The Vapac Virtuoso VE Electrode Boiler Humidifier is a state-of-the-art steam humidifier designed for both comfort (±10% RH) and close control (±5% RH) applications. It incorporates an intelligent system for feeding, boiling, and draining water to ensure efficient operation and minimize water and energy wastage.
Function Description:
The Virtuoso VE humidifier generates steam by passing an electrical current through water via electrodes. As the electrodes come into contact with water, current flows, generating heat and increasing the water evaporation rate to produce steam. The more electrode surface area exposed to conductive water, the higher the current consumption and steam production. The unit continuously monitors and controls cylinder conductivity by adjusting the amount of water drained and refilled. When starting with an empty cylinder, the controller activates the contactor and fills the cylinder until the water level reaches the electrodes and current begins to flow. If steam generation decreases below a certain percentage of the required capacity, the water inlet valve opens until the desired capacity is restored. Conversely, if the required steam capacity is lower than the actual output, the water inlet valve closes, allowing the water level to decrease through evaporation. A cylinder full electrode sensor detects when the water level is at its maximum, closing the water inlet valve after a short delay. This evaporation and refill process leads to an increase in mineral concentration. To prevent inadmissibly high current consumption due to excessive concentration, water is periodically drained from the cylinder and replaced with fresh water.
Important Technical Specifications:
The Virtuoso VE range includes various models (VE05-1P, VE09-1P, VE09-3P, VE18-3P, VE30-3P, VE45-3P, VE60-3P, VE90-3P) with steam outputs ranging from 5 kg/hr to 90 kg/hr.
Electrical supply varies by model: single-phase units (VE05-1P, VE09-1P) operate at 200V or 230V, while three-phase units (VE09-3P to VE90-3P) operate at 380V, 400V, 415V, or 440V. Full load current (FLC) ranges from 11.00A to 62.00A per cylinder, with corresponding fuse ratings from 20A to 80A.
Water supply conditions: Hardness 50-500 ppm, Conductivity 80-1000 µS/cm, pH 7.3-8.0, Silica 0, Pressure 1.5-8.0 bar (150000-800000 Pascals), Temperature 1-30°C. Chlorine levels must not exceed 170ppm for stainless steel electrodes.
Water supply rates range from 1.20 l/min for smaller units to 5.00 l/min for larger double-cylinder units.
Drain flow rate for single-cylinder models is 17 litres per minute. Double-cylinder models have two drain pumps, each producing 17 litres per minute, which can operate concurrently.
The unit is designed for indoor installation only, with ambient temperatures not exceeding 40°C or falling below 5°C.
Minimum clearances around the unit are 250mm for sides (L), 1000mm for height (H), 500mm for top (H1), and 1000mm for front access (F).
Steam pipe requirements vary by model and duct width, with 35mm and 54mm diameter pipes available. A vertical rise of at least 300mm off the unit is recommended.
Usage Features:
The humidifier features a touch screen display panel for easy access to various operating modes:
- Initial Startup Mode: Displays "Starting Up Please Wait" for up to 3 minutes while the system performs checks.
- Normal Operating Mode: Shows operational status such as STANDBY (awaiting humidification call), STEAMING (producing steam), FILLING (cylinder being filled), DRAINING (cylinder being drained), SERVICE DUE (service required), CAUTION ALARM, and CRITICAL ALARM.
- Commissioning Mode (PIN 6787): Allows configuration of parameters like humidity setpoint, input type (external demand signal 0-10V, humidity sensor 0-5V/0-10V, ON/OFF input, Modbus), maximum service interval, full drain interval, proportional factor, integral factor, number of feed/boil events, and default drain time.
- Service Mode (PIN 4112): Provides access to service-related information such as service hour interval, total power consumption, and a list of caution and critical alarms. It also allows manual override for filling and draining the cylinder.
- Advanced Mode (PIN 9999): Offers advanced settings including incoming power supply details, max current rating, max power consumption, max output, steam output demand, humidifier demand, total hours run, low output level settings for caution alarms, derate output percentage, and sensor offsets for humidity and temperature.
- Language Selection: Allows users to choose their preferred language.
- Modbus Connectivity: Supports remote monitoring and setting changes via a Modbus application when connected via Wi-Fi.
- Frost Protection: A thermistor in the electrical section provides frost protection, with a default setpoint of 5°C and 50% output until the temperature rises above 5°C. This can be deactivated.
- Safety Circuit / EPO Shutdown: Volt-free terminals (13 and 14) are provided for connecting an emergency shut-down button, fire alarm interlock, fan interlock, airflow switch, or high limit hygrostat. Breaking these terminals prevents all unit operation.
- Volt-Free Outputs: Connections for alarm signal (close on alarm) and run signal (close on run) are available.
Maintenance Features:
The humidifier requires minimal maintenance, with annual servicing recommended by a suitably qualified person. More frequent servicing may be necessary in demanding environments.
Key maintenance procedures include:
- General Cleaning: Clean the exterior of the unit with a damp cloth.
- Damage Repair: Repair any damage to the unit.
- Steam Cylinder Replacement: The life of the steam cylinder depends on water hardness and humidity demand. The manual provides a cylinder selection chart based on water conductivity. Cleanable versions of steam cylinders are available for removal of loose scale deposits.
- Feed Valve with Strainer: Inspect and clean or replace the feed valve inlet strainer if water flow restriction is suspected. The strainer is a push-fit component that can be removed with long-nosed pliers.
- Drain Pump: Inspect the condensate drain and replace the pump if necessary. The drain pump is a sealed unit and should not be dismantled. Access to the drain pump and feed/drain manifold is provided via a bottom access panel.
- Steam Hoses: Inspect steam hoses for cracks and ensure correct attachment. Replace at the first signs of deterioration.
- Pipework and Water Hoses: Inspect connections and repair any damage.
- Electrical Connections: Inspect all cables and electrical connections for tightness and security.
- Solid State Relays (SSRs): A faulty SSR should be replaced with one of the same (or higher) voltage and amperage rating. Replacement involves disconnecting the unit from electrical supply, removing the SSR, cleaning off old thermal compound, applying fresh compound, and reconnecting. Proprietary thread locking compound should be used on line voltage terminals.
- Factory Reset: Advanced mode offers options to reset service, commissioning, advanced, or all settings to their default values.
Important Safety Notices:
- Always read the manual carefully before installation, commissioning, or servicing.
- Installation, commissioning, testing, and maintenance must be carried out by suitably qualified and trained technicians in compliance with all regulations and best practices.
- Ensure mounting points are suitable for the unit's weight and loading.
- The electrical isolator should only be used for maintenance or emergencies, not for normal shutdown, as it may damage the electrode boiler and void the warranty.
- Never use the handles on the side of the casing to lift the unit.
- Shut off water supply, drain the cylinder, isolate electrically, and allow the unit to cool before any maintenance.
- Never leave water in the steam cylinder when the appliance is not in use; always drain it fully.
- Do not carry out work on the steam distribution system when the humidifier is in operation.
- Do not store or use flammable vapours or liquids near the appliance.
- Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or death.
- The unit operates with hot water vapour (steam); take extra care to avoid scalding and burns.
- Keep the manual in a safe, accessible place and pass it on to new owners/operators.
- Only use factory-authorized parts and spares.
- Do not locate the humidifier where it may be exposed to water or where ambient temperature exceeds specified limits.
- Ensure the structural elements supporting the humidifier can carry its wet weight.
- Provide sufficient space around the humidifier for access, servicing, and safety.
- Pinching or reducing the cross-sectional area of the steam line can increase steam pressure and lead to scalding accidents.
- Do not touch an operating cleanable cylinder if there is a leak.
- Do not interfere with electrodes in a cleanable cylinder; replace the cylinder if electrodes are badly eroded or the internal positioning ring is free.
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