gaSteam Gas-Fired Steam Humidifier Operation and Maintenance Manual Read and Save these Instructions! WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Installation & Maintenance Manual__________ IMPORTANT WARNINGS BEFORE INSTALLING OR HANDLING THE APPLIANCE PLEASE CAREFULLY READ AND FOLLOW THE INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ILLUSTRATED BY THE LABELS ON THE MACHINE. • Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, an explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage.
CAREL gaSteam Introduction This humidifier produces non-pressurized steam by means of a gas burner firing into a heat exchanger immersed in water inside the steam generating chamber. The steam produced can be used to humidify environments or industrial processes. This apparatus is produced exclusively to directly humidify rooms or ducts, using a distribution system.
Installation & Maintenance Manual__________ Table of Contents 1. Receiving and Unpacking Equipment................................................................................................................ 6 2. Installation .......................................................................................................................................................... 7 3. Locating and Mounting......................................................................................................
CAREL gaSteam 12.2 EXPLODED VIEW OF STEAM GENERATOR ASSEMBLY ....................................................................46 12.3 EXPLODED VIEW OF BURNER ASSEMBLY .........................................................................................48 12.4 EXPLODED VIEW OF ELECTRICAL PANEL..........................................................................................50 13. SPARE PARTS .....................................................................................................
Installation & Maintenance Manual__________ 1. Receiving and Unpacking Equipment IMPORTANT: BEFORE beginning installation: • Check for shipping damage to cartons. Mark the shipping waybill accordingly • Open cartons and check for any hidden damage. Mark the shipping waybill accordingly. • Check packing slip to ensure all items have been received. Notify Carel LLC of any shortages or damaged parts. You must notify Carel USA within 5 working days of any shortages.
CAREL gaSteam 2. Installation 1. The installation must conform with local building codes or, in the absence of local codes, to the ANSI Z223.1, National Fuel Gas Code, and/or CAN/CGA B149 Installation Codes. 2. The humidifier shall not be connected to a chimney flue serving any other appliances. 3. Provide for adequate combustion and ventilation 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.
Installation & Maintenance Manual__________ 3. Locating and Mounting Position the unit to keep the steam distribution lines as short as possible, except in the case of direct space humidification with a top-mounted blower. Plan to place the unit where enough space and floor support for the weight is available (see Dimensions and Weights). The clearance dimensions shown in this manual are for reference only and are the minimum required for maintenance of the humidifier.
CAREL gaSteam 3.1 Water Supply Note: All water supply and drain line connections should be installed in accordance with local plumbing codes, and/or national codes, whichever is more restrictive. Before making the hydraulic connections, make sure the machine is disconnected from the power supply. The gaSteam can use water of virtually any quality, including demineralized water from a deionizer or Reverse/Osmosis system.
Installation & Maintenance Manual__________ 3.2 Drain Line The drain water connection requires a piece of 1 ½” ID rubber hose. It must be able to handle a water temperature of 212ºF. The rubber hose should be secured using a standard hose clamp – be careful not to over-tighten and crack the drain fitting. If CPVC or copper pipe is used, adapt to the drain fitting with 1 ½” ID rubber hose. Insulate the drain line and make sure it has at least a 5 deg. slope to the drain.
CAREL gaSteam 3.4 Vent and Intake CAUTION: The humidifier shall not be connected to a chimney flue serving any other appliance. The unit has 4 holes for the air intake and gas vent outlet: 2 on the top and 2 on the back of the unit. The humidifier is configured from the factory as follows: • Exhaust vent through to the top of the humidifier; • Air intake from the back. Both the exhaust vent and air intake can be moved, according to the requirements of the installation.
Installation & Maintenance Manual__________ 3.5 Installation of Duct Steam Distributors NOTE: If the ventilated steam distributor is to be used, then go to section 1.4.1B. Each unit has 1-5/8” (40 mm) diameter steam outlets on top. Some units have multiple outlets.
CAREL gaSteam To install the distributor pipes: 1. Cut a key shaped hole in the side of the duct to match the steam pipe and condensate return. 2. Apply silicone sealant to the mounting plate and insert the pipe through the hole and secure it with 4 sheet metal screws. 3. Connect the steam and condensate hoses using the hose clamps supplied. (Note: end support bracked supplied only with 36” and longer distributors.
Installation & Maintenance Manual__________ 3.8 Installation of Steam Hoses NINETY PERCENT (90%) OF ALL OPERATION PROBLEMS ARE CREATED BY IMPROPER STEAM PIPING FROM THE HUMIDIFIER UNIT TO THE DUCT DISTRIBUTOR PIPES. To avoid these problems, remember one simple fact when running the steam hose: steam naturally flows up hill, and condensate naturally flows down hill.
CAREL gaSteam 4. Connect Power Wiring Before proceeding with the electrical connection, ensure that power has been removed from the electrical circuit. The appliance must be installed and electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electrical Code. An external fused disconnect, that complies with National and Local Codes, must be supplied by the installer.
Installation & Maintenance Manual__________ 5. Connect Control Wiring A typical humidifier control system includes a wall or return duct sensor or controller, a high limit duct humidistat and an air-proving switch. Placement of these devices is critical to proper operation of the overall system. 5.1 Controls Placement (See following diagram) The return air RH sensor must always be located BEFORE any outside air intake, in order to insure accurate sensing of the air from the space.
CAREL gaSteam 5.2 Connecting External Electrical Connections Make the control connections by inserting the wires into the appropriate terminal. The terminal blocks are located on the bottom of the electrical panel. Run the exterior wires through the side of the cabinet and hook them to the terminal. All the terminal blocks are pictured below. The AL connector (supply voltage) is protected by a metal enclosure, the wires passing through the grommet and attaching to the connector.
Installation & Maintenance Manual__________ 5.3 Control Wiring The humidifier has proportional modulation with the ability to vary its capacity from 25 to 100% according to the demands for humidity. The humidifier can be connected using RS485 to a remote panel Carel Humivisor (MT in the following pictures) or to a remote supervisor or BAS system. 1Z 2Z 5.3.
CAREL gaSteam 5.3.4 Control Wiring for H Type Modulating With Humidity Display The H Type control program is designed to accept an input signal from a humidity sensor (HT), not a DDC signal. This humidity sensor input signal is then displayed on the controller as the relative humidity. The set point and differential are entered into the controller, making it stand-alone. Figure 5.5.1 is the wiring for the ASWH10000 wall mount sensor and the ASDH10000 duct mount sensor. Figure 5.5.
Installation & Maintenance Manual__________ 5.3.5 Alarm Contact The controller also provides a SPDT relay contact for the remote indication of any alarm conditions. Connection to the alarm contact (max. voltage 250 Vac; max. capacity: 8A res. - 2A ind.) is made through the plug-in Z terminal block, as shown in Figure 5.6.1. 5.3.6 Dehumidification Contact In the H Type control program, a SPST – N/O relay contact is available, which can be programmed to actuate an external dehumidifier.
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CAREL gaSteam 7. Installation Checklist The following checklist needs to be reviewed BEFORE contacting your CAREL representative for system start-up. Proper electric power is connected to the control panel. This installation must be in accordance with Local and National Electric Codes. The nominal voltage provided to the humidifier must agree with the data on the units rating label. The power cable has been installed with proper strain-relief.
Installation & Maintenance Manual__________ 8. Start-Up and Shut-Down IMPORTANT WARNING: 1. Before starting, inspect the humidifier to make sure it is in good condition; that there are no water leaks and the electrical components are dry. 2. Don't apply voltage to the unit if it is damaged or wet! Complete the installation checklist before starting the gaSteam humidifier.
CAREL gaSteam 8.2 Autotest When the humidifier is started, the controller initiates an Autotest procedure to ensure that the humidifier can fill, drain, and monitor water levels properly. This test may take up to 30 minutes to complete depending on the amount of water in the unit when it is turned on. The Autotest will be signified by a flashing 'At' code on the display (see Figure 8.2.1).
Installation & Maintenance Manual__________ 8.4 Adapting the Humidifier to Different Types of Supplied Gas For proper functioning, the humidifier controller has parameters that must be set to the appropriate values depending on the type of fuel gas supplied.
CAREL gaSteam 8.5 Setting the Gas Burner The burner comes tested and pre-calibrated from the factory for natural gas, but must be checked to make sure it is regulating the combustion properly, by a qualified gas technician. To perform the setting of the burner, the controller parameter bA (fan velocity) must be accessed and modified on the controller.
Installation & Maintenance Manual__________ 8.8 Calibrating the Burner at Maximum Capacity Set the output of the burner to its highest potential by modifying the fan speed to maximum as described in the previous section and perform an analysis of the combustion gases: 1. For burners using natural gas: CO2= 9.0 - 9.4% 2. For burners using propane: CO2 = 10.8 - 11.2% 3. If the measured values are different than above, the following steps should be taken to adjust: 4.
CAREL gaSteam 8.10 Shut-Down Occasionally it may be desirable to shut down the unit completely for a seasonal pause or for maintenance on the electrical or hydraulic parts. Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operations. Power must be disconnected before servicing. Verify proper operation after servicing. To place the humidifier out of service: • Turn the ON/OFF switch (shown in Figure 8.
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CAREL gaSteam 9.2 Displaying Values on the Controller After the initial start and initialization phases are completed, the display value is determined by the parameter C0 (in case of remote operation OFF, there will simply be two dashes in the right two digits). Normally this is: • The measurement from the main probe (stand-alone control). • The % of steam production in appliances with slave control. The other values may be accessed by: • pressing the SEL button.
Installation & Maintenance Manual__________ 10. Reading and Programming the Parameters Access to the numeric parameters, the control configuration and the control panel functions, are grouped into three levels: 1. LEVEL ONE - The set point, the principal setting “St” of the humidifier, is directly accessible from the keyboard for reading or modification. 2. LEVEL TWO - Parameters for regulation and measurement are also directly accessible through the keyboard for inspection and modification. 3.
CAREL gaSteam 10.2 Reading and Programming the Regulation Parameters The regulation parameters are the most frequently accessed control parameters (P0 to P9) (see Table below). The measurement parameters are the actual values from the sensors connected to the controller (d1 to d9). Regulation parameters code range P0 P1 P2 P3 P4 P5 P6 P7 P8 P9 25…100 2.0…19.9 (P3)…100 0…(P2) 0…100 2…100 2.0…19.9 (St)…100 2.0…19.
Installation & Maintenance Manual__________ 1 – Press PRG for 5 seconds To display the regulation parameters and the measurements you must: 1. Press the PRG button for about 5 seconds until the digits P0 appear, representing the first parameter. 2. Press the buttons ∆ or ∇ to cycle through the parameters Px and dx, including the Set Point; 3. Press the SEL button to display the value of the selected parameter; the unit of measure will also be displayed for one second; 4.
CAREL gaSteam 10.3 Reading and Programming the Configuration Parameters The configuration parameters serve as a way to control some of the essential functions of the humidifier.
Installation & Maintenance Manual__________ code b0 b1 b2 b3 b4 b5 b6 b7 b8 parameters to configure the functions of accessories Default unit of description UG45 /UG90 measure (Bc)...(bb) 123 / 123 rpm/30 Pre-ventilation fan speed during burner start-up 0...3 0 special functions 1 = preheat 2 = dehumidification not accessible in ON/OFF mode 4 = disable maintenance time alarm (A0=0) 8 = use reverse osmosis feed 2.0...19.9 3.
CAREL C7 0...3 gaSteam 0 graphic terminal configuration in cases 1, 2, and 3 the OFF command is forced on start-up. 0=standard terminal 1=terminal with ON/OFF command 2=terminal with ON/OFF and control sensor 3=terminal with ON/OFF and high-limit sensor To read or modify the configuration parameters: 1 - Simultaneously press SEL 1. Simultaneously press the SEL & PRG buttons for about 5 seconds until 00 appears, signifying that the password is ready to be entered; 2.
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Installation & Maintenance Manual__________ 11. Maintenance Note: Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operations. Power must be disconnected before servicing. Verify proper operation after servicing.
CAREL gaSteam Fig. B • • • • • • • • Unscrew and remove the steam generator lid knobs G; Remove the steam generator lid; For simple cleaning, a poly brush dipped in Lime-Away, CLR or a 5% phosphoric acid solution, may be used to clean off the mineral debris on the heat exchanger and side walls of the boiler. Filling the boiler with water containing the cleaning solutions listed above could also be done.
Installation & Maintenance Manual__________ 11.2 Cleaning the Gas Burner The periodic maintenance of the burner must be performed by authorized and qualified personnel one or two times per year according to use. Before handling and cleaning the burner read and perform the following procedures: • • • • • remove the head of the burner; see Fig. C and D using a soft brush clean the burner, being careful not to damage the metallic mesh; see Fig.
CAREL gaSteam 11.3 Checking the Ionization Current The burner safety consists of an electrode that uses the actual flame of the burner as a current path to determine whether or not the burner is lit. If the flame goes out the circuit will be broken and the controller will shut the gas valve to avoid fuel gas from being released. Verification of this current of ionization can be performed by inserting a meter capable of measuring µA (continuous current) in series to the electrode flame.
Installation & Maintenance Manual__________ 12. GaSteam Parts 12.1 EXPLODED VIEW OF ENCLOSURE UG045 1 base 2 electric pump gasket (UGKGUAR040) 3 drain attachment gasket (UGKGUAR040) 4 left bracket 5 left side 6 drain pipe (1312342AXX) 7 drain pipe cap 8 fill solenoid valve (1312087AXX) 9 back 10 plumbing cover 11 gas/electronics cover 12 flue cap 13 right bracket 14 right side with 2 hinges 15 door hinge 16 grill 17 flue gas temp.
CAREL gaSteam UG090 1 base 2 electric pump gasket (UGKGUAR090) 3 drain attachment gasket (UGKGUAR090) 4 left bracket 5 left side 6 drain pipe (1312334AXX) 7 drain pipe cap 8 fill solenoid valve (1312088AXX) 9 back 10 plumbing cover 11 gas/electronics cover 12 flue cap 13 right bracket 14 right side with 2 hinges 15 door hinge 16 grill 17 flue gas temp.
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CAREL gaSteam UG090 1 heat exchanger (19C514A003) 2 gasket (UGKGUAR090) 11 lower support bar gasket (UKGUAR090) 12 ---------- 3 flue elbow 4 tank cover 5 knob 6 sensor bushing (13C483A004) 7 anti-foaming sensor 8 support bar 13 level switch (UGKSL00000) 14 door gasket 15 stainless mesh filter (14C483A007) 16 plumbing access door 17 drain pump gasket (UGKGUAR090) 18 electric drain pump (1312673AXX) 9 upper support bar gasket (UGKGUAR090) 10 -------- 19 drain pump pipe (13C479A001) 20 3/4" drain tap 4
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CAREL gaSteam UG090 1 head gasket (UGKGUAR090) 2 combustion head 3 gasket (UGKGUAR090) 4 flame detection electrode (61C483A009) 5 ignition electrode (51C483A016) 6 ignition cable 7 flanged fan elbow 8 compensation flange (UGKGUAR090) 9 fan compensation flange 10 fan gasket (UGKGUAR090) 11 transformer support bracket 12 ignition transformer 13 gas valve (13C514A004) 14 gas valve control board (UGCB00000M) 15 connector 16 connector cover 17 air tap 18 air intake elbow 19 flexible pipe attachment 20 flexib
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CAREL gaSteam ALARM CODES CONTINUED controller code for remote Carel Humivisor E533 cause automatic active check the functioning of the ambient sensor and the value of parameter P2 warning automatic active low ambient humidity check the operation of the ambient sensor and the value of parameter P3 warning automatic active over high-limit humidity check the operation of the high-limit sensor warning automatic active error in internal memory contact your service representative at Carel
Installation & Maintenance Manual__________ 15. Troubleshooting Table problem The controller does not work. cause 1. power is not supplied; 2. external interrupt is off; 3. poor electrical connection; 4. blown fuse; 5. bad transformer; solution 1. check that the correct power has been supplied; 2. turn on the external interrupt; 3. check that the connections to the controller terminals are good; 4. check the condition of the fuses F1/F2; 5.
CAREL gaSteam 16. Operating Principle and Other Functions 16.1 Operating Principle In a gas humidifier the production of humidity is generated when water inside a boiler is heated to and then held at boiling temperature. The heat required to boil the water is provided by a heat exchanger heated by a type pre-mix, modulating, room-sealed gas burner (standards compliant). This burner takes in air from and discharges the flue gas to the outside through suitable piping.
Installation & Maintenance Manual__________ 16.2.4 Measuring the Water Temperature and Preheating The controller measures the water temperature using an NTC sensor, and can be programmed to activate the preheating function around the set start humidification value; in this way, steam is produced much faster. 16.2.
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Installation & Maintenance Manual__________ LIMITED WARRANTY All products manufactured by Carel USA, LLC are warranted to the original purchaser to be free from defects in materials and workmanship in the course of normal and reasonable use for a period of 2 years from the date of installation or 2 years and 1 month from the date of shipment (The OEM controls warranty is 2 years from date of manufacture), whichever comes first, so long as the product has been installed and operated in accordance with all ap
