Carel gaSteam UG045, gaSteam UG150, gaSteam UG180, gaSteam UG090, gaSteam UG450 User Manual

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USER MANUAL

gaSteam- UG

+0300090EN - ENG Up to date version available on

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gaSteam - UG

Gas humidifier

ENG

LEGGI E CONSERVA

UESTE ISTRUZIONI

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THESE INSTRUCTIONS

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READ CAREFULLY IN THE TEXT!

ENG

IMPORTANT WARNINGS

IFTHE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURYORLOSSOF LIFE

- Do not store or use gasoline or other flammable vapors and liquids in the vicinityofthisor any otherappliance

WHAT TODO IFYOUSMELL GAS:

1. Do nottryto light anyappliance

2. Do not touch any electrical switch; do not use any phone in your building

3. Immediately callyour gas supplierfrom a neighbor’s phone.Follow the gassupplier’s instructions

4. If you cannotreach your gassupplier,callthe firedepartment

- Installation and service must be performed by a qualified installer, service agency or the gassupplier.

CAREL Industries humidifiers are advanced products, whose operation is specified in the technical documentation supplied with the product or can be downloaded, even prior to purchase, from the website www.carel.com. Each CAREL product, in relation to its advanced level of technology, requires setup/configuration/programming to be able to operate in the best possible way for the specific application. Failure to complete such operations, which are required/indicated in the user manual, may cause the final product to malfunction; CAREL accepts no liability in such cases. The customer (manufacturer, developer or installer of the final equipment) accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and/or equipment. CAREL may, based on specific agreements, act as a consultant for the installation/commissioning/use of the unit, however in no case does it accept liability for the correct operation of the humidifier and the final installation if the warnings or suggestions provided in this manual or in other product technical documents are not heeded. In particular, as well as observing the above warnings and suggestions, the following warnings must be observed for correct use of the product:

DANGER OF ELECTRIC SHOCK: the humidifier contains live electrical components. Disconnect the mains power supply before accessing inside parts or during maintenance and installation.

DANGER OF WATER LEAKS: the humidifier automatically and constantly fills/drains certain quantities of water. Malfunctions in the connections or in the humidifier may cause leaks.

DANGER OF BURNS: the humidifier contains high temperature components and delivers steam at 100°C/212°F.

In the event where there is no demand for steam production for a period exceeding 24 hours, the unit will automatically empty the boiler, so as to avoid stagnation of the water inside. Environmental conditions, fuel and power supply voltage must all comply with the specified values. All other uses and modifications made to the appliance that are not authorised by the manufacturer are considered incorrect. Liability for injury or damage caused by the incorrect use of the appliance lies exclusively with the user.

Please note that the appliance is connected to the gas mains, contains live electrical devices and hot surfaces. All service and/or maintenance operations must be performed by specialist and qualified personnel who are aware of the necessary precautions and are capable of performing the operations correctly and in accordance with the safety standards and legislation in force, with specific reference to:

1. Italian law no. 1083/71: “Safety standards relating to the use of gaseous fuel”;

2. Italian law no. 46/90: “Safety standards relating to systems in buildings”;

3. Italian Presidential Decree no. 447 of 6 December 1991: “Regulations for the enforcement of law no. 46, dated March 5, 1990, on safety relating to systems in buildings”;

2. Italian law no. 10/91: “Regulations for the enforcement of the national plan for energy savings and the development of renewable sources of energy”

Adjustment of all units (covered by UL- 998) from operation on natural gas (factory setting) to LPG must only be carried out by Carel personnel or Carel service.

IMPORTANT:

The installation of the product must include an earth connection, using the special yellow-green terminal available in the humidifier.

Important:

l Disconnect the appliance from the mains power supply

before accessing any internal parts.

l Environmental and power supply conditions must conform

to the values specified on the product rating labels.

l The product is designed exclusively to humidify rooms

either directly or through distribution systems (ducts).

l Only qualified personnel who are aware of the necessary

precautions and able to perform the required operations correctly may install, operate or carry out technical service on the product.

l Only water with the characteristics indicated in this manual

must be used for steam production.

l Only water with the characteristics indicated in this manual

must be used to produce the spray.

l All operations on the product must be carried out

according to the instructions provided in this manual and on the labels applied to the product. Any uses or modifications that are not authorised by the manufacturer are considered improper. CAREL declines all liability for any such unauthorised use.

l Do not attempt to open the appliance in any way other

than described in the manual.

l Observe the standards in force in the place where the

humidifier is installed.

l The appliance is not intended for use by persons (including

children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.

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l Do not install and use the product near objects that may be

damaged when in contact with water (or condensate). CAREL declines all liability for direct or indirect damage following water leaks from the humidifier.

l Do not use corrosive chemicals, solvents or aggressive

detergents to clean the inside and outside parts of the humidifier, unless specifically indicated in the user manual.

l Do not drop, hit or shake the humidifier, as the inside parts

and the linings may be irreparably damaged,

CAREL adopts a policy of continual development. Consequently, CAREL reserves the right to make changes and improvements to any product described in this document without prior warning. The technical specifications shown in the manual may be changed without prior warning. The liability of CAREL in relation to its products is specified in the CAREL general contract conditions, published on the website www.carel.com and/or by specific agreements with customers; specifically, to the extent where allowed by applicable legislation, in no case will CAREL, its employees or subsidiaries/affiliates be liable for any lost earnings or sales, losses of data and information, costs of replacement goods or services, damage to things or people, downtime or any direct, indirect, incidental, actual, punitive, exemplary, special or consequential damage of any kind whatsoever, whether contractual, extra-contractual or due to negligence, or any other liabilities deriving from the installation or use of the product, even if CAREL or its subsidiaries/affiliates are warned of the possibility of such damage.

DISPOSAL

The humidifier is made up of metal parts and plastic parts. In reference to European Union directive 2002/96/EC issued on 27 January 2003 and related national legislation, please note that:

1. WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately;

2. the public or private waste collection systems defined by local legislation must be used. In addition, the equipment can be returned to the distributor at the end of its working life when buying new equipment;

3. the equipment may contain hazardous substances: the improper use or incorrect disposal of such may have negative effects on human health and on the environment;

4. the symbol (crossed- out wheeled bin) shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 13 August 2005 and that it must be disposed of separately;

5. in the event of illegal disposal of electrical and electronic waste, the penalties are specified by local waste disposal legislation.

Warranty on materials: 2 years (from production date, excluding consumables).

Approval: the quality and safety of CAREL products are guaranteed by the ISO 9001 certified design and production system, as well

as by the and marks.

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ENG

Index

1. INTRODUCTION AND INSTALLATION 7

1.1 gaSteam (UG*) 7

1.2 Dimensions and weights 7

1.3 When opening the packaging 7

1.4 Positioning 8

1.5 Opening 8

1.6 Material supplied 9

1.7 Structure 10

1.8 Rating plate 11

1.9 Dimensions by model - mm(in) 12

2. CONNECTIONS 17

2.1 Pipe connections 17

2.2 Water connection diagram 17

2.3 Feed water 17

2.4 Drain water characteristics 18

2.5 Air intake and flue connections 19

2.6 Installation of the appliance with air intake from the room 22

2.7 Pressure switch 23

2.8 Checks 23

3. STEAM DISTRIBUTION 24

3.1 Steam nozzles 24

3.2 Linear distributors for air ducts or AHUs 24

3.3 High-efficiency linear distributors for air ducts or AHUs 26

3.4 Steam blower for room installation 27

3.5 Steam hose 27

3.6 Condensate drain pipe 27

3.7 Outlet pressure limits 28

4. ELECTRICAL CONNECTIONS 30

4.1 Wiring requirements 30

4.2 Power cable 30

4.3 Power supply 31

4.4 Auxiliary circuit transformer 32

4.5 Main control board 32

4.6 Operation and control 33

4.7 Steam production control signals 35

4.8 Control with humidity probes 38

4.9 Control with temperature probes 41

4.10 Alarm contact 45

4.11 Production request analogue output 46

4.12 Remote installation of the touch display 46

4.13 Final checks 46

5. PREPARING FOR OPERATION 47

5.1 Preliminary checks 47

5.2 Different types ofgas supply 47

6. START-UP AND USER INTERFACE 50

6.1 Start-up 50

6.2 Activation sequence 50

6.3 Shutdown 51

6.4 Graphic terminal 51

6.5 Touch Display 51

6.6 Complete programming tree 55

7. USER MENU AND UNIT CONFIGURATION 60

7.1 Main menu 60

7.2 Menu E. Settings - a. Control 62

7.3 Menu E. Settings - b. Functions 66

7.4 Menu E. Settings - c. Configuration 71

7.5 Menu E. Settings – d.Master/Slave 76

7.6 Menu E. Settings - e. Backup 77

7.7 Menu E. Settings - f. Manual mode 78

7.8 Menu E. Settings - g. Initialisation 78

7.9 Menu E. Settings - h. Supervision 80

7.10 Menu E. Settings - i. Logout 83

7.11 Touch display: software update 83

8. MASTER/SLAVE SYSTEM 84

8.1 Description of the system 84

8.2 Switch for connection 85

8.3 Type of installation 85

8.4 System configuration 86

9. WEB SERVER 89

9.1 Integrated web server 89

9.2 Connecting to theintegrated web server 89

9.3 Web server functions 90

10. UNIT HARDWARE BACKUP 91

11. SUPERVISOR NETWORK 92

11.1 Protocols and configuration 92

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12. WIRELESS PROBES 93

12.1 Installation and electrical connections 93

12.2 Wireless probeinstallation 94

13. ALARM TABLE 95

14. SPARE PARTS AND MAINTENANCE 100

14.1 Boiler maintenance 100

14.2 Cleaning the burner 102

14.3 Checking ionisation current 103

14.4 Flue gas temperature sensor 103

14.5 Water temperature sensor 103

14.6 Fuses 104

14.7 Cooling fan 104

15. WIRING DIAGRAMS 105

15.1 Electrical panel 105

15.2 Wiring diagram for UG045 - UG090 - UG150 106

15.3 Wiring diagram for UG180 - UG300 108

15.4 Wiring diagram for UG450 110

15.5 Electrical panel 112

16. GENERAL FEATURES AND MODELS 113

16.1 Heating-water circuit specifications 114

16.2 Technical values of theflue gas according to useful heat input 115

16.3 Steam hose models 115

16.4 Linear distributor models and typical installations 115

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1. Introduction and installation

1.1 gaSteam (UG*)

Range of isothermal gas-fired humidifiers for steam production control and distribution, fitted with touch screen graphic display.

Models available (identifiable by the part number shown on the packaging label and on the rating plate): UG045, UG090, UG150, UG180, UG300 and UG450, with steam production capacity up to 450 kg/h (992 lb/h).

gaSteam is available both for indoor and outdoor installation. Certification:

l 230 Vac models: CE; l 115 Vac models: CE and ETL.

1.2 Dimensions and weights

Note: models for outdoor installation are equipped with a rain cover (ref. P), consequently the width and depth dimensions vary slightly.

Fig.1.a

Weight- kg (lb)

A - mm (in) C - mm (in) B - mm (in) D - mm (in) E - mm (in) Packaged Empty Operating

UG045 1443(57) - 656 (26) -

1603(63)

255(562) 240(530) 440 (970) UG045 outdoor - 1560(61) - 800 (31) 270(595) 255 (562) 455(1003) UG090 1443(57) - 656 (26) 255 (562) 240 (530) 440 (970) UG090 outdoor - 1560(61) - 800 (31) 270(595) 255 (562) 455(1003) UG150 1443(57) - 656 (26) - 255(562) 240(530) 440 (970) UG150 outdoor - 1560(61) - 800 (31) 270(595) 255 (562) 455(1003) UG180 1443(57) - 993 (39) - 355(783) 340(750) 755 (1664) UG180 outdoor - 1560(61) - 1107 (44) 370(816) 355(783) 770 (1698) UG300 1443(57) - 993 (39) - 355(783) 340(750) 755 (1664) UG300 outdoor - 1560(61) - 1107 (44) 370(816) 355(783) 770 (1698) UG450 outdoor - 1620(64) - 1668 (66) 550 (1213) 530(1168) 1150(2535)

Tab.1.a

1.3 When opening the packaging

l Check that the humidifier is intact upon delivery and notify the carrier immediately, in writing, of any

damage that may be due to improper or negligent transport;

l Move the humidifier to the installation site before removing it from the packaging, lifting the box

using suitable lifting/handling equipment.

Important: make sure the humidifier does not swing when lifting it.

ENG

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1.4 Positioning

l For installation choose the most suitable position for steam distribution, that is, the position that

minimises the length of the steam pipe. The unit has been designed to be floor standing, on a base that supports its weight in normal operating conditions (see the table of “Dimensions and weights”).

l The metal casing of the humidifier heats up during operation, and the top part may reach

temperatures > 60°C (140°F); therefore make sure that this does not cause any problems.

l Make sure the humidifier is level, and that the minimum clearances are respected, as shown in the

figure below, to allow room for maintenance operations.

Important: make sure that the combustion air intake grille is not blocked or covered.

Fig.1.b

1.5 Opening

1.5.1 Front panel

Unscrew the screws using a Phillips-head screwdriver (A), grasp the handles and slide the panel slightly downwards to remove it.

Fig.1.c

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1.5.2 Accessing the electrical panel

Note: the user terminal (T) is located:

l on the indoor model: mounted on the door and accessible from the outside; l on the outdoor model: inside the unit, in the electrical panel (Q).

Indoor model Outdoor model

Unscrew the screw using a flat-head screwdriver (B) and open the door to access the electrical panel (Q).

Procedure:

1. Turn the disconnect switch (D) OFF to electrically disconnecttheunit;

2. Turn the key in the lock (L) and open the door to access the electrical panel (Q).

Fig.1.d

1.6 Material supplied

Once the packaging has been opened and the front panel removed, make sure that all of the components listed in the table are present.

UG45-90-150 UG180-300 UG450

indoor outdoor indoor outdoor outdoor

Watercircuit

Water hose with compression fitting

1 1 1 1 2

Screw-band hose clamp

4 (UG45-90); 2

(UG150)

4 (UG45-90); 2

(UG150)

4 (UG180); 2 (UG300) 4 (UG180); 2 (UG300) 3

Threaded hose coupling

1 1 1 1 2

Spring hose clamp

2 2 2 2 4

Gas shut-off valve

1 1 1 1 1

Water shutoff valve with gasket

1 1 1 1 2

Probe flanges with gasket

1 1 2 2 3

Cable gland PG13.5

1 1 1 1 1

ENG

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UG45-90-150 UG180-300 UG450

Cable gland PG9

4 4 4 4 4

Weatherproof cover

- 6 - 6 12

Flue gasexhaust:

straight pipe 1 2 2 4 6 probe section 1 1 2 2 3 reducer 1 1 2 2 3 flange with screws

1 1 2 2 3

elbow - 1 - 2 3

Tab.1.b

1.7 Structure

The figure shows the structure of model UG45; for the other models, see par. “Dimensions by model”.

Fig.1.e

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Ref. Description

1 Disconnectswitch 2 Lock 3 Fill solenoid valve 4 Fill shut-off valve 5 Conductivity meter 6 Drain column 7 Overflow/drain pipe 8 Level sensor 9 Preheating temperature sensor 10 Boiler 11 Drain pump 12 Fillpipe 13 Total boilerdrain valve 14 Tank drain 15 Gas shut-off valve

Ref. Description

16 115-230 Vtransformer(US market) 17 Gas valve 18 Combustion air intake pipe 19 Heater (accessory) 20 Flue gas exhaust pipe 21 Safety thermostat 22 Flame control board 23 Ignition electrode 24 Detection electrode 25 User terminal 26 Fan electricalpanel 27 Flue gas exhaust pipe 28 Foam sensor 29 Steam outlet 30 ON/OFF switch

Tab.1.c

1.8 Rating plate

The humidifiers can be identified by the rating plate placed on the partition in the electrical cabinet. There is also a label showing the types of gas allowed for each country and the corresponding supply pressures (classification according to EN437).

Note: tampering, removal or absence of the rating plate or anything else that does not allow certain identification of the product will make any installation or maintenance operations difficult.

ENG

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1.9 Dimensions by model - mm(in)

1.9.1 Indoor models

Fig.1.f

Key Ref. Description

A Flue gas outlet B Steam outlet C Waterinlet D Drain tempering (accessory) E Water drain

Ref. Description

F Tank drain G Drain column H Combustion airintake L Gas inlet M Flame inspection opening

Tab.1.d

Model No. burners Flue gas outlets Steam outlets Water inlet Gas inlet Air intake Tank drain

Drain tempering

(accessory)

UG45 1 1 X Ø 80(3.1) 2 X Ø40(1.6) 1X 3/4" M 1X 1"G 1 X Ø80(3.1) 1 X Ø20(0.8) 1X 3/4" UG90 1 1 X Ø 80(3.1) 2 X Ø40(1.6) 1X 3/4" M 1X 1"G 1 X Ø80(3.1) 1 X Ø20(0.8) 1X 3/4"

UG150 1 1 X Ø80(3.1) 1 X Ø 80(3.1) 1 X 3/4" M 1 X 1"G 1X Ø80(3.1) 1 X Ø20(0.8) 1 X 3/4"

Tab.1.e

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Fig.1.g

Key Ref. Description

A Flue gas outlet B Steam outlet C Waterinlet D Drain tempering (accessory) E Water drain

Ref. Description

F Tank drain G Drain column H Combustion airintake L Gas inlet M Flame inspection opening

Tab.1.f

Model No. burners F lue gas outlets Steam outlets Water inlet Gas inlet Air intake Tank drain

Drain tempering

(accessory)

UG180 2 2 X Ø80(3.1) 4 X Ø 40(1.6) 1 X 3/4"M 1 X 1"1/4 G 2 X Ø 80(3.1) 1 X Ø 20(0.8) 1 X 3/4" UG300 2 2 X Ø80(3.1) 2 X Ø 80(3.1) 1 X 3/4"M 1 X 1"1/4 G 2 X Ø 80(3.1) 1 X Ø 20(0.8) 1 X 3/4"

ENG

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1.9.2 Outdoor models

Fig.1.h

Key Ref. Description

A Flue gas outlet B Steam outlet C Waterinlet D Drain tempering (accessory) E Water drain

Ref. Description

F Tank drain G Drain column H Combustion airintake L Gas inlet

Tab.1.g

Model No. burners F lue gas outlets Steam outlets Water inlet Gas inlet Air intake Tank drain

Drain tempering

(accessory)

UG45 1 1 X Ø 80(3.1) 2 X Ø40(1.6) 1 X 3/4"M 1 X 1"G 1 X Ø 80(3.1) 1X Ø20(0.8) 1 X 3/4" UG90 1 1 X Ø 80(3.1) 2 X Ø40(1.6) 1 X 3/4"M 1 X 1"G 1 X Ø 80(3.1) 1X Ø20(0.8) 1 X 3/4"

UG150 1 1 X Ø80(3.1) 1 X Ø80(3.1) 1 X 3/4"M 1 X 1"G 1 X Ø 80(3.1) 1 X Ø 20(0.8) 1 X 3/4"

Tab.1.h

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Fig.1.i

Key Ref. Description

A Flue gas outlet B Steam outlet C Waterinlet D Drain tempering (accessory) E Water drain

Ref. Description

F Tank drain G Drain column H Combustion airintake L Gas inlet

Tab.1.i

Model No. burners F lue gas outlets Steam outlets Water inlet Gas inlet Air intake Tank drain

Drain tempering

(accessory)

UG180 2 2 X Ø80(3.1) 4 X Ø 40(1.6) 1 X 3/4"M 1 X 1"1/4 G 2 X Ø 80(3.1) 1 X Ø 20(0.8) 1 X 3/4" UG300 2 2 X Ø80(3.1) 2 X Ø 80(3.1) 1 X 3/4"M 1 X 1"1/4 G 2 X Ø 80(3.1) 1 X Ø 20(0.8) 1 X 3/4"

ENG

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Fig.1.j

Key Ref. Description

A Flue gas outlet B Steam outlet C Waterinlet D Drain tempering (accessory) E Water drain

Ref. Description

F Tank drain G Drain column H Combustion airintake L Gas inlet

Tab.1.j

Model No. burners F lue gas outlets Steam outlets Water inlet Gas inlet Air intake Tank drain

Drain tempering

(accessory)

UG450 3 3 X Ø80(3.1) 3 X Ø 80(3.1) 2 X 3/4"M 1 X 1"1/2 G 3 X Ø 80(3.1) 2 X Ø 20(0.8) 1 X 3/4"

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2. Connections

Important: before making the connections, disconnect the power supply by turning the main switch to OFF.

2.1 Pipe connections

gaSteam requires a connection to the gas and water supply and water drain pipes. The feedwater supply can be connected using a hose with a minimum inside diameter (recommended) of 6 mm. Install a shutoff valve to allow the appliance to be disconnected during maintenance. We recommend the use of CAREL hoses (P/N FWH3415003), installing a mechanical filter to trap any solid impurities.

To make the connection:

l drain water: use non-conductive plastic tubing resistant up to 100°C (212°F), with an outside diameter

of 50 mm (ref. 3 in the figure);

l gas supply: use a flexible metal pipe (with vibration isolating joint) connected to a manual shut- off

valve.

Fig.2.a

Ref. Description

1 gas shut-off valve 2 water inletshut-off valve 3 water drain connection 4 tank drain connection

Tab.2.a

2.2 Water connection diagram

Important: the drain pipe must not be obstructed, must not have back pressure and must be fitted with a drain trap immediately downstream of the connection to the humidifier.

Ref. Description

1 shut-off valve 2 filter 3 feedwater

possible reverseosmosis water treatment system

5 hose (P/N FWH3415003, not supplied)

hose (drain tempering option, not supplied)

2.3 Feed water

The feedwater supply to the humidifier must not be corrosive, must not emit bad odours, and must not have an excessive lime content to avoid scale build- up. The water supply must be potable or demineralised water, and must comply with the limits shown in the following table. For proper operation, it is recommended to use demineralised water; for this purpose, the use of a reverse osmosis demineralisation system is suggested.

Important: water treatment with polyphosphates or water softeners is allowed, guaranteeing at least 60% of the initial hardness value and no less than 5°f. Softened water reduces maintenance however favours the concentration of dissolved salts in the water inside the boiler, with the consequence of foam formation.

ENG

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Note that:

1. no relationship can be proven between water hardness and conductivity; nonetheless, as an indication only, water with a hardness of 40°f should have a conductivity of approximately 900-1000 μS/cm at 20 °C.

2. if supplied with water coming from an external reverse osmosis system, an instant flow- rate of 20 l/min (5.28 Gal/min) must be guaranteed. For UG450, there are two inlets, therefore the instant flowrate must be 2 x 20 l/min (2 x 5.28 Gal/min).

Min Max Specific conductivity at 20°C

σ20 - μS/cm 0 1500

Total dissolved solids TDS – mg/l (1) (1) Dry residue at 180°C R180 – mg/l (1) (1) Hydrogen ion activity pH 6 8.5 Total hardness TH– mg/l CaCO3 0 (2) 400 Temporary hardness mg/l CaCO3 0 (3) 300 Chlorides ppm Cl - 50 (4) Iron + Manganese mg/l Fe+Mn - 0.2 Silica mg/l SIO2 - 20 Residual chlorine mg/l Cl- - 0.2 Calcium sulphate mg/l CaSO4 - 100 Metallic impurities mg/l 0 0 Solvents, thinners, detergents, lubricants

mg/l 0 0

Tab.2.b

(1) Values dependent on the specific conductivity; in general: TDS ≈0.93* σR, 20°C; R180 ≈0.65* σR, 20°C; (2) Not lower than 200% the chloride content in mg/l Cl-; (3) Not lower than 300% the chloride content in mg/l Cl-; It may be necessary to adjust the drain rate to avoid a concentration in the boiling water higher than 300

mg/l Cl-;

2.4 Drain water characteristics

The drain water:

contains the same substances that are dissolved in the supply water, yet in greater quantities;

can reach a temperature of 100°C (212°F);

is not toxic and thus may be drained into the sewage system;

for drain tempering versions, water temperature will be 60°C (140°F), with a ma inlet temperature of 25°C (77°F).

Important: completely demineralised water is aggressive. For connection to a feedwater system with completely demineralised water, only use components made from chemically-resistant plastic (e.g. polypropylene) or stainless steel.

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2.5 Air intake and flue connections

The gaSteam humidifier is an approved type C appliance (sealed appliance). Regarding the installation type, the following configurations are possible: B23, C13, C33, C43, C53.

Important: the air intake pipes and flues must be installed and positioned according to the corresponding legislation and standards in force, as well as to the any national or local provisions, and therefore the validity of the diagrams below should always be verified.

The air intake/flue gas exhaust pipes must be connected as shown in the following figure.

Fig.2.b

Ref. Description

A Flue gas outlet B Combustion air intake

For further requirements, use flue gas accessories available on the market. The maximum lengths specified in the following installation diagrams have been verified using CAREL pipes.

For the position of the combustion air intake and flue gas outlet, see the paragraph “Dimensions by model”.

The indoor version is factory-set as follows:

flue gas outlet from the top of the humidifier;

air intake from the rear;

supplied with a 135 mm long inspectable section of piping (two sections for UG180/UG300) and a 135 mm section for condensate collection.

Note: assemble the condensate collection section and connect a pipe to the hole on the side to drain the condensate and prevent it from causing the burner to malfunction.

Both the flue gas outlet and the combustion air intake can be moved using the accessories available, based on installation requirements, with reference to the pressure drop values shown in the table.

pipe diameter (aluminium or stainless steel)

UG45 DP d=80mm d=100mm d=120mm

linear section of pipe l= 1m

2.5 1 0.4

90° bend r/d=0.5 Pa 6.4 2.6 1.2 90° bend r/d=1 Pa 2.6 1 0.5 45° bend r/d=0.5 Pa 3.2 1.3 0.6

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pipe diameter (aluminium or stainless steel)

flue gas exhaust terminal Pa 7 2.8 1.4 “T” section for condensate collection

Pa 7.7 3.1 1.5

Expansion in cross-section Pa 1 0.4 0.2

Tab.2.c

pipe diameter (aluminium or stainless steel)

UG90 DP d=80mm d=100mm d=120mm

UG180 DP 2 xd = 80mm 2 xd = 100mm 2 xd = 120mm

linear section of pipe l= 1m

7.7 2.6 1.1

90° bend r/d=0.5 Pa 19.1 7.6 3.6 90°bend r/d=1 Pa 7.6 3 1.5 45° bend r/d=0.5 Pa 9.5 3.8 1.8 flue gas exhaust terminal Pa 21 8.3 4 “T” section for condensate collection

Pa 23 9 4.3

Expansion in cross-section Pa 3 1.2 0.6

Tab.2.d

pipe diameter (aluminium or stainless steel)

UG150 DP d=80mm d=100mm d=120mm d=150mm UG300 DP 2 xd = 80mm 2 xd = 100mm 2 xd = 120mm 2 xd = 150mm UG450 DP 3 xd = 80mm 3 xd = 100mm 3 xd = 120mm 3 xd = 150mm

linear section of pipe l= 1m

22.5 7.6 4 1

90° bend r/d=0.5 Pa 66 26 12.3 5 90° bend r/d=1 Pa 27 11 5 2 45° bend r/d=0.5 Pa 33 13 6.2 2.5 flue gas exhaust terminal

Pa 73 29 13.6 5.5

“T” section for condensate collection

Pa 79 32 15 6

Expansion in crosssection

Pa 10 4 1.9 0.8

Tab.2.e

Flue gasaccessories(to be purchased separately):

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Fig.2.c

Ref. Description Code

Stainless steel flue grille, Ø80 mm

EXHZ080000

Ø 80mm extension, L =1000 mm

EXHP080100

Ø 80mm extension, L =500 mm

EXHP080500

3 Ø 80mm 90°bend EXHC080080

Stainless steel intakegrille, Ø 80 mm

EXHX080000

Internal/external flange, Ø80 mm

EXHQ080000

6 Tile for sloping roof, Ø80mm EXHNI00125 7 Flat tile Ø80mm EXHN080000

Condensate drain section, Ø 80 mm L=135mm

EXHS0A0011

9 “T” connector Ø 80mm EXHD080000 10 Cap EXHG000000

Condensate drain trap with drain pipe

EXHDS00000

12 Silicone flue gasket Ø 80mm EXHW000080

Flanged section, Ø 80mm, L=56 mm

EXHL080056

Pipesection, Ø 80 mm, L=120 mm

EXHT080120

Inspection section, Ø 80mm, L=135mm

EXHI080025

Pipesection, Ø 80 mm, L=100 mm

EXHT080100

Tab.2.f

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ENG

2.6 Installation of the appliance with air intake from the room

gaSteam humidifiers can be also installed as type B appliances, i.e. with air intake from the room where the appliance is installed.

The maximum allowable pressure drop in the ø 80 mm air intake/flue gas exhaust pipes is:

l for gaSteam 45/90/180: 0-70 Pa (0-0.70 mbars / 0-0.0101 PSI); l for gaSteam 150/300/450: 0-260 Pa (0-2.6 mbars / 0-3.771 PSI);

Important: for flues > 2 m long, a condensate collection section (part 6) or an appropriate drain (part

9) must be installed.

Fig.2.d

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2.7 Pressure switch

The pressure switch (P/N UGKPRES180, not supplied) is used to verify that there is no return of flue gases in the event of installation with a common flue/chimney.

2.8 Checks

Verity that the water connections are correct, as follows:

l the feedwater supply line can be closed using a shut-off valve; l a mechanical filter is installed on the feedwater line; l water temperature and pressure are within the permitted values; l the drain pipe is resistant to operating temperatures of 100°C (212°F); l minimum inside diameter of the drain pipe is 40 mm (1”1/2); l minimum slope of the drain pipe is greater than or equal to 5°; l an inspection section is fitted with connection to a condensate drain.

Important: when installation is completed, flush the feedwater line for around 30 minutes by piping the water directly into the drain, without sending it into the humidifier. This will eliminate any scale or processing residues that may cause foam when boiling.

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3. Steam distribution

To achieve optimal humidifier efficiency, the steam produced must be introduced into the room uniformly, in order to prevent the formation of droplets and condensation. This is achieved using linear steam distributors. The right steam distributor must be chosen according to the place where the steam is to be introduced.

3.1 Steam nozzles

Compact steam distributors for small ducts or applications such as steam baths. These can be mounted either horizontally or vertically (steam outlet upwards).

Mounting instructions (see the figure):

l drill a series of holes in the wall of the pipe, using the drilling template supplied with the distributor; l insert the distributor; l fasten the distributor flange using four screws.

Fig.3.a

Key:

A. steam inlet B. condensate drain

steam outlet The hole dimensions vary depending on the distributor model:

model SDPOEM0000: hole to be drilled manually, up to 30 mm (1.2 in) diameter;

model SDPOEM0012: hole diameter 12 mm (0.5 in);

model SDPOEM0022: hole diameter 22 mm (0.9 in).

D. drilling template

Tab.3.a

Note: if using steam pipes with an inside diameter of 30 mm (1.2 in), remove the 22 mm (0.9 in) inlet

section from the steam nozzle.

3.2 Linear distributors for air ducts or AHUs

The steam distributors for AHU (air handling unit) or duct applications (sold separately) deliver steam along their entire length in order to ensure the shortest not-wetting distance. The distributor must be chosen based on:

l maximum capacity required; l dimensions of the AHU/duct; l outlet diameter on the humidifier it is connected to.

Note: install away from any obstacles (curves, branches, changes in cross-section, grilles, filters, fans).

Minimum distance between distributor and obstacle: 1-1.5 m (3.3-4.9 ft).

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Increase the distance in the event of:

1. increased air speed in the duct;

2. less turbulence.

Mounting instructions (see the figure):

l drill a series of holes in the wall of the pipe, using the drilling jig of the distributor (found in the

packaging of the distributor);

l insert the distributor with the steam outlet holes facing upwards; l fasten the distributor flange using four screws.

Fig.3.b

Key:

1. L-shaped mounting bracket (where featured)

2. flange gasket

3. steam inlet (ØA)

4. condensate drain (ØB)

5. flange screw (see technical leaflet supplied)

6. Ltot = total length from the support to the end of the pipe, including the cover (depending on the model, see the paragraph “Linear distributors”);

Lact = actual length used (from the first to the last hole);

a = distance from the support to the first hole;

f = distance from the last hole to the end of the pipe;

1. slope (about 2°) for condensate drainage

2. diameter of the hole in the wall (ØY)

Dimensions - mm (in)

DP***D22R0 DP***D30R0 DP***D40R0

ØA 22(0.9) 30 (1.2) 40 (1.6) ØB 10 (0.4) 10 (0.4) 10 (0.4) ØY 58 (2.3) 68 (2.7) 89 (3.5) Ø 35 (1.4) 45 (1.8) 60(2.4) X 68 (2.7) 77(3.0) 99 (3.9)

Tab.3.b

Length L

P/N L tot max kg/h lbs/hr

DP035D22R0 332 4 8.81 DP045D22R0 438 6 13.22 DP060D22R0 597 9 19.82 DP085D22R0 835 9 19.82 DP035D30R0 343 5 11.01

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P/N L tot max kg/h lbs/hr

DP045D30R0 427 8 17.62 DP060D30R0 596 12 26.43 DP085D30R0 850 18 39.65 DP105D30R0 1048 18 39.65 DP125D30R0 1245 18 39.65 DP165D30R0 1640 18 39.65 DP085D40R0 834 25 55.07 DP105D40R0 1015 35 77.09 DP125D40R0 1222 45 99.12 DP165D40R0 1636 45 99.12 DP205D40R0 2025 45 99.12 DP035D30RH 343 5 11.01 DP045D30RH 427 8 17.62 DP060D30RH 596 12 26.43 DP085D30RH 850 18 39.65 DP105D30RH 1048 18 39.65 DP125D30RH 1245 18 39.65 DP165D30RH 1640 18 39.65 DP085D40RH 834 25 55.07 DP105D40RH 1015 35 77.09 DP125D40RH 1222 45 99.12 DP165D40RH 1636 45 99.12 DP205D40RH 2025 45 99.12

Important:

1. mount the distributor with a slight slope (at least 2°, to facilitate condensate drainage);

2. the L- shaped support is supplied with steam distributor models from DP085* to DP205*. For shorter lengths, the support can be supplied as an option (P/N 18C478A088).

3.3 Highefficiency linear distributors for air ducts or AHUs

High-efficiency linear distributors (sold separately), can be used in all cases where the formation of condensate needs to be reduced inside the distributor itself. All the information provided in the paragraph on linear distributors still applies; the dimensions and diameters are shown below.

Fig.3.c

Key:

1. L-shaped mounting bracket (where featured)

2. flange gasket

3. steam inlet (ØA)

4. condensate drain (ØB)

5. flange screw (see technical leaflet supplied)

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6. L = length (depending on the model)

7. slope (about 2°) for condensate drainage

8. diameter of the hole in the wall (ØY)

Dimensions - mm (in)

DP***D30RH DP***D40RH

ØA 30 (1.2) 40(1.6) ØB 10 (0.4) 10(0.4) ØY 68 (2.7) 89(3.5) Ø 45 (1.8) 60(2.4) Ø1 60 (2.4) 80(3.1) X 77 (3.0) 99(3.9)

Tab.3.c

3.4 Steam blower for room installation

Steam distributor for installation inside the room, sold separately, equipped with a fan to improve the absorption of steam into the air. The VRDXL00001 blower with 230 Vac power supply (mains) can be used for humidifiers with a capacity up to 45 kg/h (99.2 lb/h), and therefore with models UG045 and UG090 (two units). The blower can be mounted separately from the humidifier. See instruction manual +030222195.

Fig.3.d

Important: observe the distances shown in the figure for correct steam distribution.

3.5 Steam hose

Warnings:

l use CAREL hoses (max length = 4 m, see par. “Steam hose models”); l avoid the formation of pockets or traps (these cause condensate accumulation) l avoid choking the hose with sharp bends or twists. l use metal clamps to secure the ends of the hose to the connections on the humidifier and the steam

distributor so that they do not come loose due to the high temperatures.

l avoid strain, including mechanical stress on the boiler steam outlet spigot.

3.6 Condensate drain pipe

During operation of the humidifier, part of the steam may condense, causing a decline in efficiency and noise (gurgling). To drain the condensate, connect to the base of the distributor a drain pipe with a trap and a minimum slope of 5°.

CAREL condensate drain pipes: P/N 1312368AXX (ø 10mm) - (CHOSE00516 (5/16”) for the North American market) for DP* series linear steam distributors; P/N 1312353APG (ø 7mm) - (CHOSE0038 (3/8”) for the North American market) for steam blowers and steam nozzles.

Important: the condensate drain trap must be filled with water prior to turning on the humidifier.

Below are some requirements and installation examples of the steam hoses and condensate drain pipes:

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l instructions provided in this chapter, the steam outlet hoses are aimed upwards and the distributor

has an upwards slope of at least 2°;

l any curves in the pipes or hoses are sufficiently wide (radius > 300 mm - 12 in) so as to not cause

bending or choking;

l the paths of the steam hose and condensate pipe comply with the instructions provided in this

chapter;

l the slope of the steam hose is sufficient to allow correct condensate drainage (> 20° for upward

sections,> 5° for downward sections);

l the slope of the condensate drain pipe is at least 5° at every point; l the condensate drain pipe is fitted with a drain trap (filled with water before starting) to prevent

steam from escaping.

Fig.3.e Fig.3.f

Fig.3.g

3.7 Outlet pressure limits

The back-pressure at the boiler outlet, either positive or negative, depends both on the relative pressure in the duct/AHU and the pressure drop in the steam hose, due to bends or adapters, and the steam distributor. Carel steam hoses have a pressure drop of around 150 Pa/m (0.021 psi) (in compliance with the maximum flow- rate recommended by Carel). Carel DP* series linear distributors have a pressure drop of around 25 Pa (0.003psi) (in compliance with the maximum flow- rate recommended by Carel). Considering these values, the boiler outlet pressure must be:

l boiler outlet pressure > 150 [Pa/m]* steam hose length [m] + 25 [Pa] DP + pressure in duct/AHU [Pa]

Boiler outlet pressure values for gaSteam:

UG045 UG090 UG150 UG180 UG300 UG450

pressure limits at boiler outlet Pa (PSI) 0to2000 (0 to 0.290)

Tab.3.d

Note: a pressure of around - 200 Pa (-0.029 psi) at the boiler outlet corresponds to around 20 mm

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gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

(0.78”) of water inside the boiler (for all sizes).

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4. Electrical connections

4.1 Wiring requirements

The cables coming from the outside must pass through the side cable glands (see the figure).

Fig.4.a

4.2 Power cable

Before making the electrical connections, disconnect the unit from the mains power supply. Check that the unit’s power supply voltage corresponds to the rated value shown inside the electrical

panel.

230 V/50 Hz version

Run the power and earth wires into the electrical panel through the tear-resistant cable gland supplied, and connect the ends to terminal AL (L1, L2, GND), as shown in the figure.

300090_018_R01

GND

1T 2T 3T 4T 5T 6T 7T 8T 9T 10T 11T 12T 13T 14T

1Z 2Z 3Z 4Z 5Z 6Z 7Z 8Z 9Z 10Z 11Z 12Z

1S 2S 3S 4S 5S 6S 7S 8S 9S 10S 11S 12S 13S 14S

1Y 2Y 3Y 4Y 5Y 6Y 7Y 8Y 9Y

6O 7O 8O 9O

* Z

L1 L2 GND

1U 2U 3U 4U 5U 6U 7U 8U 9U 10U11U 12U 13U 14U

1A 2A 3A 4A

6O7O8O 1Z

2Z3Z4Z

6Z7Z8Z9Z10Z 11Z

L1 L2

GND

230 V / 50 Hz

Fig.4.b

115 V/60 Hz version

Run the power and earth wires into the electrical panel through the tear-resistant cable gland supplied, and connect the ends to the terminals on the DIN rail, connected directly to the main transformer (primary 115 V, secondary 230 V).

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300090_019_R01

GND

to the transformer

(connection by Carel)

115 V / 60 Hz

Fig.4.c

Note: to avoid unwanted interference, the power cables should be kept separate from the probe signal cables.

Important: connect the yellow-green wire to the earth terminal (GND).

4.3 Power supply

The humidifier power line must be fitted by the installer with a disconnect switch and protection fuses. The table shows the recommended size of the power cable and fuse ratings. These data are purely indicative; local regulations must always prevail.

power supply rated characteristics

mod. code

voltage

(V- type)

(1)

current

(A) (2)

power

(W)

(3)

production

(kg/h (lbs/h))

(2, 4)

cable size

(mm2)

(AWG14)

(3)

line

fuses

(A -

type)

(3)

UG045*D004 D0 230V 50Hz - 1~ 0.34 180 45 (100) 2.5 16 F UG045*1104 11 115V 60Hz - 1~ 0.68 180 45 (100) 2.5 16 F UG090*D004 D0 230V 50Hz - 1~ 0.67 250 90 (200) 2.5 16 F UG090*1104 11 115V 60Hz - 1~ 1.34 250 90 (200) 2.5 16 F UG150*D004 D0 230V 50Hz - 1~ 0.71 260 150 (330) 2.5 16 F UG150*1104 11 115V 60Hz - 1~ 1.41 260 150 (330) 2.5 16 F UG180*D004 D0 230V 50Hz - 1~ 1,246 385 180 (400) 2.5 16 F UG180*1104 11 115V 60Hz - 1~ 2.5 385 180 (400) 2.5 16 F UG300*D004 D0 230V 50Hz - 1~ 1.29 400 300 (660) 2.5 16 F UG300*1104 11 115V 60Hz - 1~ 2.6 400 300 (660) 2.5 16 F UG450*D004 D0 230V 50Hz - 1~ 2 660 450 (990) 2.5 16 F UG450*1104 11 115V 60Hz - 1~ 4 660 450 (990) 2.5 16 F

Tab.4.a

(1) Tolerance allowed on the nominal mains voltage: -15%, ± 10%. (2) Tolerance on nominal values: + 5%, -10% (EN 60335-1). (3) Recommended values; referred to cables laid in closed PVC or rubber conduits 20 m long; the

standards in force must always be followed. (4) Instant steam production: average steam production may be affected by external factors, such as:

ambient temperature, water quality, steam distribution system.

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4.4 Auxiliary circuit transformer

The multi-voltage auxiliary circuit transformer has a primary winding for 230 V (protected by fuses,

10.3x38 mm) and a secondary winding (24 V). The transformer is connected and checked in the factory, according to the rated voltage.

4.5 Main control board

The auxiliary connections must be made by running the cables from the outside into the electrical panel compartment through the cable gland located on the side of the humidifier until reaching the plug-in screw terminal block located on the bottom of the electrical panel (as shown in the figure). It is recommended to secure the probe, remote ON/OFF contact connection cables etc. with appropriate cable ties, in order to prevent disconnection.

Fig.4.d

Note: terminal Z only available on UG180.

c.pHC control board

300090_020_R01

M2M9

1 2 1 1 2 3 1 2 34 52 1 2 1 12 21 2 3 4 5 6

J17C

2 1

J17L J23 J24 J19J20J3 J16 M3 J18

2 1

J21

M8 M1 M5 M6M12

1 1 2 3 4 5 6 7 82 1 13 2 31 22 1 2 1 2

main probe

ext. regulator

GND

Remote

ON/OFF

limit probe

12Vdc

Control signal

Ethernet

GND

RS485 Serial

L+

L-

Alarm

elay

CNOC

Unit

status

relay

Fig.4.e

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Terminal Function Electrical characteristics

M1.1 GND (G0) M1.2 Controller power supply 24Vac +10%/-15%50/60Hz

M2.1

Main room probe input or signal from external controller

0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA, NTC10kΩ at25°C

M2.2 GND

M2.3 Probe powersupply (+G)

+12Vdc, maximum current that can be delivered 50mA; protection against short-circuits

G Probe power supply (+G) CAREL 0-10V

M2.4

Digital input for backup/rotation function

Maximum outputcurrent: 5mA; maximum voltage with open contact: 13 Vdc

M2.5

Limit humidity probe signal input

0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA, NTC

M2.6 GND M2.7 GND

M2.8

Remote on/off contact digital input

Maximum outputcurrent: 5mA; maximum voltage with open contact: 13 Vdc

M3.1

Fieldbus

Tx/RxM3.2 Tx/Rx+ M3.3 GND

M5.1

Unit status contact

250Vac; 2Awith resistive load; 2 A with inductive load(NO) M5.2 Unitstatus contact common

M6.1 Alarm common

250Vac; 2Awith resistive load; 2 A with inductive loadM6.2 NCalarm contact M6.3 NOalarm contact

M8.1

Production request analogue output

Output voltage range: 0-10V, max 10 mA

M8.2 GND

M9.1

Backup and rotation contact common

250Vac; 2Awith resistive load; 2 A with inductive load M9.2 Backup and rotation NO contact

M11 Ethernet port

M12

M12.1

BMS485

Tx/Rx-

M12.2 Tx/Rx+ M12.3 GND

Earth connection

J18 pLAN/display terminal

J19

J19.1 Auxiliary/blowercontact (NO)

250Vac; 2Awith resistive load; 2 A with inductive load J19.2

Auxiliary/blower contact common

USB port (type A)

Ethernet RJ45 port

Tab.4.b

4.6 Operation and control

Before describing the electrical connections to the terminals in detail, below is an introduction to the humidifier control principles.

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4.6.1 Operating principle of a gas-fired humidifier

In a gas-fired humidifier, the production of steam is obtained inside a boiler containing water that 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 modulating premixed gas burner. Burner operation is completely automatic and there is no pilot flame. All stages of burner operation are managed by an electronic board that, through ionisation control, constantly checks the flame. The continuously-delivered heat output reflects heat demand, across a wide modulation ratio (1: 4). The variable-speed fan (driven by the control board), combined with a proportional gas valve, ensures modulation of heat output (the gas flow- rate is proportional to the air needed for combustion). The water that evaporates over time is automatically replenished from the mains supply. When fully operational, the required level of production is achieved automatically by adjusting the heat output of the burner. The salts introduced by automatically refilling the water partly deposit in the form of scale inside the boiler, causing a progressive decline in performance, and partly remain dissolved in the water. To avoid excessive accumulation of salts, a certain amount of water is periodically and automatically drained, and then replaced with fresh water.

Control principles

The humidifier can be configured to ensure the desired humidity or temperature value. It can be controlled in the following ways:

4.6.2 ON/OFF control

Operation is all or nothing, and is activated by an external contact; the maximum percentage of unit production can be set.

4.6.3 Proportional to an external signal (modulating control)

Steam production is proportional to the value of an external signal Y (selectable by programming one of the following standards: 0-1Vdc; 0- 10Vdc; 2- 10Vdc; 0- 20mA; 4- 20mA). The maximum production Pmax corresponds to the maximum value of the external signal Y and will be the humidifier’s rated output. The activation hysteresis hy is settable by the user and refers to the external signal Y.

Fig.4.f

Key:

Steam_pr Steam production Y External signal Pmax Max production hy Activation hysteresis Pmin Min production

Note: the above graph applies if the preheating function is disabled.

4.6.4 Autonomous control with humidity probes

The production of steam is related to the % rH reading made by the relative humidity probe, and increases as the value read deviates from the set point St. The maximum production Pmax is delivered when the relative humidity read by the probe is equal to the value of BP (proportional band) from the set point. The activation hysteresis hy is settable by the user.

34|4. Electrical connections

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Fig.4.g

Key:

Steam_pr Steam production %rH Relative humidity measured Pmax Max production hy Activation hysteresis Pmin Min production

Tab.4.c

To verify that the relative humidity measured by the probe is within certain predefined values, two alarm thresholds can be set in autonomous control:

l high relative humidity; l low relative humidity.

When these thresholds are exceeded, an alarm is activated and the corresponding relay contact is closed.

4.6.5 Autonomous control with relative humidity probe and outlet limit probe

In this case too, the controller modulates steam production based on the % rH measured by the main relative humidity probe, while limiting production if the humidity measured by a second limit probe, located in the air duct downstream of the steam distributor, approaches the maximum desired value. Consequently, to prevent the relative humidity of the outlet air from exceeding a value that is considered excessive, autonomous control with a limit probe can be set with a high relative humidity alarm threshold. When this threshold is exceeded, an alarm is activated and the corresponding relay contact is closed. The limit probe allows steam production to be modulated depending on the specific set limit differential.

4.6.6 Application for steam baths

In applications for steam baths, in which the control probe measures temperature rather than humidity, the same rules apply as for autonomous control with probe. By setting control based on temperature, the humidifier will continue to produce steam until reaching the desired set point temperature inside the steam bath, and consequently the desired saturation of the air (fog effect). Recommended CAREL transducer: ASET030000 or ASET030001 or NTC probe UEKNTC0*.

4.7 Steam production control signals

Depending on the type of signal used, steam production can be enabled and/or managed in different ways (ON/OFF or modulating).

Important: the probe inputs are protected against short-circuits, and the maximum current delivered (3U) is 50 mA. Despite this, it is recommended to configure the “Control type” before connecting the probes to the terminals.

To help users configure the unit, a screen index is shown at the top right of the display. The screen index corresponds to the sequence in each menu in order to reach the specific page.

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Fig.4.h

Steam production can be started by:

HUMIDISTAT (ON/OFF operation):

l connect terminals 1U and 2U (production request) to a humidistat; l short-circuit terminals 7U and 8U (jumper) to enable production; l to enable ON/OFF operation, set:

Index Parameter Description

Ea01 Type of control External ON/OFF signal Ea04 Maximum production 25-100% of ratedproduction

Tab.4.d

Fig.4.i

HUMIDISTAT and REMOTE CONTACT (ON/OFF operation)

l connect terminals 1U and 2U (production request) to a humidistat; l connect inputs 7U and 8U (enable) to a remote contact (e.g.: switch, timer,...); l to enable ON/OFF operation, set:

Index Parameter Description

Ea01 Type of control External ON/OFF signal Ea04 Maximum production 25-100% of ratedproduction

Tab.4.e

Fig.4.j

Steam production can be enabled and controlled by:

EXTERNAL PROPORTIONAL CONTROLLER (modulating operation)

l short-circuit terminals 7U and 8U (jumper) to enable production; l connect terminals 1U and 2U (production request) to an external controller; l to enable control, set:

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Index Parameter Description

Ea01 Type of control proportionalto external signal

Ea03 Proportional band

Set: Hysteresis (0-100%) Minimum production (25-100%) Maximum production (25-100%)

Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA

Tab.4.f

Fig.4.k

EXTERNAL PROPORTIONAL CONTROLLER and REMOTE CONTACT (modulating operation)

l connect terminals 1U and 2U (production request) to a humidistat; l connect inputs 7U and 8U (enable) to a remote contact (e.g.: switch, timer,...); l to enable control, set:

Index Parameter Description

Ea01 Type of control proportionalto external signal

Ea03 Proportional band

Set: Hysteresis (0-100%) Minimum production (25-100%) Maximum production (25-100%)

Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA

Tab.4.g

Fig.4.l

EXTERNAL PROPORTIONAL CONTROLLER and REMOTE CONTACT (modulating operation) with LIMIT PROBE

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect terminals 1U and 2U (production request) to an external controller; l connect the active limit probe to terminals 5U, 3U (+12Vdc), 6U (GND); l to enable control, set:

Index Parameter Description

Ea01 Type of control Proportional to externalsignal with limit probe

Ea03 Proportional band

Set: Hysteresis (0-100%) Minimum production (25-100%) Maximum production (25-100%)

Ea06 Limit probe

Set: Set point (0-100 %rH)

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Index Parameter Description

Differential (0-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA Ec02 Limit probe type Select from: 0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA

Tab.4.h

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “G” on the

board rather than terminal 3U.

Fig.4.m

Note: in industrial environments (IEC EN61000-6-2) the signal cables leaving the unit must not exceed 30 m (98’) in length: steam production signal cable (terminals 1U, 2U), digital remote on/off input (terminals 7U, 8U) and shielded cable for RS485 communication.

4.8 Control with humidity probes

The main control board, connected to a room humidity probe, manages steam production based on the humidity measured. A second outlet humidity limit probe can also be connected: with this configuration, typical of air handling units, the controller continues managing steam production according to the humidity requirement, however production is limited according to the relative humidity measured in the outlet duct.

Fig.4.n

Key:

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HP Humidity control probe (intake/room humidity probe) HLP Limithumidity probe (outlet humidity probe) RC Remote contact

Tab.4.i

CONTROL WITH ONE HUMIDITY PROBE

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l to enable control, set:

Index Parameter Description

Ea01 Type of control one humidity probe

Ea05 Modulating control

Set:

humidity set point (0-100 %rH) differential(2-20 %rh)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA

Tab.4.j

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the

terminal block “T” inside the electrical panel, rather than terminal 3U.

Fig.4.o

CONTROL WITH ONE HUMIDITY PROBE AND LIMIT PROBE

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l connect the active limit probe to terminals 5U, 3U (+12Vdc), 6U (GND); l to enable control, set:

Index Parameter Description

Ea01 Type of control Humidity with limitprobe

Ea05 Modulating control

Set:

Humidity set point (0-100 %rH)

Differential (2-20 %rh)

Minimum production (25-100%)

Maximum production (25-100%)

Ea06 Limit probe

Set point (0-100 %rH)

Differential (0-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA Ec02 Limit probe type Select from: 0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA

Tab.4.k

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the

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terminal block “T” inside the electrical panel, rather than terminal 3U.

Fig.4.p

The following probes can be connected:

CAREL probes for rooms DPWC111000 for air ducts DPDC110000, DPDC210000 for industrial applications DPPC210000

Tab.4.l

Note: third-party active probes can also be connected to the controller.

CONTROL WITH TWO HUMIDITY PROBES

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l connect the second active probe to terminals 5U, 3U (+12Vdc) and 6U (GND); l to enable control, set:

Index Parameter Description

Ea01 Type of control Modulation with two humidity probes Ea02 Control with two probes Set the weight of the two probes (0-100%)

Ea05 Modulating control

Set:

humidity set point (0-100 %rH)

differential (2-20 %rh)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA Ec02 Second probe type Select from: 0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA

Tab.4.m

The controller will calculate the weighted average between the two probes. The weight of the two probes can also be set.

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the terminal block “T” inside the electrical panel, rather than terminal 3U.

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Fig.4.q

The following probes can be connected:

CAREL probes for rooms DPWC111000 for air ducts DPDC110000, DPDC210000 for industrial applications DPPC210000

Tab.4.n

Note: third-party active probes can also be connected to the controller.

4.9 Control with temperature probes

The controller also allows autonomous temperature control, and can be connected to a temperature probe TT. It performs complete control based on the temperature measured inside the controlled environment.

Fig.4.r

Key:

TT Activetemperature probe RC Remote contact

Tab.4.o

CONTROL WITH ONE ACTIVE TEMPERATURE PROBE

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l to enable control, set:

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Index Parameter Description

Ea01 Type of control One temperatureprobe

Ea05 Modulating control

Set:

temperature set point (0-100 °C) (32-212°F)

differential (2-20°C) (3.6-36°F)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA

Tab.4.p

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the

terminal block “T” inside the electrical panel, rather than terminal 3U.

Fig.4.s

CONTROL WITH ONE TEMPERATURE PROBE AND LIMIT PROBE

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l connect the active limit probe to terminals 5U, 3U (+12Vdc), 6U (GND); l to enable control, set:

Index Parameter Description

Ea01 Type of control Temperature with limit

Ea05 Modulating control

Set:

temperature set point (0-100 °C) (32-212°F)

differential (2-20°C) (3.6-36°F)

Minimum production (25-100%)

Maximum production (25-100%)

Ea06 Limit probe

Set point (0-100°C/°F)

Differential (0-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA Ec02 Limit probe type Select from: 0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA

Tab.4.q

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the

terminal block “T” inside the electrical panel, rather than terminal 3U.

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Fig.4.t

The following probes can be connected:

CAREL probes for rooms DPWC111000 for air ducts DPDC110000, DPDC210000 for industrial applications DPPC210000

Tab.4.r

Note: third-party active probes can also be connected to the controller.

CONTROL WITH TWO ACTIVE TEMPERATURE PROBES

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); l connect the active limit probe to terminals 5U, 3U (+12Vdc) and 6U (GND);

l to enable control, set:

Index Parameter Description

Ea01 Type of control Temperature (two probes) Ea02 Control with two probes Set the weight of the two probes (0-100%)

Ea05 Modulating control

Set: temperature setpoint (0-100°C) (32-212°F)

differential (2-20°C) (3.6-36°F)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Selectfrom: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA Ec02 Second probe type Select from: 0-1V, 0-10V, 2-10V, 0-20mA, 4-20mA

Tab.4.s

The controller will calculate the weighted average between the two probes. The weight of the two probes can also be set.

Note: when using Carel 0-10V probes, connect the probe power supply +(G) to terminal “14” on the terminal block “T” inside the electrical panel, rather than terminal 3U.

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Fig.4.u

The following probes can be connected:

CAREL probes for rooms DPWC111000 for air ducts DPDC110000, DPDC210000 for industrial applications DPPC210000

Tab.4.t

Note: third-party active probes can also be connected to the controller.

CONTROL WITH ONE NTC TEMPERATURE PROBE (passive)

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

l connect the main NTC room probe to terminals 1U and 2U; l to enable control, set:

Index Parameter Description

Ea01 Type of control one temperature probe

Ea05 Modulating control

Set:

temperature set point (0-100 °C) (32-212°F)

differential (2-20°C) (3.6-36°F)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Set probe type: NTC

Tab.4.u

Fig.4.v

CONTROL WITH TWO NTC TEMPERATURE PROBES (passive)

l short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U –

8U to a remote contact (e.g.: switch, timer,...);

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l connect the first NTC probe to terminals 1U and 2U; l connect the second NTC probe to terminals 5U and 6U; l to enable control, set:

Index Parameter Description

Ea01 Type of control Modulation with two temperature probes Ea02 Control with two probes Set the weight of the two probes (0-100%)

Ea05 Modulating control

Set:

temperature set point (0-100 °C) (32-212°F)

differential (2-20°C) (3.6-36°F)

Minimum production (25-100%)

Maximum production (25-100%) Ec01 Type of main probe Set probe type: NTC Ec02 Second probe type Set probe type: NTC

Tab.4.v

The controller will calculate the weighted average between the two probes. The weight of the two probes can also be set.

Fig.4.w

4.10 Alarm contact

The humidifier controller is fitted with a relay contact for remote signalling of one or more faults or alarms. The alarm contact (250 Vac; max. rating: 2 A resistive - 2 A inductive) is connected using terminals 7O, 8O and 9O.

Fig.4.x

7O CO -Common 8O NC - Normally closed 9O NO - Normally open

Tab.4.w

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4.11 Production request analogue output

The humidifier controller is fitted with an analogue output (0-10 V signal) that reflects the production request. The production request output (0-10 V max 10 mA) is connected to terminals 11U, 12U.

Fig.4.y

11U Production requestanalogue output 12U GND

Tab.4.x

Important: to avoid unbalanced control, the earth of the probes or external controllers must be

connected to the unit controller’s earth.

4.12 Remote installation of the touch display

To install the 4.3” touch screen in a position away from the unit, use the kit HCTXRC0000. The kit comprises a touch display, a 24 Vdc power supply, a telephone cable and a telephone splitter for simultaneous connection of the two displays (one in the remote position and the other installed on the humidifier).

4.13 Final checks

When installation is complete, verify that:

1. mains power to the humidifier corresponds to the voltage shown on the rating plate;

2. the fuses installed are suitable for the line and power voltage;

3. a mains disconnect switch has been installed so as to be able to disconnect power to the humidifier;

4. the humidifier has been correctly earthed;

5. the power cable is secured to the tear-resistant cable gland;

6. terminals 7U, 8U are jumpered or connected to an enabling contact;

7. if the humidifier is controlled by an external controller, the signal earth is electrically connected to the controller earth.

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5. Preparing for operation

5.1 Preliminary checks

Before starting the humidifier, check that:

l the water and electrical connections have been completed and the steam distribution system

configured according to the instructions contained in this manual;

l the humidifier water shut-off valve is open; l the power fuses are installed and intact; l terminals 7U and 8U are jumpered or connected to the remote ON/OFF contact, and that the latter is

closed;

l the probes or the external control device are correctly connected (and that the earth of these devices

is electrically connected to the earth of the main control board);

l the steam hose is not choked; l in the event of ducted humidification, operation of the humidifier is slaved to the operation of the air

fan (replacing or in series with the remote ON/OFF contact);

l the condensate return pipe from the blower has been installed and is not obstructed; l the drain pipe is connected correctly and unobstructed.

Important: before starting, check that the humidifier is in perfect condition, that there are no water leaks and that the electrical parts are dry. Do not connect power if the appliance is damaged or even partially wet!

5.2 Different types of gas supply

Important: the appliances are delivered calibrated and tested to operate on natural gas (methane).

The humidifier can be supplied by the following types of gas:

Natural gas (G20-G25 methane - factory setting);

Propane-Butane (LPG G30-G31);

A number of parameters on the electronic controller need to be set for correct operation, calibrating combustion by checking the values of CO2 (% vol) and CO (ppm) in the flue gas:

NATURAL GAS/LPG CALIBRATION

no. turns

UG45 UG90 UG150 UG180 UG300 UG450

Gas min max min max min max min max min max min max

G20-G25 1450 4700 1700 5050 1900 6750 2000 5300 1900 6750 1900 6750 G30-G31 1650 4200 1850 4450 2000 5150 2000 5150 - - - -

Tab.5.a

5.2.1 Gas burner calibration

The burner is pre-calibrated in the testing phase by the manufacturer; nonetheless, combustion should be checked and adjusted if necessary.

5.2.2 Preparing to analyse combustion

If the flue gasexhaust pipe is positioned horizontally or vertically:

1. remove the cap from the inspection section of the humidifier flue gas exhaust pipe;

2. insert the flue gas analyser probe;

3. perform the flue gas analysis.

Once analysis has been completed, reposition the cap on the inspection section.

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Fig.5.a

5.2.3 Type of calibration

Two different types of burner calibration are available: A. Guided; B. Manual. The guided procedure automatically provides the user, step by step, with all the information necessary to

complete the calibration process. For the manual procedure, follow the instructions below.

5.2.4 Burner calibration at maximum output

Force the burner to operate at maximum output, as shown in the table, by setting the fan to the maximum speed and verifying by flue gas analysis that the CO2 value corresponds to the table.

If the values measured are different, proceed as follows:

1. open the front door;

2. adjust the gas flow regulator B (figure) using a flat- head screwdriver or a 4 mm spanner: turn anticlockwise to increase the CO2 value, clockwise to decrease it;

3. wait until the CO2 value stabilises, then check again and, if necessary, repeat the operations.

Fig.5.b

CO2 (%)

Gas min max

G20-G25 8.5 ±0.3 9.4 ±0.2 G30-G31 9.9 ±0.3 10.5 ±0.3

Tab.5.b

5.2.5 Burner calibration at minimum output

Force the burner to operate at minimum output, by setting the fan to the minimum speed as described previously and verifying by flue gas analysis that the CO2 value corresponds to the table.

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If the values measured are different:

1. open the front door;

2. remove the gas valve pressure regulator cap and adjust the pressure regulator A (see the figure) using a no. 40 Torx screwdriver: turn clockwise to increase the CO2 value, anticlockwise to decrease it (apply small adjustments, as the adjustment screw is very sensitive);

3. wait until the CO2 value stabilises: if necessary, repeat the operations.

4. replace the cap on the regulator;

Important: once the calibration at maximum output has been performed, check the minimum calibration again, as it may have been affected by the maximum calibration; if necessary, repeat the operations described in Burner calibration at MAXIMUM output. Then reset the burner to automatic operation.

To check the correct position of the burner electrodes, see “Cleaning the burner”.

Important: make sure that the CO values in steady operation do not exceed 100 ppm.

PROPANE/BUTANE/LPG CALIBRATION

The following units only can also work on propane, butane and LPG: UG45, UG90 and UG180 (UG150, UG300 and UG450 only work on natural gas). Do not ignite the burner (factory calibrated for natural gas!) with propane or LPG until turning the screw (B) approximately 2.5-3 turns clockwise to adjust maximum gas flow. In fact, the heat power of propane is about three times that of natural gas (methane), therefore it is essential to first reduce the maximum gas flow before ignition. After having reduced the gas flow rate, ignite the burner and subsequently calibrate the gas flow rate by analysing the flue gas, as reported in the previous paragraphs.

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6. Start-up and user interface

6.1 Start-up

After having connected power using the main disconnect switch (ON), switch the appliance on by moving the switch on the front panel to “ON”. The activation sequence will start, which includes an initial phase, an autotest phase and finally actual operation. Each step in the activation sequence is identified by a different display.

6.2 Activation sequence

1. STARTING THE APPLICATION PROGRAM THE FIRST TIME

The “gaSteam” humidifier logo is displayed. When starting the first time, the menu language needs to be selected:

English Italiano Deutsch Français Español Select the desired language and confirm. This screen is displayed for 60 seconds.

2. FIRST START-UP (WIZARD)

When starting the first time, a wizard is provided to quickly set the main unit parameters. The wizard comprises ten steps (some of which may not be displayed, if not necessary):

1/10 - model (only if the replacement controller is not configured): select and set the parameters relating to the model (size, voltage,…);

2/10 - water hardness: auto or user-defined. If choosing “auto”, the controller automatically sets the water hardness, based on feedwater conductivity;

3/10 - manual water hardness setting. The possible options are:

l Demineralised, maintenance at 3000h (hours) l 0-10°f, maintenance at 3000h (hours) l 10-20°f, maintenance at 1500h (hours) l 20-30°f, maintenance at 1000h (hours) l 30-40°f, maintenance at 800h (hours);

4/10 - control type: external On/Off signal, proportional to external signal with limit probe, proportional to external signal, one humidity probe, one temperature probe, one humidity probe and limit probe, one temperature probe and limit probe, two temperature probes (average), two humidity probes (average);

5/10 – select the main room probe type: 0-1V (active), 0-10V (active), 2-10V (active), 0-20 mA (active), 4-20 (active), NTC (passive);

6/10 – select the limit probe type: 0-1V (active), 0-10V (active), 2-10V (active), 0- 20 mA (active), 4- 20 (active), NTC (passive);

7/10 - set the limits for active probes. Room min (%): set the minimum relative humidity limit rH% for the main probe; Room max (%): set the maximum relative humidity limit rH% for the main probe; Limit min (%): set the minimum relative humidity limit rH% for the limit probe; Limit max (%): set the maximum relative humidity limit rH% for the limit probe; 8/10 - set the drain to dilute cycles: auto or user-defined. If choosing “auto”, the controller automatically

sets the number of evaporation cycles that must occur between two consecutive drain to dilute cycles. This setting is based on the feedwater conductivity read by the conductivity meter, thus reducing the use of water, reducing maintenance and extending boiler life;

9/10 - manual drain to dilute cycle setting. Enter the number of evaporation cycles before forcing a dilution cycle.

10/10 - date and time setting. At the end of the guided procedure, a message prompts whether to show the wizard again when next

starting? Yes/No

3. AUTOTEST PROCEDURE

Indicated on the display by the unit status shown as “AUTOTEST”.

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Whenever the humidifier is started (switch moved from OFF to ON), an autotest procedure is run by default to check operation of the level sensor and the appliance as a whole. The autotest procedure involves a water fill cycle to above the high level (green LED), followed by a drain cycle until below the minimum level (red LED). The procedure then refills the unit with water in order to restart production (if required).

Note: all of the screens in the wizard (except for the language selection screen) remain on the display until the user enters the settings.

4. OPERATION

The humidifier starts operating and the standard display is shown. If an alarm is active, the corresponding icon (bell) comes on red, see the chapter “Alarms” for the complete list and description.

Note: model selection and configuration (only for non- configured replacement controllers). If needing to replace the controller only (controller replacement part number) UGKA0D0040), the first time the controller is powered on, the model will need to be set (capacity, power supply and version).

6.3 Shutdown

l To avoid stagnation, drain the water from the boiler using the manual procedure. l move the switch to 0, “OFF”.

6.4 Graphic terminal

The 4.3” touch graphic terminal has a graphic interface with coloured and animated icons. The contents of the display can be scrolled up and down simply and intuitively.

Fig.6.a-home page

6.5 Touch Display

“HOME” menu

The “HOME” menu comprises information on the probes, the set point and external request signal.

Fig.6.b

Position Function

1 System menu

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Position Function

2 home 3 Scheduler settings 4 System dateand time 5 Notification centre 6 Alarm list 7 ON/OFF 8 Setpoint setting 9 System information 10 Descriptive icon of humidifier status

Tab.6.a

6.5.1 System menu

The System menu provides accessto settings that are available without entering a password.

Fig.6.c- system menu

Menu Description

Clock Date and time setting Input/Output Display the analogueand digitalinputs/outputs Graphs Display historicaland real-time operation of the humidifier Functions Special and manual functions Scheduler Manage scheduling of working timebands Alarm threshold Setthealarm thresholds Language Set the menu language

Settings

Access advancedhumidifier configuration (Installer password 77). Menu: E. Settings. Change unit of measure (Imperial/International)

Tab.6.b

6.5.2 Scheduler settings

Activate and set the time bands for humidifier activation. After enabling the scheduler, six on/off time bands can be set for each day. Use the copy button to copy the set time bands from one day to the next.

Fig.6.d

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Fig.6.e

6.5.3 Notification centre

The main messages regarding the activities performed by the humidifier can be quickly displayed in the notification centre. The main screen shows whether any notifications are present, by indicating the number of active notifications. The list of messages that can be viewed in the notification centre is shown below:

Message Description

Type of notification

Maintenance required in xxx hours. boiler lifetime hours: yyy hours

The unit willrequireroutine maintenance System

The unit has performed x drain cycles due to the presence of foam

The unit has performed a drain cycle due to foam detection

System

The maximum production of the Master/Slave system is lower than the value set. Set: xxxx Current: yyyy

The maximum production of the Master/Slave system is lower than the value set.

System

The unit has restarted automatically after a shutdown. Was there ablackout?

The unit has restarted automatically after a shutdown. Was therea blackout?

User

Periodical drain cycle performed The periodical drain was performed correctly User

Factory reset

The factory parameters have been reset correctly

User

Tab.6.c

The system notifications cannot be reset by the user and will be automatically cancelled, user notifications however can be deleted.

6.5.4 ON/OFF

Switch the humidifier on and off

Fig.6.f

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Fig.6.g

6.5.5 Set point setting

Set the set point, proportional band and maximum production

Fig.6.h

6.5.6 System information

Menu providing humidifier status, software and hardware information.

Fig.6.i

Unit status may be as described below:

Unit s tatus Description

Standby unitin standby and ready to operate Production the unit isproducing steam Alarm at least one alarm isactive. Display the alarm by pressing thebutton Off from BMS steam production disabled by the supervisor Off by scheduler steam production disabled due to settime band Off by Din production of steam stopped due to opening of the “remote ON/OFF” contact; Off by keyboard the unit has been switched off from thekeypad

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Unit s tatus Description

Ready for backup

the unit is ready and awaiting to startoperation if there is afault on the main unit.

Manual mode

test mode for commissioning and to check functions (for example: activate drain pump, activate fill

valve...) Warning warning notification Preheating the unit is preheating the waterin the boiler Startup preheat. atstart-up, the unit heats the water to reach the production request Autotest the unit isrunning the autotest Inactivity drain water drain due to inactivity or periodically, the drain pump is operating

Tab.6.d

6.5.7 Descriptive icon of humidifier status

Graphic display of unit status via animated icons. The status may be:

Fill(fillvalve active) Drain (drain pump active) Steam production Minimum water levelin the boiler (yellow and red LEDs on); Water level above the maximum in the boiler(green LED on);

6.6 Complete programming tree

Below is the complete tree of the settings menu. The screen index at the top right corresponds to the sequence in each menu in order to reach the specific page. There are two levels of access: Installer and Service. To login to the settings menu, use the following passwords:

l service: 0044; l installer: 0077.

Menu A. Clock

Index Description Level

A01 Set the time, date and time zone

Installer Service

Menu B. Time bands (scheduler)

Index Description Level

B01 Enable timebands

Installer Service

B02

(visible if time bands are enabled) Set the time bands: day, on time, off time

Installer Service

Menu C. Alarm thresholds

Index Description Level

C01

Set alarm thresholds Low humidity/temperaturealarm threshold High humidity/temperature alarm threshold Limit humidity/temperature alarm threshold

Installer Service

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Menu D. Inputs/outputs

Menu Index Description Level

Analogue inputs D01

Values read by main probe, limit probe, boiler water temperature, feedwater conductivity

Installer, Service

Digital inputs D02

Read status of remote On/Off, motor protector, level sensor float position, foam sensor

Installer, Service

Analogue outputs D03 Read current production

Installer, Service

Digital outputs D04

Read status of unit On/Off, contactor, drain pump, fill valve, SSR/fan

Installer,

Service In/Out - WPrb1 (In/Out wirelessprobe 1)

D05

Read temperature and/orhumidity values Read signal level and battery level on probe 1

Installer,

Service In/Out - WPrb2 (In/Out wirelessprobe 2)

D06

Read temperature and/orhumidity values Read signal level and battery level on probe 2

Installer,

Service In/Out - WPrb3 (In/Out wirelessprobe 3)

D07

Read temperature and/orhumidity values Read signal level and battery level on probe 3

Installer,

Service In/Out - WPrb4 (In/Out wirelessprobe 4)

D08

Read temperature and/orhumidity values Read signal level and battery level on probe 4

Installer,

Service

Menu E. Settings(password)

Menu Index Description Level

a. Control

Control type Ea01 Set the type of control Installer Weights Ea02 Set the weight of thetwo probes Installer

Control proportional to external signal Ea03

Set the hysteresis, minimum production and

maximum production

Installer

External ON/OFF Ea04

Set the maximum production with external

ON/OFF control

Installer

Modulating control Ea05

Set the set point, differential, min production,

max production

Installer

Integral function Ea05a

Set the integral time and the neutral zone

Installer

Limit probe Ea06 Set the set point and differential Installer

Boileroperating hours Ea07

Display boiler operating hours Reset hour counter and set

maintenancepre-alert threshold

Service

Burners rotation Ea10 Set the burner activation sequence Installer

b. Functions

Enable preheating Eb02

Enable preheating Set the water temperature to maintain Set the offset

Installer

Partfillcycles Eb03

Enable part fill cycles Set partfilltime

Installer

Drain do to inactivity Eb04

Enable drain due to inactivity Set the inactivity threshold

Installer

Periodical drain Eb05

Enable periodical drain cycles Set the threshold for the periodical

drain cycles

Installer

M5 Signal. M6 Signal Eb07

Enable the output relay for unit status (production) ormaintenance pre-alert

Installer

Blower unit Eb08 Set on and off delay for blower unit Installer

Export logs Eb09

Save the log of main variables to USB pen drive

Service Installer

Export Alarms Eb10 Save alarm log to USBpen drive

Service Installer

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Menu Index Description Level

Frost protection Eb11 Set thefrost protection function Installer

c. Configuration

Main probe Ec01

Set the main probe: 0-1V, 0-10V, 2-10V, 0-20mA,4-20mA, NTC

Installer

Limit/second probe Ec02

Set the limit probe: 0-1V, 0-10V, 2-10V, 020mA, 4-20mA, NTC

Installer

Wirelessprobes Ec03 Set the wireless probes (main/limit) Installer

Wirelessprobe 1 Ec04

Set the weight of probe 1 Set the communication times

Installer

Wirelessprobe 2 Ec05

Set the weight of probe 2 Set the communication times

Installer

Wirelessprobe 3 Ec06

Set the weight of probe 3 Set the communication times

Installer

Wirelessprobe 4 Ec07

Set the weight of probe 4 Set the communication times

Installer

Number of evaporation cycles before drain

Ec11

Set the number of evaporation cycles between two drain cycles

Installer

Variation in fill and drain time Ec12

Set the fill and drain time in relation to factory default

Installer

Water hardness Ec13 Hardness value Installer Missing waterwarning retry time Ec14 Set timeto check for no water Installer

High conductivity Ec15

Enable the high conductivity alarm Set the alarm delay

Installer

High conductivity Ec16

Set conductivity thresholds: warning, alarm and hysteresis

Installer

Remote ONinput logic Ec22 Operating logic for remoteON/OFF Installer

Burner 1settings Ec23

Set pre-purge speed, minimum speed and maximum speed for production (Burner 1)

Installer

Burner 2settings Ec24

Set pre-purge speed, minimum speed and maximum speed for production (Burner 2)

Installer

Burner 3settings Ec25

Set pre-purge speed, minimum speed and maximum speed for production (Burner 3)

Installer

Burners calibration Ec28

Start the procedure to calibrate the burners.

Installer

d. Master/Slave

Master/Slave Ed01

Initial Master/Slave system configuration

Press “PRG” to configure the Master/Slave network

Installer

Unit 1 Unit 2 .. . Unit20

Ed02 Add unit to the Master/Slave system Installer

Maximum production of Master/Slave system. Unit rotation

Ed03

Set maximum production of the Master/Slave system

Set the unit rotation logic

Installer

Advanced preheating. Rotation time Ed04

Enable the advanced preheating function for Master/Slave systems

Set the rotation time between one unit and the next

Installer

Offline timeout Ed05

Set the unit offline time in the Master/Slave system

Installer

Disconnect unit from Master/Slave system

Ed06

Disable/disconnect the current unit from the Master/Slave system

Installer

Master/Slave production Ed07

Display the request (%) and the production (kg/h / lbs/h) of the Master/Slave system

Press “PRG” to configure the Master/Slave network

Installer

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Menu Index Description Level

Display Master/Slave system Ed08

Unit status withrelative production as a %. Press “PRG” to configure the Master/Slave network

Installer

Display info on individual unit. Unit 1, Unit 2, ...,Unit 20

Ed09

Display unit operating hours, current production and any alarms

To move between the various units use the UP and DOWN arrows

Installer

Unit switched-off for maintenance Ed10

Unit switched off to carry out maintenance

Installer

e. Backup

Enable backup Ee01

Enable automatic unit backup in the event of shutdown, using a second independent unit

Installer

Priority when starting Ee02

Define the priority of the units when in backup mode

Installer

f. Manual mode

Manual mode Ef01

Enable manual mode: Disabled, manual management of outputs and manualrequest

Service, Installer

Manual managementof outputs Ef02

Test the outputs: fill valve, drain pump, ...

Service, Installer

Manual request management Ef03 Manually settheproduction request

Service, Installer

g. Initialisation

Wizard Eg01

Start the wizard for initial unit configuration

Set whetherto display the wizard when next restarting

Service, Installer

Language Eg02 Setthelanguage

Service, Installer

Unit of measure and language when starting

Eg03

Set unit of measure (International or Imperial). Select the language when starting

Installer

Change password Eg04

Change the password (Service, Installer).

Service, Installer

Inst. default Eg06

Unit factory reset. Warning, when changing the model all the control settings will be lost and the values will return to the factory defaults

Service, Installer

Software update Eg07

Update the unit software from USB pen drive

Service, Installer

Export parameters Eg08

Export the unit configuration parameters to aUSB pen drive

Service, Installer

Import parameters Eg09

Import configuration parameters from USB pen driveto the unit

Service, Installer

h. Supervisor

Unit supervision address on BMS port Eh01

Set the unit address for supervision. Enable and set type of supervisor protocol

Installer

BMSport configuration settings Eh02

Set the communication parameters for supervision via BMS: Baud rate, stop bits and parity

Installer

BACnetMS/TPconfiguration Eh03

Set the address, maximum number of masters and maximum number of frames

Installer

Device Inst. Eh06

Device inst. configuration for BACnet protocol

Installer

Ethernet network settings Eh04

Set DHCP, IP address, mask, gateway, DNS for the Ethernet network. Important: these values must be provided by the local network administrator

Installer

Supervsion settings on Ethernetport Eh05

Select the protocol on the Ethernet port: ModBus or BACnet

Installer

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Menu Index Description Level

Regulation from SV Eh07

Select the port that the supervisor is connected to

Installer

i. Logout Logout Ei01

Information on the type of login performed. Possibility to logout

Service, Installer

Tab.6.e

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7. User menu and unit configuration

The following paragraphs describe the gaSteam programming menus. The screen index at the top right corresponds to the sequence in each menu in order to reach the specific page.

7.1 Main menu

7.1.1 Clock menu

The Clock menu is used to set the time, date and time zone. Setting the time zone will automatically update standard/daylight saving time. To access, enter the system menu and then click the clock icon:

Fig.7.a

7.1.2 Inputs/outputs

The Inputs/outputs menu is used to read the status of the inputs and outputs and check unit operation and status.

From the system menu, enter the “Input/Output” menu:

Fig.7.b

Parameter Description

Analogue inputs

Values read by main probe, limit probe, boiler water temperature, feedwater

conductivity. Digital inputs Read status of remote On/Off, level sensor float position, foam sensor. Analogue outputs Read current production Digital outputs Read status of unitOn/Off, contactor, drain pump,fillvalve, SSR/fan In/Out - WPrb1 In/Out wirelessprobe 1

Read temperature and/orhumidity values

Read value of levelsignaland battery level on probe 1 In/Out - WPrb2 In/Out wirelessprobe 2

Read temperature and/orhumidity values

Read value of levelsignaland battery level on probe 2 In/Out - WPrb3 In/Out wirelessprobe 3

Read temperature and/orhumidity values

Read value of levelsignaland battery level on probe 3 In/Out - WPrb4 In/Out wirelessprobe 4

Read temperature and/orhumidity values

Read value of levelsignaland battery level on probe 4

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7.1.3 Alarm thresholds

To check that the relative humidity measured by the probe transducer is within certain predefined values, two alarm thresholds can be configured:

l high relative humidity alarm threshold, for both the main probe and limit probe; l low relative humidity alarm threshold for the main probe.

On exceeding these thresholds, an alarm is activated and the corresponding relay contact on the main control board is closed. Temperature thresholds can also be set.

From the system menu, enter the “alarm thresholds” menu:

Fig.7.c

Parameter Description

Alarm thresholds

Set alarm thresholds

Low humidity/temperaturealarm threshold

High humidity/temperature alarm threshold

Limit humidity/temperature alarm threshold

Default:

low humidity/temperature: 0% rH / 0°C(32°F);

high humidity/temperature: 100% rH / 100°C(° F);

humidity/temperature limit:100% rH / 100°C(°F);

Range: 0-100

7.1.4 Scheduler menu

Parameter Description

Scheduler

Enable timebands

Default: time bands disabled

Fig.7.d

After having enabled the scheduler in the corresponding menu, the humidifier operating intervals can be set for one day (24h) and for the whole week. A time band can be set with production disabled (OFF), enabled (ON), or enabled with s specific set point (ON+SET). Setting the ON time band, the unit uses the main set point configured. If setting ON+SET, the specific set point for the time band can be configured.

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Fig.7.e

Symbol Unit of measure

% %rH °C Degrees Celsius °F Degrees Fahrenheit

Tab.7.a

Note: if control is by external signal, the humidifier can only be switched ON or OFF.

The “Special period” function can be used to set operation (or switch off) for a specific period of time (from day x to day y).

Fig.7.f

The “Special day” function can be used to set operation (or switch off) on a specific day.

Fig.7.g

7.2 Menu E. Settings

- a. Control

l service: 0044; l installer: 0077.

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Fig.7.h

from the system menu, enter the “Settings” menu and enter the password. Then click the “Configuration” icon:

Fig.7.i

The “Settings” menu also has functions to:

l set the units of measure; l manually drain the water in the boiler.

7.2.1 Control type (Installer menu)

Index Parameter Description

Ea01 Control type

Set the type of control Default: humidity (one probe) Possible settings: proportional to external signal, proportional to external signal with limit probe, On/Off signal, humidity (one probe), temperature (one probe), humidity with limit, temperature with limit, humidity (two probes), temperature (two probes)

The possible settings are:

l proportional to external signal: proportional control with signal from an external controller; l proportional to external signal with limit probe: proportional control with signal from an external

controller plus limit probe;

l On/Offsignal: humidity control with humidistat; l humidity (one probe): humidity control with main probe; l temperature (one probe): temperature control with main probe; l temperature with limit: temperature control with main probe and limit probe; l temperature with limit: temperature control with main probe and limit probe; l humidity (two probes): humidity control with two probes, the controller calculates the weighted

average of the two values read;

l temperature (two probes): temperature control with two probes, the controller calculates the

weighted average of the two values read.

For “humidity (one probe)” or “temperature (one probe)” control, one single main probe can be connected and configured, either wired or wireless.

For “humidity with limit” or “temperature with limit” control, a wired probe can be connected as the main probe and a wired probe as the limit. If using wireless probes (maximum of four), two groups of probes can be defined: the group of main probes and the group of limit probes. In this case, the average

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will be calculated between the main probes, depending on the defined weight, and the limit probes will also have their own average, again depending on the defined weight.

For “humidity (two probes)“ or “temperature (two probes)” control, only a group of main probes can be defined. Wired probes can be connected to the main probe input (1U) and the limit probe input (5U), which will be used as a second probe, with the average calculated. If using wireless probes (maximum of four), only a group of main probes can be defined, with the average calculated, depending on the defined weight.

For the connections of the signals and/or probes, see chap. “Electrical connections”.

7.2.2 Weighted average of the probes (Installer menu)

If using two temperature probes or two humidity probes, the humidifier controller will calculate the weighted average of the probe readings. In this way, two probes can be used, for example humidity probes, at opposite ends of the room, calculating the average.

Index Parameter Description

Ea02 Weights

Set the weight of the probes Default: 100 Range: 0-100 Step: 1

The weight of each probe is expressed with a value from 0 to 100. The weighted average is calculated as follows: Weighted average = ((S1×p1)+(S2×p2)) / (p1+p2)

where “Si” is the probe reading, and “pi” the relative weight. To calculate the arithmetic average, equal weights should be set (for example: p1 = p2 = 100). If using wireless probes, the weights of each device can also be defined; in this case a maximum of four

wireless probes can be connected, and consequently the formula shown previously for calculating the weighted average is extended to four devices.

7.2.3 Proportional control configuration

If using control proportional to external signal or control proportional to external signal with limit probe, the hysteresis, minimum and maximum production need to be set.

Index Parameter Description

Ea03

Control proportional to external signal

Set the hysteresis, min production and max production Default: Hysteresis =5% Minimum production = 25% Maximum production =100% Possible settings: Hysteresis =0.5-100% Minimum production = 0-10% Maximum production =0-100%

7.2.4 Control from external ON/OFF signal configuration

If using control with On/Off signal, the maximum production needs to be set.

Index Parameter Description

Ea04 External ON/OFF

Set the maximum production with external ON/OFF control Default: 100% Range: 0-100%

7.2.5 Modulation configuration (Installer menu)

If using modulating control, the related parameters need to be set:

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Index Parameter Description

Ea05 Modulating control

Set the set point, differential, min production,max production Default: Set point =50%rH (42°C) (107.6°F) Differential =5%rH (5°C) (9°F) Minimum production = 25% Maximum production =100% Range: 0-100

7.2.6 Integral function in probe control

If using a probe that is connected directly to the humidifier (control: humidity probe), the Integral (I) control function can be selected. This means the humidity level over time can be considered, bringing the value to the set point even when the proportional action (P) alone is null.

To activate the Integral function, set humidity control (single probe) on screen [Ea01]; also adjust the proportional band on screen [Ea05] (for example, by setting it to a value of 50%). The proportional band has to be at least 10% or higher, so that screen Ea05a will be visible. On screen [Ea05a], two parameters can be set, “integral time” and “neutral zone”.

Index Parameter Description

Ea05a

Integral time

Integral time setting Default: 120s Minimum: 0 sec (integralfunction disabled) Maximum: 300 s

Neutral zone

Integral neutralzone setting, inside which gain remains constant Default: 2.5% Minimum: 0% Maximum: 20%

7.2.7 Limit probe configuration (Installer menu)

A second probe can be connected as a limit probe at the outlet. This probe has the purpose of preventing the relative humidity downstream of the steam distributor from exceeding a set value, configured by the user. As this probe has a modulating action, the differential can also be set. The limit probe, within its range of activation, has priority over the main probe (as the limit probe set point is higher than the main probe set point).

Index Parameter Description

Ea06 Limit probe

Limit probe setpointand differential Default: Set point =100% rH Differential =5% Range: 0-100

7.2.8 Boiler operating hours (Service menu)

The “Boiler op. hours” screen displays the effective number of boiler working hours.

Index Parameter Description

Ea07 Boiler operating hours

Display boiler operating hours, reset hour counter and set maintenancepre-alert threshold Default: Pre-alert =240 hours Range: 0-999

If the boiler needs to be replaced, the hour counter must be reset using the “Reset” parameter; the hour counter will then start again from zero.

The “Pre-alert” item sets the maintenance pre-alert, which is activated “x” hours before the maintenance alarm, and where “x” is the value set for the “Pre- alert” parameter. This allows time to plan the

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maintenance operation. The “maintenance alarm” time is the number of boiler operating hours before it needs to be cleaned. During the start- up wizard, the feedwater hardness is entered, and the ”maintenance alarm” depends on this value, as shown in the table below:

Water hardness Maintenance alarm

Demineralised Cleaning/maintenance 3000 hours (NO STOP) 0-10°f STOP for cleaning/maintenance3000 hours 10-20°f STOP for cleaning/maintenance 1500 hours 20-30°f STOP for cleaning/maintenance 1000 hours 30-40°f STOP for cleaning/maintenance 800 hours

If during the wizard the value is set to “automatic”, rather than entering the hardness value, the maintenance alarm is automatically associated to the feedwater conductivity read by the conductivity meter. The following table shows the dependency of the maintenance alarm on water conductivity.

Water conductivity Maintenance a larm

1-50µS/cm

Warning at 3000 hours without STOP for cleaning-maintenance (it is

assumed that the watercomes from a reverse osmosis system). 50-100 µS/cm STOPfor cleaning/maintenance3000 hours > 100 µS STOPfor cleaning/maintenance 1500hours

The conductivity is read periodically, and the maintenance alarm times is thus updated as a consequence. Thus, for example, if a water hardness of 15°f is set, the “maintenance warning” time will correspond to

1500 actual boiler operating hours; if the “maintenance pre-alert” time is set to 240 hours (default value), the maintenance pre-alert will be activated after 1260 hours.

The humidifier will signal an alarm (and STOP the unit) for maintenance once the pre-set hours have been reached, plus an additional 120 hours (in the above example, 1500 + 120 = 1620 hours).

It must be stressed that if demineralised water (manual mode) or 1- 50μS/cm (automatic mode) are selected, the unit will signal maintenance and cleaning via the warning only, without ever shutting down the humidifier.

7.2.9 Burner rotation/activation

Burner rotation and activation can be configured. gaSteam 180/300/450 manages burner operation according to the setting of the “Burners Sequence”

parameter. In normal operation, depending on the humidity request and the selected control mode (series or

parallel), the control logic automatically calculates the production for each unit. Rotation of the request involves periodically changing these production references. In the long term, operating hours of the burners are balanced, with consequently more uniform wear of the components and scale build-up in the heat exchangers.

There are two types of rotation:

l IN PRODUCTION: timed rotation, i.e. whenever the gap between the operating hours of the two

burners reaches 10 hours, the production references are reversed.

l ON IGNITION: the burner with the lowest number of operating hours is ignited first, as long as the

difference between the operating hours is greater than 10.

There are also two types of activation:

l “PARALLEL”: the steam request is divided equally between the burners so that steam production is the

same.

l “SERIES” (also called “sequential”): if the steam request is less than 50% of the rated production, only

one burner is operated. Only if the request exceeds 50% does the other burner start.

Index Parameter Description

Ea10 Burners rotation

Set the burner sequence (series or parallel).

Burner rotation (in production, on ignition, no rotation)

Operating hours before rotation.

7.3 Menu E. Settings

- b. Functions

7.3.1 Preheat boiler water (Installer menu)

To ensure production starts quickly, the preheat function can be enabled. In this way, even when there is no steam request, the water temperature in the boiler is kept at a value specified by the user. When

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production is next needed, the water is thus warmer than ambient temperature and consequently production will start faster.

Index Parameter Description

Eb02 Enable preheating

Enable preheat

Set the water temperature to maintain

Set watertemperature offset

Default:

Preheating disabled

Water temp. set point in the boiler =70°C (176°F)

Offset =3%rH (3°C/5.4°F)

Set point range: 50-80°C(122-194°F)

Offset range: 2-20%rH (0-20°C/32-68°F)

The water temperature in the boiler is read by the passive NTC temperature probe in contact with the boiler. The operating principle of the preheat function is described in the following graphs, the first for control with probes, the second for control by external signal.

Preheat with autonomous modulating control with probes

The preheating function, if active, overlaps the control diagram and modulates the power delivered to the heaters in relation to the water temperature and the preheating set point.

Fig.7.j

Key

Steam_pr Steam production Pmax Max production Pmin Min production St Set point

%rH Humidity measurement hy Activation hysteresis BP Proportional band

Tab.7.b

Preheat with control by external signal

The preheating function, if active, shifts the control diagram by a value equal to the “offset”. The preheat function modulates the power delivered to the heaters in relation to the water temperature and the preheating set point.

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Fig.7.k

Key

Steam_pr Steam production Pmax Max production

Pmin Min production y External signal

Tab.7.c

7.3.2 Fill cycles in PWM mode after drain to dilute cycles and high level/foam (Installer menu).

After a drain to dilute cycle or high level/foam, the fill valve is opened to replenish water up to the maximum level of the float. The addition of fresh water affects steam production, as it decreases the average water temperature inside the boiler: to reduce the negative impact of fresh water on steam production, the user can activate PWM mode for the fill cycles after drain to dilute cycles and due to high level/foam.

PWM mode for fill cycles works as follows:

1. the mass of fresh water needed to replenish the water level is divided into smaller amounts of fresh water;

2. by keeping the partial fill cycles as far apart as possible, each small amount of fresh water has more time to heat up before more fresh water is filled. This reduces the negative impact of the fresh water on steam production.

The duration of each fill cycle can be defined in seconds:

Index Parameter Description

Eb03 Part fill cycles

Enable part fill cycles. Set the part fillduration. Default: part fill: enabled fill time: 5 seconds Range 1-199 seconds

7.3.3 Total drain due to inactivity (Installer menu)

For reasons of hygiene, it is recommended to empty the boiler so as to prevent water from stagnating inside when there is no humidification request for an extended period. The user can set the automatic total drain due to inactivity time in hours:

Index Parameter Description

Eb04 Drain do to inactivity

Enable drain due to inactivity; set the hoursof inactivity without production request that must expire

before draining Default: drain due to inactivity: enabled; hour threshold: 72 hours Range: 1-999hours Remarks: gaSteam must remain on in order to empty the boiler. The display shows “DRAIN TO DILUTE” during the drain due to inactivity

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Index Parameter Description

cycle.

Automatic total drain due to inactivity cycle is enabled by default and the maximum inactivity time is three days (72 hours). The boiler will be automatically emptied when gaSteam remains on for at least three days without humidification request.

7.3.4 Periodical drain (Installer menu)

If the feedwater is turbid or has a high mineral content, the boiler can be periodically drained in order to clean and dilute the water as much as possible. For this operation to be effective, it is recommended to carry it out at least once every two-three days. The user can set the automatic periodical total drain cycle as follows:

Index Parameter Description

Eb05 Periodic drain

Enable periodical drain; Set the time between one periodical drain cycle and the next (in

hours); Default: periodical drain: disabled; hour threshold: 10 hours Range: 0-999hours Remarks: gaSteam must remain on in order to empty the boiler. The display shows “PERIODICAL DRAIN”during the periodical drain cycle.

Periodical drain is disabled by default. The periodical drain hour counter considers the effective production time.

7.3.5 Unit status signal or maintenance pre-alert (Installer menu)

The humidifier controller features two relay contacts for remote warning of the maintenance pre-alert or unit status (production). The terminals for these functions are 13U, 14U and 7O, 8O, 9O.

Index Parameter Description

Eb07

M5 Signal

Alarm typeon relay output M5 Default: maintenance pre-alert Normally-closed

M6 signal

Alarm typeon relay output M6 Default: alarm (general) Normally-closed

Digital outputs M5 and M5 can be configured as follows:

production

failed autotest alarm

high conductivity warning

level sensor malfunction alarm

motor protector alarm (overtemperature)

high boiler temperature alarm

model not selected

no water alarm

low production warning

main probe broken or disconnected alarm

limit probe broken or disconnected alarm

pre-heating probe broken or disconnected alarm

main wireless probe group not working

limit wireless probe group not working

maintenance pre-alert (warning)

maintenance alarm

offline

Note: the alarm shuts the unit down, the warning is an alert only

M5 (13U, 14U) = pre-alert for maintenance

maintenance early warning signal, helps plan maintenance in advance. See the paragraph "Boiler operating hours" for more details on pre-alertconfiguration

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M6 (7O, 8O, 9O)=alarm (general)

The general alarm (associated, for example, with output M6 - 7O, 8O, 9O) considers all the alarms with shutdown in the list, unless the alarm in question is selected for the other digital output (in this example M5 - 13U, 14U).

7.3.6 Blower unit configuration (Installer menu)

To best manage the blower units in applications where steam is delivered directly into the room, the blower on and off times can be set. Delaying activation of the blower unit allows the system to reach the operating temperature before the fan is activated. Delaying deactivation of the blower unit guarantees that parts in contact with the steam will be completely dried, and that when next starting, there is no condensate in the blower (no droplets delivered into the room).

Index Parameter Description

Eb08 Blower unit

Set the delay time (seconds) for activation and deactivation of blower units Default: startdelay: 0 seconds

stop delay: 90 s Range: 0-600s

7.3.7 Save logs (Service and Installer menu)

The log of the main variables can be saved to USB pen drive; these are:

Unit On/Off

Unit status

Active alarms

Request (%)

Production (kg/h)

Level sensor status

Fill

Drain

The file is saved in .csv format. The logs are constantly saved to internal memory. To export them to the memory key in the USB Host port, enter menu screen Eb09. Set “Export to USB” to “YES”. Progress of the operation will be shown under “progress”.

Index Parameter Description

Eb09 Exportlogs

Save the log of main variablesto USBpen drive Export to USB =Yes, to save thelog

300090_035_R01

USB key

Fig.7.l

7.3.8 Save alarm log

The alarm log can be saved to USB pen drive. To export the file, plug the USB pen drive into the c.pHC and go to screen Eb10, then set “YES” for the “Export?” parameter.

Index Parameter Description

Eb10 Exportalarms

Save alarm log to USBpen drive Default: No

The file will be saved in the pen drive’s root directory and will be called “AlrmLog.txt”.

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7.3.9 Frost protection

The temperature of the unit is controlled using the burners. When the internal temperature measured is lower than the value of the “Forced preheating threshold” parameter (default value = 10°C (50°F)), the unit switches on the burners to keep the water and therefore the humidifier warm. If the temperature inside the unit is lower than the temperature set for the “Pump drain threshold” parameter (default value = 5°C (41°F)), the unit completely drains the water inside the boiler.

Index Parameter Description

Eb11 Frost protection

Set the frost protection function with burner management. Settthesafety function to completely drain the water in the boiler.

In addition to these functions, on outdoor models there is also a normally-open valve connected to a temperature probe (independent), which completely drains the boiler if it measures a temperature of 3°C (37.4°F) (default value, can be set manually). It is also possible to install heaters inside the unit, which work independently (kit to be purchased separately, P/N: UGKHEAT115 for models powered at 115 Vac, UGKHEAT230 for models powered at 230 Vac). The recommended calibration temperature for the heaters is 8°C (46.4°F).

7.4 Menu E. Settings

- c. Configuration

7.4.1 Main probe (Installer menu)

The main probe can be configured on the screen with index Ec01.

Index Parameter Description

Ec01

Main probe

Main probe configuration; Default: Enable: Enabled (depending on the type of control) Type: 0-10V Minimum: 0% rH Maximum: 100% rH Offset: 0 Enable Al(enable alarms): YES Delay: 120seconds Possible settings: Type: 0-10V/0-1V/NTC/4-20mA/0-20mA/2-10V Minimum: 0-100%rH Maximum: 0-100% rH Offset: 0 Enable Al(enable alarms): YES Delay: 0-999seconds

For each probe, after having specified the type, the minimum and maximum values readable can be defined, as well as an “offset” to compensate for any imprecisions in the value read (example: offset = 3 % rH corresponds to 3 percent increase of the humidity value read by the probe). Parameter “En. Al.” activates the alarms corresponding to any probe faults. If a malfunction is detected for a time greater than the value of “Delay” (seconds), the “main probe broken or disconnected” alarm is activated.

7.4.2 Limit probe (or second probe - Installer menu)

The limit probe (if present) can be configured on the screen with index Ec02.

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Index Parameter Description

Ec02 Limit/second probe

Limit probe configuration; Default: Enable: Enabled (depending on the type of control) Type: 0-10V Minimum: 0% rH Maximum: 100% rH Offset: 0 Enable Al(enable alarms): YES Delay: 120seconds Possible settings: Type: 0-10V/0-1V/NTC/4-20mA/0-20mA/2-10V Minimum: 0-100%rH Maximum: 0-100% rH Offset: 0 Enable Al(enable alarms): YES Delay: 120seconds

The same explanations provided in the previous paragraph also apply here.

7.4.3 Wireless probes (Installer menu)

Configuration of the wireless probes involves defining the weight of each probe; for further details on the averages see paragraph 7.2.2 “Weighted average of the probes”. Screen Ec03 can be used to deactivate, activate as main probe or limit probe each of the four possible wireless probes.

Index Parameter Description

Ec03 Wirelessprobes

Wirelessprobe configuration (main and limit) Default: Probe 1:disabled Probe 2:disabled Probe 3:disabled Probe 4:disabled Possible settings: disabled, main probe, limitprobe

To configure the wireless probes, weights and communication times, use screens Ec04, Ec05, Ec06 and Ec07, depending on the number of probes connected.

Index Parameter Description

Ec04 Ec05 Ec06 Ec07

Wirelessprobe 1 Wirelessprobe 2 Wirelessprobe 3 Wirelessprobe 4

Configureprobe weight and communication times; Default: Weight: 100 Transmission time: 10 s Disconnection delay: ms Range: Weight: 0-100 Transmission time: 5-3600 seconds Disconnection delay: ms

Note:

l if wanting to use two wireless probes, simply set “humidity (one probe)” control (Ea01) and then

activate the two wireless probes on screen Ec03;

l “humidity+limit” control (Ea01) can also be used, in this case on screen Ec03 choose which of the

four wireless probes is the limit, and set the others as main;

l “humidity+limit” control (Ea01) can also be used, in this case on screen Ec03 choose which of the

four wireless probes is the limit, and set the others as main;

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7.4.4 Maximum number of evaporation cycles between drain to dilute cycles settable by the user (Installer menu)

The “Evaporation cycles before drain” parameter is used to manually set the maximum number of evaporation cycles allowed between two drain to dilute cycles. The number of evaporation cycles between two successive drain to dilute cycles can also be calculated internally, based on feedwater conductivity. To use the automatic formula, set “Evaporation cycles before drain” = “Auto”. The number of evaporation cycles used by the controller will be the lower of the value set manually by the user and calculated automatically.

Index Parameter Description

Ec11

Number of evaporation cycles before drain

Set the number of evaporation cycles between two drain to dilute cycles. Default: number of cycles: Auto; Possible settings: Auto (automatic management according to feedwater conductivity); 1 to 40

7.4.5 Duration of the fill and drain to dilute cycles settable by the user (Installer menu)

On screen Ec12, the duration of the fill time after the evaporation cycle and the duration of the drain to dilute cycle can be set in relation to the default parameter values.

Index Parameter Description

Ec12

Variation in fill and drain time

Set the fill after evaporation and drain to dilute times in relation to the default values Default:

variation in filltime: 100% variation in drain time: 100% Possible settings: variation in filltime: 20-100% variation in drain time: 0-190%

The duration of the drain to dilute cycle is set using the “variation in drain time” parameter, which defines the time as a% of the default value:

new drain time = (default drain time × variation in drain time)/100 Example: if the default time is 10 s and “variation in drain time” = 50%, then the new time will be = 10 s

x 50/100 = 5 s. The same also applies to the fill time after the evaporation cycle, in this case using the “variation in fill

time” parameter: new fill time = (default fill time × variation in fill time)/100

Note: if the drain to dilute time is very short, there may be the RISK OF FOAM/CORROSION due to increased internal conductivity. Low values should be set for the “variation in drain time” parameter only after having carefully evaluated the water quality and the consequences. Warning: RISK OF FOAM FORMING WHEN “variation in drain time” IS TOO LOW FOR THE WATER

QUALITY. “variation in drain time” = 100 % means that the default value will be used. “variation in drain time”< 100 % means that the drain time will be less than the default, consequently

introducing less fresh water when next refilling, reducing the negative impact on steam production (important in high-precision applications).

Setting the “variation in drain time” for precise %RH control: the “variation in drain time” must be set as low as possible, without however causing formation of foam/corrosion. Proceed by trial and error so as to find the most suitable value.

Note: the duration of the water fill cycle can be used to offset water pressure upstream of the

humidifier. Decrease the fill time in the case of high pressure and vice-versa. Nonetheless, feedwater

pressure must be within the range of pressure values specified in “General characteristics and models”

(1-8 bars)

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7.4.6 Set feedwater hardness (Installer menu)

To read feedwater hardness, Carel provides an analysis kit (P/N: KITTH00000). The “Water hardness” parameter defines the maintenance alarm for cleaning the boiler and the heat exchanger.

Index Parameter Description

Ec13 Water hardness

Set the feedwater hardness Possible settings: Hardness: Auto, Manual Manual setting: demineralised, 0-10°f, 10-20°f, 20-30°f, 30-40°f. Remarks: if the value is set to Auto, the water hardness is estimated by the controllerbased on the conductivity value.

If water hardness is not set, the controller independently manages the type of water based on the conductivity reading. Although there is no reliable relationship between water hardness and conductivity, a hardness of 40°f is typically equivalent to a conductivity of approximately 900-1000 μS/cm at 20°C. See “Boiler operating hours” for information on the maintenance alarm times in relation to water hardness or conductivity.

7.4.7 No feedwater setting (Installer menu)

In the event of no feedwater, the corresponding “No water” alarm is displayed. After the alarm has been displayed and the “no feedwater time” has elapsed, the controller attempts a new fill cycle. At each attempt, the “no feedwater time” is multiplied by the number of times it has already been carried out. The controller therefore performs a series of attempts to refill with water, for a maximum time of five hours after the alarm occurs. The alarm is reset only if the water level effectively reaches the intermediate position (yellow LED).

Index Parameter Description

Ec14

Missing waterwarning retry time

Set the time to check for no feedwater. Default: 10 minutes Range: 0-20minutes Step: 1minute Remarks: if the value is set to 0, no more attempts will be made to refill the waterand the alarm will not be reset

7.4.8 Enable and set high conductivity alarm (Installer menu)

The controller allows conductivity thresholds to be set for the activation of alarms when the limits are exceeded. Excessive conductivity and consequently high concentration of salts in the feedwater can be signalled. These alarm thresholds are programmable using the following parameters:

Index Parameter Description

Ec15 High conductivity

Enable the high conductivity alarm and set the alarm delay. Default: enabled: YES alarm delay: 60 seconds Possible settings: enabled: YES/NO; alarm delay: 0-300seconds Remarks: once the threshold has been exceeded (if the alarm is enabled), the controller waits for the “alarm delay” to elapse before displaying the alarm. If during this waiting time the conductivity falls back below the threshold, the alarm is not activated. This helps avoid false alarms due to variations in the conductivity reading.

7.4.9 Set high conductivity alarm thresholds (Installer menu)

Two high conductivity thresholds can be set. If exceeding:

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l the first (lower) threshold, a warning is shown without stopping operation; l the second (higher) threshold, an alarm is activated and the unit shuts down as a precaution.

Index Parameter Description

Ec16 High conductivity

Set the high conductivity thresholds. Default: pre-alert: 1250μS/cm alarm: 1500µS/cm Hysteresis: 25μS/cm Possible settings: pre-alert: 0-1500 μS/cm alarm: 0-1500 µS/cm Hysteresis: 0-100 μS/cm Remarks: the hysteresis is used to reset the alarm if the conductivity falls below thethreshold minus the “Hysteresis”.

7.4.10 Remote ON/OFF operating logic (Installer menu)

Screen Ec22 is used to set the operating logic of the remote ON/OFF contact (normally open or normally closed).

Index Parameter Description

Ec22 RemoteON input logic

Set the operating logic of the remoteON/OFF input Default: Remote ON input logic = N.O Possible settings: RemoteON inputlogic: N.O., N.C.

7.4.11 Fan speed setting

Setting the fan speed for minimum and rated production. These values are set by default to ensure the correct air/gas mix with the natural gas

Pre-purge speed. The pre-purge speed is indicated in “RPM” and is normally set by the manufacturer based on the characteristics of the combustion system and the gas.

Note: these parameters must only be modified by qualified personnel.

Display Value and notes Default Unit of measure

Pre-Purge

Pre- purge fan speed set points

UG045 =2500 UG090 =2500 UG150 =2500 UG180 =2500 UG300 =2500 UG450 =2500

RPM

Min speed

Fan speed set point at minimum production

UG045 =1450 UG090 =1700 UG150 =1900 UG180 =2000 UG300 =1900 UG450 =1900

RPM

Max speed

Fan speed set point at rated production

UG045 =4700 UG090 =5050 UG150 =6750 UG180 =5300 UG300 =6750 UG450 =6750

RPM

Index Parameter Description

Ec23 Burner 1settings

Set pre-purge speed, minimum speed and maximum speed for rated steam production

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Index Parameter Description

Ec24 Burner 2settings

Set pre-purge speed, minimum speed and maximum speed for rated steam production

Ec25 Burner 3settings

Set pre-purge speed, minimum speed and maximum speed for rated steam production

7.4.12 Burner calibration

Also see the chapter “Preparing for operation”. The Burner Calibration submenu is used to access the procedure for configuring and calibrating the

burners on the humidifier. Two types of gas can be selected:

l Natural gas (G20-G25); l LPG (G30-G31).

Note: on selecting the type of gas, the humidifier automatically sets all the control parameters for

correct operation with that specific family of gas.

Index Parameter Description

Ec28 Burners calibration

Start the procedure to calibrate the burners. Follow the instructions shown on thedisplay

Guided calibration is a step-by-step procedure that helps the installer correctly set up the burner. It is divided into three different steps:

1. Calibration at maximum fan speed (maximum output delivered by the humidifier);

2. Calibration at minimum fan speed (minimum output delivered by the humidifier=;

3. Verification of calibration at maximum output. The first step once the type of gas has been selected; the humidifier will be switched on, if off, and

operated at the maximum output available. The screen will show info on the unit operating status, such as pre-purge, fan speed and waiting. Wait for the humidifier to reach maximum output, then calibrate the gas valve (see chap. “Type of calibration”), adjusting it so that the percentage of CO2 measured is within the allowed range.

Repeat the operations for the other two steps, following the instructions shown on the screen, to complete the calibration procedure.

Note:

l if an alarm is activated during calibration, the procedure stops and a warning message is shown; l If during calibration no button is pressed for 5 minutes, the procedure will be interrupted and the

unit will return to normal operation.

7.5 Menu E. Settings – d.Master/Slave

7.5.1 Master/Slave system network settings (Installer menu)

To increase total production capacity when one single unit is not sufficient, the Master/Slave function can be used to connect up to 20 units together in just one system. To set and enable the individual units in the system, go to the “Network” menu, specifically starting from screen Ed01.

Initial Master/Slave system configuration:

Index Parameter Description

Ed01 Master/Slave

InitialMaster/Slave system configuration Press“PRG” to configurethe Master/Slave network

Ed02

Unit 1 Unit 2

Unit 20

Add unit to the Master/Slave system

To add a unitto the network enter the unit’s IPaddress. Scroll between the units using theUP/DOWN buttons

Master/Slave system function configuration: from screen Ed07 (Master/Slave production) press “PRG” for the following settings:

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Index Parameter Description

Ed02

Unit 1 Unit 2

Unit 20

Add unit to the Master/Slave system. To add a unitto the network enter the unit’s IPaddress. Scroll between

the units using theUP/DOWN buttons

Ed03

Maximum production of Master/Slave system. Unit rotation

Set maximum production of the Master/Slave system. Load: this is the maximum capacity effectively required for the

Master/Slave system, settable by the user. Maximum: this is the sum of the maximum capacities of the units

added to the Master/Slave system Set the unit rotation logic. Rotation: Grouped (Default), Balanced

Ed04

Advanced preheating Rotation time

Enable the advanced preheating function forMaster/Slave systems. Possible settings: YES/NO Set the auto-rotation time between units Possible settings: 0-65535 hours (Default 3 hours). If auto-rotation time=0thefunction is disabled.

Ed05 Offline timeout

Set the offline time for units in the Master/Slave system Range: 500-1000 ms

Ed06

Disconnectunit from Master/Slave system

Disconnectthe current unit from the Master/Slave system Possible settings: YES/NO Remarks: this disconnects and removes the current unit from the

Master/Slave system.

Display Master/Slave system production.

Index Parameter Description

Ed07

Master/Slave production

Display the request (%) and the production (kg/h / lbs/h) of the Master/Slave system

Display unit status and the percentage of production for each unit in the Master/Slave system:

Index Parameter Description

Ed08 Display Master/ Slave system Unitstatus with corresponding % of production

Ed09

Display info on individual unit. Unit 1, Unit 2, ...,Unit20

Display unit operating hours, current production and any alarms To move between the various units use the UP/DOWN arrows The display is availablefor each unit

Maintenance on the units in the Master/Slave system:

Index Parameter Description

Ed10 Unit switched-off formaintenance Unit switched off to carry out maintenance.

For detailed information on the Master/Slave system, see the chapter “Master/Slave system”.

7.6 Menu E. Settings

- e. Backup

7.6.1 Enable backup unit (Installer menu)

In some critical applications where relative humidity control is very important, it may be essential have a backup unit available in the event of malfunctions on the main unit. To enable the backup unit, go to screen Ee01:

Index Parameter Description

Ee01 Enablebackup

Enable automatic unit backup in the event of shutdown, using a second independentunit Default: Disabled Possible settings: Enabled/Disabled

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After having enabled the backup function, the unit that will start first in the event of simultaneous activation can be selected.

Index Parameter Description

Ee02 Priority when starting

Define the priority of the units when in backup mode Default: Disabled Possible settings: Enabled/Disabled

The priority must be set to “YES” only on one of the two units; the “priority” parameter on the second unit must be set to “NO”.

7.7 Menu E. Settings

- f. Manual mode

7.7.1 Manual mode (Service and Installer menu)

During first start-up or maintenance, “manual mode” may be useful in order to check the operation of the main devices on the humidifier. Manual mode is only available when the unit is OFF and without any active alarms. In addition, to safeguard the unit, the heaters can only be activated when there is water in the boiler (high level, corresponding to green LED on)

Important: manual mode should only be activated by qualified personnel; improper use may cause serious damage to the unit.

Index Description Parameter

Ef01

Manual mode

Enable “Manual mode” to check operation of the individual components. Default: Disabled Possible settings: Disabled, manual outputs, manual production Remarks: when exiting “Manual mode”, the settings are restored and normal operation resumes automatically. If the user does not set any parameters in the “Manual mode” menu for 30 minutes, manual mode is automatically disabled.

Ef02 Manualmanagement of outputs

Enable “Manual mode” to check operation of the individual components. Test fill valve Test drain pump Activatethe blower relay

Ef03 Manualrequestmanagement Manually set the production request.

7.8 Menu E. Settings

- g. Initialisation

7.8.1 Initial wizard (Service and Installer menu)

The Wizard menu, screen index Eg01, is used to initiate step-by-step programming of the parameters required for commissioning the unit. Below are the steps included in the first start-up procedure (some steps may not be displayed, if not necessary):

1/9 - Choose the model (only if the replacement controller is not configured); 2/9 - Water hardness: auto or user; defined; 3/9 - Manual water hardness setting; 4/9 - Control type; 5/9 – Select the main room probe type: 6/9 – Select the limit probe type; 7/9 - Set the limits for active probes; 8/9 - Set the drain to dilute cycles: auto or user-defined; 9/9 - Set manual drain to dilute cycles.

Index Parameter Description

Eg01 Wizard

Start the wizard for initial unit configuration Set whetherto display the wizard when next restarting Default: wizard enabled: YES

For further information, see the paragraph “Activation sequence”.

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7.8.2 Set the language (Service and Installer menu)

The first time that the unit is powered on, the menu language needs to be selected. To change the language, go to screen Eg02. Press “ENTER” and UP/DOWN to set, ESC to exit without changes.

Index Parameter Description

Eg02 Language

Set the language. Default: English Possible settings:

1. English

2. Italiano

3. Deutsch

4. Français

5. Español

7.8.3 Set the unit of measure (Installer menu)

Screen Eg03 is used to select the units of measure: International (°C, kg/h) or Imperial (°F, lb/h). In addition, the language selection screen when starting can be disabled.

Index Parameter Description

Eg03

Unit of measure and language when starting

Selectthe unitsof measure. Show change language when starting. Default: units of measure: depending on unitP/N show change language when starting: YES Possible settings: units of measure: International, Imperial show change language when starting: YES, NO

7.8.4 Set and change passwords (Service and Installer menu)

Screen Eg04 is used to change and/or set the Service and Installer passwords. The passwords are 4-digit numbers. The default Installer password is: 0077 The default Service password is: 0044

Index Parameter Description

Eg04 Changepasswords

Set and change the passwords Default: Installer:0077 Service: 0044

7.8.5 Factory reset (Service and Installer menu)

To reset all parameters to the default values, use screen Eg06.

Index Parameter Description

Eg06 Inst. default

Unit factory reset. Remarks: follow the directions shown on the display Confirmation will be requested before resetting the values

Important: when performing a reset, all the control settings will be lost and the values will return to the factory defaults.

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7.8.6 Software update from USB pen drive

The update package can be downloaded from ksa.carel.com. The unit’s software can be updated using a USB pen drive plugged directly into the c.pHC controller. In the pen drive’s root directory, create an UPGRADE directory and copy the software update file to this directory. Once having plugged the pen drive into the controller, go to screen Eg07 and set the “Update unit software” parameter to “YES”.

Index Parameter Description

Eg07 Softwareupdate

Start software update from USB pen drive Default: No

The steps to update the SW/OS (software/operating system) are:

l Save user parameters; l SW/OS upgrade; l Restore default parameter values; l Write user parameters.

Once the update is complete, remove the USB pen drive from the controller. After updating, the main user parameters do not need to be configured as the update automatically

restores them.

7.8.7 Export parameters to USB pen drive

The unit’s parameter configurations can be exported to USB pen drive, and subsequently loaded onto a second unit, making installation and setup even faster. To save the parameters, plug the USB pen drive into the c.pHC and then go to screen Eg08 and set the “Export?” parameter to “YES”.

Index Parameter Description

Eg08 Exportparameters

Start exporting configuration from unit to USBpen drive Default: No

The exported file will automatically be saved in the pen drive’s root directory and will be called: “UG4cgg.txt”

7.8.8 Import parameters onto the unit

The unit’s parameter configurations can be imported from a USB pen drive. To import the parameters, make sure that the exported file is in the pen drive’s root directory and is called: “UG4cgg.txt”. Then plug the USB pen drive into the c.pHC and go to screen Eg09, and set the “Import?” parameter to “YES”.

Index Parameter Description

Eg09 Import parameters

Start importing configuration from USB pen driveto unit Default: No

7.9 Menu E. Settings

- h. Supervision

7.9.1 Supervisor network address setting (Installer menu)

Supervision can be enabled on the Ethernet network or BMS serial port. The following protocols are available to be set by the user:

Port Protocol

BMS Carel, ModBus, BACnet Ethernet ModBus, BACnet

On screen Eh01, the port and supervisor protocol can be set, as well as the unit’s supervision address for the BMS port.

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Index Parameter Description

Eh01

Unit supervision address on BMS port

Set the unit’s supervision address and protocolfor BMS port. Default: Address: 1; Protocol: ModBus; On/Off from SV: No; Control from SV: No; Possible settings: Address: 1-247 Protocol: Modbus, BACnet, Carel

Address is the device’s supervision address on the BMS port. Enabling or disabling the parameters “On/Off from SV” and “Control from SV” activates or deactivates the response to the corresponding signals from the supervisor. For other supervisor protocols, select Carel protocol and use the Carel external gateway (supernode for humidification).

7.9.2 BMS port (Installer menu)

Screen Eh02 is used to set supervisor communication on the BMS port.

Index Parameter Description

Eh02

BMSport configuration settings

Set the communication parameters for supervision via BMS: Baud rate, stop bits and parity Default:

Baudrate: 19200 Stop bits: 2 Parity: None

7.9.3 BACnet MS/TP supervisor settings (Installer menu)

To set the address, maximum number of master units and maximum number of frames for BACnet MS/TP supervision systems, use screen Eh03. The screen is only displayed when supervision is configured on the BMS port with the BACnet protocol.

Index Parameter Description

Eh03

BACnetMS/TP config

Set the address, maximum number of masters and maximum number of frames Default:

Address: 0 Max masters: 127 Max frames: 10

For BACNet MS/TP, in addition to setting the parameters in screen Eh03, it is also necessary to set the parameter on screen Eh06.

Index Parameter Description

Eh06 Device inst. Default: 77000

7.9.4 Ethernet network (Installer menu)

To connect the unit to the local Ethernet network for operation in Master/Slave mode, software Backup/Rotation or use the webserver, set the DHCP, IP, subnet mask, gateway and DNS parameters.

Important: these values must be provided by the local network administrator.

Index Parameter Description

Eh04 Ethernet network settings

Set the unit's IPaddress for the Ethernetconnection. Set DHCP, subnet mask, gateway,DNS. Default:

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Index Parameter Description

DHCP: Off IP: 192.168.0.1(unit’s IPaddress) Mask: 255.255.255.0 (subnet mask) GW: 192.168.0.1(gateway) DNS: 0.0.0.0 Update ?: NO

The following values are set by default on each unit: DHCP: Off unit’s IP address: 192.168.0.1 subnet mask: 255.255.255.0 gateway: 192.168.0.1 DNS: 0.0.0.0

After having modified the parameters, set the “Update?” parameter to “YES” to update the IP address. To start the update, set the “Update?” parameter to “YES”.

Important: the controller is not accessible directly on the internet as a firewall guarantees remote access only via a secure connection (Carel tERA cloud or encrypted VPN connection).

7.9.5 Supervisor settings for ModBus or BACnet on TCP/IP (Ethernet port) (Installer menu)

Both Modbus and BACnet are available on the Ethernet port; to enable the protocol go to screen Eh06:

Index Parameter Description

Eh05

Settings of supervisor from Ethernet port

Selectthe protocol on the Ethernet port En. ModBus TCP/IP:Enabled/Disabled En. BACnetTCP/IP: Enabled/Disabled Default: En. ModBus TCP/IP:Disabled En. BACnetTCP/IP: Enabled

If using the BACnet protocol, the address must be set on screen Eh04.

Note: only one instance of the BACnet protocol is available, therefore it is not possible to activate BACnet on the BMS port and on the Ethernet port at the same time.

7.9.6 Supervisor port

Go to screen Eh07 to set which serial port the supervisor is connected to: BMS or Ethernet.

Index Parameter Description

Eh07 Regulation from SV

Selectthe supervisor port Default: Disabled Possible settings: None, Ethernet (BACnet), BMSport

Important: after changing the protocol, restart the controller. Any changes made to the communication protocols will require a controller

To restart, simply press the “ENTER” button when the following flashing message is shown:

Fig.7.m

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7.10 Menu E. Settings

- i. Logout

7.10.1 Logout from the settings menu (Installer and Service menu)

To logout, use the icon available in the “Settings” menu

Fig.7.n

In “character terminal” mode, screen EI01 screen is used to exit the Settings menu and logout. The screen also describes the type of login performed (installer or service). When accessing this screen, the following information will be shown (in the currently selected language). “To log out, press "ENTER””: the main screen will then be shown again. Press “ESC” to exit if not wanting to end the session.

7.11 Touch display: software update

To update the touch display, simply enter the system menu (from the home page), Settings menu and enter the password. The following screen will be displayed:

Fig.7.o

Plug the USB key into the display (the mini USB port on the display is accessible from inside the electrical panel (outdoor model) or from inside the panel (indoor model), the “update display” menu will be shown. Click this menu and follow the steps described on the display to update the software.

ENG

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7. User menu and unit configuration|83

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8. Master/Slave system

8.1 Description of the system

To obtain steam production higher than that provided by one single unit, several humidifiers can be connected together in a Master/Slave system.

A maximum of 19 Slave units can be connected to each Master, meaning a total of 20 humidifiers. The Master and Slave units are connected using a local Ethernet network, and in the case of just two units

(one Master and Slave) involves a direct connection between the two controllers via Ethernet RJ45 Category 5 cable.

Fig.8.a

If the Master/Slave system comprises three or more units, a network switch is required.

Fig.8.b

The Ethernet port is available on the humidifier’s c.pHC controller:

Fig.8.c

Note: use CAT-5 STP Ethernet cable with a maximum length of 100 m. To connect the shield, use the earth connector provided on the controller.

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8.2 Switch for connection

The Master/Slave connection of more than two units requires the use of an industrial grade switch. Carel supplies a switch (P/N: KITSE08000) that can connect a maximum of eight units (8 Ethernet ports). If necessary, use several switches with a cascaded arrangement.

Technical specifications:

Number of ports 8 Installation DIN rail Operating temperature -10 to 60°C (14to 140°F)

Power supply

12/24/ 48Vdc

18-30Vac (47-63Hz) Current @ 24Vdc 0.13 A Protection IP30

Tab.8.a

8.3 Type of installation

The Master/Slave system features one main unit (Master), which manages operation of the secondary units (Slaves). The external signal or probe connections, depending on the set control type, are made to just one of the humidifiers in the system. The unit that the signal is connected to will automatically be identified as the Master. Consequently, the Master does not need to be especially configured.

Fig.8.d

As long as the Master unit is powered, the system will operate even if the Master itself has a malfunction (e.g. alarms, production stopped, ...), as the controller on this unit will send all the necessary data to the Slaves. Obviously, if system redundancy is not provided for, the amount of steam produced will be lower than actual requirements. If the Master is completely switched off, the Master/Slave system cannot read the signals/control probes. Therefore, it is recommended to connect at least two (or all) of the humidifiers in the system to the external signal or to fit them with distinct probes.

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8. Master/Slave system|85

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Fig.8.e

Systems set up in this way will be able to cover the humidification requirement. In this specific case, the Master will always be the unit with the lowest IP address of those connected to the signal/probes. If necessary, an additional humidifier (backup) can be installed to cover request in the event of malfunctions on one of the units in the system.

8.4 System configuration

To configure the Master/Slave system, proceed as follows:

1. Connect the probes or the external signal to the unit and complete the configuration (control type, type of signal, maximum production …);

2. Set the IP addresses of the individual units so that they belong to the same subnetwork (subnet mask); the screen index for this configuration is Eh02 (E. Settings – h. Supervision). The IP address is set on the display on each unit, assigning a different address to each unit in the same subnetwork. If necessary, contact the local network administrator. Remember that the default address for each unit is

192.168.0.1, and the default subnet mask is 255.255.255.0.

3. Connect the units making up the Master/Slave system to the local Ethernet network via a switch. If using just two units, an RJ45 category 5 cable can be used, connected directly to the Ethernet ports on the two c.pHC controllers.

4. Configure the Master/Slave system by enabling the units one at a time (this operation can be performed on the display on any of the units): I. Display screen index Ed01 and then access configuration mode by pressing “PRG”;

II. Enter the IP address for “Unit 1” and confirm by pressing “Enter”;

III. Repeat the operations described above (1 and 2) for all the other units in the Master/Slave system.

(The units will join the Master/Slave system (online status) immediately after being connected to the network.)

Note:

l the Master unit will always (automatically) be the one with the lowest IP address out of the units

connected to the probes or external signal;

l it may take a few seconds (max 10 s) for the Master to start sending the production request to the

Slave/Slaves. This is also true when, automatically, the Master unit is changed (for example, in the event of malfunctions).

A cascaded connection of several units can also be made by simply using terminals 11U and 12U, which provide the production request (0-10 V).

8.4.1 Maximum production

In the same way as for the individual unit configuration, for the Master/Slave system the maximum capacity can also be set.

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Procedure:

Enter menu Ed07 (E. Settings - d. Network), press PRG and scroll with UP/DOWN until reaching menu Ed03. The “Capacity” parameter identifies the maximum production request for the Master/Slave system, and can therefore be set by the user. The “Maximum capacity” parameter (read-only), on the other hand, indicates the sum of the sizes of each unit added to the system; this value is therefore the maximum effectively available to the Master/Slave system. Consequently, “Capacity” will always be ≤ “Maximum capacity”. In any case, the maximum production can be defined for each individual unit in the system by limiting production from its maximum according to the size. In this case, “Maximum capacity” will be updated keeping in consideration these reductions.

8.4.2 Rotation logic

The activation logic of the units in the Master/Slave system can be set, choosing between “Grouped” or “Balanced” (screens Ed03 and Ed04). On screen Ed07 (E. Settings - d. Network), scroll with UP/DOWN until reaching Ed03 or Ed04 (NB: Ed04 is only visible if rotation is enabled on Ed03).

Grouped:

l the units are activated in series, one after the other, according to the request.

If the steam request does not require operation of all of the units, rotation can also be divided between the units with the lowest operating hours (auto-rotation function), so as to ensure uniform operation of the units over time (same number of operating hours). To enable and configure the rotation times, the “auto-rotation time” parameter must be set on screen Ed04.

Note: if the “auto-rotation time” parameter is = 0, the auto-rotation function is disabled.

Balanced:

l the units are activated in parallel at the same time, splitting the total production request between the

number of units.

8.4.3 Advanced preheating

Note: the function has meaning only in the case of “Grouped” rotation.

By activating the advanced preheating it is possible to automatically pre-activate the Slave units that are currently in standby. When the request reaches 90% of production (of the units currently in production), the preheating of the remaining units is activated. The function is enabled/disabled on screen Ed04.

8.4.4 Disconnecting a unit

To remove a unit from the Master/Slave system, thus reducing the number of units available in the system, use the “Disconnect unit” function on screen Ed06. This can be done on any of the humidifiers in the system.

Note: once the unit has been disconnected, this will no longer be visible in the Master/Slave system, as its IP address will be removed from the list. If a unit is disconnected erroneously, the system can be restored on screen Ed01 (entering its IP). This must be done from the display on a unit that is already connected to the system.

8.4.5 Display the system

To display a summary of the Master/Slave system, go to screen Ed08. On screen Ed07 (E. Settings - d. Network), press DOWN to access menu Ed08. This has a total of five pages that display all of the units (01, 02, ..., 20), the status of each unit and current production as a percentage. The following table lists the Master/Slave network unit status indications:

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Symbol Unit status

Current unit (unit being accessed, display or web server)

Online

Offline

Not configuredand not included in the Master/Slave system

Tab.8.b

The units in the Master/Slave system can also be selected one by one, displaying maximum production, unit status, operating hours, current production request and any alarms. To enter this display, from screen Ed08, select the desired unit and press ENTER, thus accessing screen Ed09. Scroll using the UP/DOWN buttons to display the details of all the units.

8.4.6 Software backup

Master/Slave mode can also be used to manage the software backup function; if one or more units in the Master/Slave system is affected by a malfunction, the system automatically restores humidification production by activating the backup units. The lost production in relation to the request is thus compensated by increasing production on the individual units (where possible) and/or starting any units in standby. Even if not strictly necessary, to ensure the backup function, the external control signal must be sent to all the units in the Master/Slave system; if using probes on the other hand, each unit must be fitted with a probe. Only in this way can complete operation be guaranteed in the event of malfunctions.

Note: if a unit goes offline due to a malfunction or shutdown, it will temporarily be excluded from the system, and when next restarted it may take 15 seconds or more to automatically come online again.

8.4.7 Software backup for maintenance

During maintenance or cleaning on a unit in the Master/Slave system, the backup for maintenance function can be activated. This allows production to start on a unit in standby, set as backup, before switching off the humidifier in question for maintenance. In this way, service continuity can be guaranteed in applications where required humidity control is very precise and continuous over time.

Procedure:

1. Access screen Ed07 (Network);

2. Press DOWN to display the list of units (Ed08);

3. Scroll to the unit on which maintenance is required (Unit 1, Unit 2, …) and press ENTER to confirm (screen Ed09).

4. Press PRG to access screen Ed10 and set “Request switch unit off” = YES. Wait for the display to show the message: “The unit can now be switched off for maintenance” and then switch the unit off.

Once maintenance has been completed, simply switch the humidifier on again, and it will automatically come back online.

Note: to activate the advanced software backup functions for maintenance, the backup unit must be connected to the probes or external signal.

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9. Web server

9.1 Integrated web server

The integrated web server is used to configure and monitor the main unit parameters directly from a PC. In fact, using the Ethernet port on the humidifier controller, the unit can be accessed via a local network by simply entering its IP address in the browser.

Fig.9.a

To log in and access the various menu items, use the installer or service password (see the chapter “Startup and user interface”).

9.2 Connecting to the integrated web server

For the physical connection to the controller from a PC, must use the RJ45 Ethernet port on the c.pHC and an Ethernet category 5 cable.

Fig.9.b

Location of the Ethernet port on the c.pHC controller.

Fig.9.c

The PC and the humidifier controller (or all controllers, for Master/Slave systems) must be part of the same subnetwork.

The default network configurations for the c.pHC are:

l unit’s IP address: 192.168.0.1; l subnet mask: 255.255.255.0; l gateway: 192.168.0.1.

For example, the PC’s network settings can be changed as follows:

l unit’s IP address: 192.168.0.2 l subnet mask: 255.255.255.0 l gateway: 192.168.0.1

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to do this, access the “Network and sharing center” on the PC and go to “Local network connection”. Then modify the addresses, as shown above, for Internet protocol version 4.

Each c.pHC controller can obviously also be added to the Ethernet local network, allowing the web server to be accessed from any point in the network and for each humidifier.

Important: the controller is not accessible directly on the internet as a firewall guarantees remote access only via a secure connection (Carel tERA cloud or encrypted VPN connection).

9.3 Web server functions

The web server “Home” page provides access to the display, so as to carry out all the configuration operations in the same way as if working directly on the unit. In addition, there will be an immediate response from the unit on its display.

Fig.9.d

The main menus are:

l UNIT l NETWORK l MAINTENANCE l INFO

Unit menu

Probes: information and configuration of the main and limit probe. Select the type of signal and define the minimum and maximum values.

Wireless: enable and associate each wireless probe to the main probe group or limit probe group. Read the humidity and/or temperature, level and battery status.

Control: select the control type. Set the set point, differential, minimum and maximum. Configuration: set the time and date. Configure the main alarms and variation in percentages of fill and

drain times. Scheduler: enable and set the daily and weekly time bands.

Network menu

Display a summary of the status of the units in the advanced Master/Slave system.

Maintenance

Timers: display boiler and unit operating hours. Display the time remaining until maintenance is required and set the maintenance pre-alert.

Logs: display the log of main variables (production, set point, drain pump status, fill valve status, request, unit status).

Live: real time display of the main variables (production, set point, drain pump status, fill valve status, request, unit status).

Info

Unit info: information on the unit model and software version. Select language and unit of measure. Resources: useful links (Carel website, gaSteam manuals and pages on Carel website). Guide & FAQ: general information on using the web server.

Note: to avoid incorrect settings, some of the main unit operating parameters can only be modified

via the web server when the unit is off (off from keypad).

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10. Unit hardware backup

For applications that require continuous humidity control, a second backup unit may be required, which is automatically activated in the event of a malfunction on the first. The gaSteam controller features a dedicated digital input and output for the backup connection, so as to guarantee, via the normally-open contact, activation of the second unit.

Fig.10.a

Connection between two units for the hardware backup function:

Terminal Function

9U Backup and rotation contact common 10U Backup and rotation contact (NO) 2U GND 4U Digitalinput for backup/rotation function

Tab.10.a

Fig.10.b

The hardware backup function must be activated on the menu in screen Ee01. Screen Ee02 is used to set the unit with higher priority in the event of simultaneous activation. To ensure service continuity, the external signal or probes must be connected to both units; in this way, both the main unit and the backup unit will be completely independent. If using autonomous control with probes, it is recommended to use dedicated probes for each unit (main probe and limit probe), in other words, do not share the probes between the units. This will guarantee service even in the event of probe malfunctions.

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10. Unit hardware backup|91

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11. Supervisor network

11.1 Protocols and configuration

The humidifier can be connected to a supervisor via serial (BMS) or Ethernet network. The Carel, ModBus and BACnet protocols are supported as standard by the units.

Fig.11.a

Port Terminal on c.pHC controller Protocol

BMS(1) M12.1,M12.2, M12.3 Carel, ModBus, BACnet

Ethernet (2) ModBus, BACnet

Tab.11.a

To configure supervision on the BMS port (1), go to “SETTINGS – SUPERVISION”, specifically screens Eh01, Eh02 and Eh03. If connecting the supervisor to the Ethernet port (2), set the network parameters (DHCP, IP address, subnet mask, gateway, DNS) on screen Eh04. For other supervisor protocols, select the Carel protocol on the BMS serial port and use the Carel external gateway (supernode for humidification: SNU0000EM0), combined with the desired supervision card (depending on the protocol).

Note:

l use CAT-5 STP Ethernet cable, max length = 100 m. To connect the shield, use the earth connector

provided on the controller;

l for BMS and Fieldbus, use shielded cables with the shield connected to earth.

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12. Wireless probes

12.1 Installation and electrical connections

For installations where standard wired probes can not be used, (for example, modifications to existing systems), wireless probes can be used. These are connected via a device called an access point (Carel P/N: WS01AB2M20), for up to four wireless probes. The Carel wireless probes available are for room installation (WS01G01M00) or industrial applications (WS01F01M00), both of which measure humidity and temperature. Installation diagram (with four wireless room probes):

Fig.12.a

Key:

1. gaSteam humidifier;

2. humidifier/access point connection;

3. Access point;

4. Wireless probes for measuring temperature and humidity;

gaSteam/access point connection:

To connect the humidifier to the access point, use the Fieldbus connection on terminal M3 (M3.1: Tx/Rx-, M3.2: Tx/Rx +, M3.3: GND):

Fig.12.b

Note: the devices have a range of around a hundred metres in a free space, i.e. without any obstacles. In a closed space, the range varies considerably depending on the type of environment and the surrounding objects (shelves, metal partition walls etc.).

If installing multiple wireless probes, the controller will calculate the weighted average between the various probe readings, depending on the settings made by the user and the defined probe groups. Also see the paragraph “Wireless probes”. The controller also displays (locally only) the battery and signal level for each probe (screens D05 to D08). The table below shows the part numbers and descriptions of the Carel devices that can be used:

P/N Model Characteristics Power supply

WS01F01M00 SI sensor Temperature/humidity for industrial use Battery

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P/N Model Characteristics Power supply

WS01G01M00 SA sensor Room temperature/humidity Battery

WS01AB2M20 Access Point ZigBee™ radio gateway - RS485ModbusR

12-24Vac/dc ±10% 100 mA;

50/60Hz; usea ClassIIsafety

transformer with a minimum power

rating of 2 VA. A 12 Vac transformeris

recommended

Tab.12.a

12.2 Wireless probe installation

The main steps for installing the wireless devices are:

l power up the access point (12/24 Vac/dc ±10%m, 100 mA) and complete the initialisation procedure,

creating the network and selecting the channel;

l after having opened the domain on the access point, complete the binding procedure so as to

uniquely identify each probe.

The address to be used by the access point is set using the dipswitches on the device, and is the following:

Fig.12.c

Dipswitch Access point add.

Serial port baud

rate (bit/s) N82

1 2 3 4

2 19200

OFF ON OFF ON

Tab.12.b

This assigns the address 2 to the access point, with a baud rate (bit/sec) of 19200 (N82). The addresses of the four serial probes, on the other hand, must be set as shown in the table below:

Address Dipswitch

1 2 3 4 5 6 7 8

Probe 1 16 0 0 0 0 1 0 0 0 Probe 2 17 1 0 0 0 1 0 0 0 Probe 3 18 0 1 0 0 1 0 0 0 Probe 4 19 1 1 0 0 1 0 0 0

Tab.12.c

Remember to verify the quality of the wireless signal between the access point and each wireless probe. For a complete description of the installation procedure, see the Carel manual on the corresponding probes and access point. To configure the probes, go the screens: Ec03, Ec04, Ec05, Ec06 and Ec07, described in the paragraph “Wireless probes”. In particular, screen Ec03 is used to enable the wireless probes connected to the access point, knowing that addresses 16, 17, 18 and 19 are Probe 1, Probe 2, Probe 3 and Probe 4 respectively.

Fig.12.d

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13. Alarm table

Any active alarms will be shown on the corresponding screen with direct access from the display. The Alarm icon starts flashing; pressing the Alarm button once displays the type of alarm. In the event of

potentially dangerous alarms, the humidifier automatically stops steam production. For certain alarm events, as well as the alarm signal, the alarm relay is activated (see the Alarm table). When the cause of the alarm is no longer present:

l the alarm is reset automatically or manually: the humidifier starts again and the alarm relay is

deactivated;

l the message shown on the display can only be cleared manually.

Even if no longer active, the alarm status continues to be indicated until “reset display” button is pressed. Alarms that are still active cannot be reset. If there is more than one alarm, the display shows the entire list. From the alarm screen, the alarm log can be displayed (“Enter” on displays with keypad).

Code Alarm Cause Possible solution Reset Action

ALC01

Autotest failed (unit blocked)

Probable problems with:

Feedwater, levelcontrol, fillsolenoid

valve

Note: check the alarm log for any

warnings relating to theeventsthat

generated thealarm (autotest

warning, level sensor warning, low

production warning)

Make sure thatthe unitreceives water Switch the unit off and clean the level control and the fillvalve

Restart

required

Total

shutdown

ALW03

Warning: High conductivity

High water conductivity warning

Check feedwater conductivity If necessary, feature a suitablewatertreatment system The problem cannotbesolved by softening the feedwater

Manually

resetthe warning

Signal only

ALC02

High conductivity (unit blocked)

High water conductivity alarm

Switch the unit off and clean the electrodes that measure the water conductivity

If the problem persists, change the origin of the feedwater or feature a suitable treatment system (demineralisation, even partial)

The problem cannotbesolved by softening the feedwater

Closed

ALC03

Level sensor blocked (unit blocked)

The levelsensor may not be working

correctly

Switch the unit off and clean the boiler, the level sensor and the fill solenoid valve

Check correct water supply to the boiler;

Restart

required

Total

shutdown

ALB01

Missing water

No feedwater

Check that the supply pipe to the humidifier and the internal tubing are not blocked or choked and that there is enough pressure(0.1-0.8 MPa, 1-8 bars)

Check operation of the fill solenoid valve Check that there is not excessive back-pressure in the steam outlet,

preventing water from entering the boilerdue to gravity Check that the steam outlet hose is not choked or that there are no

pockets of condensate Check that the level sensor is working correctly, clean if necessary

Manual/

Automatic

Stop

production

ALB02

Low production

Input power not available;

With the uniton, there is no steam

production or water preheating;

flue gas outlet orairintake blocked;

gas shut-off valve closed, burner

and/orcontroller malfunction

intake; burner flame malfunction; check the connections between the flame control board and the

burner, and between the electrical panel and theflame control; check the connections between the unit controller and the

intermediateterminal block in the electrical panel

Manual

Stop

production

ALA01

Main probe broken or

Main room probe not connected or

damaged

Check probe connection and the type of controlselected Manual

Stop

production

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13. Alarm table|95

ENG

Code Alarm Cause Possible solution Reset Action

not connected

ALA02

Limit probe broken or not connected

Limit probe or second probe not

connected or damaged

Check probe connection and the type of controlselected Manual

Stop

production

ALA03

Preheat. probe broken or not connected

NTC water temperature probe not

connected or damaged

Check preheating operation and the settings of the parameters on screen Eb02;

Automatic

Stop

production

ALH01

High humid/temp (regulation probe)

High humidity in the room (high

temperature with temperature

control)

Check operation of the probe and the limits set on screen c01 Automatic Signalonly

ALH02

Low humid/temp (regulation probe)

Low humidity in the room Check operation of the probe and the limits set on screen c01 Automatic Signalonly

ALH03

High humid/temp (limit probe)

High humidity at outlet Check the operation of the outletlimit probe Automatic Signal only

ALW01

Foam presence

Entrainment of foam in the boiler

during boiling

The entrainment of foam is generally due to the presence of surfactants in the water (lubricants, solvents, detergents, water treatment or softening agents) or an excessive concentration of dissolved salts. Purge the feedwater lines

Clean theboiler

Automatic Signal only

ALT01

Maintenance required

Planned maintenance reminder

Stop the unit and carry out complete maintenance on the humidifier, then resetthe “boiler operating hours”counter (screen Ea07)

Automatic

(reset

operating

hours)

Signal only

Unit

shutdown

in relation

to water

hardness.

ALW02 Cylinder full

Boilerfull of waterto the high level

sensor on the cover, without

humidification request

Check the fillvalve for leaks; Check whether the high level sensor is dirty; Check that there is no condensatereturn along the steam hose;

Automatic Signal only

ALA04

Conductivity sensor

Conductivity meter not connected

or damaged

Check the connection of the conductivity meter for measuring feedwater conductivity

Manual

Stop

production

ALR01

Retain memory error

Problem in the electronic controller Replace thecontroller Automatic Signal only

ALP01..4

Wireless probe 1..4 offline

No communication with probe 1..4

Check binding between probe and access point, check the battery. Check the probe signal level.

Automatic Signal only

ALM01

No model selected

Model not set Seta model

Automatic

when the

model is selected

Stop

production

ALN01..20

Network: problem with unit

1..20

Network unit alarm (seethe specified

unit for details)

Carry out the checks based on the alarm displayed on the unit in question

Automatic Signal only

ALP05..8

Warning: low battery wireless probe 1..4

Battery discharged on wireless probe

1..4

Check battery charge, replace if necessary; Automatic Signal only

ALA05

Cannot read main probe Wireless probe

Allthemain wireless probes are not

working

Check probe connections and binding to the access point

Stop -

automatic

Stop

production

96|13. Alarm table

gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

Code Alarm Cause Possible solution Reset Action

ALA06

Cannot read lim. probe Wireless probe

Allthelimitwireless probes arenot

working

Check probe connections and binding to the access point

Stop -

automatic

Stop

production

ALP09

High boiler temp.

The boiler temperature read by the

NTC probe is too high > 110°C

Check that there is water inthe boiler; check that the levelsensor isworking and/or clean it

Stop with

manual

reset

Stop

production

ALA07..9

Klixon fan

1..3

thermal protector on fan 1..3. Safety

thermostat activated due to

abnormaloverheating of the boiler

from operation withoutwater

stop the unitand perform complete maintenance on the boiler

Stop with

manual

reset

Stop

production

ALP10..12

Flue gas probe 1..3 broken

flue gas temperatureprobe 1

broken. NTC probe for measuring

the flue gas temperature not

connected or not working

Check the probe connections and/or operation

Stop with

manual

reset

Stop

production

ALP13..15

Warning flue gas temp.

1..3

flue gas temperatureprobe 1..3

warning > 175°C. Extremely high flue

gas temperature, boilerfullof scale

switch the unit off, clean the heat exchanger, check burner calibration.

ALP16..18

Alarm flue gas temp.

1..3

flue gas temperatureprobe 1..3 alarm > 180 °C. Extremely high flue gas temperature, boilerfullof scale

switch the unit off, clean the heat exchanger, check burner calibration

Stop with

manual

reset

Stop

production

ALA10..12

Alarm burner

1..3 missing flame

ignition failure on burner 1..3. No

flame with production request.

• when the unit isactivated there is

no steam production; • flue gas

outlet or airintake blocked;

• gas shut-off valve closed, burner and/orcontroller malfunction;

• No gas supply

• check the gas pressure and that thegas shut-off valve is open;

• make sure that the air intake is not blocked;

• check the fan powerconnection;

• check operation of the brushless fan, the flue gas outlet and air intake;

• burner flame malfunction;

• check the connections between the flame control board and the burner, and between the electrical panel and theflame control;

• check the connections between the unit controller and the intermediateterminal block in the electrical panel

Stop with

manual

reset

Stop

production

ALA13

AntiFreeze check components

temperature below 5°C, water

drained using the pump to protect

the humidifier

check the temperature inside and outside of the humidifier. Increase the temperature inside the humidifier by fitting additional heaters where necessary.

Stop with

manual

reset

Stop

production

ALA20..22

Speed fault burner 1..3

Speed fault on burner 1..3

check the electrical connections between the control board and the fan. if necessary, remove the brushless fan and check operation.

Stop with

manual

reset

Stop

production

ALP24

Missing model Slave

model not set on slaveunit Set the model on the slave

Stop with

manual

reset

Stop

production

ALP25

Missing water Slave

No feedwater

Check that the supply pipe to the humidifier and the internal tubing are not blocked or choked and that there is enough pressure(0.1-0.8 MPa, 1-8 bars)

Check operation of the fill solenoid valve Check that there is not excessive back-pressure in the steam outlet,

preventing water from entering the boilerdue to gravity Check that the steam outlet hose is not choked or that there are no

pockets of condensate Check that the level sensor is working correctly, clean if necessary

Stop with

manual

reset

Stop

production

ALM21

Aarm foam slave

Entrainment of foam in the boiler

during boiling

Clean theboiler

Stop with

manual

reset

Stop

production

ALB03

Low production Slave

Input power not available; With the

unit on, there isno steam

production or water preheating; flue

gas outlet or airintake blocked; gas

shut-off valve closed, burnerand/or

ENG

gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

13. Alarm table|97

ENG

Code Alarm Cause Possible solution Reset Action

controller malfunction

electrical panel and the flame control; check the connections between the unit controller and the intermediate terminal block in the electrical panel

ALC05

Lev. sensor Slave

The levelsensor may not be

workingcorrectly

Switch the unit off and clean the boiler, the level sensor and the fill solenoid valve. Check correct water supply to the boiler;

Stop with

manual

reset

Stop

production

ALC06

Alarm autotest Slave

Probable problems with:

Feedwater, levelcontrol, fillsolenoid

valve

Note: check the alarm log for any

warnings relating to theeventsthat

generated thealarm (autotest

warning, level sensor warning, low

production warning)

Make sure thatthe unitreceives water Switch the unit off and clean the level control and the fillvalve

ALW12

Alarm cylinder Slave

Boilerfull of waterto the high level

sensor on the cover, without

humidification request

Check the fillvalve for leaks; Check whether the high level sensor is dirty; Check that there is no condensatereturn along the steam hose;

ALC07

High Conductivity Slave

High feedwater conductivity alarm

Switch the unit off and clean the electrodes that measure the water conductivity

If the problem persists, change the origin of the feedwater or feature a suitable treatment system (demineralisation, even partial)

The problem cannotbesolved by softening the feedwater

Stop with

manual

reset

Stop

production

ALA18

PreHeat probe Slave

NTC water temperature probe not

connected or damaged

Check preheating operation and the settings of the parameters on screen Eb02;

Stop with

manual

reset

Stop

production

ALA19

Conduct probe Slave

Conductivity meter not connected

or damaged

Check the connection of the conductivity meter for measuring feedwater conductivity

Stop with

manual

reset

Stop

production

ALR02

Retain memory Slave

Problem in the electronic controller Replace thecontroller

ALA23

AntiFreeze Slave drain pump forced

temperature below 5°C, water

drained using the pump to protect

the humidifier

check the temperature inside and outside of the humidifier. Increase the temperature inside the humidifier by fitting additional heaters where necessary.

Stop with

manual

reset

Stop

production

ALW04

Warning: Autotest

Probable problems with:

Feedwater, levelcontrol, fillsolenoid

valve

Note: check the alarm log for any

warnings relating to theeventsthat

generated thealarm (autotest

warning, level sensor warning, low

production warning)

Make sure thatthe unitreceives water Switch the unit off and clean the level control and the fillvalve

Signal only

ALW05

Warning: Level sensor malfunct.

The levelsensor may not be working

correctly

Switch the unit off and clean the boiler, the level sensor and the fill solenoid valve

Check correct water supply to the boiler;

Signal only

ALW06

Warning: Low production

Input power not available;

With the uniton, there is no steam

production or water preheating;

flue gas outlet orairintake blocked;

gas shut-off valve closed, burner

and/orcontroller malfunction

check the gas pressure and that the gas shut-off valve is open; make sure that the air intake is not blocked; check the fan power connection; check operation of the brushless fan, the flue gas outlet and air intake; burner flame malfunction; check the connections between the flame control board and the burner, and between the electrical panel and the flame control; check the connections between the unit controller and the intermediate terminal block in the electrical panel

Solo

segnalaz.

ALA14

Unit Slave Offline

Slave unit Offline

ALA15

Master Offline

Masterunit Offline

ALA16

AntiFreeze AntiFreeze. Temperature below 10°C, check the temperature inside and outside of the humidifier. Increase

98|13. Alarm table

gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

Code Alarm Cause Possible solution Reset Action

force preheating

preheating activation to protectthe

humidifier

the temperature inside the humidifier by fitting additional heaters where necessary.

ALA17

AntiFreeze Slave force pre-heating

AntiFreeze in Slaveunit. Temperature

below 10°C, preheating activation to

protect thehumidifier

check the temperature inside and outside of the humidifier. Increase the temperature inside the humidifier by fitting additional heaters where necessary.

ALP21 SVOffline Supervisor Offline

ALW07

Warning Autotest Slave

Autotestwarning in Slave unit.

Probable problems with: Feedwater, levelcontrol, fillsolenoid valve Note:

check the alarm log for any

warnings relating to theeventsthat

generated thealarm (autotest

warning, level sensor warning, low

production warning)

Make sure that the unit receives water. Switch the unit off and clean the level control and the fillvalve

Signal only

ALW09

Alarm Autotest Slave

Autotestalarm in Slave unit. Probable

problems with: Feedwater, level control, fill solenoid valve. Note:

check the alarm log for any

warnings relating to theeventsthat

generated thealarm (autotest

warning, level sensor warning, low

production warning)

Make sure that the unit receives water. Switch the unit off and clean the level control and the fillvalve

ALW10

Warning Sensor level Slave

Warning level sensor in Slave unit.

The levelsensor may not be working

correctly

Switch the unit off and clean the boiler, the level sensor and the fill valve. Check correct filling of waterin boiler

Signal only

ALW11

Warning Low production Slave

Warning low production in Slave

unit. Input power not available; With

the unit on, thereisno steam

production or water preheating; flue

gas outlet or airintake blocked; gas

shut-off valve closed, burnerand/or

controller malfunction

Signal only

Tab.13.a

ENG

gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

13. Alarm table|99

ENG

14. Spare parts and maintenance

Before all operations:

l disconnect the appliance from the mains power supply; l close the water supply and gas shut-off valves; l drain the water circuit using the manual electric pump function or the drain valve provided, after

connecting a pipe to drain the water outside of the unit and avoid flooding.

Important:

l do not use detergents or solvents to clean the plastic components. l descaling can be performed using a 20% acetic acid solution, then rinsing with plenty of water.

14.1 Boiler maintenance

Access the boiler as described in the chapter “Introduction and installation”. Remove panels A, B and C as follows (see the figure):

l detach the steam hose from the boiler; l undo screws V and V1; l undo the internal and external screws that hold secure panel B; l remove panels A, B and C.

Fig.14.a

100|14. Spare parts and maintenance

gaSteam - UG +0300090EN rel. 1.2– 09.10.2018

Carel gaSteam UG045, gaSteam UG150, gaSteam UG180, gaSteam UG090, gaSteam UG450 User Manual

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