up by the rotor and then mixed with the reactivation airflow, after the reactivation heater. The
recycled heat from t he rotor increases the efficiency and r educes the energy consumption.
Compared to a standard unit, ERP will give the same dehumidification capacity with reduced reactivation
heater energy.
190TEN–106 7–J1408
Dehumidifierdesign
9
3 Ins tallat ion
3.1 Safety
WARNING!
Allelectricalequipmentconnectionsmustbecarriedoutinaccordancewithlocalregulationsandbyqualified
personnel. Riskofelectricalshock.
WARNING!
Theunitmustneverbeconnectedtoavoltageorfrequencyotherthanthatforwhichitwasdesigned. Refertothe
unitidentificationplate.
WARNING!
Themainspowersupply
ispermanentlyconnectedtothemainpowerswitchoftheunit.
WARNING!
Neverliftanassembledunitusingliftingeyeboltsattachedtothetopbox. Liftingeyeboltsmustonlybeusedfor
liftingthetopboxduringinstallationofasplitunit. Failuretoobservethiscancausepersonalinjuryanddamageto
theunit.
CAUTIO N!
Neverclimbontheunitoruseitasscaffolding.
3.2 General
Thedehumidifier is norm ally delivered on a single pallet. Due to height restrictions, the dehumidifi er is
sometimes delivered as a split unit, divided into four pallets with rotor box, top box, fans and filter box.
10
Installation
190TEN–106 7–J 1408
3.3 Inspectionofdelivery
1. Inspect the deliver y and compare with the delivery note, order confir mation or other deliver y
documentation. M ake sure that everything is included and nothing is damaged.
2. Contact Munters immediately if the delivery is not complete in order to avoid installation delays.
3. If the unit is to be put into storage prior to installation, see section Storing the equipment.
4. Rem ove all packaging material from the unit, and make sure that no damage has occurred during
transportation.
5. Any visible damage must be repor ted in writing to Munters within 5 days and prior to installation of
the unit.
6. Dispose of the packaging material according to local regulations.
NOTE!
Ifthedehumidifierisdeliveredasasplitunit,especiallycheckthatthesealsontherotorboxarenot
damaged.
Figure 3.1 Rotor box seals
NOTE!
Afterdeliveryinspection,theconsignmentnoteshouldbesignedtoconfirmapprovalofdelivery.
3.4 Movingthedehumidifier
Thedehumidifier must be handled with care. All panel doors must be closed during transportation. Use
a fork lift or pallet loader to m ove the dehumidifier. The forklift/pallet loader must be equipped w ith
extended forks to ensure even weight distribution. See section 8.4, Technical data for weight data.
WARNING!
Movethedehumidifiercarefullyasthereisariskofthedehumidifiertippingover.
Figure 3.2 Correct length on forklift arms
190TEN–106 7–J1408
Installation
11
CAUTIO N!
Nevermovethedehumidifierwhentheprocessfanandfilterboxhavebeeninstalled. Failuretoobservethiswill
causedamagetothedehumidifier.
3.5 Storingthedehumi difier
The following is impor tant if t he dehumidifi er is to be stored prior to installation:
■
Place the dehumidifier in an upright position on a horizontal surface.
■
Protect the dehumidifier from physical damage.
■
Store the dehumidifier under cover and protect it from dust, frost, rain and agg r essive contaminants.
See section 8.4, Technical data for cor rect storage temperature.
3.6 Siterequirements
NOTE!
Itisimportantthattheintendedinstallationsitemeetstherequirementsinordertoachievethebest
possibleperformanceandtrouble-freeoperation.
NOTE!
Itisimportantforbothmaintenanceandservicepurposesthattheminimumservicespacerequirements
arecompliedwith.
Thedehumidifier is only intended for indoor installation. Avoid installing the dehumidifier in a damp
environment where there is a risk of water entering the unit, or in a very dusty environment. Refer to
Munters for advice if in doubt.
NOTE!
Ifthereisaneedforreductionofvibrationsfromthedehumidifier,contactMuntersforinstructions. Refer
tostandardEN1299+A1:2008.
See section 8.3, Dimensions a nd service sp ace for unit and service dimensions.
3.7 Splitunitinstallation
WARNING!
Topreventpersonalinjuryordamagetothedehumidifier,alwaysuseapprovedliftingequipment.
WARNING!
Checkthattheliftingequipmentiscapableofsupportingthetopboxbeforelifting.
Seesection8.4,Technicaldataforweightdata.
CAUTIO N!
Aliftingframewithfourslingsmustbeusedwhenliftingthetopbox. Theliftinganglemustnotexceed15°,
seeFigure3.9.
12
Installation
190TEN–106 7–J 1408
Figure 3.3 Rotor box Figur e 3.4 To p box
Figur e 3.5 Fans Figure 3.6 Filter b ox
1
2
3
3
Figur e 3.7
1. Reactivation fan
2. Process fan
3. Filter boxes
190TEN–106 7–J1408
Installation
13
3.7.1 Assembly
1. Pull off the protection tape from the rotor box seals.
2. Make sure th at the four lifting eye bolts for the top box are tightened.
Figure 3.8 Lifting eye
bolts for top box
3. Lift the top box onto the rotor box and make s ure that the guide lips a nd M8 screws align in e ach cor ner,
see Figure 3.9 .
A
B
max 15°
C
Figur e 3.9 Lifting the top box
A.M8screw
B.Guidelip
C.Liftingframe
14
Installation
190TEN–106 7–J 1408
A
Figure 3.10 A : M8 screw seen from underneath.
D
Figure 3.11 D: Cover plates
4. Tighten the four M 8 screws (A) to compress the seals.
5. Fasten the two cover plates (D) with pop rive ts (4 x 10 mm) .
6. Unscrew the lifting eye bolts from the top box to prevent lifting of the assem bled unit.
7. Move the unit to its final position o n the site using a fork lift or pallet loader, before installing the fans
and filter box(es).
8. Install the process fan and process filter box(es) to the rotor box.
NOTE!
Standarddeliveryincludesoneprocessfilterbox.
9. Attach a sling to the reactivation fan according to Figure 3.12 and lift the fan into position on the rotor
box.
10. Tighten the screws holding the fan before removing the sling.
Figure 3.12 Lifting the reacti vation fan Figure 3.13 Reactivation fan lifted into position
190TEN–106 7–J1408
Installation
15
3.7.2 Electricalconnections
1. Install the infeed box and the cable for power supply.
E
Figure 3.14 Power supply infeed box (E)
2. Connect the cables for the reactivation fan and process fan, see Figure 3.15 , Figure 3.16 and Figure 3.17 .
Figure 3.15 Fan motor wiring Figur e 3.16 Pr ocess fan
Figure 3.17 Re activation fan Figure 3.18 Rotor drive motor
3. Connect the cables for the rotor drive motor according to Table 3.1 and Figure 3.18 .
16
Installation
190TEN–106 7–J 1408
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