Carnes HCAGB Installation Manual
1
READ AND SAVE THESE INSTRUCTIONS
ELECTRONICALLY CONTROLLED STEAM HUMIDIFIER
DESIGN SERIES “G”
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
External Disconnect
or Circuit Breaker
(Not Provided by Carnes)
Water Shutoff Valve
(Not Provided by Carnes)
Digital Output
Rate Meter
for Cylinder 1
“Service”
Light
On-Off-Drain
Switch
Digital
Diagnostic
Panel
Brass Cylinder
Fittings
Drain Solenoid
Valve
Cylinder
Retaining
Band
Steam
Cylinder #2
Steam
Cylinder #1
Terminal
Connectors
Steam Hose
“On” Light
Door
Interlock
Fill
Solenoid
Valve
Photo A
(Model HCHG Shown)
FORM 16789-I
ISSUED: 04-12
Display for
Cylinder #2
CARNES COMPANY 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 Phone: (608)845-6411 Fax: (608)845-6504 www.carnes.com
High Water
Sensor
Condensate
Return Line
Connection (2)
2
INSTALLATION
UNPACKING AND INSPECTION
1. Cabinet keys are attached, by ty-rap, to side of
humidifier.
2. Open the cabinet and check for concealed shipping
damage. Report 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 operation and maintenance manual,
operation addendum, parts replacement catalog,
customer satisfaction card, and parts order list
card.
MOUNTING THE HUMIDIFIER
Locate the humidifier cabinet level and plumb on a surface
as close to the steam distributor as possible at a convenient
height for servicing. Allow 1” or more on the side for ventilation and 16” from the bottom of the unit to floor to allow for
drain connections. If there is no common drain within close
proximity of humidifier, a drain pump (Carnes HXWA) may
be required to accommodate this distance. Allow 18”-38” in
front of cabinet for door opening or when necessary,
remove door with quick release pin. The humidifier must
never be located outside or where it may be exposed to
freezing temperatures unless a heated, ventilated weather
proof enclosure by others is provided. Do not mount humidifiers on a hot or vibrating surface.
Table 1 - MAXIMUM OPERATING WEIGHT
WATER SUPPLY CONNECTION
Use ordinary tap water (20 to 120 psi) - DO NOT use hot
water, DI (deionized water), RO (reverse osmosis)
water. If softened water is considered, please contact
factory for further assistance. A 3/8” FPT fitting is provid-
ed at the bottom 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. Locate the air gap fitting in accessory bag in unit.
Have proper tooling available to attach fitting.
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
HBAG, HCAG 80
HBDG, HCDG 85
HBGG, HCGG 105
HBHG, HCHG 185
Drain Line
Connection
Photo B
MODEL FASTENERS REQUIRED
HBAG, HCAG 4
HBDG, HCDG 4
HBGG, HCGG 4
HBHG, HCHG 6
Table 2 - FASTENER RECOMMENDATION*
*1/4” Lag Screw, 1” Minimum Length
Fasten the mounting bracket to wood studs or solid wood
using fasteners shown in Table 2 below. Place the mounting flange on the humidifier cabinet over the mounting
bracket. A sheet metal screw should be installed through
the back of the humidifier cabinet to secure the humidifier
to the mounting bracket. Fasteners are not provided by
Carnes.
1½”
Air Gap Fitting
(Included)
3
STEAM DISTRIBUTOR PIPE LOCATION
Each steam cylinder requires a separate distributor pipe,
steam hose and condensate return line. A cylinder may
supply more than one distributor pipe by using an
accessory “T” fitting but the output cannot be controlled
separately. In a typical installation the humidifier is located
below the duct as shown in Figure A. The length between
the humidifier cabinet and the steam distributor pipe should
be the minimum distance possible. Refer to Table 3 for
maximum length that may be installed, based on duct static pressure. Under less then perfect conditions, (installation
issues, routing problems for steam and condensate return
hose and extreme steam hose lengths) it is possible to lose
a certain amount of lbs. per hour capacity. See Table 3-A.
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”, 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 then slope downward to the
distributor pipe as shown. If sufficient headroom is not
available it is possible to install with an upward slope but
the rise should be 2” in 12” to allow for proper condensate
drainage and steam flow. Carnes electrode steam humidifiers are non-pressurized, maximum of 1/2 psi. It is critical
to provide proper routing of flexible hose and hard tubing to
maximize efficiency and effectiveness. See Figure D.
Figure B
MAXIMUM STEAM HOSE LENGTH
(Table 3)
Duct Static
Pressure “wg”
012345
Maximum Steam
Hose Length (Ft.)
40 35 30 25 15 10
AFFECT ON CAPACITY DETERMINED BY STEAM HOSE
LENGTH
(Table 3-A)
Distance Loss
10 Ft. 1.0 lb./hr.
20 Ft. 2.0 lb./hr.
25 Ft. 2.5 lb./hr.
40 Ft. 4.0 lb./hr.
Figure C
Common Drain
Trap
Condensate
Extended Length
Optional if
sufficient
head room
is not
available
When hose is difficult to support
within this length, straight
copper tube should be used
and insulation applied.
Steam line
must pitch
down toward
drain tee —
NO pockets,
sags or
horizontal
runs.
Mounting
plate must
be plumb.
Condensate hoses
must pitch down continuously to humidifier —
NO pockets, sags or
horizontal runs.
Drain Tee
To Drain
MODELS
HOSE LOCATION
FOR RUNS FROM
12 FEET TO 40 FEET
TYPICAL HOSE LOCATION
FOR LENGTHS UP TO
12 FEET
Figure A-1
Mounting plate
must be plumb.
Condensate hoses
must pitch down continuously to humidifier —
NO pockets, sags or
horizontal runs.
MODELS
If hose is difficult to
support within this
length, straight
copper tube should
be used and
insulation applied.
4
STEAM DISTRIBUTOR PIPE LOCATION (Continued)
Steam distributor pipes must be located on a plumb surface so
condensate that forms will run back into the return line. The pipe
should be located in the center of the duct to insure distribution of
steam into the airstream. A minimum clearance of 4” must be
maintained between the top of the duct and the distributor pipe.
The steam distributor pipes are usually located in the supply duct
downstream of the fan. When installed in packaged units the distributor should be mounted just downstream of the fan discharge.
It is important to locate the distributor as far upstream as possible
from any obstructions in the ductwork so that air can absorb
moisture before it impinges on a surface and accumulates. There
must be minimum of six feet between the distributor and any fans,
coils, filters, dampers, elbows or outlets downstream to reduce the
possibility of condensation.
Figure G
It is very important that both the steam hose and condensate
return line, whether flexible or hard tubing, be installed so there
are no sags, low points, dips or horizontal runs. The steam is at a
very low pressure and it cannot overcome any resistance caused
by accumulating water standing in the steam hose. Accumulation
in the condensate return hose will hamper the flow and may cause
water to enter the duct work by way of back up in distributor pipe.
In a vertical duct with either upward or downward air flow the
distributor pipe should be installed horizontally (Figure E).
If multiple pipes are used they should be staggered as shown
(Figure F).
Figure E
Figure F
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 excessive condensation. A short length of steam hose
must be used to connect the cylinder
in the humidifier to the
copper tube and another short length to connect the copper tube
to the distributor pipe. Size 3/4” copper tube (with 7/8” steam hose)
can be used with steam cylinders having output rates up to 30
pounds per hour. Size 1-1/2” copper tube (with 1-5/8” steam hose)
should be used with steam cylinders having output rates over 30
pounds per hour. Length restrictions shown in Table 3 also apply
to installations where copper tube is used and any use of 90°
elbows add approximately three feet of equivalent length, thus
negatively affecting loss of capacity, efficiency and effectiveness.
Hose lengths of no longer then 10-20 ft. and proper inclines or
routing, as expressed in this manual, will provide the best chance
of having a proper operating humidifier and efficient and effective
steam dispersion.
Figure I
Figure H
Pipe Insulation
Note: Over time and extended
heat, the situations described
in the previous paragraph can
occur. That’s why it is important
to perform monthly visual
inspections to maintain and
correct, when necessary,
improper routing of steam
and condensate lines.
Exaggerated for emphasis.
Steam
2”
12”
.5”
12”
Figure D
Mounting
plate must
be plumb.
Condensate hoses
must pitch down continuously to humidifier or
common drain — NO
pockets, sags or
horizontal runs.
Drain Tee
HOSE LOCATION
WHEN DUCT IS LOWER
THAN HUMIDIFIER
Water trap required to
prevent live steam
from returning.
It may be possible to minimize the absorption distance by using
multiple distributor pipes, or for extremely short absorption
distances, a manifold may be required (See Short Absorption
Manifold Section in this manual). Duct air temperatures below
50-60°F may require a condensate drain pan supplied by others
below the steam distributor pipe.
The distributor pipe may be located below the humidifier if the
installation is made in accordance with Figure G. A trap may be
necessary to prevent steam from flowing back through the
condensate return line.
Trap to
common
drain.
5
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, or to common drain.
2. Insert 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. Support the
steam hose at intermediate points to prevent dips, pockets,
sags or horizontal runs. See Figure H.
2. Any turns should have a minimum radius of 8” to prevent the
hose from kinking. Fasten the steam hose to the distributor
pipe with one of the hose clamps provided.
3. 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.
4. If long lengths of steam hose, (or hard tubing) are used, the
use of periodic “T’s” to drain condensate should be used.
See Figure C.
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 return 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 return line directly to the
air gap drain fitting or some other drain.
5. A trap (of sufficient size) may be necessary to prevent loss of
steam through the return line and reduce the temperature of
condensate water to the common drain. Do not install a trap
if condensate is returned to the top of cabinet.
STEAM DISPERSION CRITERIA
1. Distributor pipe location must be at a minimum of 6 feet
upstream from any elbows, splits, coils, turning vanes, grilles,
diffusers, etc.
2. If temperature in duct is 55° to 60°F or less, recommended 10
feet of distance be used.
3. Under normal and average conditions, most absorption distances will probably fall into the 4 to 5 feet length. This is true,
whether the unit is a 30 lb./hr. or less capacity or 30 lb./hr. or
more capacity.
4. If distance recommended can not be possible, then a drain
pan with drain capability may be required.
5. If the air in the duct can not hold the volume of steam, the only
recourse may be to lower the maximum output of the unit.
6. If shorter absorption distances are required, 3 ft. or less,
multiple distributor pipes could be used. 2 pipes split off one
steam house or 2 pipes from a dual cylinder unit.
7. If even shorter absorption distances are required, 2 ft. or less,
then multi tube short absorption manifolds may be required.
NOTES: Identifying and explaining the following electrical
data and unit detail sheet
“Model” and “Optional Circuit Breaker” columns designate
presence, quantity and amp rating of optional circuit breakers. All
models have overload protection provided by the electronic circuit
board. In addition, as an option, internally mounted, switchable
on-off, circuit breakers are available in models preceded by “HB
”.
“Maximum Lb./Hr.” designates maximum capacity of humidifier.
Units are shipped from the factory preset at the maximum rate.
The output rate may be easily reset after installation anywhere
between 100% and 25% of maximum capacity.
“Voltage” and “Phase” designate available phase and nominal
voltages. Single phase units may be operated from two legs of a
three phase supply but the load will be unbalanced.
“kW” ratings shown is at maximum output rate. If a unit is reset
for less than maximum output, the kW is reduced proportionally.
“Line Amp” and “Disc. Size” are amp ratings shown for use in
selecting electrical service requirements.
“Steam Cylinder” column shows the quantity and the model of
steam generating cylinders mounted in the humidifier. Each
cylinder requires its own steam distribution pipe, steam hose and
condensate return line.
“Digital Display Code” column shows the code that will appear
on the digital display when in the “Calibration” function. The
calibration function of the circuit board can be checked for
accuracy with the model shown on the rating label.
“J4 (Set) & J5 (GND) Vdc” - test lead rating of circuit board when
in calibration mode. Consult factory for procedures.
“Cylinder Wire Current” - as a process of troubleshooting, it may
be necessary to confirm current flow through individual cylinder
wires during operation. Match humidifier with electrical data.
“Minimum Output Settings” - the minimum setting that a
maximum output can be adjusted to and still maintain normal
effective and efficient operation.
STEAM DISPERSION CRITERIA
(Continued)
You must keep in mind that there are a lot of variables involved in
proper steam distribution and absorption distances (duct length
downstream from the dispersion method, required absorption distance determined by design, capacity of humidification, velocity of
air flow, temperature of air flow, location of humidifier/s, distance
between humidifier/s to distribution point and so on). Since this is
important to successful humidification, proper planning must be a
pre-requisite to good performance - PRIOR PREPARATION
PREVENTS POOR PERFORMANCE.
ELECTRICAL CONNECTIONS
POWER MUST BE OFF BEFORE MAKING ANY ELECTRICAL
CONNECTIONS
Check unit electrical characteristics on label outside of cabinet. It
must agree with power provided to the unit. If it does not, contact
your Carnes Representative.
A fused disconnect or circuit breaker not provided by Carnes,
MUST be installed per local and national codes. See Table 4 for
recommended circuit ratings. The optional circuit breaker switch,
offered as an accessory, installed in the humidifier, is NOT for use
as a replacement for the required external disconnect switch, but
as a maintenance convenience addition.
1. Remove screws securing hinged panel for access to wiring.
2. An opening is provided on the bottom of the electrical
section. Bring electrical power lines through this opening and
connect to electric power terminals.
3. Connect cabinet ground terminals to an independent ground.
DO NOT use the neutral of a four-wire power supply.
4. Replace electrical cover panel.
6
Optional Digital Min.
Maximum
Line Disc. Circuit Steam Display J4-J5 Cyl. Wire Output
Model Lb/Hr. Voltage Phase kW Amp Size Breaker Cylinder Code VDC Current Setting
HCAGA 5 120 1 1.7 14.4 20 1-20 Amp 1-AX220 0005 3.89 14.4 1
HCAGB 5 208 1 1.7 8.3 15 1-15 Amp 1-AX380 1005 2 8.3 1
HCAGD 5 230 1 1.7 7.5 15 1-15 Amp 1-AX380 3005 1.61 7.5 1
HCAGF 5 277 1 1.7 6.2 15 1-15 Amp 1-AX380 5005 1.26 6.2 1
HCAGM 5 460 1 1.7 3.7 15 1-15 Amp 1-AX700 8005 0.52 3.7 1
HCAGN 5 575 1 1.7 3.0 15 1-15 Amp 1-AX700 9005 0.35 3 1
HCAGA 10 120 1 3.4 28.7 40 1-40 Amp 1-AX220 0010 8.72 28 2
HCAGB 10 208 1 3.4 16.6 25 1-25 Amp 1-AX380 1010 4.6 16 2
HCAGD 10 230 1 3.4 15.0 20 1-20 Amp 1-AX380 3010 4.06 15 2
HCAGF 10 277 1 3.4 12.4 20 1-20 Amp 1-AX380 5010 3.23 12.4 2
HCAGM 10 460 1 3.4 7.5 15 1-15 Amp 1-AX700 8010 1.7 7.5 2
HCAGN 10 575 1 3.4 6.0 15 1-15 Amp 1-AX700 9010 1.2 6 2
HCDGB 20 208 1 6.9 33.1 45 1-45 Amp 1-B500 1020 10.24 33.1 4
HCDGD 20 230 1 6.9 29.9 40 1-40 Amp 1-B500 3020 9.1 30 4
HCDGF 20 277 1 6.9 24.9 35 1-35 Amp 1-B500 5020 7.41 24.9 4
HCDGM 20 460 1 6.9 15.0 20 1-20 Amp 1-B700 8020 4.06 15 4
HCDGN 20 575 1 6.9 12.0 15 1-15 Amp 1-B700 9020 3.09 12 4
HCDGC 20 208 3 6.9 19.1 25 1-25 Amp 1-B500 2020 5.42 19.1 4
HCDGE 20 230 3 6.9 17.3 25 1-25 Amp 1-B500 4020 4.83 17.3 4
HCDGG 20 460 3 6.9 8.6 15 1-15 Amp 1-B700 6020 2 8.7 4
HCDGH 20 575 3 6.9 6.9 15 1-15 Amp 1-B700 7020 1.5 6.9 4
HCDGC 30 208 3 10.3 28.7 40 1-40 Amp 1-B500 2030 8.63 28.7 6
HCDGE 30 230 3 10.3 25.9 35 1-35 Amp 1-B500 4030 7.73 25.9 6
HCDGG 30 460 3 10.3 13.0 20 1-20 Amp 1-B700 6030 3.42 13 6
HCDGH 30 575 3 10.3 10.4 15 1-15 Amp 1-B700 7030 2.56 10.4 6
HCGGB 30 208 1 10.3 49.7 70 2-35 Amp 1-C62 1030 7.42 24.8 6
HCGGD 30 230 1 10.3 44.9 60 1-60 Amp 1-C62 3030 14.2 22.4 6
HCGGF 30 277 1 10.3 37.3 50 1-50 Amp 1-C62 5030 11.53 18.6 6
HCGGM 30 460 1 10.3 22.5 30 1-30 Amp 1-C65 8030 6.53 22.4 6
HCGGN 30 575 1 10.3 18.0 25 1-25 Amp 1-C65 9030 5.15 17.9 6
HCGGC 40 208 3 13.8 38.2 50 1-60 Amp 1-C62 2040 11.82 19.1 8
HCGGE 40 230 3 13.8 34.6 45 1-50 Amp 1-C62 4040 10.5 17.2 8
HCGGG 40 460 3 13.8 17.3 25 1-25 Amp 1-C65 6040 4.77 17.2 8
HCGGH 40 575 3 13.8 13.8 20 1-20 Amp 1-C65 7040 3.65 13.8 8
HCGGC 50 208 3 17.2 47.8 70 2-35 Amp 1-C62 2050 7.12 23.9 10
HCGGE 50 230 3 17.2 43.2 60 1-60 Amp 1-C62 4050 13.54 21.6 10
HCGGG 50 460 3 17.2 21.6 30 1-30 Amp 1-C65 6050 6.29 21.6 10
HCGGH 50 575 3 17.2 17.3 25 1-25 Amp 1-C65 7050 4.77 17.3 10
HCGGC 60 208 3 20.7 57.4 80 2-40 Amp 1-C62 2060 8.58 28.7 12
HCGGE 60 230 3 20.7 51.9 70 2-40 Amp 1-C62 4060 7.74 26 12
HCGGG 60 460 3 20.7 26.0 35 1-40 Amp 1-C65 6060 7.74 26 12
HCGGH 60 575 3 20.7 20.8 30 1-30 Amp 1-C65 7060 5.98 20.8 12
HCGGC 80 208 3 27.5 76.5 100 2-60 Amp 1-C62 2080 11.91 38.2 16
HCGGE 80 230 3 27.5 69.2 90 2-50 Amp 1-C62 4080 10.5 34.6 16
HCGGG 80 460 3 27.5 34.6 50 1-50 Amp 1-C12 6080 10.5 17.3 16
HCGGH 80 575 3 27.5 27.7 40 1-40 Amp 1-C12 7080 8.12 13.8 16
HCGGC 100 208 3 34.4 95.6 125 2-60 Amp 1-C62 2100 14.95 47.8 20
HCGGE 100 230 3 34.4 86.4 125 2-60 Amp 1-C62 4100 13.54 43.2 20
HCGGG 100 460 3 34.4 43.2 60 1-60 Amp 1-C12 6100 13.54 21.6 20
HCGGH
100 575 3 34.4 34.6 45 1-50 Amp 1-C12 7100 10.5 17.3 20
HCHGC 125 208 3 43 119.5 175 4-40 Amp 2-C62 2125 9.01 29.8 12 ea.
HCHGE 125 230 3 43 108.0 150 4-40 Amp 2-C62 4125 8.08 27 12 ea.
HCHGG 125 460 3 43 54.0 75 2-40 Amp 2-C12 6125 8.08 13.5 12 ea.
HCHGH 125 575 3 43 43.2 60 2-30 Amp 2-C12 7125 6.32 10.8 12 ea.
HCHGC 150 208 3 51.7 143.4 200 4-50 Amp 2-C62 2150 10.97 35.8 15 ea.
HCHGE 150 230 3 51.7 129.7 200 4-50 Amp 2-C62 4150 9.97 32.4 15 ea.
HCHGG 150 460 3 51.7 64.8 90 2-50 Amp 2-C12 6150 9.97 16.2 15 ea.
HCHGH 150 575 3 51.7 51.9 75 2-35 Amp 2-C12 7150 7.71 13 15 ea.
HCHGC 175 208 3 60.3 167.3 250 4-60 Amp 2-C62 2175 13.06 41.8 17 ea.
HCHGE 175 230 3 60.3 151.3 225 4-60 Amp 2-C62 4175 11.66 37.8 17 ea.
HCHGG 175 460 3 60.3 75.6 110 2-60 Amp 2-C12 6175 11.66 18.9 17 ea.
HCHGH 175 575 3 60.3 60.5 90 2-50 Amp 2-C12 7175 9.17 15.1 17 ea.
HCHGC 200 208 3 68.9 191.2 300 4-60 Amp 2-C62 2200 14.95 47.8 20 ea.
HCHGE 200 230 3 68.9 172.9 250 4-60 Amp 2-C62 4200 13.54 43.2 20 ea.
HCHGG 200 460 3 68.9 86.4 125 2-60 Amp 2-C12 6200 13.54 21.6 20 ea.
HCHGH 200 575 3 68.9 69.2 100 2-50 Amp 2-C12 7200 10.5 17.2 20 ea.
ELECTRICAL DATA AND UNIT DETAIL SHEET - Table 4
7
HUMIDIFIER COMPONENT LISTING -
Figure J
1. On / Off / Drain Switch
2. LCD Display
3. Power “On” Light
4. Optional Circuit Breaker
5. Service & Fault Light
6. Diagnostic Panel
7. Door Interlock Switch
8. Drain Solenoid Valve
9. Fill Water Inlet Fitting
10. Water Fill Tube Sub-Assembly
11. Red Terminal Connector (Connector
could be black for larger output units)
12. Fill Solenoid Valve
13. Molded Fill Cup
14. Internal Water Hose (Clear) 5/8” ID
15. Unit Specific Wiring Diagram
16. High Water Sensor
17. Operational Instructions
18. Circuit Board
19. Power Distribution Block
20. Current Sensing Transformer
21. Power Transformer
22. Contactor
23. Low Voltage Wiring Harness
24. Unit Identification Tag
25. Door Pivot Release
26. Condensate Return Hose
27. Condensate Return Hose Connection
Fitting From Distributor Pipe
28. Steam Hose Connection Point
29. Cylinder — Specific to Model
30. Diagnostic Panel Calibration Buttons
(Up, Down, Mode, Enter)
31. Bridge Rectifier
1
2
3
5
30
6
7
4
24
8
9
29
11
26
10
12
27
HBDG
HCAG
23
18
22
16
28
17
15
14
21
20
19
13
25
31
8
CONTROLS
CONTROL OPTIONS - Figure K
CONTROL HUMIDISTAT
If an on-off humidistat is used the humidifier will generate
steam at the preset output rate and cycle on or off as
necessary to satisfy the conditioned area requirements. All
humidifiers are preset at the factory for the maximum rating
of the unit. The maximum output may be easily reset to a
lower limit in the range of 25-100% using the push buttons
on the front of the electronic control panel.
If Carnes proportional humidistat is used the humidifier will
automatically vary the steam output rate in the range of 25100% of the humidifiers maximum rating in response to the
signal from the humidistat. Proportional control provides
less cycling of the humidifier.
Either a wall humidistat or duct mounted humidistat in
the return air may be used. The wall mounted humidistat is
the most common as it allows the setting to be easily
changed to accommodate changing requirements or to
lower the level of relative humidity in the space to prevent
condensation on windows during extremely cold weather. In
applications where it may be desirable to prevent the occupants of a space from changing the setting, a duct mounted
humidistat in the return may be used. This is
normally mounted in the equipment room or in the duct
where it is accessible only to maintenance personnel.
AIR FLOW DETECTION
The humidifier control circuit should include some method
to determine air flow. If the steam distributor pipe is located
in a duct where there is no air flow and the control humidistat is calling for humidity, steam would be discharged into
the duct where it would immediately condense. Air flow may
be detected by several methods. The humidistat circuit may
be interlocked by using a fan relay if the fan is direct driven.
A fan relay is not recommended if a belt driven fan is used
as a broken belt would stop air flow even though the fan
relay was closed.
Among the alternatives are the use of a pressure differential switch that determines air flow by sensing a pressure
differential caused by air movement in the duct. A paddle
type switch is also available to determine air flow. The pressure differential switch is normally the preferred device as it
is less susceptible to erratic operation caused by improper
positioning in the duct system. Paddle switches require
careful positioning in the duct to insure sufficient air flow to
activate the switch. A combination return air duct on-off
humidistat and sail switch is available but care must be
taken during installation to insure proper operation.
CONTROL HUMIDISTAT AIR FLOW DETECTION CONDENSATION
PROTECTION
WALL HUMIDISTAT
PROPORTIONAL CONTROL
CARNES MODEL HXHCG
OR
WALL HUMIDISTAT
ON-OFF CONTROL
CARNES MODEL HXHAA
OR
DUCT HUMIDISTAT
PROPORTIONAL CONTROL
CARNES MODEL HXHCH
OR
PRESSURE
DIFFERENTIAL
SWITCH
CARNES MODEL HXAAE
OR
DUCT HUMIDISTAT
ON-OFF CONTROL
CARNES MODEL HXHAB
AIR
FLOW
SWITCH
CARNES MODEL HXAAF
OR
PROPORTIONAL
HIGH LIMIT
HUMIDISTAT
CARNES MODEL HXHCH
ON-OFF
HIGH LIMIT
HUMIDISTAT
CARNES MODEL HXHAD
OR
TEMPERATURE COMPENSATED
(NEW) ON-OFF HUMIDISTAT
CARNES MODEL HXHAMT
OR
PROPORTIONAL
HIGH LIMIT
HUMIDISTAT (NEW)
CARNES MODEL HXHAN
WALL HUMIDISTAT (NEW)
PROPORTIONAL CONTROL
CARNES MODEL HXHAM
OR
OR
DUCT HUMIDISTAT (NEW)
PROPORTIONAL CONTROL
CARNES MODEL HXHAN
9
CONTROLS
CONTROL CONNECTIONS
IMPORTANT: TURN OFF POWER AT EXTERNAL DISCON-
NECT BEFORE MAKING ANY CONNECTIONS TO PREVENT
POSSIBLE DAMAGE TO ELECTRONIC CIRCUIT BOARD.
1. A 7/8” opening is provided on the bottom of the cabinet.
The control wiring should pass through the opening to
the terminal strip.
NOTE: A built-in transformer provides power for the
control circuit. No outside power supply is required for
the control circuit.
2. If an air flow switch or high limit humidistat is not used
jumpers must be installed before the humidifier will operate.
CONDENSATION PROTECTION
A third device may be desirable to provide condensation
protection in the duct system. A high limit humidistat may be
installed ten feet downstream from the steam distributor pipe. This
humidistat is normally set to 90-95% RH and opens the circuit if
the humidity level in the duct exceeds the set-point. Use of this
device is recommended particularly when the humidifier is used in
applications where cooling air is being humidified or where a VAV
system may throttle back to a point where air flow is insufficient to
absorb the steam being introduced
.
Either an on-off or proportional control high limit humidistat may be
used with Carnes humidifiers. If a proportional humidistat is used
the output of the humidifier will automatically be decreased to
reduce the possibility of condensation. Two proportional humidis
tats may be used to control Carnes humidifiers if desired, one in
the area to be humidified or return duct and another as a high limit
in the supply duct. The humidifier will automatically select the
lowest signal to control the humidifier output.
CONTROL HUMIDISTAT / TEMPERATURE COMPENSATED
If your application has a requirement for an outdoor temperature
compensation feature, the HXHAT control is what would be needed. This control will provide monitoring of RH percentage and
optionally outdoor temperature, automatically adjust RH set-point
as outdoor temperature changes, automatic or manual operating
mode, display RH or outdoor temperature, installed on the duct or
within the space, relay contacts control humidity for on/off control,
can be wired for activation with heating or any time, easy to read
LCD display with blinking RH symbol when humidifier is activated
and outdoor sensor is included.
CONTROL CONNECTIONS
Two cylinder humidifiers may be wired for simultaneous or separate
and independent operation. Controls should be connected to the terminals on the electronic circuit board as shown below using No. 18
AWG wire. Avoid running control wiring near high voltage primary
wires, due to the possibility of interference and signal distortion.
Connections shown in Figure L are for typical on-off controls. For
Carnes proportional controls see the diagram Figure M. All
controls are shipped with detailed wiring instructions.
EXTERNAL DDC CONTROL SIGNALS
Carnes humidifiers can also accept a 0-10 volt DC signal to
modulate the output of the humidifier. Polarity must be observed.
Input impedance is 20K ohms. If a 4-20 mA input signal is
provided to the humidifier a 470 ohm 1/4 watt resistor must be
installed as shown below.
EXTERNAL MONITORING
Terminals 11 and 12, shown in Figure L, are provided for indicating operation of the humidifier at a remote location. When the unit
is operating terminals 11 and 12 are closed. Terminals 13 and 14
are provided to indicate the need for service. When the output of
the humidifier is less than 50% of set-point terminals 13 and 14
are closed. Each set of terminals are capable of switching 1/2 amp
at 24 volts maximum.
NETWORKING
If multiple units are required due to high capacity demand (over
200 lbs. per hour, single unit), networking can be done. Units
would be interconnected with parallel signal wiring. This set up is
usually done to facilitate running multiple units from a single signal
source. Other networking requirements please contact factory.
Figure M
Figure N
PROPORTIONAL
HUMIDISTAT
(BY CARNES)
PROPORTIONAL
HI-LIMIT
HUMIDISTAT
(BY CARNES)
0-10 VDC
PROPORTIONAL
SIGNAL
(BY OTHERS)
0-10 VDC
PROPORTIONAL
HI-LIMIT
HUMIDISTAT
(BY CARNES)
4-20ma
PROPORTIONAL
HI-LIMIT
HUMIDISTAT
(BY CARNES)
470 OHM
RESISTOR
(BY OTHERS)
470 OHM
RESISTOR
(BY OTHERS)
EXTERNAL
ON
EXTERNAL
SERVICE
ELECTRONIC CONTROL
CIRCUIT BOARD
ON/OFF
HUMIDISTAT
AIR FLOW
SWITCH
ON/OFF
HIGH LIMIT
HUMIDISTAT
Figure L
1/2 AMP
@ 24V
MAX
4-20ma
PROPORTIONAL
SIGNAL
(BY OTHERS)
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