humiSteam
electrode steam humidifiers
Installation
Operation
User Manual
Read and save these instructions.
Models UE001 to UE065
Single Cylinder Units
CAREL
humiSteam
2
Installation, Operating & Maintenance Manual
IMPORTANT
BEFORE INSTALLING OR HANDLING THE HUMIDIFIER PLEASE CAREFULLY READ AND FOLLOW THE
INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ILLUS TRATED ON THE
LABELS ATTACHED TO THE MACHINE.
This humidifier produces non-pressurized steam by means of el ectrodes immersed in the water contai ned in
the cylinder-boiler (hereafter called the cylinder). The electrodes pass current through the water, whi ch also
provides resistance, heating the water into steam, which is used to humidify environments or industrial
processes, using special distributors.
The quality of the water used affects the process of evaporation, so the humidifier may be suppl ied wi th
untreated water, as long as this is drinkable and not softened or demineralized; the evaporated water is
automatically replaced using a fill val ve. This humidifier has been designed excl usi vely to directly humidify
room s or ducts, using a distribution system. T he installation, use and maintenance operations must be carried
out according to the instructions contained in this manual and on the labels applied internally and externally.
The conditions of the env ironment and the pow er supply v oltage must comply w ith the specified
values.
All other uses and modifications made to the humidifier that are not authorized by the manufacturer are
considered incorrect.
Liability for injury or damage caused by the incorrect use of the humidifier lies exclusively with the
user.
Please note that the humidifier contains pow ered electrical devices and hot surfaces.
All service and/or maintenance operations must be performed by specialist and qualified personnel
w ho are aware of the necessary precautions and are capable of performing the operations correctly.
Disconnect the humidifier from the main pow er supply before accessing any internal parts.
The humidifier must be installed in accordance with the local standards in force.
The local safety standards in force must be applied in all cases.
The humidifier is made up of metallic and plastic parts. All parts must be disposed of according to the
local standards on waste disposal.
Certification: the quality and safety of CAREL products are assured by CAREL's ISO 9001 certi fied design
and producti on system, as well as listi ngs from UL, cUL, CE, TUV, ET L and others.
WARNING: Your humidifi er requires water to operate. Do NOT mount it above materials or machinery that
could be damaged i f a l eak occurs. Carel assumes no responsi bility for consequential or inconsequenti al
damage as a result of any l eaks.
Copyright © 2005 by Carel USA, LLC. All rights reserved.
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CAREL
humiSteam
Table of Contents
How The Humisteam Works.........................................................................................................................5
1 Installation ...............................................................................................................................................6
1.1 Positi oning........................................................................................................................................6
1.2.1 Removing the front cover ............................................................................................................7
1.2.2 Fastening to the wall...................................................................................................................7
1.3 Plumbing...........................................................................................................................................8
1.3.1 Water supply ..............................................................................................................................8
1.3.2 Water drai n ................................................................................................................................8
1.4 Steam distribution............................................................................................................................11
1.4.1A Duct i njection .........................................................................................................................11
1.5 Power wi ring ...................................................................................................................................15
1.6 Connect Control Wi ring....................................................................................................................17
1.6.1 Control s Placement...................................................................................................................17
1.7 Control wiring..................................................................................................................................17
ASWH / ASDH – ASDH / ASDC Wall – Duct Temperature/Humidity Sensors........................................20
HC-101 and HC-201 Wall and Duct Humidistats..................................................................................21
PC-301 Air Provi ng Switch.................................................................................................................22
2 Start-Up.................................................................................................................................................23
2.1 Startup Checklist .............................................................................................................................23
2.2 The HumiControl Controller..............................................................................................................24
2.3 Start-up Procedure..........................................................................................................................24
2.3.1 Starti ng with a new cylinder.......................................................................................................24
3 Operation...............................................................................................................................................25
3.1 Display Information..........................................................................................................................25
3.2 Changing The Set Point...................................................................................................................25
3.3 Acti vating Manual Drain...................................................................................................................25
3.4 Accessi ng/Changing Configuration Parameters.................................................................................25
3.5 Notes about special parameters.......................................................................................................28
STANDARD CONFIGURAT ION SETTINGS...........................................................................................29
3.6 Seasonal Shut Down .......................................................................................................................30
3.7 The Remote Control ........................................................................................................................30
3.8 Resetting the Hour Counter..............................................................................................................31
3.9 Alarms............................................................................................................................................31
3.10 Trouble-Shooting...........................................................................................................................35
3.11 Resetting Factory Defaults.............................................................................................................36
4 Maintenance..........................................................................................................................................37
4.1 Periodic checks...............................................................................................................................37
4.2 Cylinder maintenance......................................................................................................................37
4.2.1 Replacing the cylinder...............................................................................................................37
4.2.2 M aintenance of the other plumbing components.........................................................................39
4.3 Replacement Parts..........................................................................................................................40
4.3.1 Single Phase Humidifiers ..........................................................................................................40
4.3.2 T hree Phase Humidifi ers...........................................................................................................40
4.3.3 Replacement Steam Cylinders & Parts.......................................................................................41
5 Wiring Diagrams.....................................................................................................................................43
6 Techni cal Specificati ons .........................................................................................................................46
6.1 Model Numbers...............................................................................................................................47
IMPORTANT: BEFORE beginning installation:
• Check for shipping damage to cartons. Mark the shipping waybill accordingly
• Open cartons and check for any hidden damage. Mark the shi pping waybill accordingly.
• Check packing slip to ensure all items have been received. Notify Carel LLC of any shortages or
damaged parts. You must notify Carel LLC within 5 working days of any shortages.
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Installation, Operating & Maintenance Manual
How The Humisteam Works
HumiSteam is an electrode humidifier. It produces steam for humidification by passing electrode current through the water i n the steam
generator cylin der between metal electr odes. There are no hea ter el em ents . Steam output is direc tly proportional to the conductivit y of the
water, and the amount of electrode immersed in the water.
On a call for humidity, the HumiSteam controller will open the water fill val ve
(1) and allow water to enter the s ystem. A flow restrictor (2) prevents the
unit from filling too quic kl y or with too much pressure. The water flo ws up
the fill tube (3) and i nto the fill cup (7), where it flows over the conductivit y
probes (6), which feed the water conductivity back to the controller for
anal ysis. Water then flows over the dam i n the fill cup (7), whic h creates a
1” air g ap t o pr event bac kflow of cont ami nated water into the feed lines, and
through the fill tube (4) and into the bottom of the steam cylinder (11).
As the water fills the c ylinder, it will reach the el ectrodes (10) and current
will begin to flow. As the wat er continues to fill the cylinder, the c urrent will
increase, and t his is monitore d by an amperage transformer pl aced on one
of t he power wires (9). When the desired current is reached, the fill valve
will close (1) and the water will then begin to warm and produce steam. If
the water reaches the cylinder full probes (8) prior to re aching t he desired
current level, the fill valve (1) will be cl osed to prevent overflow. If the
current rises too much as the water fills the cylinder, the drain valve or
pump (13) will b e activated to drain a way some water and reduce the
current flow.
Periodicall y, bas ed on the incoming water conducti vity, the unit will drain
some wat er to r educ e t he mineral concentration. A str ainer (1 2) in the c ylinder helps to preve nt mineral debris from jamming the drain
val ve (13) .
If th ere is no water in the cylinder, there will b e no current flow and no steam production. The electrodes do not burn out, but they will
even tuall y become compl etel y coated with mineral and the c ylinder will then need to be r eplaced or cleaned.
UE 001 through UE 015
No. Description
1 Stea m ge nerator cylinder
2 Wat er drain val ve
3 Power contac tor
4 Fuses
5 Power transfor mer
6 Relay board
7 On/Of f and Ma nual drai n switch
8 Wiring terminal bloc k
9 Wat er fill val ve
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UE 025 through UE06 5
No. Description
1 Stea m ge nerator cylinder
2 Wat er drain pump
3 Wat er fill val ve
4 Amp erage tra nsformer
5 Power contac tor
6 Power transfor mer
7 Relay
8 Fuses
9 Wiring terminal bloc k
10 Cable raceway
11 On/Of f and Ma nual drai n switch
CAREL
Dimension
1 Installation
1.1 Positioning
The HumiSteam has been designed for wall mounting
(although it can be placed on a stand) and, since it is an
atmospheric steam humidifier, should be placed close to
the point where the steam wi ll be used, to minimi ze the
steam hose length (and condensate). Certain clearances
must be maintained around the unit:
Minimum
(inches)
With room blower units, other clearances are
needed:
Unit Dimensions:
Dimensions
(inches)
Weight
(lbs)
A B C D E F
12 8 8 16 28
001-008 009-015 025-045* 045**-065
A
B
C
packaged
empty
installed
15 15 22 26
11 11 15 18
25 28 35 38
36 44 86 113
30 38 75 97
42 60 134 207
<0.5°
VSDU0A
A B C D E F H
Minimum
dimension
(inches)
Model - UE
humiSteam
20 72 72 24 20 72 24
VRDXL
36 120 72 48 36 120 48
* = UE045 for 460-575/3 Vac
** = UE045 for 208-230/3 Vac
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Installation, Operating & Maintenance Manual
1.2 Mounting
1.2.1 Removing the front cover
The front cover i s secured by a capture screw l ocated underneath the CAREL
logo. Twist the CAREL logo to reveal the screw, and use a phillips head
screwdriver to remove it. Then simpl y lift the front cover and pull out to remove
it. Return it i n reverse order.
1.2.2 Fastening to the wall
Using the screws and anchors supplied, fasten the mounti ng bracket to the wall.
Be sure that the screws anchor fi rm ly into studs or supports. Note the unit
installed weights from the Positioning section.
Once the mounti ng bracket is secured to the wall, hang the unit on the bracket. Fasten the remaining capture
screw s through the bottom holes in the unit to secure it to the wall.
X
Y
Z
Z’
001-008 009-015 025-045 065
8.67 8.67 12.21 15.75
19.69 23.23 28.55 30.91
4.53 1.5
4.41
Model UE
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CAREL
0.7 gph
2.2 gph
3.7 gph
5.9 gph
humiSteam
1.3 Plumbing
1.3.1 Water supply
The HumiSteam must be supplied with water (not softened) havi ng the
following characteristi cs:
Instant flow rate
Connection
Temperature limits
Pressure limits
Hardness limits
Conductiv ity range
The water feed line should be 1/2” copper, PVC or poly tubing run to within 3 feet of the humidifier, then bushed
down to 1/4” O.D. or 3/8” O.D. copper or poly to make the final connection to the 1/4” O.D. or 3/8” O.D.
compression fitting underneath the humidifier. With poly tubing an i nsert should be used to support the tubing
and prevent leaks. This insert is not provided.
001-008 009-015 025-045 65
0.2 gpm 0.3 gpm 1 gpm 1.9 gpm
1/4" O.D. Compressi on 3/8" O.D. Compressi on
125 to 1250 µS/cm (micromhos)
Model UE
34 to 104°F
15 to 116 psi
<= 400 ppm CaCO3
NOTE: Softened w ater should NOT be used as it is generally corrossiv e to the electrode plating.
1.3.2 Water drain
The HumiSteam also requi res connection to a drain. T he drain water characteristics are:
Drain rate per hour
Instant drain rate
Connection
Typical temperature
The drain line can be 1-1/2” schedule 40 CPVC, 1-1/2” copper, or 1-1/2” Polypropylene. In all cases, the drai n
tube is slipped over the drain outlet on the bottom of the humidifier. It is not glued or otherwise attached to the
humidifier, so it must be supported by itself.
Drain line must be installed and plumbed to an open drain immediatel y after the unit.
For proper operation of the unit, the open drain should be installed before the trap (if allowed by local code).
8
001 003 005 008 009 010 015 025 035 045 065
6.6 gph 7.3 gph11 gph 18.3 gph 25.7 gph33 gph 47.7 gph
1.3 gpm 6 gpm
Model UE
1-1/2" nominal diameter
212°F
See the foll owing diagram for a drain line installation diagram
Note: If utilizing the optional drain tempering devices, the drain line needs to be increased to a 2"
minimum nominal size for the UE025 to UE065.
WARNING: Do NOT use PVC piping unless the unit has the optional drain tempering valve installed.
Installation, Operating & Maintenance Manual
9
CAREL
Water supply and drain connections are made according to the following diagram.
humiSteam
Note: Drain line must be installed and plumbed to an open drain immediately after the unit. For proper
operation of the unit, the open drain should be installed before the trap (if allow ed by local code).
Physical locati on of the supply and drain connections are located as shown below.
UE 010-015 UE 025-065
NOTE: Carel can provide a drain tempering system which limits the water drai n to no more than 140°F.
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Installation, Operating & Maintenance Manual
1.4 Steam distribution
1.4.1A Duct injection
NOTE: If the ventilated steam distributor is to be used, then go to section 1.4.1B.
Each unit has either 7/8” (22 mm), 1-1/4” (30 mm) diameter outlet or 1-5/8” (40 mm) diameter outlets. Som e
units have multiple outlets. The duct distributors and steam hose must be m atched i n size to the diameter of
the steam outlets for the units:
UNIT MODEL NUMBER
UE001 UE003 UE005 UE008 UE009 UE010 UE015 UE025 UE035 UE045 UE065
No.
Cyl inders 1
Steam
outlets 22mm x 1 30mm x 1 40mm x 1 40mm x 2
Duct steam distributors must also be matched to the duct si ze they will be i nserted into:
Quantity Required per Unit
Humidifier Steam Outlets, mm 22 30 40 2x4 0
Humidifier Steam Outlets, inches 7/ 8 1-1/4 1-5/8 2x1-5 /8
Ordering
Code
Nominal Duct Size, Inches
12 11.9 DP030D22RU
18 17.8 DP045D22R0
24 23.7 DP060D22R0
36 33.5 DP085D22R0
12 11.9 DP030D30RU
18 17.8 DP045D30RU
24 23.7 DP060D30RU
36 33.5 DP085D30R0
48 41.4 DP105D30R0
60 49.3 DP125D30R0
72 65 DP165D 30RU
24 23.7 DP060D40RU
36 33.5 DP085D40R0
48 41.4 DP105D40R0
60 49.3 DP125D40R0
72 65 DP165D 40R0
84 80.8 DP205D40R0
Distributor Length, Inches
22 mm Duct Distributors:
30 mm Duct Distributors:
40 mm Duct Distributors:
Description
Duct steam distributor, 22mm, 12'', 20 l bs/hr
Duct steam distributor, 22mm, 18'', 20 l bs/hr
Duct steam distributor, 22mm, 24'', 20 l bs/hr
Duct steam distributor, 22mm, 36'', 20 l bs/hr
Duct steam distributor, 30mm, 12'', 33 l bs/hr
Duct steam distributor, 30mm, 18'', 42 l bs/hr
Duct steam distributor, 30mm, 24'', 42 l bs/hr
Duct steam distributor, 30mm, 36'', 47 l bs/hr
Duct steam distributor, 30mm, 48'', 47 l bs/hr
Duct steam distributor, 30mm, 60'', 47 l bs/hr
Duct steam distributor, 30mm, 72'', 47 l bs/hr
Duct steam distributor, 40mm, 24'', 99 l bs/hr
Duct steam distributor, 40mm, 36'', 103 lbs/hr
Duct steam distributor, 40mm, 48'', 103 lbs/hr
Duct steam distributor, 40mm, 60'', 103 lbs/hr
Duct steam distributor, 40mm, 72'', 103 lbs/hr
Duct steam distributor, 40mm, 84'', 103 lbs/hr
UE 001,003
UE 005,008,009,010,015
1
1
1
1
1
1
1
1
1
1
1
1 2
1 2
1 2
1 2
1 2
1 2
UE 025,035,045HM,04 5HN
UE 045HW,045HK,065
11
CAREL
Distributor pipes should be mounted per the diagram s shown below, with a m inimum of 6” from the center of
the distributor pipe to the top of the duct and 3” mini mum to the bottom.
humiSteam
To install the distributor pipes:
1. Cut a key shaped hole in the side of the duct to match the steam pipe and condensate return.
2. Apply silicone sealant to the mounting plate and insert the pipe through the hole and secure it with 4 sheet
metal screws.
3. Connect the steam and condensate hoses using the hose clamps supplied.
(Note: end support bracked supplied only with 36” and longer distributors.)
IMPORTANT: Allow 2 feet of straight duct dow nstream of the distributor pipes when the air temperature
w ill be >55oF. Allow 3 feet of straight duct if the air temperature will be <50oF. Alw ays allow 2 feet
upstream. Turbulent air flow may require longer lengths.
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Installation, Operating & Maintenance Manual
1.4.1B Room distribution blower units
Refer to the m anual supplied with the Room Distribution Units for specifics on the blower units themselves.
Clearances requi red are shown below.
VSDU0A
A B C D E F H
Minimum
dimension
(inches)
20 72 72 24 20 72 24
VRDXL
36 120 72 48 36 120 48
Model
UE001 UE003 UE005 UE008 UE009 UE010 UE015 UE025 UE035 UE045 UE065
Room Blower
Unit Model
Rated Power
Watts
Air Volume
CFM
Noise Level
dBA
Operati ng Temp/Humidity
(°F / %RH)
VSDU0A VRDXL
30 35
100 380
50 40
14 t o 104°F
/ 10 to 60%
14 t o 140°F
/ 10 to 80%
Cold rooms can be humidified using a Room Distribution Unit, making sure that this operates within its
operating limits. The room must have operating temperatures of between -10°C and +20°C, with a percentage
of rel ati ve humidity of no greater than 80% RH. If these limits are not possible, the steam can be distributed in
the cold room using a distributor pipe in duct work. In any case, the steam must not come into direct contact
with ai r discharge from the refrigeration unit in the cold room, to avoid possible condensati on.
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CAREL
humiSteam
1.4.2 Steam Hoses
NINETY PERCENT (90%) OF ALL OPERATION PROBLEMS ARE CREATED BY IMPROPER STEAM
PIPING FROM THE HUMIDIFIER UNIT TO THE DUCT DIS TRIBUTOR PIPES. To avoid these problems,
remember one simple fact when running the steam hose: steam naturally flows up hill, and condensate
naturally flows down hill. Run the steam hose or piping to avoid any kinks, sharp elbows, or l ow spots that could
collect or restrict the fl ow of steam to the distributor pipe, or the flow of condensate back to the humidifier.
Support the hose adequately to avoid sags.
The following diagrams are to provide you with some guidelines. If you have a situation you are unsure of,
please contact the factory for i nstructions.
IMPORTANT: Maximum length of rubber steam hose is 20 feet. Insulated copper tubing may be up to 40
feet. In all cases, minimize sharp bends and elbows – use 2-45° elbows instead of 90°s.
Hose size for UE 001, 003 = 22 mm.
Hose size for UE 005, 008, 009 and 015 = 30 mm.
Hose size for UE 025, 035, 045, 065 = 40 mm.
UE045 208-230V & UE065 need 2 hoses and distributors.
14
Singl
e Phase Terminals
Three Phase Terminals
Installation, Operating & Maintenance Manual
1.5 Power wiring
Check that the power supply voltage to be
connected matches the value indicated on the
rating plate inside the electrical panel. Insert the
power and ground connection cables into the
electrical panel compartment using the strain
reliefs supplied, and connect to the terminals.
An external fused disconnect must be installed.
All wiring must be in accordance with local,
state and national electric codes.
NOTE: to avoid unwanted interference, the
power cabl es should be kept separate from any
control wi ring.
Per the table on the following page, make sure
that the unit has the proper number of turns
through the TAM (Torroid Amperage Monitor),
which is on the control board i n models UE001
through UE015, and separate i n models UE025
through UE065. Also make sure that the TA
Rate DIP switches on the control board are set
correctl y per the table.
In models UE001 - UE015 make sure that the TAM on the
circui t board has the proper number of power wire turns
through it, and that the TA Rate DIP switches on the
control board are set per the table on the followi ng page.
In models UE025 - UE065 the TAM is independent and the jumper must then be on the right terminals per the
tabl e on the following page.
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