Carnes HBAF Installation Manual

READ AND SAVE THESE INSTRUCTIONS

ELECTRONICALLY CONTROLLED STEAM HUMIDIFIER

DESIGN SERIES F

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

CARNES COMPANY, 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 - Phone:[phone]- Fax:[phone] [e-mail] http://www.carnes.com

External Disconnect
or Circuit Breaker

(Not Provided by Carnes)

Water Shutoff Valve

(Not Provided by Carnes)

Steam Output
Rate Meter

“Abnormal”
Lamp

Steam Output
Control

On-Off-Drain
Switch

Optional
Circuit
Breakers

Power
Contactors

Brass Cylinder
Fittings

Drain Solenoid
Valve

Cylinder
Retaining
Band

Steam
Cylinder

Terminal
Connectors

Overflow
Sensor

Steam Hose

“On” Lamp

Door
Interlock

Make-Up
Solenoid
Valve

Photo A

(Model HBHF Shown)

FORM 16713

ISSUED: 12-95

INSTALLATION

UNPACKING AND INSPECTION

1. An envelope attached to the outside of the cabinet
contains one cabinet key.

2. Open the cabinet and check for concealed shipping
damage. Repor t any damage immediately to the
carrier who delivered the shipment.

3. The following components are packed in a shipping
carton for connection when installing humidifier.
A. Distribution pipe.
B. Steam hose.
C. Condensate return line.

4. Optional accessories may be packed with the cabinet
or in the same shipping carton. Large accessories
may ship in separate cartons.

5. Inside the cabinet is an envelope containing the
following items:
A. Steam hose clamps.
B. Condensate return line clamps.
C. Air gap drain fitting.
D. Installation instructions.

MOUNTING THE HUMIDIFIER

Mount the humidifier cabinet securely on a level and plumb
surface near the ductwork. Allow 6” or more on each side
for proper ventilation and minimum of 16”from the bottom of
the cabinet to the floor to allow space for the drain connec­tion. The humidifier must never be mounted outside or
where it may be exposed to freezing temperatures.
Maximum operating weights for the humidifier are shown
below.

Table 1 -

MAXIMUM OPERATING WEIGHT

WATER SUPPLY CONNECTION
Use ordinary tap water (20 to 120 psi) - DO NOT use hot
water, deionized water, or water that has been treated
by a water softener without consulting the factory. A

3/8” FPT fitting is provided at the top of the humidifier for
connection to tap water supply. A shutoff valve, not provid­ed by Carnes, must be installed just ahead of this fitting.

DRAIN LINE CONNECTION

1. Remove the large nut and plastic gasket located on
the fitting on the bottom of the cabinet.

(Photo B)

.The
nut and gasket may be used with standard type drain
fitting if an air gap fitting is not required by local
codes.

2. Connect the air gap drain fitting to the cabinet drain
connection. It may be necessary to cut off some of
the air gap fitting depending on available space.

3. Connect the drain or air gap fitting to S or P trap.Use
plumbing material capable of handling hot water.

Note:

If the drain water pump accessory package is
used, follow instructions included with the drain water
pump package.

Model Pounds

HBAF, HCAF 80
HBDF, HCDF 85
HBGF, HCGF 105
HBHF, HCHF 185

Drain Line
Connection

Photo B

6 FASTENERS REQUIRED (Models HBAF, HCAF, HBDF, HCDF)

TYPE OF WALL 8 FASTENERS REQUIRED (All Other Models)

Wood Studs or Solid Wood 1/4” Lag Screw, 1” Minimum Length
Hollow Plaster 1/4” Molly Bolts or Toggle Bolts, 3” Minimum Length
Sheet Metal 1/4” Thread Forming Screws, 1/2” Minimum Length
Cement or Masonry 1/4” Lead Type Anchor and Bolts, 1-1/2” Minimum Length

Table 2 -

FASTENER RECOMMENDATION

STEAM DISTRIBUTOR PIPE LOCATION

Each steam cylinder in two-cylinder units require a separate
steam distributor pipe, steam hose, and condensate return
line.

In a typical installation, the humidifier is located below the
duct as shown in

Figure A

. It is recommended that the
length between the humidifier cabinet and the steam dis­tributor pipe in the duct be the minimum possible distance.
Refer to

Table 3

for maximum lengths that may be installed.

Figure A

The maximum length of steam hose that may be installed as
shown in

Figure A

is 12 feet. For a steam hose length over

12 feet refer to

Figure B

.

A drain “T”, as shown in Figure B, must be used to remove
condensation that occurs in steam hose lengths over 12
feet. It is preferable to have the steam hose rise vertically
from the cabinet and the slope toward the distributor pipe as
shown. If sufficient head room is not available, it is possible
to install with an upward slope to the hose.

Figure B

If airflow is vertical, the steam distributor pipe should be
installed horizontally

(Figure C)

.

In two-cylinder units the pipes should be staggered as
shown

(Figure D)

.

Figure C

Figure D

MAXIMUM STEAM HOSE LENGTH

(Table 3)

Duct Static

Pressure “wg”

012345

Maximum Steam

Hose Length (Ft.)

40 35 30 25 15 10

3

STEAM DISTRIBUTOR PIPE LOCATION (Continued)

Steam distributor pipes must be located on a plumb surface.
This is required so the condensate which forms in the dis­tributor pipe will drain to the return line and back to the unit.
Steam distributor pipes should be mounted in the duct to
insure even distribution of steam across the center portion
of the duct.The condensate return line must alwa ys be kept
on the bottom. A minimum clearance of 4” must be main­tained between top of the duct and distributor pipe.
The steam distributor pipe should be located in the supply
air stream, downstream of the fan.When installed in pack­aged units (central station air handlers, multizone units,
make-up air units, etc.) the distributor pipe should be
mounted just downstream of the fan discharge in the pri­mary air stream.
In multizone applications it is preferable to have a separate
humidifier serving each zone. However, steam can be intro­duced into the hot deck upstream of the zone dampers. In
this case, good distribution of steam across the entire hot
deck is very important.
The steam distributor pipe may be located below the humid­ifier if the installation is made in accordance with

Figure E

.
A trap must be installed as shown to prevent steam from
flowing back through the condensate return line.

Figure E

It is preferable to locate the steam distributor pipes down­stream from any obstructions in the ductwork so that air can
absorb moisture before it impinges on a surface and accu­mulates. There must be a minimum of six feet between the
steam distributor pipes and any fans, coils, filters, zone
dampers, elbows or outlets which may be installed down­stream of the distributor pipe. However, in all cases, the
steam distributor pipes should be located as far upstream
from any such obstruction as possible.
It is very important that the steam hose is installed so that
sags in the hose are prevented. Because the steam is at
very low pressure it cannot overcome resistance caused by
water standing in the steam hose.The steam hose is flexi­ble so it must be supported adequately to prevent any low
point from occurring. The steam hose and condensate
return line must have a continuous pitch so that standing
water will not develop.

If it is difficult to install the steam hose to prevent sags, it is
recommended that copper tube be used as a substitute. If
copper tube is used, a minimum of one inch of insulation
must be applied to prevent excess condensation. A shor t
length of steam hose should be used to connect to the cylin­der in the humidifier and another short length to connect to
the steam distributor pipe. Size 3/4” copper tube should be
used with steam cylinders having output rates up to 30
pounds of steam per hour. Size 1-1/2” copper tube should
be used with steam cylinders over 30 pounds per hour. The
condensate return line which connects the outlet on the
steam distributor pipe to the inlet on the top of the humidifi­er also must be supported to prevent sags that would
restrict the flow of water.

INSTALL STEAM DISTRIBUTOR PIPE

EACH CYLINDER REQUIRES SEPARATE STEAM HOSE,
CONDENSATE RETURN LINE, AND STEAM DISTRIBU­TOR PIPE.

1. Steam distributor pipe must be mounted on a plumb
surface.When on a plumb surface the standard
distributor pipe is inclined upward.This is required so
the condensate which forms in the distributor pipe
will drain to the return line and back to the unit.

2. Inser t distributor pipe into duct and secure with four
sheet metal screws, not provided by Carnes.

3. Special distributor pipes are shipped with specific
instructions on how to mount them.

4. If the optional fan distribution unit is to be used,
follow the instructions included with the unit.

CONNECT THE STEAM HOSE

COPPER OR BRASS TUBE IS THE ONLY ACCEPTABLE
SUBSTITUTE FOR CARNES STEAM HOSE OR CON­DENSATE HOSE.

1. The steam hose should be installed so there is a
continuous rise from the humidifier to the distributor
pipe. Suppor t the steam hose at inter mediate points
to prevent dips or pockets.

2. Any turns should have a minimum radius of 8” to
prevent the hose from kinking.

3. Fasten the steam hose to the distributor pipe with one
of the hose clamps provided.

4. Push the steam hose through the opening on the top
of the humidifier cabinet and slip over the outlet stub
on the top of the cylinder.Fasten the hose clamp
provided.

CONDENSATE RETURN LINE

1. Fasten the condensate return line to the distributor
pipe with the hose clamp provided.

2. Follow the steam hose to the humidifier cabinet and
secure the return line to the steam hose.

3. Connect the return line to the condensate retur n inlet
with hose clamp provided.

4. If it is impossible to maintain a drop to the top of the
cabinet, it is necessary to run the condensate retur n
line directly to the air gap drain fitting or some other
drain.