Carnes HRAA Installation Manual
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MODEL HRAA TECHNICAL MANUAL
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS
CARNES COMPANY, 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 - Phone: 608/845-6411 - Fax: 608/845-6470 carnes@carnes.com www.carnes.com
FORM 16799
ISSUED: 06-08
TYPICAL INSTALLATION
Figure A
High Limit
Humidistat
Steam
Hose
Steam Distributor
Pipe
Condensate
Return Line
Water Shutoff
Valve (By Others)
Wall Humidistat
Cold Water Line
Fused Disconnect
or Circuit Breaker
(By Others)
Air Flow Switch
Air Flow
Humidifier
Cabinet
Drain Line
Air Gap
Drain Fitting
WARNING:
THE HUMIDIFIER CABINET CONTAINS HIGH VOLTAGE WIRING AND HOT
SURFACES. THE CABINET DOOR INCLUDES A LOCK AND ACCESS MUST BE LIMITED TO
TRAINED AND QUALIFIED PERSONNEL ONLY. THE DOOR MUST BE LOCKED AND KEY MUST
BE KEPT IN A SECURE LOCATION AWAY FROM THE HUMIDIFIER
2
Steam
Cylinder
Hinged Door
with Key Lock
Steam Hose
Diagnostic
Display Panel
Condensate
Return Inlet
Figure B
Hole For
Power Wiring
Hole for
Control Wiring
Water Inlet
Fill Solenoid
Valve
Door
Interlock
Switch
Drain Solenoid
Valve
Figure C
Wiring Access
Panel
Electric Power
Terminals
Current
Sensing
Transformer
Control Connection
Terminals
Power
Contactor
(Relay)
Power Transformer
Figure D
WARNING:
INSTALLING AND SERVICING THIS EQUIPMENT CAN BE HAZARDOUS DUE TO
ELECTRICAL COMPONENTS AND HOT SURFACES. ONLY TRAINED AND QUALIFIED PERSONNEL
SHOULD INSTALL, REPAIR OR SERVICE THIS EQUIPMENT. INSTALLATION MUST BE MADE IN
ACCORDANCE WITH ALL APPLICABLE CODES AND STANDARDS.
INSTALLATION
UNPACKING AND INSPECTION
1. An envelope shipped with the cabinet contains the
cabinet keys and Installation, Operation and
Maintenance Instructions.
2. The following optional components are packed in a
separate shipping carton for connection when
installing the humidifier.
A. Steam Distributor Pipe.
B. Steam Hose.
C. Condensate Return Line.
D. Humidistats and Air Flow Switches.
E. Steam Hose Clamps.
F. Condensate Return Clamps.
G. Air Gap Drain Fitting.
The distributor pipe should be located to insure best
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 pipe is usually located in the supply
duct downstream of the fan. It is important to locate the
distributor as far upstream as possible from any obstructions in the ductwork so that air can absorb the steam
before it impinges on a surface and condenses. There
must be minimum of three feet between the distributor
and any fans, coils, filters, dampers, elbows or outlets
downstream to reduce the possibility of condensation.
Duct air temperatures below 60°F may require a condensate drain pan, supplied by others, below the steam
distributor pipe.
STEAM DISTRIBUTOR PIPE LOCATION
In a typical installation the humidifier is located below a
duct as shown in Figure A. The distance between the
humidifier cabinet and the steam distributor pipe should
be the shortest possible.
In a vertical duct with either upward or downward air flow
the distributor pipe should be installed horizontally.
The maximum length of steam hose that may be
installed is 10 feet.
Figure E
AIR
FLOW
The distributor pipe may be located below the humidifier
if the installation is made as shown in Figure F. A trap
may be necessary to prevent steam from flowing back
through the condensate return line.
Figure F
INSTALL STEAM DISTRIBUTOR PIPE
The steam distributor pipe must be mounted on a plumb
surface so that it is inclined upward. This is required so
the condensate, which forms in the distributor pipe, will
drain into the return line.
Insert the distributor pipe into duct and secure with four
sheet metal screws, not provided.
3
DRAIN LINE CONNECTION
1. Remove the large nut and plastic gasket located on
the fitting on the bottom of the cabinet. 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 or run
piping to a floor drain. Use plumbing material capable
of handling hot water, such as copper or CPVC.
CONNECT THE STEAM HOSE & CONDENSATE
RETURN LINE
COPPER TUBE IS THE ONLY ACCEPTABLE SUBSTITUTE FOR STEAM HOSE OR CONDENSATE RETURN
LINE.
1. The steam hose should be installed so there is a
continuous rise from the humidifier to the distributor
pipe. The rise should be 2” in 12” to allow proper
condensate drainage.
Support the steam hose at intermediate points to prevent
dips or pockets. It is very important that both the steam
hose and condensate return line be installed so that sags
are prevented. The steam is at very low pressure and it
cannot overcome resistance caused by water standing in
the steam hose. Water accumulating in sags in the return
line will restrict the flow and may cause water to enter the
duct from the distributor pipe.
If it is difficult to install the steam hose to prevent sags, it
is recommended that copper tube be used as a substitute. Size 3/4” copper tube can be used. Any 90° elbows
are approximately equivalent to three feet of steam hose.
If copper tube is used, a minimum of one inch of
insulation must be applied to prevent excessive
condensation and contact with the hot pipe. A short
length of steam hose must be used to connect the
cylinder in the humidifier to the copper tube. Another
short length should be used to connect the copper tube
to the distributor pipe. Any turns in the hose should have
a minimum radius of 8” to prevent kinking.
2. 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 with the hose clamp
provided.
4. Fasten the condensate return line to the distributor pipe with
the hose clamp provided. Connect the return line to the
condensate return inlet with the hose clamp provided.
If it is impossible to maintain a drop to the top of the
cabinet, it will be necessary to run the condensate return
line directly to the air gap drain fitting or some other drain.
A trap (usually 8” is sufficient) may be necessary to prevent loss of steam through the return line. Do not install
a trap if condensate is returned to the top of the cabinet.
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
sides for ventilation and 16” from the bottom to the floor
to allow for drain connections. Allow at least 16” in front
of cabinet for door opening. Consult local and national
codes prior to installation and comply with any provisions
they require.
The humidifier must never be located outside or where it
may be exposed to freezing temperatures unless a
heated, ventilated, weatherproof enclosure by others is
provided. Do not mount humidifiers on a hot or vibrating
surface.
Maximum operating weight is 70 pounds. Fasten the
mounting bracket to wood studs or solid wood.
Recommended fasteners: Four 1/4” x 1” long lag screws.
Fasteners are not provided.
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.
WATER SUPPLY CONNECTION
DO NOT
use hot water, deionized water, or water
that has been treated by a water softener without
consulting the factory.
Use ordinary tap water (20 to 120 psi). A 1/4” FPT fitting
is provided at the top of the humidifier. A shutoff valve,
not provided, must be installed ahead of this fitting.
MOUNTING FLANGE
MOUNTING BRACKET
AIR GAP
DRAIN FITTING
Figure G
4
5
Line Recommended Digital
Maximum Amp Disconnect Steam Display
Model Lb./Hr. kW Voltage Phase Rating Size (Amps) Cylinder Code
HRAAA U 005 5 1.7 120 1 14.4 20 HXCBAX220 0005
HRAAD U 005 5 1.7 230 1 7.5 15 HXCBAX380 3005
HRAAD U 010 10 3.4 230 1 15.0 20 HXCBAX380 3010
U = UL
C = cUL
ELECTRICAL DATA
Check unit electrical characteristics on label outside of
cabinet. They must agree with power provided to the unit.
A fused disconnect or circuit breaker, not provided, must
be installed per local and national codes.
1. Remove screws securing hinged panel for access to
wiring.
2. An opening is provided on the top of the electrical
section. Bring electrical power lines through this
opening and connect to the electric power terminals
as shown on wiring diagram.
3. Replace electrical cover panel.
CONTROLS
CONTROL HUMIDISTAT
Either a wall-mounted 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 adjusted to accommodate changing requirements or to lower the level of relative humidity in the
space to prevent condensation on windows during
extremely cold weather. Room humidity is usually set in
range of 30-40% RH. Other settings may be necessary
for certain conditions.
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.
If a proportional humidistat is used the humidifier will
automatically vary the steam output rate in the range of
25-100% of the humidifiers maximum rating in response
to the humidistat. Proportional control provides less on-off
cycling of the humidifier.
ELECTRICAL CONNECTIONS
WARNING:
BEFORE MAKING ANY
ELECTRICAL CONNECTIONS SWITCH
POWER OFF AT SERVICE PANEL, FUSED
DISCONNECT OR CIRCUIT BREAKER AND
LOCK THE DISCONNECTING MEANS TO
PREVENT POWER FROM BEING
SWITCHED ON ACCIDENTALLY.
AIR FLOW DETECTION
The humidifier control circuit should include some method
to confirm air flow. If the steam distributor pipe were
“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 using a pressure differential
switch that detects air flow by sensing static pressure in
the duct.
CONDENSATION PROTECTION
An additional device may be used to provide condensation protection in the duct system. A high limit humidistat
may be installed 10 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. Once the humidity level returns
below the set-point, humidifier operation will resume
following a delay of several minutes after reclosure of the
circuit. Use of this device is recommended particularly
when the humidifier is used in applications where cooling
air is being humidified.
Either an on-off or proportional high limit humidistat may
be used. If a proportional humidistat is used the output of
the humidifier will automatically be decreased to reduce
the possibility of condensation. Two proportional humidistats may be used. One may be located in the area to be
humidified or its 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.
EXTERNAL MONITORING
Terminals 11 and 12, shown in Figure H are provided for
remote monitoring of the status of the humidifier if
desired. When the unit is on terminals 11 and 12 are
closed. When the output of the humidifier is less than
50% of set-point terminals 13 and 14 are closed indicating a need for service. Each set of terminals is capable of
switching 1/2 amp at 24 volt maximum.
WARNING:
BEFORE MAKING ANY
ELECTRICAL CONNECTIONS SWITCH
POWER OFF AT SERVICE PANEL, FUSED
DISCONNECT OR CIRCUIT BREAKER AND
LOCK THE DISCONNECTING MEANS TO
PREVENT POWER FROM BEING
SWITCHED ON ACCIDENTALLY.
CONTROL CONNECTIONS
1. A 7/8” opening is provided on top 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.
Controls should be connected to the terminals on the
electronic circuit board as shown Figure H using #18
AWG wire. Avoid running control wiring near high voltage
wires.
Figure H
6
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