Carel compactSteam CH002V1000, compactSteam CHF05V2000 User Manual

compactSteam – residential/light commercial steam humidifiers

User manual

We wish to save you time and money! We can assure you that the thorough reading of this manual will guarantee correct installation and safe use of the product described

WARNINGS

BEFORE INSTALLING OR HANDLING THE HUMIDIFIER PLEASE CAREFULLY READ AND FOLLOW THE INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ON THE LABELS ATTACHED TO THE compactSteam.

compactSteam produces non-pressurized steam by means of electrodes immersed in the water contained in the plastic steam generator cylinder. Electric current passes through the water between the electrodes, heating the water into steam, which is then used to humidify the air.

The quality of the water used affects the operation of this unit, so the compactSteam may be supplied with untreated water, as long as this is drinkable and not softened or demineralized. The water converted into steam is automatically replaced through an electric fill valve. Periodically, based on the water quality, the unit will also drain some water to dilute the buildup of minerals in the steam generator and thus extend its life. This humidifier has been designed exclusively to directly humidify rooms or ducts, using a distribution system. The installation, use and maintenance operations must be carried out according to the instructions contained in this manual and on the labels applied internally and externally.

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 USA of any shortages or damaged parts. You must notify Carel USA

within 5 working days of any shortages.

The conditions of the environment and the power supply voltage must comply with the specified values listed on the data label in the humidifier. All other uses and modifications made to the humidifier that are not authorized by the manufacturer are considered incorrect, and the manufacturer assumes no liability for the consequences of any such unauthorized use. Please note that the humidifier contains powered electrical devices and hot surfaces. All service and/or maintenance operations must be performed by qualified personnel who are aware of the necessary precautions and are capable of performing the operations correctly. Disconnect the humidifier from the main power supply before accessing any internal parts. The humidifier must be installed in accordance with all local and national standards. The humidifier is made of metallic and plastic parts. All parts must be disposed of according to the local and national standards for waste disposal.

Certification: the quality and safety of CAREL products are assured by CAREL's ISO 9001 certified design and production system, as well as listings from UL,

cUL, CE, TUV, ETL, cETL and others.

WARNING: Your humidifier requires water to operate. Do NOT mount it above materials or machinery that could be damaged if a leak occurs. Carel assumes no responsibility for consequential or inconsequential damage as a result of any leaks.

Disposal of the parts of the humidifier: standards on waste disposal. Warranty on materials: 2 years (from the date of production, excluding the consumable parts).

the humidifier is made up of metallic and plastic parts. All parts must be disposed of according to the local

CONTENTS

1. How The compactSteam Works .............................................................................................................. 7

2.

Models............................................................................................................................................ 8

Installation ...................................................................................................................................... 9

3.

3.1 1.1 Positioning .............................................................................................................................. 9

3.2 Mounting ....................................................................................................................................10

3.3 Plumbing ....................................................................................................................................11

3.4 Steam distribution .........................................................................................................................12

3.5 Power wiring................................................................................................................................14

3.6 Control wiring ..............................................................................................................................15

3.7 Wiring Connections: .......................................................................................................................16

Start-Up.........................................................................................................................................17

4.

4.1 Startup Checklist...........................................................................................................................17

4.2 The compactSteam Controller...........................................................................................................17

4.3 Starting compactSteam ...................................................................................................................18

4.4 Starting with a new cylinder .............................................................................................................18

Operating compactSteam ....................................................................................................................19

5.

5.1 3.1 Displaying Information ...............................................................................................................19

5.2 Changing The Maximum Production.....................................................................................................19

5.3 Activating Manual Drain ..................................................................................................................19

5.4 Resetting the hour counter...............................................................................................................19

5.5 Alarms .......................................................................................................................................20

Trouble-Shooting ..............................................................................................................................21

6.

7.

Maintenance....................................................................................................................................22

7.1 Periodic checks ............................................................................................................................22

7.2 Cylinder maintenance.....................................................................................................................22

7.3 Replacement Parts ........................................................................................................................23

Technical Specifications......................................................................................................................24

8.

compactSteam

1. How The compactSteam Works

compactSteam is an electrode humidifier. It produces steam for humidification by passing electric current through the water in the steam plastic generator cylinder between metal electrodes. There are no heating elements. Steam output is directly proportional to the conductivity of the water, and the amount of electrode immersed in the water.

On a call for humidity, the compactSteam controller will open the water fill valve (1) and allow water to enter the cylinder. A flow restrictor (2) prevents the unit from filling too quickly or with too much pressure. The water flows up the fill tube (3) and into the fill cup (7). Water then flows over the dam in the fill cup (7), which creates a 1” air gap to prevent backflow of contaminated water into the feed lines, and through the fill tube (4) and into the bottom of the steam cylinder (11). Any backflow or overflow of water travels through the overflow hose (5) to the drain.

10

As the water fills the cylinder, it will reach the electrodes (10) and current will begin to flow. As the water continues to fill the cylinder, the current will increase, and this is monitored by an amperage transformer connected to one of the power wires (9) and located on the electronic controller. When the desired current is reached, the fill valve will close (1) and the water will then begin to warm and produce steam. If the water reaches the cylinder full probes (8) prior to reaching the desired current level, the fill valve (1) will be closed to prevent overflow and the drain valve (13) will be opened to

12

11

drain away some water so as to move the water apart from the cylinder’s top. If the current rises too much as the water fills the cylinder, the drain valve (13) will be activated to drain away some water and reduce the current flow to acceptable levels. Note that, any time the drain valve is activated, the

nd

fill valve will be opened for tempering the hot drained water down to 140 °F / 60 °C in accordance

2 to local and national standards.

F

Periodically, based on the incoming water conductivity, the unit will open the drain valve (13) and drain some water to reduce the mineral concentration. A strainer (12) in the cylinder helps to prevent mineral debris from jamming the drain valve (13). In case compactSteam remains powered but idel, i.e. without producing steam, for more than 72 hours (3 days), the cylinder will be emptied not to have stagnant water inside.

If there is no water in the cylinder, there will be no current flow and no steam production. The electrodes do not burn out, but they will eventually become completely coated with mineral and the cylinder will then need to be replaced or cleaned.

9

13

8

7

6

5

4

3

15

2

14

1

ig. 1.a

2

No. Description

1 Steam generator cylinder 2 Room blower/manifold (optional)

3

3 User interface/display 4 On/Off, SET buttons 5 Fill & tempering valves 6 Fill & drain connections

1

4

7

5

7 Drain valve

Tab. 1.a

6

Fig. 1.b

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 7

2. Models

There are two basic models for steam distribution:

Duct Injection Direct Room Discharge

compactSteam

Fig. 2.a Fig. 2.b

compactSteam comes in two voltages and five capacities:

CH m ss c v xx r

CH means CompactSteam Humidifier and is a fixed field m = model: 0 for Duct Injection, F for Direct Room Discharge ss = nominal steam flow in kg/h (read table on page 14 for the complete list of nominal steam flow) c = control type v = power supply: 1 = 110 VAC 1-phase, 2 =230 VAC 1-phase xx = customisation r = release

Examples:

CH002V1000: compactSteam for duct injection (m = 0), nominal steam flow 5.5 lbs/h / 2.5 kg/h (ss = 02), on/off control (c = V), 110 VAC 1-phase (v = 1), not

customized (xx = 0), release 0 (r = 0)

CHF05V2000: compactSteam for direct room discharge (m = F), nominal steam flow 12 lbs/h / 5.4 kg/h (ss = 05), on/off control (c = V), 230 VAC 1-phase (v

= 2), not customized (xx = 0), release 0 (r = 0)

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compactSteam

3. Installation

3.1 Positioning

The compactSteam has been designed for wall mounting and, since it is an atmospheric steam humidifier, should be placed close to the point where the steam will be used, to minimize the steam hose length (and the amount of condensate). Certain clearances must be maintained around the unit for safety and maintenance.

A 6” (150 mm) B 6” (150 mm) C 6” (150 mm) D 6” (150 mm) E 24” (600 mm) F max. 0.2°

Tab. 3.a

F

With room distributor units, other clearances apply:

A 6” (150 mm) B 36” (900 mm) C 72” (1800 mm) D 24” (600 mm)

Tab. 3.b

Unit Dimensions:

Fig. 3.a

D

C

Fig. 3.b

A 13.5“ (341 mm) B 8.1“ (204 mm) C 23.7“ (600 mm) Weight empty 18 lbs (8 kg) Weight packaged 22 lbs (10 kg) Weight installed with water 26 lbs (12 kg)

Tab. 3.c

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 9

Fig. 3.c

3.2 Mounting

5

3.2.1 Removing the front cover

The front cover is secured by four screws located at the four corners of the unit. Use a phillips head screwdriver to remove the four cover screws. Then simply pull the front cover away from the back part of the unit. Return it in reverse order.

Be careful not to overtighten the screws.

Fig. 3.d Fig. 3.e

3.2.2 Fastening to the wall

Drill the wall according to the drilling template supplied; then secure compactSteam firmly to the wall by the screws and anchors supplied.

UP UP

2

6

128 128

compactSteam

448

DOWN DOWN

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 10

55 60

115

Fig. 3.f

3.3 Plumbing

3.3.1 Water supply

The compactSteam must be supplied with water (not softened or demineralized) having the following characteristics:

compactSteam

Instant flow rate:

Connection:

Temperature limits:

Pressure limits:

Hardness limits: Conductivity:

0.12 gpm / 0.45 L/min

1/4” O.D. Compression

34 to 104°F / 1 to 40 °C

15 to 116 psi / 1 to 8 bar

<= 400 ppm CaCO

3

125 to 1250 µS/cm (micromhos)

Tab. 3.d

Fig. 3.g

The water feed line should be 1/2” copper, PVC or poly tubing run to within 3 feet of the humidifier, then bushed down to 1/4” O.D. poly to make the final connection to the 1/4” O.D. compression fitting supplied with the unit. WARNING: WE RECOMMEND TO USE A SOFT POLY HOSE TO ABSORB THE WATER HAMMERING IN ORDER TO AVOID DAMAGES TO THE FILL VALVE. With poly tubing an insert should be used to support the tubing and prevent leaks. The fitting then threads onto the fill valve inlet located on the bottom of the humidifier. Note that there is a strainer built into the fill valve fitting underneath the unit, which will require periodic cleaning, so be sure to allow clearance for access.

NOTE: softened water should NOT be used as it is generally corrossive to the electrode plating.

3.3.2 Water drain

The compactSteam also requires connection to a drain. The drain water characteristics are:

Drain rate per hour:

Instant drain rate:

Connection:

Typical temperature:

0.7 gph / 2.6 L/h

1.3 gpm / 5 L/min

1-1/4” / 33 mm nominal diameter

140°F / 60 °C

Fig. 3.h

The drain line can be 1-1/4” schedule 40 PVC or CPVC, 1-1/4” copper, or 1-1/4” Polypropylene. In all cases, the drain tube is slipped over the drain outlet on the bottom of the humidifier. It is not glued or otherwise attached to the humidifier, so it must be supported by itself. If 1-1/4” schedule 40 PVC or CPVC is used, then a coupling should be used between the drain line and unit drain. The compactSteam includes a drain tempering valve that opens whenever the drain valve opens and flushes cool feed water into the drain line to insure that the drain water temperature never exceeds 140 °F / 60 °C. NOTE: Drain line must be trapped under the unit to prevent flash steam from condensing in the unit cabinet.

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3.4 Steam distribution

3.4.1 Duct steam injection

The maximum allowed duct counterpressure is 39.37 in WC / 980 Pa.

The compactSteam duct injection models include a plastic duct injection nozzle:

A 1.24” (31.5 mm) B 1.96” (50 mm) C 2.20” (56 mm) D 2.26” (57.5 mm) E 3.93” (100 mm) F 0.31” dia. (8 mm) G 0.86” dia. (22 mm) H 1.18” dia. (30 mm)

I 0.47 or 0.87” (12 or 22 mm)

Fig. 3.i

Or a stainless steel duct distributor:

compactSteam

Fig. 3.l

To install the distributor pipes:

1. Cut a round 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 bracket supplied only with 36” and longer distributors.)

IMPORTANT: allow 2 feet of straight duct downstream of the distributor pipes for evaporation of the steam. Always allow 2 feet upstream. Turbulent air flow may require longer lengths.

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compactSteam

3.4.2 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. Run the steam hose or piping to avoid any kinks, sharp elbows, or low spots that could collect or restrict the flow of steam to the distributor pipe, or the flow of condensate back to the humidifier. Support the hose adequately to avoid sags.

The following diagrams are to provide you with some guidelines. If you have a situation you are unsure of, please contact the factory for instructions.

5FT max.

≥20%

20 FT max.

10 FT max.

≥20% ≥20%

OBSTRUCTION

SUPPORTED STEAM HO SE

AN D/ O R COPPER PI PE

IF NO TRAP

≥5%

GENTLE BEND

≥5%

DRAINS

20 FT max.

WITH TRAP

≥5%

DRAINS

TYPICAL IN STALLATION

WH EN U N I T I S ABO VE

THE DISTRIBUTOR PIPE

P - T RAP NOTE: H EIGH T OF TRAPS MUST BE GREATER THAN TH E DUCT STATIC PRESSURE

5FT max.

IF NO SLOPE

≥20%

3FT max.

DRAINS

YES

N OTES:

• SLOPE PIPING UP IN DIRECTION OF STEAM FLOW AT 20% OR GREATER, WHICH MEANS 2 1/ 2 ” PER FOOT;

• SLOPE PI PING D O WN IN TH E D I RECTI O N OF STEAM FLO W AT 5 % O R G REATER, WHI CH M EANS 3 / 4” PER FOO T;

• MAX. LENGTH OF RUBBER STEAM HOSE IS 20 FT. INSULATED COPPER TUBING MAY BE USED UP TO 40 FT.

NO SLOPE

KIN KED

SAG

IMPORTANT: Maximum length of rubber steam hose 2-45° elbows instead of 90°s. Hose size = 7/8” (22 mm). Hose size = 1-1/4” (30 mm).

NO SLOPE

NO

UNDRAINED

ELBO W

NO TRAP

Fig. 3.m

is 10 feet. Insulated copper tubing may be up to 20 feet. In all cases, minimize sharp bends and elbows – use

UNDRAINED

ELBO W

NO DISTRIBUTION

PIPE DRAIN

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 13

3.5 Power wiring

Check that the power supply voltage to be connected matches the value indicated on the rating plate inside the electrical panel.

Insert the power and ground connection cables into the electrical panel compartment using the strain reliefs supplied, and connect to the terminals. An external fused disconnect must be installed.

All wiring must be in accordance with local, state and national electric codes.

NOTE: to avoid unwanted interference, the power cables should be kept separate from any control wiring.

F F

Model Code

CH*01VX000 110Vac 50/60Hz

CH*02VX000 110Vac 50/60Hz

CH*01VD000 230Vac 50/60Hz

CH*03VD000 230Vac 50/60Hz

CH*05VD000 230Vac 50/60Hz

NOTE: Tolerance allowed on main voltage = -15% to +10%

Connect power wires to the power terminal block located at the bottom left of the control module.

Power supply

(single phase)

Steam Output

(lbs/hr)

3.5 1.6

5.5 2.5

3.5 1.6

7 3.2

12 5.4

Steam Output

(kg/h)

POWER

CURRENT

(kW)

1.18 10.74 AWG12 16

1.86 16.88 AWG10 32

1.18 5.14 AWG14 10

2.36 10.27 AWG12 16

4.05 17.61 AWG10 32

(A)

compactSteam

ig. 3.n

EXTERNAL POWER WIRES EXTERNAL FUSE (A)

Connect the wiring ground wire to the unit’s chassis ground, located just behind the power wiring terminal block.

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 14

Fig. 3.o

Fig. 3.p

compactSteam

t

3.6 Control wiring

compactSteam allows connection of any simple humidistat, and safety devices such as high-limit humidistat, air flow proving switch, and remote on/off.

REMARK: we suggest to select the proper type of control signal by the keyboard before wiring.

Proceed as follows:

1. Switch compactSteam off.

2. Keep pressed both buttons, “reset/sel” and “drain”, and switch compactSteam back on until the display

shows 00 and the spanner Keep pressed “reset/sel” until the display shows 02. WARNING: do NOT confirm any value higher than 04. In case, press “reset/sel” until the display goes back to the normal operating mode and restart from step 1.

3. Press “drain” (min. 1 second) to confirm: the display shows “P1” for 1 second and then P1’s current value;

se

will be displayed beside.

4. By pressing “reset/sel” the value of P1 will loop between 0 and 1: 0 = humidistat; 1 = external 0-10 Vdc modulating signal

5. Press “drain” (min. 1 second) when done to confirm the new value of P1 and exit to the normal operating mode.

6. Switch compactSteam off: you can now proceed with connecting the control wiring.

Thread the control wiring through the bottom of the unit, and the strain relief (see photo at top of previous page), and then up the side of the control module to the top right wiring terminal blocks. Connect the control wiring to the control wiring terminal blocks found at the top right side of the control module.

For On/Off Operation:

Connect an external humidistat between terminals IN-GND.

Remove the jumper between terminals AB-AB and connect any simple high-limits, air flow switch, and remote contacts in series to terminals AB-AB; otherwise, if no such dry contacts are available, the jumper must remain in place between terminals AB-AB. DO NOT apply any voltage to AB-AB.

For modulating Operation:

Connect an external 0-10 Vdc modulating input between terminals IN-GND. Connect any Safeties (high-limit, air flow switch, remote on/off) in series to terminals ABAB. If no safeties are used, then a jumper must be installed between AB-AB. DO NOT apply any voltage to AB-AB.

blinks; then release the 2 buttons.

connecting the control

F

ig. 3.q

Fig. 3.r

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 15

compactSteam

R

)

3.7 Wiring Connections:

Terminals Input/Output Type Description N1-GND-N2 NTC NTC air proving sensor AB-AB 24 V Bridge Remote On/Off IN-GND 24 V Bridge Humidistat NC-C-NO Dry contact Alarm relay NO-C Dry contact External fan relay 24-GND 24 VAC Power for external humidistat

3.7.1 Wiring diagram of controller

EMBEDDED BLOW E (IN CHF*

KEY: EVF = FILL VALVE DT = DRAIN TEMPERING VALVE HL = HIGH-LEVEL SENSOR

STEA M

BOILERUNIT

DRAIN VALVE

KEY

LCD AND

KEY BOARD

HL

N

EVF

HL

ON/OFF

DT

EVF

BUTTON

5

EVD

N

F

INT FA N

E2

E1

12124

L1 L2

POWER SUPPLY

(110 VAC 1-PHASE 50-60 HZ

OR

230 VAC 1-PHASE 50-60 HZ)

EXTERN AL FUSED DISCONNECT TO BE INSTALLED (NOT SUPP LI ED) RESPECT LOCAL CODES

IN GND AB AB N1 GND N2NO C

ALARM

NC C NO

EXT FAN

24Vac GND

PROGRAMM I NG PORT

NTC

REMOTE ON-OFF

HUMIDI ST AT

ALARM

EXTERNAL D UCT FAN

24 VAC FOR EXTE RNA L HUMIDI STATS

Fig. 3.s

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 16

compactSteam

4. Start-Up

IMPORTANT WARNINGS:

1. Before starting, check that the humidifier is in perfect condition, that there are no water leaks and that the electrical parts are dry;

2. Do not connect power if the humidifier is damaged or even partially wet!

When installation is completed, flush the supply pipe for around 10 minutes by piping water directly into the drain, without sending it into the humidifier;

this will eliminate any scale or residues that may cause foam when boiling.

4.1 Startup Checklist

Before starting the humidifier, the following should be checked:

Water is connected, the line has been flushed, and external valves are open. Drain is connected, run to an open drain, and has a trap under the unit. Electricity is connected in accordance with instructions, local codes and data labels in the unit. The power fuses are installed and intact. All control wiring is done and tested. Airflow switch is wired to open on air flow loss. Hi-limit humidistat is wired to open on humidity rise above set point. Unit wires have been checked to make sure they and all connectors are tight from shipping. The steam hose(s) are run correctly with no sags or kinks and sloped properly according to the manual. Condensate hoses are run correctly with no sags or kinks and sloped properly according to the manual.

NOTE: If you ordered a factory startup, this checklist will be required. Failure to complete this checklist may result in additional charges.

4.2 The compactSteam Controller

he compactSteam controller features a comprehensive information display that shows the operation of the system at a glance:

Legenda:

1. Display is % of nominal capacity

2. Maintenance required

3. Display is amperage (default)

4. Steam is being produced

5. Cylinder filling

6. Foaming

7. Cylinder full

8. Cylinder draining

9. LEDs indicate: power (yellow), operation (green) and alarms (red)

10. Drain button for manual draining of cylinder and confirming parameter values

11. ON/OFF button

12. Reset button to reset alarms and access parameters

13. Level of output: 33%, 66%, 100%

14. Fan relay is activated

14

13

1

2

3

4

5

6

7

8

9

1012

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 17

11

Fig. 4.a

compactSteam

4.3 Starting compactSteam

• Insure that the external power is turned on. The yellow Power LED will be lit.

• Push the top part of the On/Off button so that the I part is in. The compactSteam is now ready to operate.

• When there is a call for humidity, compactSteam will close its power relays and send power to the electrodes in the plastic steam generator. The green

Operation LED will light, indicating that operation has begun.

4.4 Starting with a new cylinder

When starting with a new cylinder, you should activate the cylinder cleaning function as follows:

1. Switch compactSteam off.

2. Keep pressed both buttons, “reset/sel” and “drain”, and switch compactSteam back on until the display shows 00 and the spanner the two buttons.

3. Keep pressed “reset/sel” until the display shows 04. WARNING: do NOT confirm any value higher than 04. In case, press “reset/sel” until the display goes back to the normal operating mode and restart from step

1.

4. Press “drain” (min. 1 second): the cleaning starts.

During the cleaning, the electrodes are powered and water is filled in until it touches the high-level sensor OR the phase current equals 20 A, whichever occurs first. After either of the events is detected, the boiler is fully discharged with the electrodes un-powered (the drain valve and the drain tempering valve are activated for 3 minutes). Warming the filling water helps washing out any mould release or dirt.

When starting the unit with a new or empty cylinder, it may take a significant amount of time (hours) for the unit to build up enough mineral concentration to reach rated capacity. This time can be shortened by the addition of Alka-Seltzer or salt (teaspoon) through the steam outlet on top of the cylinder.

blinks; then release

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 18

compactSteam

t

5. Operating compactSteam

5.1 3.1 Displaying Information

By pressing the “reset/sel” button for 2 seconds, the display will loop from amperage to production in % of the maximum production to the hour counter and back to amperage:

A

⇒

1. Amperage: it is the value of the current that flows through the water making it boiling off (default display)

2. Production %: it is the current production expressed as a percentage of the nominal production

3. Hour counter: it is expressed in tens; for instance, when the display shows 13 the real hour value will be between 130 and 139 hours. Note that the hour counter increment rate is proportional to the steam flow: e.g., in case the steam flow is 40% of the nominal value, the hour counter increment rate will be 40% and after 100 hours of production the hour counter will show 4 which stands for 40 hours.

⇒

%

⇒

5.2 Changing The Maximum Production

The maximum production can be adjusted between 20% to 100% of the nominal production in steps of 5% in order to suit the environment characteristics:

1. Switch compactSteam off.

2. Keep pressed both buttons “reset/sel” and “drain” and switch compactSteam back on: the display shows 00 and the spanner two buttons.

3. Keep pressed “reset/sel” until the display shows 01. WARNING: do NOT confirm any value higher than 04. In case, press “reset/sel” until the display goes back to the normal operating mode and restart from step 1.

4. Press “drain” (min. 1 second) to confirm: the display shows “P0” for 1 second and then P0’s current value;

5. By pressing “reset/sel” the value of P0 will loop from 20% to 100% in steps of 5%

6. Press “drain” (min. 1 second) when done to confirm the new value of P0 and exit to the normal operating mode.

5.3 Activating Manual Drain

Press and hold the “drain” button on the front of the unit until the cylinder is drained.

5.4 Resetting the hour counter

The hour counter should be reset every time the cylinder is changed in order to reset and restart the ineternal maintenance timer:

1. Switch compactSteam off.

2. Keep pressed both buttons “reset/sel” and “drain” and switch compactSteam back on: the display shows 00 and the spanner two buttons.

3. Keep pressed “reset/sel” until the display shows 03. WARNING: do NOT confirm any value higher than 04. In case, press “reset/sel” until the display goes back to the normal operating mode and restart from step 1.

4. Press “drain” (min. 1 second) to confirm: the hour counter will be reset at once and compactSteam will go back to the normal operating mode.

⇒

se

will be displayed beside.

A

⇒

blinks; then release the

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 19

compactSteam

5.5 Alarms

In the event of an alarm, the red alarm LED will flash, the alarm relay will close, and the alarm code will flash in the display. Multiple alarms will flash in sequence, alternating with the main display. Pressing the sel button for 2 seconds will reset the alarms, although still active alarms will continue to display.

Display Description Action Notes

E0 Control board configuration not valid Unit disabled Turn off, check control board, reprogram

E1 High current alarm Unit disabled Turn off, check connections, check cylinder (no

E2 Low production, low supply water

conductivity or excessive foam/limescale in the cylinder

E3 Cylinder lifetime expired (1200 hours) Press “reset/sel” key for 1 seconds to reset. The warning will be

E4 Fill alarm, unable or slow fill

(current does not increase within timeout)

E5 Drain alarm, unable to drain

(current does not decrease within timeout)

E6 Cylinder exhausted

(critical performance detected)

E7 Foam detected Press “reset/sel” key for 1 seconds to reset If it continues, do some cleaning cycles (read chap.

E8 Cylinder lifetime expired (2000 hours) Reset the hour counter (read chap. Resetting the hour counter”) Change the cylinder.

E9 High controller temperature (above 176 °F

/ 80 °C)

Unit disabled. Press “reset/sel” key for 1 seconds to reset.

displayed 50 hrs later until the hour counter is reset and the cylinder replaced.

Press “reset/sel” key for 1 seconds to reset, otherwise the warning will be reset automatically every 10 minutes until the supply water is available again.

Press “reset/sel” key for 1 seconds to reset Check drain valve and drain connection

The warning is automatically reset if compactSteam can produce the demand, otherwise turn off and then on.

The warning is automatically reset if the temperature decreases below 176 °F / 80 °C.

limescale bridges between electrodes, no electrodes short-circuited)

Check supply water conductivity (too low?), replace the boiler.

Change cylinder (not urgent)

Check water supply and fill valve; check drain valve for leakage

Change cylinder (urgent)

“Starting with a new cylinder”)

Check the ambient temperature, replace the controller.

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 20

6. Trouble-Shooting

problem causes solutions

The humidifier does not turn on 1. no electrical power

2. on/off switch of the humidifier in position 0 (open)

3. control connectors improperly connected

4. blown fuses

5. transformer failure

compactSteam

1. check the safety devices upstream from the humidifier and the presence of power

2. close the switch on the panel: position I

3. check that the connectors are properly inserted in the terminal block

4. check the condition of fuses

5. check that the proper voltage is connected and turned on

The humidifier does not start operation 1. remote ON/OFF contact open

The humidifier fills with water without producing steam

The humidifier wets the duct 1. the distributor is not installed correctly (too near the

The humidifier wets the floor below 1. the humidifier drain is blocked

2. the humidistat has not been connected correctly

3. humidistat failure

4. control signal not compatible with the type set

5. value measured by the sensor/s higher than the corresponding set point

1. high steam back pressure

2. fill valve strainer clogged

3. mineral in the fill cup

4. drain solenoid valve leaking

top of the duct or the condensate return is blocked)

2.system over-sized

3.humidifier active when the fan in the duct is off

2. the supply water or overflow circuit has leaks

3. the condensate drain pipe does not bring the water back to the drain pan

4. the steam hose is not properly fastened to the cylinder

Water in the cylinder turns black 1. minerals in the cylinder have overconcentrated and

Heavy arcing occurs within hours of startup 1. The feed water contains large amounts of Iron,

Humidifier continuously fills and drains without producing steam

problem causes solutions

are deteriorating the electrodes.

Copper or other conductive contaminants.

1. Mineral has bridged between the electrodes.

2. There is back pressure from the steam hoses or duct.

3. The flow regulator in the fill valve is broken or out of place.

4. Water conductivity is very high.

5. Water is foaming excessively.

1. close ON/OFF contacts

2. check the external connection

3. replace the humidistat

1. check that the steam hose is not kinked or sagging, trapping condensate

2. clean the fill valve strainer

3. clean the fill cup

4. check for voltage at the drain solenoid valve and/or drain solenoid replacement

1. check that the steam distributor is installed correctly

2. decrease the steam production set on the control

3. check the connection of the device (flow switch or differential pressure switch) slaving the humidifier to the ventilation in the duct

1. clean the drain assembly and pan

2. check the entire water circuit

3. check the correct position of the condensate drain hose in the drain pan

4. check the fastening of the hose clamps on the steam outlet

1. Check for sags & kinks that could trap condensate in the steam hoses that could cause a back pressure on the cylinder.

2. Check the duct static pressure.

3. Check the fill valve and inlet strainer.

4. Check the drain valve operation.

5. Correct installation problems and replace cylinder.

1. Contact the factory for an optional drain timer to force additional drains to control the minerals.

2. If you are using a softener, check the salt being used. If it contains any additives, discontinue use, flush all lines and convert to pure salt or unsoftened water.

3. Check the electrodes in the cylinder to be sure they were not damaged in shipping.

1. Clean or replace the cylinder.

2. Check the steam hoses for kinks or gullies that might be trapping condensate.

3. Replace the fill valve.

4. Consider using a mix of demineralized water with raw water.

5. Check cylinder - replace if exhausted. If feed water contains silica or nitrates, install a 1 micron water filter.

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 21

compactSteam

7. Maintenance

7.1 Periodic checks

• After one hour of operation: Check that there are no significant water leaks.

• Every fifteen days or no more than 300 operating hours: Check operation, that there are no significant water leaks and the general condition of the

cylinder. Check that during operation there is no arcing between the electrodes.

• Every three months or no more than 1000 operating hours: Check operation, that there are no significant water leaks and, if necessary, replace the

cylinder. Check that there are no blackened parts of the cylinder. If there are blackened parts of the cylinder, check the condition of the electrodes, and if necessary replace the cylinder.

• Annually or no more than 2500 operating hours: Replace the cylinder.

CAUTION: ALWAYS DISCONNECT THE MAIN POWER BEFORE DOING MAINTENANCE!

CAUTION: always disconnect the main power before touching the cylinder in the event of leaks, as current may flow through the water.

7.2 Cylinder maintenance

The life of the cylinder depends on a number of factors, including: the amount and type of mineral in the water, the correct use and sizing of the humidifier, and the output, as well as careful and regular maintenance.

IMPORTANT WARNINGS

The humidifier and its cylinder contain live electrical components and hot surfaces, and therefore all service and/or maintenance operations must be performed by expert and qualified personnel, who are aware of the necessary precautions. Before performing any operations on the cylinder, check that the humidifier is disconnected from the power supply. Remove the cylinder from the humidifier only after having drained it completely using the manual “drain” button or procedure. Check that the model and the power supply voltage of the new cylinder correspond to the data on the rating label.

7.2.1 Replacing the cylinder

IMPORTANT WARNING: the cylinder may be hot. Allow it to cool before touching it or use protective gloves.

To replace the cylinder:

• completely drain the cylinder by pressing and holding the “drain” button until the cylinder is empty;

• turn the humidifier off and disconnect the main power;

• remove the cover;

• duct version:

o remove the steam hose from the cylinder; o flip up the cylinder holding bracket and lift the cylinder out of the unit;

• room version:

o undo the 2 bolts of the embedded fan; o flip up the cylinder holding bracket; o disconnect the distributor from the cylinder and lift the cylinder out of the unit;

• disconnect the electrical connections from the top of the cylinder;

• install the new cylinder in the humidifier by performing the previous operations in reverse.

WARNING: Electrical connections to the cylinder must be tight or possible fire hazard may result. Threaded nuts on power wires must be connected with 22 to 29 inch-pounds of torque (2.5 to 3.3 Nm).

Fig. 7.a

7.2.2 Maintenance of the other plumbing components

IMPORTANT WARNINGS:

• When cleaning the plastic components do not use detergents or solvents;

• Scale can be removed using a solution of Lime-A-Way

• External power must always be disconnected when performing any maintenance on the humidifier.

Cleaning the fill valve: After having disconnected the cables and the hoses, remove the valve and check the condition of the inlet filter; clean if necessary using the same cleaning solution as for the steam cylinder and a soft brush. Cleaning the drain valve: Remove the valve body or pump, clean if necessary using the same cleaning solution as for the steam cylinder and a soft brush. Cleaning the drain pan: Clean the pan of any mineral deposits and check that the water flows freely from the pan to the drain at the drain valve. Cleaning the supply, fill, overflow pipes: Check that these are clear and clean or replace if necessary. IMPORTANT WARNING: after having replaced or checked the plumbing, check that components have been reconnected correctly with the proper seals. Re-start the humidifier and perform a number of cleaning cycles (from 2 to 4, read chap. “Starting with a new cylinder”), then check for any water leaks.

®

, CLR®, or 5% phosphoric acid, then rinse with water.

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 22

compactSteam

7.3 Replacement Parts

Item Part No. Description

Read the table below Steam generator cylinder

1

2

CHKCABLE00 Internal cables kit

3 0504349AXX On/off switch

4

5 13C564A044 Blower filter 6 CHKDIST000 Internal steam distributor of the room blower

7

8

9 1312249AXX 90deg drain adapter

KITVASC000 Fill cup

CHKSCREW00 Cover holding screws

Cylinders

(item 1)

Rated steam flow Vac 1-phase Supply water conductivity (µS/cm) Remarks

CY0SA0000 3.5 lbs/h 1.6 kg/h 110 normal 350-1250 Default in compactSteam

CY0SA0000 3.5 lbs/h 1.6 kg/h 110 low 125-350

CY0SA0000 5.5 lbs/h 2.5 kg/h 110 normal 350-1250 Default in compactSteam

CY0SA0000 5.5 lbs/h 2.5 kg/h 110 low 125-350

CY0SB0000 3.5 lbs/h 1.6 kg/h 230 normal 350-1250 Default in compactSteam

CY0SC0000 3.5 lbs/h 1.6 kg/h 230 low 125-350

CY0SB0000 7 lbs/h 3.2 kg/h 230 normal 350-1250 Default in compactSteam

CY0SC0000 7 lbs/h 3.2 kg/h 230 low 125-350

CY0SC0000 12 lbs/h 5.4 kg/h 230 normal 350-1250 Default in compactSteam

CY0SD0000 12 lbs/h 5.4 kg/h 230 low 125-350

KITCY0FG00

CHMCONT10 Control module 110 VAC 1-phase CHMCONT20 Control module 230 VAC 1-phase

1312557AXX Room blower assembly 110 VAC 1-phase 1312558AXX Room blower assembly 230 VAC 1-phase

1312071AXX Fill/tempering valve assembly 110 VAC 1-phase 1312070AXX Fill/tempering valve assembly 230 VAC 1-phase 13C564A039 Drain valve assembly 110 VAC 1-phase 13C564A040 Drain valve assembly 230 VAC 1-phase

CHKTR00000 Internal hoses kit for room versions CHKTD00000 Internal hoses kit for duct versions

Fig. 7.b

Internal filter and gasket valid for all cylinders

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 23

8. Technical Specifications

compactSteam

notes

Steam flows, VAC, kW

Steam pressure 39.37 in WC / 980 Pa For duct only

Dimensions (mm ) 24” x 14” x 8”

Weight empty/packaged/installed with water 18/22/26 lbs.

IP class IP20

Door power switch Yes cuts 24V to control board

Electrode power cables 14 AWG

Power relays 2 x 30 Amp on board

Ground connection Faston

Input water type Potable water no demin. or softened water

Conductivity range 125-1250 µS/cm Special cylinders for cond. < 350

Water fill connection 1/4” O.D. Comp. Adapter to ¾” FPS

Water fill - instant flow 0.09 – 0.12 gpm

Drain connection 33 mm O.D. horizontal, orientable

Drain water temp < 140°F

Drain flow Max 1.3 gpm

Embedded fan flow 71 cfm

3.5 lbs/hr (1.6 kg/h): 110 VAC 1-phase 50-60 Hz, 1.18 kW

3.5 lbs/hr (1.6 kg/h): 230 VAC 1-phase 50-60 Hz, 1.18 kW

5.5 lbs/hr (2.5 kg/h): 110 VAC 1-phase 50-60 Hz, 1.86 kW 7 lbs/hr (3.2 kg/h): 230 VAC 1-phase 50-60 Hz, 2.36 kW

12 lbs/hr (5.4 kg/h): 230 VAC 1-phase 50-60 Hz, 4.05 kW

(600 x 341 x 204 mm)

(8/10/12 kg)

(0.35 – 0.45 l/min)

(< 60°C)

(max 5 l/min)

(120 m³/hr)

(Height x Width x Depth)

drain tempering device

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 and 1 month from the date of shipment (The OEM controls warranty is 2 years from date of manufacture), humidifier replacement parts warranty is 90 days from date of Invoice. Warranty replacement parts are warranted for remainder of original unit warranty or 90 days, whichever is longer, so long as the product has been installed and operated in accordance with all appropriate manuals and wiring diagrams, and started up by a qualified Carel USA technician. Any product or part that is found to be defective will, at the option of Carel USA, LLC be replaced or repaired. Carel USA, LLC reserves the right to inspect any part or installation before replacing or repairing defective parts. After startup of the product, labor for repairs or replacement of parts is not covered by this warranty. Products not included in this warranty are NTC and PTC probes, transformers (TRA series), and routinely replaceable parts such as steam cylinders and gaskets. Carel USA, LLC assumes no liability for consequential or inconsequential damage, or damage due to negligence or improper use. Under the terms of this warranty, the original purchaser may have certain legal rights and other rights, which may vary from state to state. The Warranty will not be considered valid if a product is damaged due to negligence, mishandling or misapplication, or if the product label is missing. Carel USA will attempt to repair or replace the products within two (2) months of the receipt of the returned goods.

Cod. +030221905 – rel 1.0 - 18 Jannuary 2006 24

NOTE ________________________________________________________________________

_______________________________________________________________________________________________________________________

NOTE ________________________________________________________________________

_______________________________________________________________________________________________________________________

Agenzia / Agency:

CAREL S.p.A.

Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 Fax (+39) 049.9716600 http://www.carel.com - e-mail: carel@carel.com

cod. +030221905 rel. 1.0 18 Jannuary 2006

Carel compactSteam CH002V1000, compactSteam CHF05V2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual