Express SERIES “H” Installation, Operation And Maintenance Manual

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Page 1

READ AND SAVE THESE INSTRUCTIONS

TRUE TOUCHSCREEN CONTROLLED ELECTRODE STEAM HUMIDIFIER

DESIGN SERIES “H”

INSTALLATION, OPERATION

AND MAINTENANCE MANUAL

Air Specialties Express, 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 Phone: (877)945-9175 Fax: (608)845-6504 www.airspecialties.com

ASX “H” SERIES HUMIDIFIER

On-Off-Drain Switch

True Touchscreen

Contactor

Door Lock

Blue Fill LED

Red Drain LED

Orange High Water LED

Door Interlock Switch

Cylinder

Drain Valve

Drain Pipe

Circuit Board

(Behind Door)

Voltage Transformer

Current Transformers

Circuit Breaker (Optional)

Ground Lug

Distributor Block

Photo A

(Model HTGH Shown)

FORM ASX-16834-I

ISSUED: 08-16

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TABLE OF CONTENTS

Introduction - Cautions .......................................................................................................3

Models ................................................................................................................................4

Installation ...................................................................................................................... 5-9

Electrical Data Sheet and Definition ............................................................................10-12

Humidifier Component Listing - Combo Unit HT/SAH, HT/SDH & HT/SGH .................... 13

Controls .......................................................................................................................14-19

Operation .......................................................................................................................... 20

True Touchscreen - Displays and Internal Control .....................................................21-27

Humidifier Mandatory Pre-startup Checklist ..................................................................... 28

Humidifier Startup Checklist .............................................................................................29

Humidifier Startup and Operations ................................................................................... 30

Fan Distribution Units ..................................................................................................31-32

Distribution Pipes.............................................................................................................. 33

Short Absorption Manifold ...........................................................................................34-35

Troubleshooting - Symptom, Cause and Action .........................................................36-41

Humidifier Operational Specifications ..............................................................................42

Humidifier Maintenance Checklist .................................................................................... 43

Preventative Maintenance ............................................................................................... 44

Extended Shutdown/Starting After Extended Shutdown .................................................. 45

Replacement Cylinder ......................................................................................................46

Removing the Cylinder ..................................................................................................... 47

Installing the Cylinder .......................................................................................................48

Replacement Cylinder Order Form .................................................................................. 49

Replacement Parts ......................................................................................................50-53

Warranty ...........................................................................................................................54

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INTRODUCTION

CAUTIONS

CAUTION! DO NOT INSTALL, USE OR OPERATE THIS EQUIPMENT UNTIL THIS

MANUAL HAS BEEN READ AND UNDERSTOOD. READ AND SAVE THESE INSTRUCTIONS FOR FUTURE USE.

CAUTION — Perform all basic safety steps before starting unit.

1. Proper mounting of unit cabinet to wall as described in following pages.

2. Make sure voltage and phase supply matches that of Product Identification Label located on left side of unit cabinet and located on back plane in electrical section.

3. Qualified installers should be used for electrical and plumbing installation, being aware of all current and corresponding codes.

WARNING: HOT SURFACES — Water/Steam and Distribution Methods

The process of humidification, using an electrode style humidifier, creates steam through the boiling process. Temperatures of this boiling water and steam can reach 212°F (100°C). This system in turn, creates extremely hot surfaces (cylinder surface, steam hose, steam pipe, condensate hose/pipe, distribution piping) and hot water or visible/non-visible steam. Even discharged condensate water can be extremely hot. Contact with these surfaces water or steam can cause personal injury. To avoid severe burns, always proceed with extreme caution. Before any service or maintenance is performed, turn off unit, disconnect electrical service and allow humidifier unit to cool down completely.

WARNING — De-energize Electrical Supply

Before any service or maintenance is performed make sure main power supply is disconnected and safety labeled (If Carnes unit is set up with a built-in circuit breaker, turn off circuit breaker and additionally turn off main power supply breaker). Failure to turn off main power supply could result in fire, electrical shock or both, resulting in damage to property, personal injury or death.

CAUTION

Follow all recommendations, instructions and precautions in this Installation, Operation and Maintenance Manual to maximize performance, maintain efficiency and to provide a safe operational environment.

Liability:

Carnes does not accept any liability for installations of humidifier equipment installed by unqualified personnel or the use of parts, components, equipment or alterations of Carnes manufactured equipment that is not authorized or approved by Carnes.

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HSHH

HTGH / HSAH / HSDH

HRAB

Page 5

TYPICAL INSTALLATION

Figure A

Wall Humidistat

Cold Water Line

(Comes into the bottom of the humidifier)

High Limit

Humidistat

Water Shutoff Valve (By Others)

Fused Disconnect or Circuit Breaker

(By Others)

Steam

Hose

Air Flow

Steam Distributor Pipe

Condensate Return Line

Air Flow Switch

Air Gap Drain Fitting

Humidifier Cabinet

Drain Line

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.

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INSTALLATION

UNPACKING AND INSPECTION

1. Inside the cabinet is an envelope containing the

following items: A. Keys to the humidifier cabinet B. Steam hose clamps C. Condensate return line clamps D. Drain pipe fitting E. Installation, operation and maintenance manual, yellow caution sheet for hose routing, replacement parts list and spec sheet F. Keys to unlock the humidifier cabinet

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 the humidifier. A. Distribution pipe B. Steam hose C. Condenstate return line

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

MOUNTING THE HUMIDIFIER

Locate the humidifier cabinet level and plumb, using the level screws (Photo B) on a surface as close to the steam distributor as possible at a convenient height for servicing. Allow 12” or more on each side for panel access 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” in front of single cylinder cabinets and 38” for dual cylinder cabinets to allow for opening and removal of the cabinet door.

Photo B

An air gap fitting must be included in drain plumbing

setup (non-Carnes

installation). See picture:

Table 1 - MAXIMUM OPERATING WEIGHT

Model Pounds

H_AH 61 H_DH 72 H_GH 110 H_HH 203

Fasten the mounting bracket to wood studs or solid wood using fasteners shown in fastener recommendation 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.

Table 2 - FASTENER RECOMMENDATION* *1/4” Lag Screw, 1” Minimum Length

Model Fasteners Required H_AH 4 H_DH 4 H_GH 4 H_HH 6

SUPPLY WATER CONNECTION

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

SUPPLY WATER GUIDELINES Use ordinary cold tap water (20 to 120 psi) - DO NOT use hot water, DI (deionized water), RO (reverse osmosis) water. Using mechanically softened water, or tap water with conductivity over 800 Micromhos is not recommended. Supply water quality is a very important factor

on how a humidifier functions and how often it will need to be maintained. There are many substances in untreated water. When water is boiled into steam, it creates a scale build-up that is left behind in the cylinder. These substances left behind continue to change the properties of the supply water. Having corrosive supply water can decrease the service life of the humidifier and the cylinder. Also using excessively hard supply water can increase maintenance requirements. It’s recommended using a water supply that has a total water hardness between 50-120 (ppm) parts per million. Corrosion caused by high amounts of chlorides or other corrosive substances in the supply water can cause damage and rapid corrosion to the cylinders electrodes and humidifier. It’s recommended using a water supply that has < 50 ppm of measured chlorides.

Leveling Screws

NOTE: Drain Pipe is NOT an air gap fitting.

Call Carnes to

purchase an air gap.

(P/N 690-0176)

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.

DRAIN LINE CONNECTION

1. Locate the drain pipe fitting in the accessory bag

included with the unit. Have proper tooling available to attach the drain pipe.

2. Connect the drain pipe fitting to the cabinet drain hole on the bottom of the unit (Refer to Photo B).

3. Connect the drain pipe fitting to an S or P trap. Use plumbing material capable of handling hot water. Include a 1” air gap fitting as part of the drain plumbing. See Photo B. Note: If the drain water pump accessory package is

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

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Photo C

Outer diameter of drain pipe is 1-1/4”. Air gap fitting must be added.

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 B

STEAM DISTRIBUTOR PIPE LOCATION It is critical to provide proper routing of flexible hose and hard tubing to maximize efficiency and effectiveness. See Figure B-E. Not following the instructions in this Installation, Operation, and Maintenance Manual could void all warranties, unless you have consulted with the factory and have prior written approval. 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 distance 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 and pound output. Under less than perfect conditions, (installation issues, routing problems for steam and condensate return hose, and extreme steam hose lengths) it is possible to lose significant amounts of output. The use of 90° elbows add approximately three

feet of equivalent length when hard tubing is used, thus negatively affecting capacity, efficiency, and can cause back pressure issues and cylinder arching.

MAXIMUM STEAM HOSE LENGTH (Table 3)

Duct Static

Pressure “wg”

Maximum Steam

0 1 2 3 4 5

40 35 30 25 15 10

Hose Length (Ft.)

For a residential unit (HRAB) the maximum length of steam hose that may be installed is 10 feet.

TYPICAL HOSE LOCATION FOR LENGTHS UP TO 12 FEET

Mounting plate must be plumb.

Condensate hoses must pitch down continuously to humidifier — NO pockets, sags or horizontal runs.

If hose is difficult to support within this length, straight copper tube should be used and insulation applied.

Figure B-1

The maximum length of steam hose that may be installed as shown in Figure B & B-1 is 12 feet. For a steam hose length over 12 feet refer to Figure D. 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. Every application is different. Hose lengths for small capacity units will be considerably shorter than larger units. All variables must be taken into consideration.

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HOSE LOCATION FOR RUNS FROM 12 FEET TO 40 FEET

Condensate hoses must pitch down continuously to humidifier — NO pockets, sags or horizontal runs.

Figure C

When hose is difficult to support within this length, straight copper tube should be used and insulation applied.

Mounting plate must be plumb.

To Drain

Drain Tee

Trap, if condensate routes to drain.

Extended Length

Steam line must pitch down toward drain tee — NO pockets, sags or horizontal runs.

Optional if sufficient head room is not available.

If multiple pipes are used they should be staggered as shown in Figure G.

Figure G

Air Flow

Condensate

Trap

Figure D

Figure E

12”

Common Drain

2”

Steam

.5”

12”

In a vertical duct with either upward or downward air flow the distributor pipe should be installed horizontally as shown in Figure F.

Figure F

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 pipe as far upstream as possible from any obstructions in the ductwork so that moisture can be absored before it contacts a surface and accumulates. There must be a minimum of six feet between the distributor and any fans, coils, filters, dampers, elbows, or outlets downstream to reduce the possibility of condensation.

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 60°F may require a condensate drain pan below the steam distributor pipe. Always avoid locating the distribution pipe upstream from any insulation in the duct as excess moisture may cause damage.

The distributor pipe may be located below the humidifier if the installation is made in accordance with Figure H. A trap may be necessary to prevent steam from flowing back through the condensate return line.

HOSE LOCATION WHEN DUCT IS LOWER THAN HUMIDIFIER

Mounting plate must be plumb.

Trap to common drain.

Figure H

Condensate hoses must pitch down continuously to humidifier or common drain — NO pockets, sags or horizontal runs.

Drain Tee

Water trap required to prevent live steam from returning.

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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 back up into the duct.

Figure I

Exaggerated for emphasis.

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, improper routing of steam and condensate lines.

Figure J

Steam Pipe

1” Minimum Pipe Insulation

If it is difficult to install the steam hose to prevent sags, it is recommended that a copper tube be used as a substitute. If a copper tube is used, a minimum of one inch of insulation must be applied to prevent excessive condensation (See Figure J). 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.

Hose lengths of no longer then 10-20 feet and proper inclines or routing, as expressed in this manual, will provide the best chance of having a proper operating humidifier with efficient and effective steam dispersion.

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

1. The steam distributor pipe must be mounted on a plumb surface and 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 a common drain.

2. Insert distributor pipe into duct and secure with four sheet metal screws (not included).

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 I.

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 it over the outlet stub on the top of the cylinder. Fasten with 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 D.

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 a 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 the 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 duct temperature is 60°F or less, 10 feet is recommended.

3. Under normal conditions, most absorption distances will be approximately 4 to 5 feet.

4. If distance recommended is not possible, then a drain pan may be required.

5. If the air in the duct cannot accommodate the steam output, the only recourse may be to lower the maximum output of the unit.

6. If shorter absorption distances are required, 3 feet or less, multiple distributor pipes could be used. Two pipes split off one steam hose or two pipes from a dual cylinder unit.

7. If even shorter absorption distances are required, 2 feet or less, then multi tube short absorption manifolds may be required.

It is important to keep in mind that there are a lot of variables involved in proper steam distribution and absorption distances such as 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 humidifiers, distance between humidifiers to distribution point, and so on. Proper planning is a prerequisite to good performance.

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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.

POWER MUST BE OFF BEFORE MAKING ANY ELECTRICAL CONNECTIONS.

Check unit electrical characteristics on the label on the outside of the cabinet. The power provided must be the same as what is described on the label. If it does not, contact your Carnes Representative. All local and national codes must be followed when connecting power to the unit.

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 installed in the humidifier is NOT for use as a replacement for the required external disconnect switch but as a maintenance convenience.

1. Remove screws securing hinged panel for access to wiring.

See Photos D, E and F for different electrical locations.

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.

HTHH

Incoming Electrical

Screws

Residential Humidifier

Photo F

Incoming Electrical

Screws

Photo D

Screws

ELECTRICAL DATA SHEET DEFINITIONS

1. Optional Circuit Breaker designates the quantity and amp rating of optional factory installed circuit breakers. Circuit breakers are available in models with an ‘HT

’

prefix. All models over 48 amps have internal circuit breakers factory installed.

2. Maximum Lb./Hr. designates maximum capacity of the 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 20% of maximum capacity.

3. Voltage and Phase designates 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.

4. kW is the power rating of the maximum output rate of the humidifier. If a unit’s max output is adjusted lower, the kW is reduced proportionally.

5. Line Amp and Disc. Size are amp ratings shown for use in selecting electrical service requirements.

6. Steam Cylinder shows the quantity and model of steam generating cylinders mounted inside the humidifier. Each cylinder requires its own steam distribution pipe, steam hose, and condensate return line.

7. Cylinder Wire Current is the current a single cylinder wire should be carrying for a given unit at max output. This does not include ‘dummy’ electrode wires that never carry any current, i.e. humidifiers with C65 cylinders and single phase humidifiers not using AX cylinders.

(H_AH) (H_DH) (H_GH)

Humidifiers

Photo E

Incoming Electrical

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ELECTRICAL DATA AND UNIT DETAIL SHEET - Table 4

HSAH HTAH

HSDH HTDH

HSGH HTGH

Max

Model

H_AHAU 5 120 1 1.725 14.4 25 1-20 Amp AX220 14.4

H_AHBU 5 208 1 1.725 8.3 15 1-15 Amp AX380 8.3

H_AHDU 5 230 1 1.725 7.5 15 1-20 Amp AX380 7.5

H_AHFU 5 277 1 1.725 6.2 15 1-15 Amp AX380 6.2

H_AHLU 5 380 1 1.725 4.5 15 1-15 Amp AX600 4.5

H_AHQU 5 415 1 1.725 4.2 15 1-15 Amp AX600 4.2

H_AHMU 5 460 1 1.725 3.7 15 1-15 Amp AX700 3.7

H_AHNU 5 575 1 1.725 3.0 15 1-15 Amp AX700 3

H_AHAU 10 120 1 3.45 28.7 45 1-40 Amp AX220 28.7

H_AHBU 10 208 1 3.45 16.6 25 1-25 Amp AX380 16.6

H_AHDU 10 230 1 3.45 15.0 25 1-25 Amp AX380 15

H_AHFU 10 277 1 3.45 12.4 20 1-20 Amp AX380 12.4

H_AHLU 10 380 1 3.45 9.1 15 1-15 Amp AX600 9.1

H_AHQU 10 415 1 3.45 8.3 15 1-15 Amp AX600 8.3

H_AHMU 10 460 1 3.45 7.5 15 1-15 Amp AX700 7.5

H_AHNU 10 575 1 3.45 6.0 15 1-15 Amp AX700 6

H_DHBU 20 208 1 6.9 33.1 50 1-45 Amp B380 33.1

H_DHDU 20 230 1 6.9 29.9 45 1-40 Amp B380 30

H_DHFU 20 277 1 6.9 24.9 40 1-35 Amp B380 24.9

H_DHLU 20 380 1 6.9 18.1 30 1-30 Amp B600 18.1

H_DHQU 20 415 1 6.9 16.6 25 1-25 Amp B600 16.6

H_DHMU 20 460 1 6.9 15.0 25 1-25 Amp B700 15

H_DHNU 20 575 1 6.9 12.0 20 1-15 Amp B700 12

H_DHCU 20 208 3 6.9 19.1 30 1-25 Amp B500 19.1

H_DHEU 20 230 3 6.9 17.3 30 1-25 Amp B500 17.3

H_DHTU 20 380 3 6.9 10.4 20 1-20 Amp B600 10.4

H_DHWU 20 415 3 6.9 9.6 20 1-20 Amp B600 9.6

H_DHGU 20 460 3 6.9 8.6 15 1-15 Amp B700 8.6

H_DHHU 20 575 3 6.9 6.9 15 1-15 Amp B700 6.9

H_DHCU 30 208 3 10.3 28.7 45 1-40 Amp B500 28.7

H_DHEU 30 230 3 10.3 25.9 40 1-35 Amp B500 25.9

H_DHTU 30 380 3 10.3 15.6 25 1-25 Amp B600 15.6

H_DHWU 30 415 3 10.3 14.4 25 1-25 Amp B600 14.4

H_DHGU 30 460 3 10.3 13.0 20 1-20 Amp B700 13

H_DHHU 30 575 3 10.3 10.4 20 1-15 Amp B700 10.4

H_GHBU

H_GHDU 30 230 1 10.3 44.9 70 1-60 Amp C62 22.4

H_GHFU 30 277 1 10.3 37.3 60 1-50 Amp C62 18.6

H_GHLU 30 380 1 10.3 27.2 45 1-40 Amp C62 13.6

H_GHQU 30 415 1 10.3 24.9 40 1-40 Amp C62 12.5

H_GHMU 30 460 1 10.3 22.5 35 1-30 Amp C62 11.3

H_GHNU 30 575 1 10.3 17.9 30 1-25 Amp C62 9.0

H_GHCU 40 208 3 13.8 38.3 60 1-60 Amp C62 19.1

H_GHEU 40 230 3 13.8 34.6 60 1-50 Amp C62 17.2

H_GHTU 40 380 3 13.8 20.9 35 1-35 Amp C65 20.9

H_GHWU 40 415 3 13.8 19.2 30 1-30 Amp C65 19.2

H_GHGU 40 460 3 13.8 17.3 30 1-25 Amp C65 17.3

H_GHHU 40 575 3 13.8 13.8 25 1-20 Amp C65 13.8

Lb/Hr Voltage Phase kW

* 30 208 1 10.3 49.7* 80 2-35 Amp* C62 24.8

Line

Amp

Disc.

Size

Optional

Circuit

Breaker*

Steam

Cylinder

Cyl Wire

Current

* = Circuit Breaker is REQUIRED per NEC 48 amp guideline.

Page 12

ELECTRICAL DATA AND UNIT DETAIL SHEET - Table 4 (continued)

HSGH

HTGH

HSHH HTHH

Max

Model

H_GHCU 50 208 3 17.2 47.8 80 2-35 Amp C62 23.9

H_GHEU 50 230 3 17.2 43.2 70 1-60 Amp C62 21.6

H_GHTU 50 380 3 17.2 26.2 40 1-40 Amp C65 26.2

H_GHWU 50 415 3 17.2 24.0 40 1-40 Amp C65 24

H_GHGU 50 460 3 17.2 21.6 35 1-30 Amp C65 21.6

H_GHHU 50 575 3 17.2 17.3 30 1-25 Amp C65 17.3

H_GHCU

H_GHEU

H_GHTU 60 380 3 20.7 31.4 50 1-50 Amp C65 31.4

H_GHWU 60 415 3 20.7 28.8 45 1-45 Amp C65 28.8

H_GHGU 60 460 3 20.7 26.0 40 1-40 Amp C65 26

H_GHHU 60 575 3 20.7 20.8 35 1-30 Amp C65 20.8

H_GHCU

H_GHEU

H_GHTU 80 380 3 27.5 41.9 70 1-60 Amp C12 21

H_GHWU 80 415 3 27.5 38.4 60 1-60 Amp C12 19.2

H_GHGU 80 460 3 27.5 34.6 60 1-50 Amp C12 17.3

H_GHHU 80 575 3 27.5 27.7 45 1-40 Amp C12 13.9

H_GHCU

H_GHEU

H_GHTU

H_GHWU 100 415 3 34.4 47.9 80 2-40 Amp C12 24

H_GHGU 100 460 3 34.4 43.3 70 1-60 Amp C12 21.7

H_GHHU 100 575 3 34.4 34.6 60 1-50 Amp C12 17.3

H_HHCU

H_HHEU

H_HHTU

H_HHWU

H_HHGU

H_HHHU 125 575 3 43 43.2 70 2-30 Amp C12 (2) 10.8

H_HHCU

H_HHEU

H_HHTU

H_HHWU

H_HHGU

H_HHHU

H_HHCU

H_HHEU

H_HHTU

H_HHWU

H_HHGU

H_HHHU

H_HHCU

H_HHEU

H_HHTU

H_HHWU

H_HHGU

H_HHHU

Lb/Hr Voltage Phase kW

* 60 208 3 20.7 57.4* 90 2-40 Amp* C62 28.7

* 60 230 3 20.7 51.9* 80 2-40 Amp* C62 26

* 80 208 3 27.5 76.5* 125 2-60 Amp* C62 38.2

* 80 230 3 27.5 69.2* 110 2-50 Amp* C62 34.6

* 100 208 3 34.4 95.6* 150 2-60 Amp* C62 47.8

* 100 230 3 34.4 86.4* 150 2-60 Amp* C62 43.2

* 100 380 3 34.4 52.3* 110 2-50 Amp* C12 34.2

* 125 208 3 43 119.5* 200 4-40 Amp* C62 (2) 29.8

* 125 230 3 43 108* 175 4-40 Amp* C62 (2) 27

* 125 380 3 43 65.3* 100 2-50 Amp* C12 (2) 16.3

* 125 415 3 43 59.8* 90 2-45 Amp* C12 (2) 15

* 125 460 3 43 54.0* 90 2-40 Amp* C12 (2) 13.5

* 150 208 3 51.7 143.5* 225 4-50 Amp* C62 (2) 35.8

* 150 230 3 51.7 129.7* 200 4-50 Amp* C62 (2) 32.4

* 150 380 3 51.7 78.6* 125 2-60 Amp* C12 (2) 19.7

* 150 415 3 51.7 71.9* 110 2-60 Amp* C12 (2) 18

* 150 460 3 51.7 64.8* 100 2-50 Amp* C12 (2) 16.2

* 150 575 3 51.7 51.9* 80 2-35 Amp* C12 (2) 13

* 175 208 3 60.3 167.3* 300 4-60 Amp* C62 (2) 41.8

* 175 230 3 60.3 151.3* 250 4-60 Amp* C62 (2) 37.8

* 175 380 3 60.3 91.6* 150 4-35 Amp* C12 (2) 22.9

* 175 415 3 60.3 83.9* 150 2-60 Amp* C12 (2) 21

* 175 460 3 60.3 75.6* 125 2-60 Amp* C12 (2) 18.9

* 175 575 3 60.3 60.5* 100 2-50 Amp* C12 (2) 15.1

* 200 208 3 68.9 191.2* 300 4-60 Amp* C62 (2) 47.8

* 200 230 3 68.9 172.9* 300 4-60 Amp* C62 (2) 43.2

* 200 380 3 68.9 104.7* 175 4-40 Amp* C12 (2) 26.2

* 200 415 3 68.9 95.9* 150 4-35 Amp* C12 (2) 23.9

* 200 460 3 68.9 86.4* 150 2-60 Amp* C12 (2) 21.6

* 200 575 3 68.9 69.2* 110 2-50 Amp* C12 (2) 17.2

Line

Amp

Disc.

Size

Optional

Circuit

Breaker*

Steam

Cylinder

Cyl Wire

Current

* = Circuit Breaker is REQUIRED per NEC 48 amp guideline.

Page 13

HUMIDIFIER COMPONENT LISTING -

Figure K

1. On-Off-Drain Switch

2. Circuit Board

3. Door Interlock Switch

4. Voltage Transformer

5. Current Transformer

6. Distribution Block

7. Ground Lug

8. Contactor

9. High Water Sensor (behind cylinder)

10. Fill Cup

11. Fill Valve (not shown)

12. Steam Hose

13. Electrode Connector

14. LCD - True Touchscreen

15. Circuit Breakers (Option)

16. Cylinder

17. Cylinder Fitting

18. Drain Valve

19. Lock

20. Water Inlet Hose

21. Water Inlet Fitting

22. Fill Valve Inlet Push - On Connector (not shown)

23. Cooling Fan

Page 14

CONTROL CONNECTIONS -

NOTES:

1. Observe proper polarity when using voltage or current measuring devices.

2. If air flow and high limit switches are not used, a jumper must be installed.

Supplied By Carnes Supplied By Others

Figure L

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.

1. A 7/8” opening is provided on top or 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.

Controls should be connected to the terminals on the circuit board as shown in Figure L using #18 AWG wire.

Avoid running control wiring near high voltage wires.

Page 15

CONTROLS

CONTROL OPTIONS - Figure M

CONTROL HUMIDISTAT AIR FLOW DETECTION CONDENSATION

PROTECTION

WALL HUMIDISTAT

PROPORTIONAL CONTROL

CARNES MODEL HXHCG

WALL HUMIDISTAT

PROPORTIONAL CONTROL

CARNES MODEL HXHAM

WALL HUMIDISTAT

ON-OFF CONTROL

CARNES MODEL HXHAA

DUCT HUMIDISTAT

PROPORTIONAL CONTROL

CARNES MODEL HXHCH

DUCT HUMIDISTAT

PROPORTIONAL CONTROL

CARNES MODEL HXHAN

DUCT HUMIDISTAT

ON-OFF CONTROL

CARNES MODEL HXHAB

TEMPERATURE COMPENSATED

PROPORTIONAL or

ON-OFF HUMIDISTAT

CARNES MODEL HXHAMT

PRESSURE

DIFFERENTIAL

SWITCH

CARNES MODEL HXAAE

AIR

FLOW

SWITCH

CARNES MODEL HXAAF

DUCT ON-OFF

HIGH LIMIT

HUMIDISTAT

CARNES MODEL HXHAD

DUCT PROPORTIONAL

HIGH LIMIT

HUMIDISTAT

CARNES MODEL HXHCH

DUCT PROPORTIONAL

HIGH LIMIT

HUMIDISTAT

CARNES MODEL HXHAN

CONTROL HUMIDISTAT

If an on-off humidistat is used, the humidifier will generate steam at the max 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 between 20-100% in the settings menu of the touchscreen.

If Carnes proportional humidistat is used the humidifier will automatically vary the steam output rate in the range of 20-100% of the humidifier’s maximum output (set by the user) in response to the 0-10V signal from the humidistat. However, the output of the humidifier will not drop below 20% of the preset nominal output of the humidifier set at the factory. Proportional control provides less cycling of the humidifier.

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 for 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 is 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.

Page 16

OPTIONAL ACCESSORY CONTROLS

WALL HUMIDISTAT, PROPORTIONAL CONTROL

Model HXHAM

The Model HXHAM is a wall-mounted, microprocessor-controlled humidistat solution for humidity control. The HXHAM employs a backlit LCD module, which displays both the ambient temperature and humidity of the surrounding air. The embedded software allows user navigation between temperature/ humidity viewing mode, setpoint adjustment mode, and outdoor temperature/humidity viewing mode.

WALL HUMIDISTAT, ON-OFF CONTROL

Model HXHAA

Mount this humidistat four or five feet above the floor in freely circulating air for average temperature and humidity to be controlled for the entire space. Avoid locations near the hot or cold air ducts and discharge air from the humidifier. Scale range is from 10-90% RH. Differential is 5% non-adjustable.

“N.C.” (Red) is switched to common (Orange) during RH Rise.

“N.O.” (Brown) is switched to common (Orange) during RH Drop.

BROWN (N. O.)

RED (N. C.)

(To Terminal 2 or 4)

Unit may be installed on either a flush switch box, a surface switch box, or directly on a wall.

Mount with Number 6 screws provided for switch box mounting. Different screws are required for wall mounting (not included).

NOTE: The HXHAA has 6” (152mm) leads and a green grounding wire for use with non-conducting conduit.

ORANGE (COMMON)

(To Terminal 2 or 4)

Page 17

DUCT HUMIDISTAT, ON-OFF CONTROL

Model HXHAB

This duct mounted humidistat is installed in the return air duct to sense the humidity level in the area being served. Scale range is 10-60% RH. Differential is 4-6% non-adjustable.

PUSH IN RELEASE - 3

PUSH IN TERMINAL - 3

PUSH TO

RELEASE

PUSH SCREWDRIVER IN AND HOLD

MOUNTING HOLES - 2

COM.

SETPOINT ADJUSTMENT

DUCT HUMIDISTAT, PROPORTIONAL CONTROL

Model HXHAN

The Model HXHAN is an intelligent humidistat solution used exclusively for duct mounted installations. The humidistat is capable of providing both humidity and temperature measurements from inside the duct. The microprocessor control takes the temperature into consideration when calculating the humidity to provide an extra degree of precision.

WIRE TO HUMIDIFIER TERMINAL 2 OR 4

The control should be located in the duct where it will be affected by normal air flow. The control can be mounted in any position but should be located on the side of the duct when possible to make the setpoint adjustment easily accessible.

DUCT

Allen screws

Snap-on plastic cover

Aluminum housing

Use Allen wrench to unlock cover

Remove any excess insulation from the duct that would prevent the probe from extending a minimum of 4” (106mm) into the air stream.

Make a 1-1/2” (38mm) hole in the duct for inserting the probe.

Use a gasket, sealer, or other means to seal the area between the unit and the duct to ensure proper operation.

WHEN USED TO CONTROL ROOM RELATIVE HUMIDITY

WHEN USED AS HIGH LIMIT HUMIDISTAT

Page 18

AIR FLOW SWITCH, PRESSURE DIFFERENTIAL TYPE

Model HXAAE

Air flow in the duct may be sensed by using this differential pressure switch. The differential in pressure between the interior of the duct closes a switch when air is moving. Air pressure differential as low as .07 w.g. may be sensed with this switch.

Environment: Ambient Temperature Limits, Shipping -40 to 140°F (-40 to 60°C).

Operating 35 to 140°F (0 to 60°C). Humidity, 5 to 95% RH, non-condensing. Locations, NEMA Type 1 indoor only.

Mounting: In vertical position on any surface free of vibration

(N.C.)

•

When there is an increase of air pressure to above setpoint, the switch is switched from normally closed (N.C.), common ground contact to normally open (N.O.) contact. On a decrease of air pressure to below setpoint, normally closed, common ground contact of the switch is switched to normally closed contact. Avoid locations where excessive moisture, corrosive fumes, or vibrations are present.

Setpoint: Factory Set, 0.07” (1.8mm) w.g. Field Adjustable, 0.07 to1” (1.8 to 25.4mm) w.g. Sensing Element: Neoprene diaphragm. Adjustment Note: Units are shipped at minimum setpoint.

To increase setpoint, turn adjustment screw clockwise. Adjustable

0.05 +0.02” to 1.0” (1.25mm +0.5mm to 25mm) w.g. To decrease setpoint, turn adjustment screw counterclockwise.

To Terminal 5 or 6 COMMON

Switch to “N.O.” on increase of pressure

•

To Terminal 5 or 6

(N.O.)

•

HIGH LIMIT HUMIDISTAT

Model HXHAD

The Model HXHAD is available to reduce the potential of condensation occurring in the supply duct. The control must be mounted a minimum of 10 feet downstream of the steam distributor pipe. Setpoint range is 15-95% RH. Differential is 5% non-adjustable.

The HXHAD may be mounted in any position on the outside surface of the supply air duct where it is exposed to freely circulating air (horizontal mounting is preferred).

“N.C.” (Red) is switched to common (Orange) during RH Rise.

“N.O.” (Brown) is switched to common (Orange) during RH Drop.

BROWN (N.O.) To Terminal 8 or 10

RED (N.C.)

ORANGE (COMMON)

To Terminal 8 or 10

EXTERNAL DDC CONTROL SIGNALS

The 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.

0-10 VDC

PROPORTIONAL SIGNAL

(BY OTHERS)

PROPORTIONAL

HIGH LIMIT HUMIDISTAT

(BY OTHERS)

0-10 VDC

470 OHM

RESISTOR

(BY OTHERS)

4-20ma

PROPORTIONAL SIGNAL

(BY OTHERS)

PROPORTIONAL

HIGH LIMIT HUMIDISTAT

(BY OTHERS)

4-20ma

470 OHM

RESISTOR

(BY OTHERS)

Page 19

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 setpoint. 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 humidistats may be used to control Carnes humidifiers if desired. One humidistat is in the area to be humidified or return duct and another humidistat is used 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

The HXHAT or HXHAMT can be used if your application has a requirement for an outdoor temperature compensation feature. Both controls will provide monitoring of RH percentage and outdoor temperature, along with automatically adjusting the RH setpoint as outdoor temperatures change. The HXHAT is a dry contact on-off humidistat, while the HXHAMT provides a 0-10V signal in either a proportional or on-off configuration.

CONTROL CONNECTIONS

The circuit board can provide either a Carnes legacy 18VDC or an industry standard 24VAC, as a supply for those humidistats which require it. The supply for both the control humidistat and high limit humidistat are output on pin1 of J16 and J17 respectively. 18VDC is set as the supply default, but the switches on designators SW5 can be flipped to the left to alternatively supply 24VAC as seen in Photo G for the H690-0107 circuit board (blue). The humidistat and high limit can be changed independently. The switch labeled Hu is switched for humidistat voltage output, and the switch labeled HL is switched for high limit humidistat voltage output. Switch(es) in the right position will supply 18VDC and switch(es) in the left position will supply 24VAC.

Figure N

ON/OFF

HUMIDISTAT

ELECTRONIC CONTROL CIRCUIT BOARD

ON/OFF

HIGH LIMIT

HUMIDISTAT

Connections shown in Figure N are for typical on-off controls. For Carnes proportional controls see the diagram Figure O. All controls are shipped with detailed wiring instructions.

AIR FLOW

SWITCH

Figure O

PROPORTIONAL HUMIDISTAT

(BY CARNES)

PROPORTIONAL

HIGH LIMIT HUMIDISTAT

(BY CARNES)

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 (

Figure P)

Photo G

Two cylinder humidifiers may be wired for simultaneous or separate and independent operation. Controls should be connected to the terminals on the circuit board as shown below using No. 20 AWG wire. Attempting to use two wires in a single control connection will require a No. 22 AWG wire or less. See wiring diagram for parallel connections. Avoid running control wiring near high voltage primary wires due to the possibility of interference and signal distortion.

Figure P

0-10 VDC

PROPORTIONAL SIGNAL

(BY OTHERS)

470 OHM

RESISTOR

(BY OTHERS)

PROPORTIONAL SIGNAL

HIGH LIMIT HUMIDISTAT

4-20ma

(BY OTHERS)

0-10 VDC

PROPORTIONAL

(BY OTHERS)

4-20ma

PROPORTIONAL

HIGH LIMIT HUMIDISTAT

(BY OTHERS)

470 OHM

RESISTOR

(BY OTHERS)

Page 20

EXTERNAL MONITORING

Pins 1 and 2 of connector J10, shown in Photo H, are provided for indicating operation of the humidifier at a remote location. When the unit is operating, pins 1 and 2 (EXT PWR) are closed. Pins 3 and 4 of connector J10 (EXT SRV) are provided to indicate the need for service. A “Service Required” warning on the home screen of the LCD will indicate the type of service that is needed. Both the EXT PWR and EXT SRV relays have a maximum ratings of 0.3A at 125VAC or 1A at 24VDC maximum.

CarnesLink is an option to have full external monitoring and control of your Carnes humidifier(s) by allowing the humidifier(s) to link to a Building Management System (BMS) using one of the following protocols: BACnet® (MS/TP), Modbus® (RTU), Metasys® (N2) and Siemens® (FLN).The user friendly interface on the True Touchscreen makes setting up CarnesLink easy and convenient. (See the CarnesLink Communication Protocol Installaion, Operation, and Maintenance Manual for further info.)

The circuit board also closes a power contactor allowing current to flow to vertical electrodes sealed inside the cylinder. Current flows between the electrodes using minerals in the water as a conductor. The water is heated to boiling and converted to steam which leaves the cylinder through the flexible steam hose which is connected to the steam distributor pipe.

The circuit board reacts to current flow between the electrodes and automatically opens the fill solenoid valve when more water is required to maintain the desired output rate and closes when the desired rate is reached. The operation of the drain solenoid valve is automatically controlled by the circuit board which responds to any changes in water conditions and drains the required quantity of water to provide stable operation and long cylinder life.

Figure Q

STEAM DISTRIBUTOR PIPE

FILL SOLENOID VALVE

AIR GAP

STEAM HOSE

Photo H

NETWORKING

If multiple units are required due to high capacity demand (over 200 lb. per hour, single unit), networking can be done. Units can be interconnected with parallel signal wiring. This setup is usually done to facilitate running multiple units from a single signal control (Humidistat, BMS System, etc.). For other networking requirements, please contact factory.

CONTROL CONNECTIONS

FOR SAFETY: MAKE SURE TO TURN OFF POWER AT THE

EXTERNAL DISCONNECT BEFORE MAKING ANY INTERNAL CHANGES TO THE HUMIDIFIER.

1. A 7/8” opening is provided on the top or bottom of the cabinet. The control wiring should pass through the opening to the provided connection points at J16, J17, and J18.

2. If an air flow switch or high limit humidistat is not used, jumpers must be installed before the humidifier will operate. On J17, jump terminals 2 and 4 together to bypass the high limit. On J18, jump terminals 1 and 2 together to bypass the air flow switch.

OPERATION

When the circuit board verifies all four basic controls have been satisfied (control humidistat, high limit humidistat, air flow, door interlock), a signal is sent to open a fill solenoid valve, allowing water to flow across an air gap into a standpipe. The standpipe provides a column of water to be fed into the cylinder using gravity. The air gap prevents the cylinder from pressurizing. See Figure Q. The steam cylinder normally operates at a pressure of approximately 1/2 psi.

NON CONTACT HIGH WATER SENSOR

OVERFLOW TUBE

STAND PIPE

FROM POWER CONTACTOR

CYLINDER

VERTICAL ELECTRODES

DRAIN SOLENOID VALVE

STEAM

WATER

TO DRAIN

As mineral deposits build up within the cylinder the water level will slowly rise to uncovered electrode surfaces to maintain the desired steam output rate. When mineral deposits have covered all available electrode surfaces, current flow will be reduced to a level where the desired steam output cannot be reached and the service light will signal the need for maintenance. When the cylinder is filled with minerals it is easily changed in less than five minutes (not including cool down time). Important Note: Due to the many variables effecting the operation of humidifiers (water condition, conductivity, hardness, etc.) it could take up to 24 hours of operation before a humidifier is truly operating normally and the water is completely conditioned. Conditioned water is a state where the amount of minerals dissolved within the water is at a steady state. Conditioned water is more conductive than new water from the fill valve.

Page 21

DISPLAYS AND INTERNAL CONTROLS

FRONT PANEL DISPLAYS & CONTROLS

The display on the front panel of the humidifier cabinet contains the “On-Off-Drain” switch, the LCD True Touchscreen display and the “Fill”, “Drain”, and “High Water” LED.

“SERVICE REQUIRED” PAGE

The “Service Required” page outlines any service issues that are in need of being resolved. Many issues can be traced back to variability in water parameters, and often the solution can be dealt with through the changing of cylinders or modifying timer values within the “Settings” page. This page is used to alert the user and direct them on the right path towards resolution.

Figure P

“ON-OFF-DRAIN” SWITCH

In the “On” position the humidifier will operate if all controls are calling for humidity. The “Off” position is used for seasonal shut down if desired. The “Drain” position is used to drain water from the steam cylinder for maintenance. The fill solenoid valve will be on whenever the drain is activated to reduce the drain water temperature.

LCD TRUE TOUCHSCREEN DISPLAY

This LCD True Touchscreen display offers a user friendly interface to control and monitor many aspects of the humidifier. The screen uses pressure sensitive technology. Depressing on the labeled buttons on the designated area of the screen will allow you to navigate through the different menu pages.

“HOME SCREEN” PAGE

The “Home Screen” page is the main screen through which most other pages can be accessed. The “Home Screen” displays the current steam output in Lb./Hr. (or Kg/Hr., selected in “Settings”). The main “Home Screen” features four navigation buttons, Carnes Logo (providing contact info to the factory and the company website), Steam Menu, Menu, and Settings. The “Home Screen” will display a “Service Required” indicator when a current service issue is indicated. The “Service Required” and Steam Output number will illuminate red. Tap on “Service Required” to access the service required page which indicates what service issue is being detected.

When CarnesLink is being used, the “Back End Override” indicator is displayed only when the connected building management system requests the unit to be set to “off” or “drain” while the unit is “on”. When selected more information is provided about the override.

“FILL” LED

The FILL LED is a blue light illuminated when the Fill Valve is activated. An activated Fill Valve allows water to flow into the cylinder of the humidifier. An analogous indicator, and a description of its operation, is offered in the “Menu” screen under “Component Activity”.

Page 22

“DRAIN” LED

The DRAIN LED is a red light illuminated when the Drain Valve is activated. An activated Drain Valve allows water to drain from the humidifier. An analogous indicator, and a description of its operation, is offered in the “Menu” screen under “Component Activity”.

“HIGH WATER” LED

The HIGH WATER LED is an orange light illuminated when the High Water Sensor is activated. An activated High Water Sensor indicates that the water has risen to the maximum allowable level in the cylinder. This can be a normal situation, particularly if the cylinder is being filled with mostly unconditioned water. An activated High Water Sensor can also be a sign that the cylinder is close to end-of-life and needs replacing, or in rarer cases, the water in the cylinder is not conductive enough for the fresh water entering the humidifier. An analogous indicator, and a description of its operation, is offered in the “Menu” screen under “Component Activity”. More information on troubleshooting High Water situations can also be found under the “Help” button, on the “Menu” screen.

“ ” LOGO

The Carnes logo on the “Home Screen” will take you to a page that displays the Carnes Company contact information (address, phone number, and company website). This feature is for the purpose of contacting the factory for any startup questions, troubleshooting, or service issues that may arise.

A Red “X” will be displayed to indicate if the control is not sending a signal indicating a need for humidification. If any one component is not satisfied, the “Home Screen” will indicat on the display using “RED” illumination on the Steam Output number and the “Steam” icon.

“STEAM” MENU

The “Steam Menu” page will display the status of the four basic controls (Control Humidistat, High Limit Humidistat, Air Flow Switch, and Door Interlock). The humidifier will only produce steam when the unit is switched into the “ON” position and if all four controls are satisfied.

A green “” will be displayed to indicate if the control is sending a signal and requesting humidification.

1. Control Humidistat - Explains the status and also shows the current demand of the Control Humidistat. The Control Humidistat must call for a demand greater than 20% for the humidifier to run. If needed, terminals ‘S’ and ‘GND’ on J16, on the main control board, can be wired together to force a 100% demand.

Page 23

2. High Limit Humidistat - Explains the status and shows the current demand of the High Limit Humidistat. The High Limit must call for a demand greater than 20% for the humidifier to run. If needed, terminals ‘S’ and ‘GND’ on J17, on the main control board, can be wired together to force a 100% demand.

The Control Humidistat, which provides the Control

Demand, is normally the humidistat located in the room being humidified. It is either installed in the room itself or the return air duct. The High Limit Humidistat, which provides the High Limit Demand, is a safe-guard humidistat, is usually set to a high level (80-90%), and will shut down the humidifier if the humidity gets too high in the supply duct. Without a High Limit Humidistat properly installed the supply duct could reach a humidity level where any steam entering the duct would readily condense. Both Control Humidistats and High Limit Humidistats are wired in the same way, only Control Humidistats are wired to port J16 of the circuit board and High Limit Humidistats are wired to port J17. Both ports have the same number of pins and connection layout.

3. Air Flow - Explains the status of the Air Flow switch. The Air Flow switch must sense proper air flow in order for the humidifier to activate. Insufficient air flow or an improperly installed air flow switch will cause the indicator to change to a red “X” and the unit will not operate. If needed, terminals ‘AFS’ and ‘GND’ on J18, on the main control board, can be wired together to force activation of the switch.

4. Door Interlock - Explains the status of the Door Interlock switch. The Door Interlock needs to be engaged for the unit to operate. This can be accomplished by either locking the door shut or pulling out the plunger for temporary operation while servicing the unit.

The “Menu” page displays four features: Setpoint, Component Activity, Dim LCD and Help. Tapping any of these buttons will show dialog explaining the subject or status of that button and display pictures.

When using an on-off humidistat, the percentage

should be either 100% or below 20%. In this case, the control is either calling for full output or no output. On-Off humidistats are dry contact switches. They will have two wires; each connected to pins 2 and 4 (in no particular order/polarity).

For a proportional humidistat, any percentage value

is possible between 0% and 100%. In this case, the humidifier can be modified to output any fraction of its max output. If the proportional control falls to 20% or below, the humidifier is shut off. The input signal of a proportional humidistat must be 0-10V DC. Proportional humidistats will have three wires, with ‘power’ going to pin 1, ‘signal’ to pin 3 and ‘ground’ to pin 4. In lieu of a humidistat, a DDC signal from a building management system may also be used. Here, the ‘signal’ should be connected to pin 3, and ‘ground’ to pin 4. In this case, ‘power’ can be ignored. A DDC signal must be of a 0-10V signal by adding a 470 ohm resistor between the ‘signal’ (pin 3) and ‘ground’ (pin 4).

“SETPOINTS”

The Setpoints page displays the Setpoints (the target

steam output of the humidifier) associated with the unit. There are three different Setpoints, but only one Setpoint is active at any given time. Each Setpoint is accompanied by the current value of the Setpoint to the right, and an indicator that represents its status.

The Max Setpoint is the user-specified Setpoint that is

active when no external controls or internal reduction is taking place. The Max Setpoint is always modifiable via the “Max Output Adjust” within the “Settings” menu.

Page 24

The Controlled Setpoint is the Setpoint when a

humidifier (Control or High Limit), reduces the target output of the humidifier due to changing room requirements.

The Reduced Setpoint is active when the unit requires

a reduction in output due to a high water situation.

The Setpoints have the following priorities: The Reduced

Setpoint has the highest priority and always overrides the Controlled Setpoint and the Max Setpoint when active. The Controlled Setpoint has the next highest priority, and always overrides the Max Setpoint. It should be noted that the Reduced Setpoint is always lower than or equal to the Max Setpoint (or Controlled Setpoint, if active) and the Controlled Setpoint is always lower or equal to the Max Setpoint.

“COMPONENT ACTIVITY”

“HELP” MENU

The Component Activity page lists all internal components that can switch on and off during operation. This includes the Fill Valve, Drain Valve, Contactor, High Water Sensor, and Board Communication. Each component listed is accompanied by a green “” or a red “X” indicator representing whether or not the component is currently ‘on’. The Fill Value is on when the unit is either filling or draining the cylinder. The Drain Valve is on when the humidifier is draining and can be on while the humidifier is producing steam. The High Water Sensor is on when the humidifier has identified a high water situation. When in a high water situation, the fill valve is disabled for 5 minutes. At the end of 5 minutes the high water sensor light will go out, the fill valve will open, if there is a call for more humidity, and then the unit will continue normal operation. High water sensors can be cumulative depending on the condition of the water.

The other component in the “Component Activity” page is the Board Communication (Comm.) button. The Board Communication button represents whether the touchscreen controller on the circuit board is properly communicating with the microcontroller and that the microcontroller is properly communicating with the data communication chip, if present. The Communication indicator is a green “” when the LCD display is communicating properly with the control board. If there is a red “X”, the touchscreen has likely lost communication with the control board, and the information on the screen may be inaccurate. For troubleshooting, contact Carnes Company at 608-845-6411.

Page 25

The help pages consist of buttons labeled with subjects. When a button is pressed, information will be given about the subject in question. A basic help page consists of text and/or diagrams to help the user through basic problems. For example, in the pictures above, the question “How Do I Install My Control Humidistat?” is answered with a diagram and corresponding text. Some pages consist of more buttons to help guide a user through different processes. These buttons can be used and referenced as needed.

“SETTINGS” MENU

Cylinder Life Counter

This page consists of a counter where the user can monitor the life, in hours, of the cylinder. When changing a cylinder, press the ‘Reset’ button on this page to reset the timer. The Cylinder Life Counter only counts the amount of actual runtime of the cylinder (the time when the contactor is pulled in). The counter value is saved even when the humidifier is powered down. The national average cylinder life is about 1150 hours, but this can vary greatly depending on individual water conditions.

Fan Speed Adjust

The “Settings” menu has pages where all operational values can be set. It is password protected by default, with a default password of ‘1212’. The default password can be changed or disabled under the “Change Password” page. See “Settings Password” page for more details.

Max Output Adjust

The maximum steam output of the unit can be set on this page. The maximum output value cannot exceed the nominal output value of the unit and cannot be set below 20% of the nominal output. The nominal output of the unit is listed on the nameplate and the “Electrical Data” help page.

This page consists of a slider bar that can change the speed of the fans when the humidifier is connected to an optional blower box. This slider bar will not affect the operation of the humidifier if no blower box is attached. The bar can change the speeds of the fans from 0 to 100% of the max fan speed. Also displayed on this page is an estimate of the current fan air output, in Cubic Feet per Minute (CFM). This adjustment is particularly useful if the humidifier is of a smaller capacity, and less noise from the fans is appreciated.

Page 26

Setpoint Timeout

Boil Down Timer

This page is where the Setpoint Timeout value is set. The maximum amount of time allowed for the unit to reach Setpoint during a fill sequence is designated by the Setpoint Timeout. Its default value is 30 minutes, but can be set as high as 255 minutes. After the timer expires during a fill sequence, the humidifier assumes the drain valve is stuck open (due to sediment buildup), and begins pulsing the drain valve to attempt to unclog it. After the pulsing routine, the humidifier will attempt to reach Setpoint for a second and third time. After the third attempt without reaching Setpoint, the unit will shut down.

High Water Timeout

This page is where the High Water Timeout value is set. This is the maximum amount of time allowed for the unit to run in a “Reduced Setpoint” mode (see Setpoints page). The timeout has a range from 0 to 168 hours, with the default being 24 hours. If the humidifier Setpoint is artificially reduced due to a high water situation, the humidifier will continue to run. If the humidifier cannot reach normal max/ controlled Setpoint, the humidifier will shut down after the High Water Timeout value elapses.

This page is where the Boil Down Timer is set. The Boil Down Timer is variable between 0 and 255 seconds, with a default value of 25 seconds. Setting the Boil Down Timer higher will result in an increased water level, and less conditioned water. This may be helpful in reducing low water level induced arcing and corrosion of cylinders. More water is consumed by the humidifier when the Boil Down Timer value is increased.

Settings Password

This page is where the password for the settings menu can be changed or disabled. If the password for the Settings menu is forgotten the it can be reset. To do this, remove power to the humidifier, flip the switch SW3’s bottom “Clear” switch to the right and power the unit back on. Return the switch’s afterwards from the right to the left.

The different buttons on both setting pages allow for the changing of different values. Below is a brief summary of each, and more information can be accessed within the page itself.

Page 27

Corrective Drain Length

CarnesLink Communication Protocol Setup

This page is where the Corrective Drain Length is set. This value represents how much water should be drained from the cylinder when the humidifier senses a corrective drain is needed. As water boils from the humidifier, minerals increase in the cylinder causing the water to get more conductive. Increasing the length of the drain flushes more conductive material from the humidifier, decreasing the water conductivity. The input here is a percentage value. To set the Corrective Drain Length to drain 20% of the cylinder during a corrective drain, input 020. To drain all the tank, input 100. 030 is the default value, and only multiples of 10 between 20 and 100 can be entered.

Default Settings

This page is where you can select and setup the communication protocol you will be using with your Building Management System (BMS) for full external monitoring capabilities. (See the CarnesLink Communication Protocol Installation, Operation and Maintenance Manual for further information.)

ON/OFF Setting Buttons

There are a few operational options that do not need separate pages, and therefore are only enabled/disabled via the ON/OFF Buttons on the main “Settings” menu page. Their functionality is described as follows:

Selecting Default Settings on the settings page will allow for the restoring of factory default settings. The factory settings will be set to the following:

Setting Default Setting Default

Max Output Nominal Output Comm. Setup Unchanged

Fan Speed 100% Drain Pulse Off

Setpoint Timeout 30 Min. 72-Hour Drain On

High Water Timeout 24 Hrs LCD Auto-Dim Off

Boil Down Timer 25 Sec Steam Output Units Lb

Corrective Drain Length 30%

Restoring default settings can be helpful when troubleshooting an oddly behaving humidifier. Although some settings will stay visible on their respective screens after applying a factory reset, it is recommended to take note of all adjustments previously applied as some may be important for efficient operation given specific water conditions.

The Drain Valve Pulse option is enabled by default. This option allows the drain valve to pulse when the humidifier executes a corrective drain. This actuates the water within the drain piping, allowing for minerals buildup to be discharged more easily. Enabling this option will make the unit noisier whenever a corrective drain is executed.

The 72-Hour Drain is disabled by default. This option, when enabled, allows the humidifier to drain the cylinder completely after 72 hours of idle operation.

The LCD Auto-Dim is disabled by default. This option, when enabled, will automatically turn off the backlight of the LCD after 15 minutes of idleness. This feature can save on energy consumed.

The Steam Output Units is disabled or set to “Lb.” by default. This option, when set to “Kg.”, will turn the steam readout on home page into Kg./Hr .instead of Lb./Hr.

Page 28

HUMIDIFIER MANDATORY PRE-STARTUP CHECKLIST

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

WATER QUALITY:

Well Water ______ City Water ______ Softened Water ______ Water Conductivity (if known): mhmos: ______ Hardness: ______ gr.

HUMIDIFIER MOUNTING:

Clearances around the unit Acceptable Front (door opens freely?) yes  no Top (steam lines) yes  no Bottom (fill, drain, controls) yes  no Both Sides yes  no

STEAM HOSE: CONDENSATE HOSE:

Sloping up 2 in. every 12 in. yes  no Sloping down 0.5 in. every 12 in. yes  no Lengths/Size ______/______ Material ______________________________ Runs of hose over 12 ft. yes  no (if yes, drain T is needed, check IOM for details) (if yes, drain T is needed, check IOM for details) Can condensate be trapped Can condensate be trapped anywhere

anywhere in the steam line? yes  no

Lengths/Size

 18" (Residential/Commercial)  38” (Dual Cylinder Cabinet)  12” (Residential/Commercial)  16” (Residential/Commercial)



Sloping back to drain yes  no

 Condensate routes to drain?

______/______





Material __________________________ Runs of hose over 12 ft. yes  no

in the condensate line? yes  no



WATER SUPPLY LINE (do not use hot water):

3/8 in. connection at fill yes  no Water supply shutoff within 6 ft. yes  no

DRAIN LINE:

Connection pipe fitting to trap yes  no

CYLINDER:

Properly installed and secured yes  no Wire connectors pushed completely down on electrode rods? yes

WIRING:

No lose wiring connections and connectors yes  no

CONTROLS:

Humidistat location: High limit location: Air flow location: __________________________________ ________________________________________________

POWER:

Voltage/current rating and fuse correspond to spec label yes  no Disconnect switch located close to humidifier unit yes  no

_________________________________

__________________________________

 



Water pressure 20-120 psi yes  no PVC yes no

Slope to drain yes  no

Water pressure 20-120 psi yes  no





Copper yes





Humidistat to terminal J16 yes  no High limit to terminal J17 yes  no

Air flow to terminal J18 yes  no

 



 



Started by: ________________________________________ Date of Startup: ___________________

Company: ________________________________________

Page 29

HUMIDIFIER STARTUP CHECKLIST

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

PRELIMINARY:

• Pre-startup Checklist completed yes  no If no, perform Pre-startup Checklist before starting humidifier.

STARTUP PROCEEDURE:

The prerequisites for the humidifier filling and contactor pulling in to make steam are as follows:

• Front door closed or door interlock switch pulled out yes  no

• Water supply valve opened yes  no

• Main disconnect switched on yes  no

• Turn on the On-Off-Drain switch yes  no

CONTROLS:

• Installed controls match configuration yes  no

• Control setpoint yes  no

• Proportional wall humidistat (HXHAM, HXHCH or HXHCG) yes  no

• On/Off wall humidistat (HXHAA) yes  no

• Air flow switch (HXAAE) yes  no

• Pressure differential high velocity air flow switch (HXAAF) yes  no

• Duct mounted, proportional high limit switch (HXHAN) yes  no

• Wall mounted high limit humidistat (HXHAD) yes  no



   

       

The humidifier will undergo a self-diagnostic when the power is turned on activating the LED’s and other internal components.

If the above listed prerequisites are fulfilled, the humidifier will start filling the cylinder and begin normal operation.

NOTE: Most water does not contain enough conductivity for full boil on initial startup and after new cylinder replacement. Units will need to concentrate the water over a time period (up to 24 hours). It’s normal for the humidiﬁ er status to cycle between “Filling” and “High Water” (max water level) during this time period.

Started by: ________________________________________ Date of Startup: ___________________

Company: ________________________________________

Page 30

HUMIDIFIER STARTUP & OPERATION

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

PRELIMINARY:

• Pre-startup Checklist completed yes  no If no, perform Pre-startup Checklist before going to the starting procedure.

• Startup Checklist completed yes  no If no, return to the Startup Checklist before going to the startup procedure.



INITIAL STARTUP:

While the external disconnect is in the off position, be sure that the terminal connectors on the top of the cylinder are firmly secured and pushed completely down over the pins in the cylinder.

1. Open all the water supply valves external to the humidifier.

2. Turn external disconnect switch on.

3. Turn on optional circuit breakers if present.

4. For safety, door interlock disconnects power to cylinder(s) when the door is opened.

The humidifier may be operated for service purposes by pulling out the knob of the door interlock switch into a fixed, always on, position. CAUTION: HIGH VOLTAGES ARE PRESENT.

5. Turn the “On-Off-Drain” switch to the “On” position. The blue fill LED will turn on.

6. The Steam Indicator will turn red if any of the basic four controls on the home page are not ready, indicated with a red

“X”

7. Adjust the controls as necessary to satisfy the requirements for steam output (see Controls and Home Page for more information). The humidifier will begin to operate if all four controls are satisfied.

8. As water slowly fills into the cylinder, the LCD Lb./Hr. output will begin to increase when water comes in contact with the electrodes.

9. Water will continue to fill until output is 10% above setpoint. If water reaches the top of the cylinder before setpoint is reached, the “High Water Sensor” will be activated and the fill will close.

10. When starting a new cylinder and fresh water, the fill and drain solenoid valve may cycle for brief periods until the water has come to a complete boil.

11. In areas with low conductivity water, full output may not be reached until the humidifier has conditioned the water by repeated cycles of filling, boiling, and refilling. The length of this process will vary but may require several hours, up to a day, under certain conditions.

AUTOMATIC DRAIN CYCLE:

The circuit board automatically controls the operation of the drain valve to react to two situations:

Controlling mineral content:

1. When the current reaches 10% above the active setpoint, the fill solenoid valve closes and water gradually boils away in the cylinder. Because the quantity of water covering the electrode surface is being reduced, current slowly falls.

2. An internal timer within the operation algorithm starts to count seconds when steam output drops to 90% of setpoint.

3. The timer runs until steam output drops to 90% of setpoint.

4. If steam output drops too rapidly during this transition, a corrective drain is necessary to reduce the mineral concentration of the water.

5. If the steam output changes slowly it indicates that mineral concentration is satisfactory and a corrective drain is not necessary.

6. Measurements are made during each cycle and a drain only occurs when necessary thereby maximizing energy and water usuage efficiency.

Reduced Overcurrent

1. If current to any electrodes in the cylinder reaches more than 20% above the setpoint, the drain valve will open.

2. Draining water from the cylinder reduces current by covering less electrode surface.

3. If current is successfully reduced to acceptable levels normal operation continues.

4. If current is not reduced because of mineral blockage in the drain lines or solenoid valve, the power contactor will be opened for approximately 10 seconds while the drain valve remains open.

5. If current is successfully reduced, normal operation continues.

6. If current is not reduced the cycle is repeated 8 more times. If still unsuccessful, the humidifier is placed in an overcurrent shutdown mode and the “Service Required” page will be updated accordingly.

Page 31

FAN DISTRIBUTION UNITS

Fan distribution units are available for use in areas which do not have duct systems or where duct air temperatures are too low to provide sufficient humidification. For example, in computer areas, the desired relative humidity may not be possible in the conditioned space without causing condensation in the duct. Fan distribution units may be either remote mounted or directly mounted on the humidifier unit.

Fans

12-1/2”

Box

6-3/8”

Fan distribution units must be mounted securely on a level and plumb surface at least three feet below the ceiling for a Model HXBHB and at least four feet below the ceiling for a Model HXBHC to prevent steam condensing on the ceiling surface. Allow 20 feet in front of the HXBHB and 30 feet in front of the HXBHC for the steam to be absorbed into the air. Do not mount the units above any items that would be damaged if a water leak or spitting were to develop.

6-3/8”

Steam

Hose

12-1/2”

Photo I

Humidifier

Model

H_AH 005, 010 HXBHB (1 Required)

H_DH 020, 030 HXBHB (1 Required)

H_GH 030, 040, 050, 060, 080, 100 HXBHC (1 Required)

H_HH 125, 150, 175, 200 HXBHC (2 Required)

Nominal Steam

Output Rate

Fans

Remote Mounted

Fan Unit Model

12-Pin Fan

Connection

9-5/8”

25”

20”

11-3/4”

31-3/8”

Photo L

A Mounted Fan Distribution Unit and its associated humidifier are shipped as a complete assembled unit. In this case, a 12-wire connection is made from the circuit board to the 12-Pin fan connection (Green). This connection is already assembled in the factory.

Photo J

Cooling fan for circuit board when mounted and remote fan distribution unit is used.

999-5739

Cooling Fan included with all fan distribution units as well as with all other units manufactured. As soon as power is supplied, the fan will start to run from the 12 volt source from circuit board.

Page 32

A Remote Fan Distribution Unit comes with two separate male plugs to connect 12-conductor wire from the humidifier to the fan distribution unit at a remote location. One of the male connectors goes to the humidifier’s female connector, the other goes to the remote unit. We recommend Alpha Wire 1181C (non-Carnes) as an appropriate 12 conductor wire, but there are many available that will suffice. Each conductor should be rated at minimum for 1 Amp. If individual wires are used, utilize 26 or 28 gauge wire.

When connecting the humidifier male ends to the wire, pin 1 of the humidifier connector should be routed to pin 1 of the fan distribution unit connector. Pin 2 should be routed to pin 2, etc. Use a small regular head screwdriver to connect each conductor into the male connector. It is important to make sure the conductor is grasped inside the screw compression, and not the wire insulation.

A remote fan distribution unit should not be mounted any more than 40 feet away from the humidifier but this is dependent on the capacity of the unit. Small capacity units cannot provide steam at greater distance. See Table 3-A, page 7. When wiring the fan distribution unit remotely, it is not absolutely necessary to wire through the electrical conduit, but it is recommended for providing some strain relief on the connector.

20”

6-3/8”

Photo K

Page 33

STEAM DISTRIBUTOR PIPES

Lengths 012-036

5”

(127)

9-1/2”

(241)

Lengths 048-120

4”

(102)

3/8”

Distributor Pipes for Models: HTA, HSA, HTD, HSD

PIPE N T

HXPBB012S 11-13/16 (300mm) 7/8

HXPBB018S 17-13/16 (452mm) 7/8

HXPBB024S 23-13/16 (605mm) 7/8

HXPBB030S 29-13/16 (757mm) 7/8

HXPBB036S 35-13/16 (910mm) 7/8

Minimum**

Maximum**

PIPE N N T

HXPBB040S 35 (889mm) 38 (965mm) 7/8 HXPBB044S 39 (991mm) 42 (1067mm) 7/8 HXPBB048S 43 (1092mm) 46 (1168mm) 7/8 HXPBB052S 47 (1194mm) 50 (1270mm) 7/8 HXPBB056S 51 (1295mm) 54 (1372mm) 7/8 HXPBB060S 55 (1397mm) 58 (1473mm) 7/8 HXPBB064S 59 (1499mm) 62 (1575mm) 7/8 HXPBB068S 63 (1600mm) 66 (1676mm) 7/8 HXPBB072S 67 (1702mm) 70 (1778mm) 7/8 HXPBB076S 71 (1803mm) 74 (1880mm) 7/8 HXPBB080S 75 (1905mm) 78 (1981mm) 7/8 HXPBB084S 79 (2007mm) 82 (2083mm) 7/8 HXPBB088S 83 (2108mm) 86 (2184mm) 7/8 HXPBB092S 87 (2210mm) 90 (2286mm) 7/8 HXPBB096S 91 (2311mm) 94 (2388mm) 7/8 HXPBB100S 95 (2413mm) 98 (2489mm) 7/8 HXPBB104S 99 (2515mm) 102 (2591mm) 7/8 HXPBB108S 103 (2616mm) 106 (2692mm) 7/8 HXPBB112S 107 (2718mm) 110 (2794mm) 7/8 HXPBB116S 111 (2819mm) 114 (2896mm) 7/8 HXPBB120S 115 (2921mm) 118 (2997mm) 7/8

**See Note A

4”

(102)

3/8”

Distributor Pipes for Models: HTG, HSG, HTH, HSH

PIPE N T

HXPBC012S 11-13/16 (300mm) 1-5/8

HXPBC018S 17-13/16 (452mm) 1-5/8

HXPBC024S 23-13/16 (605mm) 1-5/8

HXPBC030S 29-13/16 (757mm) 1-5/8

HXPBC036S 35-13/16 (910mm) 1-5/8

PIPE N N T HXPBC048S 43 (1092mm) 46 (1168mm) 1-5/8

HXPBC060S 55 (1397mm) 58 (1473mm) 1-5/8 HXPBC072S 67 (1702mm) 70 (1778mm) 1-5/8 HXPBC084S 79 (2007mm) 82 (2083mm) 1-5/8 HXPBC096S 91 (2311mm) 94 (2388mm) 1-5/8 HXPBC108S 103 (2616mm) 106 (2692mm) 1-5/8 HXPBC120S 115 (2921mm) 118 (2997mm) 1-5/8

**NOTE A

The mounting plate on these pipes is adjustable to compensate for slight variations in ductwork dimensions. The “N” dimension is shown at both maximum and minimum depending on the position of mounting plate. A mounting strap is provided on the end of the pipe to secure to the top or side of the duct for support.

MATERIAL

Standard distributor pipes are fabricated from stainless steel.

Minimum** Maximum**

Page 34

CARNES STEAM MANIFOLDS reduce the non-wetting distance when required because of space constraints in duct system.

SHORT ABSORPTION MANIFOLD

Carnes Steam Manifolds are designed to provide dry steam with rapid absorption in the duct air stream. It achieves this by distributing steam evenly across the face of the duct. The distance needed for absorption is dependent on a number of factors, some of which are air velocity, steam volume, air temperature, and characteristics of air flow in the duct. For minimum absorption distance, the manifold should be located in the warmest air stream of the duct and where fully developed laminar air flow occurs.

Table 5

Duct Height Tubes 012 014 016 4 018 020 022 6 024 026 028 8 030 032 034 10 036 038 040 12 042 044 046 14 048 15

1-1/2”

3” (76)

Duct

Height

3” (76)

(38)

3-1/2” (89)

Duct Width

5”

(127)

1-1/2” (38)

4”

(102)

Type

B, C

Type

6”

(152)

Page 35

CARNES STEAM MANIFOLDS with strong galvanized flanged frames are factory assembled to reduce installation costs.

LOCATION OF MANIFOLD

The manifold is usually located in the supply duct downstream of the fan, heating coil, cooling coil, and/or filter. When installed in packaged units, the manifold is to be mounted just downstream of the fan discharge.

The non-wetting dimension is the distance necessary to prevent condensation on any obstruction downstream from the manifold. Condensation could occur on a cooling coil because of lower temperatures. Steam plumes may be visible beyond the non-wetting dimension and may moisten high efficiency filters. Additional distance is required for installation upstream of high efficiency filters.

Carnes humidifiers operate at 1/2 psi or less so there are limitations on the length between the humidifier cabinet and the steam manifold. The maximum distance depends on the static pressure in the duct and is shown in Table 6.

MAXIMUM STEAM HOSE LENGTH (Table 6)

Duct Static

Pressure “wg”

Maximum Steam Hose Length (Ft.)

In a typical installation, the humidifier is located below the duct and the steam manifold is installed as shown in Figure R. The maximum recommended length of steam hose for this type of installation is 12 feet.

For lengths beyond 12 feet additional steps are shown in Figure S. If sufficient headroom is not available, it is possible to install the steam hose with an upward slope with a minimum rise of 2” for every 12” of run.

The steam manifold may be located below the humidifier if the installation is made in accordance with Figure T. The steam manifold cannot be installed in a vertical duct.

The manifold has an integral mounting flange for ease of installation. Separate mounting flanges, supplied by others, are needed to mate with the manifold. Refer to Figure U.

If the steam manifold is used with a humidifier having two cylinders it will require two separate lengths of steam hose. Do not

combine the outputs of two cylinders into one steam hose.

It is very important that both the steam hose and condensate return line be installed so that sags are prevented.

If it is difficult to prevent sags, it is recommended that a copper tube be used as a substitute. If a 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 plastic cylinder in the humidifier to the copper tube and another to connect the copper tube to the steam manifold. It is very important to include adequate space to move the steam hose far enough when replacing cylinders. Any turns in the steam hose should have a minimum radius of eight inches to prevent kinking.

Size 3/4” copper tube can be used with steam cylinders having output rates up to 30 pounds per hour. Size 1-1/2” copper tube should be used with steam cylinders over 30 pounds per hour. Length restrictions shown in Table 6 also apply where copper tube is used and any 90° elbows add approximately three feet of equivalent length.

0 1 2 3 4 5

40 35 30 25 15 10

Figure R

Figure S

Figure T

Figure U

Page 36

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION -

Table 7

SYMPTOM CAUSE ACTION

Arcing Naturally very high conductivity water. Water may be too high in conductivity. Test water.

Drain lines restricted causing low water levels. Inspect & clean drain & tubing regularly.

Defective drain solenoid valve. Repair, clean, or replace as necessary.

Insufficient flow of incoming water. Levels low. Maintain 20 psi or above. Clean strainer, repair,

clean, or replace fill solenoid as necessary.

High back pressure in steam line. Check kinks or severe bends in steam hose. Check

system static pressure.

Excessive lengths of steam hose and/or high static pressure.

Attempted cleaning of cylinder by flushing or banging producing flakes causing restricted lines.

“Service” indicator on Various. See “Service Required” page for more information

Water doesn’t fill into cylinder (blue LED fill indicator)

Water doesn’t fill into cylinder (water level doesn’t rise in cylinder)

Humidifier drains continuously

Water in duct or spitting from distributor pipe

All 4 basic control signals not satisfied. Make sure all control circuits are closed and the

Fill valve strainer is restricted. Remove strainer from fill valve assembly and

Fill valve is defective. Repair or replace as necessary.

24 Volts AC not coming from circuit board. Consult factory, replace circuit board.

Piece of mineral is partially blocking drain so it will not close properly.

Drain plunger is worn out, preventing drain valve from closing completely.

Steam hose and condensate return hose do not have a continuous slope. Condensate accumulates and gets pushed out of distributor.

Condensate return is blocked, kinked and prevents proper drainage of condensate water and accumulates in distributor pipe and pushed out into duct.

Distributor pipe is not installed properly or manufactured properly, not allowing for a continuous backward slope to steam hose and condensate hose connection.

If condensate return hose has a drop less than 12”.

Condensate return is connected to top of unit, but a trap was installed too close to elbow, split, turning vane, grille, or diffuser.

Shorten distance between humidifier & dispersion, maintain proper incline in steam hose, eliminate as many 90° or 45° bends, insulate steam line as necessary.

Do not use solutions to clean cylinders, dispose as necessary. Solutions could cause chemical reactions not conducive to good operation.

regarding the problem.

humidifier is ‘On’.

clean.

Cycle drain. If it does not clear, clean as necessary.

Repair or replace as necessary.

Improve routing of all hoses and/or install condensate drains as necessary. Add a trap in the steam hose in front of the distributor.

Eliminate restriction in hose and routes as required for proper flow of condensate water.

Re-assemble, repair, or replace as necessary.

Route the condensate return to a common drain and include a trap.

Whenever condensate hose is returned to top of unit a trap is not required, remove it. Distributor pipe must be a minimum of 6 feet upstream from elbows, grilles, etc. If temperature in the in duct is 60°F or lower the distance should be 10 feet. If distance, as mentioned, is not possible, a drain pan may be required. If the air in the duct cannot hold the volume of steam, the only recourse is to reduce the maximum output of the unit. If very short absorption distances are required, a short absorption manifold can be installed.

Page 37

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION

(Continued)

SYMPTOM CAUSE ACTION

No LCD display The LCD has been dimmed. Touch LCD screen.

Voltage to the humidifier is not that which is required per rating label.

3 phase voltage but not all legs have power. Check electrical connections and make necessary

Internal or external circuit breakers are not closed.

24VAC supply to circuit board is not available. Make sure the protection on the transformer

Humidifier unable to reach maximum output or required setpoint

LCD not on Verify that voltage being supplied to the humidifier

Capacity of unit is too low. Determine proper load calculation and capacity of

Too high of a system static pressure. Supply air system must be evaluated if static

Back pressure in steam hose is too high. Check for the following: too long of steam line runs,

Foaming. Remove impurities inside the cylinder. If cleaning

Wrong cylinder. Make sure proper cylinder and configuration is

Change humidifier or make necessary changes to confirm compatibility.

repairs or hook ups.

Close all circuit breakers.

is not tripped (fuse or breaker). Confirm the required 24VAC is leaving transformer. Make sure connection to circuit board at J1 is intact. If situation does not resolve, replace circuit board.

humidifier. Use properly sized unit.

pressure is too high. Locate and correct issue.

sags, dips, horizontal runs not allowing for proper condensate removal, improper sloping of steam lines and condensate line.

of cylinder was attempted, throw away.

used.

is the same as that listed on the rating label on the front left hand corner of cabinet.

If humidifier is 3 phase, verify that all legs have power.

If the humidifier has optional internal circuit breakers, they must be on.

Verify LCD is not in dimmed mode by touching it.

Verify that 24VAC is being supplied by the voltage transformer by taking voltage reading between TP6 and TP7 (Photo L). Check the connection at J1 (Photo M).

If 24VAC is not present reset the overload protection (breaker or fuse) located on the transformer.

If 24VAC is present, the circuit board may be defective.

Photo L

Photo M

Page 38

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION

(Continued)

SYMPTOM CAUSE ACTION

Water doesn’t fill into cylinder

Drains continuously The most common cause is to have a piece

Confirm that indicators for the four basic controls all have green checkmarks in the “Steam” menu, and the humidifier is switched ‘On’.

If all four control requirements are checked green, consult the “Controls” section of the IOM.

If all four control requirements are checked green, and the ‘Steam’ indicator is not red, check the service required page for a possible shutdown scenario.

If no service required information is available, check the Fill Valve indicator (the blue LED on the front). If the LED is on, check for 24VAC at the coil of the fill valve. If 24VAC is present water should be flowing if water is available. Be sure all shut off valves ahead of the humidifier are open.

If water is available, check the fill valve strainer for sediment. The strainer may be checked by removing the plastic nut from input side of the valve and reaching inside the housing with a non-sharp tool and pulling the strainer out.

If 24VAC is present and strainer is clean, the fill valve may be defective.

If the High Water Sensor is activated, the fill valve will not be allowed to open. In this case the blue LED on the front panel will be off.

Make sure the drain solenoid is not partially open due to blockage, restriction, or malfunction.

of mineral in the drain solenoid valve that prevents the valve from closing properly. Simply cycling the “On-Off-Drain” switch back and forth between “Off” and “Drain” may dislodge the sediment. In extreme cases it may be necessary to disassemble drain lines to clean them. If mineral buildup is a reoccurring issue, make sure the “Repetitive Drain Valve” option is enabled in the settings menu.

Check movement of the solenoid actuator to verify that the plunger moves freely in the coil. If the coil has overheated so that movement of the plunger is restricted, it will require replacement of the valve.

When the Drain Valve” Red LED is lit, the circuit board is sending 24VDC to the drain valve. If the Red LED is on but 24VDC is present at the drain valve, the circuit board may be defective.

Page 39

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION

SYMPTOM CAUSE ACTION

Water in the duct Note: This is usually an installation problem.

The first step is to determine whether water is spitting from the steam distributor pipe or if steam is condensing on some object downstream from the steam distributor pipe. If water is spitting from the steam distributor pipe there may be several causes.

The steam hose and condensate return line MUST have continuous slopes without any sags or low areas where water could accumulate. If water accumulates in the steam hose it may be suddenly pushed into the distributor pipe and the condensate return line may be unable to handle the large volume.

Make sure that the condensate return line is not restricted anywhere. Areas where the hose bends or where it is tied using cable ties are often the problem.

The distributor pipe must be installed so that the far end of the distributor pipe is higher than the incoming end where the condensate return connection is located. The mounting plate on the distributor pipes (with lengths up through 36”) should be mounted on a plumb surface to automatically provide proper pitch. On longer pipes, it is necessary to support the pipe using the bracket on the end of the pipe to insure that proper slope is maintained.

If the condensate return line has a drop of less than 12” from the distributor pipe to the top of the humidifier cabinet, it may be better to route the drain below the unit rather than connecting at the top of the cabinet.

If the condensate return line is connected to the fitting at the top of the humidifier cabinet, make sure that traps have not been installed in the return line. A trap is only needed if the return line is routed to a separate drain and it is necessary to prevent steam from being discharged from the line.

It may be beneficial, particularly on longer routes, to put a trap in the steam hose right before the distributor pipe. In this case, it is absolutely necessary to run the condensate at the bottom of the trap away to a separate drain.

If water is condensing on an object in the duct or on the duct itself it will be necessary to take other steps.

The distributor pipe must be a minimum of 6 feet upstream from any elbow, split, coil, turning vane, grille, or diffuser. The lower the air temperature is in the duct the further upstream the pipe must be located. If the air temperature is 60°F it may be necessary to have 10 feet between the pipe and any obstruction.

If it is not possible to have the required distance from the distributor pipe to an obstruction a drain pan may be required to accommodate the water.

It may be that air in the duct simply can’t hold the volume of steam that is being added. Normally the only practical solution is to reduce the steam output of the humidifier, as it is usually not feasible to increase the air temperature or quantity.

(Continued)

Page 40

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION

SYMPTOM CAUSE ACTION

Arching in the steam cylinder

An occasional arc is not a problem. When a cylinder is restarted after a long period of off time arcing may occur as pieces of mineral flake off the electrode surface. During a drain cycle, arcing may occur if water is very low in the cylinder. Arcing is a problem if it occurs frequently or if it causes dark brown or red discoloration in the cylinder. The dark deposits are caused by deterioration of electrode material and must be prevented. Arcing may be caused by several conditions:

Incoming water may have high conductivity. Conductivity, the ability to conduct current, is measured in “micromhos”. In any electrode type humidifier there are maximum values of conductivity that may be used in the humidifier. It is very unusual for any naturally occurring water to have conductivity that is too high for operation. It is recommended that water conductivity be less than 900 micromhos. If water is treated by a water softener its conductivity will be higher than untreated water. As it is boiled away its conductivity also increases at a higher rate than untreated water. Softened water may be too high in conductivity to operate without arcing.

Drain lines within the humidifier that have become restricted by mineral deposits prevent proper drain rates. This causes minerals to concentrate inside the cylinder, which in turn causes low water levels. Low water levels cause arcing. Drain lines should be inspected when cylinders are changed and thoroughly cleaned if necessary.

A defective drain solenoid valve will prevent proper draining. The solenoid should be checked to verify that it moves freely when 24VDC is applied to the coil. When placed in the “Drain” position, both the drain and fill valves open and it is very important the water level falls in the cylinder.

Insufficient flow of incoming fresh water will cause arcing by causing low water levels. Since an automatic drain is not initiated until setpoint is reached, a drain will not occur if the flow rate is too low. Therefore, if low water pressure at the humidifier (below 20 psi) or a clogged water strainer restricts the flow of water, arcing will result.

High back pressure, which can be caused by an obstruction in the steam hose, prevents fresh water from entering the cylinder and results in arcing. Care must be taken to prevent kinking of steam hose when making bends.

Excessive lengths of steam hose in conjunction with high duct static pressures cause low water levels and arcing.

Frequent cleaning of the steam cylinder by removing and flushing or by striking the side of the cylinder potentially dislodges flakes that can build up a “dam” in the drain lines. It is not recommended that the cylinder be removed except for replacement.

Chemicals should never be used to attempt to prevent mineral build up in the cylinder or to dissolve minerals that accumulate. Chemical treatment may affect conductivity.

Only untreated tap water is recommended for use in the humidifier.

(Continued)

Page 41

TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION

(Continued)

SYMPTOM CAUSE ACTION

Foaming Foaming is usually due to foreign matter or

impurities getting into the cylinder through normal water supply. Detergents, cleaning agents used to clean dirty cylinders (cylinders are not to be cleaned, but to be disposed of at end of cylinder life), and water issues precipitated by very slow or fast drain cycles. It is important to note that when foam is generated it is as conductive as the conditioned water and could, if circumstances are right, force a high water level situation.

Clean all water lines, replace if necessary.

Replace cylinder.

Reduce softening mix or concentration.

Increase water volume by correcting drain issues.

Changing cylinder, but with a different electrode configuration to accommodate the water condition.

WATER CONTROL

The water contained in the cylinder must be controlled, in order for the humidifier to function properly. The fill and drain rates must be maintained. Filling too quickly can cause over-current and automatic shutdown, circuit breaker tripping or blown fuses. Filling too slowly can cause insufficient steam output or insufficient humidity levels. Water supply pressure should be between 30 and 80 psig, ideally 55 to 60 psig. Draining too quickly can cause dangerous arcing and electrode corrosion. Draining too slowly can cause over-concentration and malfunction due to foaming. These are just some examples of what can go wrong if the fill and drain rates are not controlled and maintained.

24V DC Coil Terminals

Valve Shown In

Normally Closed

Position

Solenoid Valve

Clear Plastic End Cap, Dependent on Model, Could Be In 3 Different Positions

Must Move Freely, Clean As Necessary

Water In - From Cylinder Fitting

Water Out, Into Drain

Page 42

HUMIDIFIER OPERATIONAL SPECIFICATIONS:

1. Provide self-contained electronically controlled steam generating humidifiers of the size(s) shown on plans as manufactured by Carnes Company, Verona, WI.

2. Carnes Humidifiers shall have the capacity to operate at 115, 208, 230, 277, 380, 415, 460 and 575 volt (or nominal value), 60 or 50 hz (cycle), single or 3 phase power. Specific combination of maximum output, voltage and phase for order application determined by electrical data chart.

3. The humidifier(s) shall be UL and cUL listed.

4. The humidifier(s) shall have a total Color “True Touchscreen” user interface. Features:

a. True Touchscreen navigation for all aspects of operation and

information access.

b. Cylinder life counter for hours of operation. Found by accessing

the “Settings” button.

c. With Fan Distribution Unit, there is a fan speed Slide Bar

control with CFM indication. Found by accessing Settings button.

d. “Help” screen button. e. “Service Required” button and indicator and corresponding

screen explaining service issues and possible troubleshooting tips.

f. “Dim LCD” feature button. g. “Settings” button - where all operational values can be set. h. “Setpoints” button - target steam output of the humidifier.

5. Steam shall be generated from tap water or softened water (see factory representative) in a factory sealed cylinder containing electrodes. Cylinders shall not require setting of electrode spacing, cleaning or maintenance and shall be of the disposable type.

6. The humidifier(s) shall include an automatic drain cycle controlled electronically to maximize energy and water usage efficiency. Drain cycle shall adapt to variations in water conditions (high/low conductivity and high/low hardness) and not require manual setting. There is also a default setting for a pulsing drain action to assist in keeping drain lines open.

7. In the event of over-current, the humidifier shall signal that a fault condition exists by a message on the touchscreen.

Option: Humidifier(s) shall also include secondary magnetic

overload switches (circuit breakers) that shall be manually resettable and shall be of the type that positively disconnects power to the steam cylinder.

8. Humidifier(s) shall include a door interlock safety switch to disconnect power to steam cylinder(s) when cabinet door is opened.

9. The system shall include one steam distributor pipe for each steam generating cylinder mounting in the duct as shown on the plans. Steam distributing pipe(s) shall be of corrosion resistant design (stainless steel) and be designed to provide uniform distribution over the entire length of the pipe.

Option: Supply and install remote (or humidifier mounted) fan

distribution units to discharge steam directly into the conditioned space.

Provide the following components: a. Three 12VDC fans operated by the circuit board. b. Integral steam manifold trap. b. Remote mounted on/off, proportional control humidistat. Option: When plans call for a specific short absorption distance

from dispersion system, a multi-tube Short Absorption Manifold is available sized specifically to duct dimensions, with horizontal stainless steel cross tubes and vertical headers.

10. The system shall include flexible hose to connect the steam cylinder(s) to the steam distributor pipe(s). A separate condensate return line shall return condensate to the humidifier for reuse to minimize consumption. If due to specific routing issues or application of unit, condensate line cannot run back to unit, the line can go directly to the common drain, and the addition of a “circle” or “U” trap will be required (see IOM). Long distances from unit to common drain can be accommodated with accessory option Water Pump (HXWA). Hard tubing can be used for Steam Hose and Condensate Return to prevent sags, restrictions or obstructions (see IOM), but it is recommended a minimum of 12 inches of flexible hose be used from unit and before distributor pipe. We recommend a maximum distance of 10 feet from unit to distributor pipe(s) or short absorption manifold and proper routing and inclination of hoses and hard tubing be adhered to for proper, overall consistent and dependable operation.

11. The humidifier(s) shall incorporate a 1” air gap on the fill water line to prevent backflow. It is recommended that a drain air gap fitting be installed by a non-Carnes contractor to prevent backflow of water. Carnes offers an air gap fitting as a purchased option.

12. The humidifier cabinet(s) shall be constructed of 304 B 20 gauge stainless steel and shipped with a protective film. The cabinet door shall be hinged and provided with a lock and key. The main door is

13. The humidifier(s) shall be controlled by a humidistat which operates

Option: Provide the following accessory controls: a. Wall mounted humidistat, on/off control. b. Wall mounted humidistat, w/ LCD combo. c. Duct mounted humidistat, on/off control. d. Duct mounted humidistat, proportional control. e. Duct mounted humidistat w/digital humidity and temperature,

f. High limit duct mounted humidistat, on/off control. g. High limit duct mounted humidistat, proportional control. h. Pressure differential type air flow switch. i. Paddle type air flow switch. j. Wall or duct mounted temperature compensated, on/off or

14. External Control Signals - All Carnes humidifiers will accept

Option: CarnesLink offers the ability to monitor and control Carnes

15. The fill water line shall include a strainer to remove sediment

16. Humidifier(s) shall include a “Service Required” button (illuminated

17. Dedicated buttons with indicator lights on the steam page of the

18. The humidifier(s) electronic circuit board shall include

19. The humidifier(s) shall include a non-water contact capacitance

20. The fill solenoid valve shall open whenever the drain solenoid is

21. Humidifiers, dependent upon capacity, will have one (1) or two (2)

22. Automatic Drain of cylinder water will take place when there is a

also provided with a quick release pin for removal to provide easy access to internals. The True Touchscreen Home Page will show a digital LCD steam output meter calibrated in pounds of steam per hour (kg of steam per hour selection is included as a built in option), fill cycle, drain cycle and high water indicator lights will be visible with the cabinet door closed.

through the circuit board. Humidifier(s) shall incorporate terminals for connection of humidistat, air flow switch and high limit control humidistat.

combo.

proportional control, digital display humidistat.

external DDC control signals of 0-10 volt DC. Signal to modulate the output of humidifier. Polarity must be observed and input impedance is 20 kilo-ohms. If 4-20 mA signal is provided a 470 ohm, 1/4 watt resistor must be installed. Humidifiers will also accept internal (BMS) building management system or (BAS) building automation system signal.

humidifier(s) (“H” Series and newer) by allowing the humidifier(s) to link to your Building Management System (BMS) using communication protocols; BACnet® (MS/TP), Modbus® (RTU), Metasys® (N2) and Siemens® (FLN). CarnesLink uses a communication chip that is factory installed on our electronic circuit board, mounted internally inside the humidifier(s) cabinet. The electronic circuit control board has a translucent protective conformal coating that protects the electronic components on the board. Features include: Oxidation Resistant, Ozone Resistant, Thermal Resistant, UV Resistant, Water Resistant, high temperature stable, low temperature stable and operational temperature range -45°C to 200°C.

from incoming water and a flow regulating control to automatically compensate for water pressures from 20-120 psi.

in RED) on the total “True Touchscreen” home page which shall explain service issues and possible troubleshooting tips. The light shall be visible with the cabinet door closed and terminals shall be provided for remote signal. Terminals are also provided to indicate normal operation to a remote location.

total “True Touchscreen” shall indicate status of the control humidistat, high limit humidistat, air flow switch and door interlock switch. Operation of fill solenoid, drain solenoid, power contactor and high water sensor shall be shown after accessing the “Component Activity” button on the home page of the total “True Touchscreen”.

automatic controls to compensate for varying water conditions without changing cylinders or electrode spacing. The control shall activate the fill and drain solenoid valves to automatically maximize efficiency. Unit will perform system self-correction procedures to assist in preventing unit shut-down due to any fault in operational sequence. A drain pulsing feature is included to assist in expelling any blockage that may occur during a self-correcting drain cycle. If self-correction procedures are unable to correct problems after specific cycles, unit will automatically shut-down.

proximity high water sensor to prevent overfilling and loss of water.

activated, whether in automatic or manual operation, to prevent discharge of boiling water into drainage system. Drain light shall indicate the switch is in drain position.

cylinders for operation. If a capacity is desired of 125, 150, 175 or 200 lb./hr., the units will be equipped with two (2) cylinders, each independently and separately controlled by their own control signal.

demand signal loss for 72-hour drain setting is turned on. Unit will remain in stand-by in the event that a quick startup is required.

Page 43

HUMIDIFIER MAINTENANCE CHECKLIST:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

CYLINDER/SYSTEM CHECK:

• “Service Required” warning (Cylinder Life Counter) yes  no

• Fault cylinder spent yes  no (If panel displays “Service Required” warning and the warning states “Cylinder near end of life” the cylinder will need to be

replaced soon.)

• Orange LED on with high water warning yes  no (If orange LED is on with High Water Warning and cylinder is not new, cylinder may have to be replaced soon.)

• Other warnings or faults shown in display yes  no (See Troubleshooting chapter for actions to address warnings and faults if present.)

REPLACE CYLINDER:

• Drain cylinder, first with water shutoff open yes  no

• Drain cylinder, next with water shutoff closed yes  no

• Disconnect open, On/Off switch is off, water shut off closed yes  no

• Remove cylinder yes  no

• Drain valve removed/cleaned/new O-ring yes  no

• Optionally added lubricating sealant to O-ring (C series only) yes  no

• Drain valve installed/ground wire attached yes  no

• New cylinder installed and hose clamps tightened yes  no New cylinder model # _____________________________ (Should be same as removed cylinder.)

 



       

• Cylinder plug numbers match cylinder numbers yes  no

• Cylinder plugs snug and in good condition yes  no

• Electrical wiring not loose and in good condition yes  no

• Steam and condensate hoses in good condition/no kinks in hose yes  no

• No signs of water leaking around humidifier, internal plumbing, steam line, condensate returns yes  no

• Door replaced, water shut off valve opened, On/Off switch to on, disconnect closed yes  no

• “Reset Cylinder Life Counter” in settings. (Settings password: 1212) yes  no

Started by: ________________________________________ Date of Startup: ___________________

Company: ________________________________________

   



 

Page 44

PREVENTATIVE MAINTENANCE:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

PREVENTATIVE MAINTENANCE: RECOMMENDED MONTHLY PREVENTATIVE MAINTENANCE FOR HUMIDIFIERS

Service contractor or maintenance agent - be prepared to:

1. Investigate and observe.

2. Recognize issues.

3. Determine procedures.

4. Implement solutions.

5. Inform customers.

Preventative maintenance is not intended to replace quality manufacturing and assembly from the company of origin. Products get older, wear and tear occurs, personnel changes and simple attention to detail sometimes become lax. Basic preventative maintenance for humidifiers should be required follow-up for continued proper operation of products. Preventative maintenance is a means to prevent future costly failures. The following are recommended preventative maintenance procedures for humidifiers on a monthly basis:

PLEASE FOLLOW ALL REQUIRED SAFETY PROCEDURES BEFORE WORKING ON HUMIDIFIER UNITS.

1. Visually inspect steam hose(s) and condensate hose(s) for proper routing and installation from humidifier unit. Prevent sags, dips, or kinks in hoses. Eliminate horizontal runs. Make sure there is an adequate slope up for the steam hose and slope down for the condensate return. Correct as necessary. Recommend no hose lengths longer than 10 feet. Refer to earlier pages of this IOM.

2. Visually inspect steam hose and condensate attachment to dispersion pipe or short absorption manifold. Recommend periodic removal of dispersion systems for inspection (restricted dispersion holes, damage, plumb mounting, and clamping tightness).

3. Humidifier unit - inspect internal hoses for sediment build up or degradation. Clean or replace as necessary. Also, check tightness of hose clamps. Tighten as necessary.

4. Inspect fill valve strainer. Industrial/commercial unit fill valve strainer is located at the connection point of the water inlet hose to valve. Strainer is located inside the valve at the threads. Pop out using a non-sharp tool and inspect. Clean or replace as necessary.

5. Visually check operation of the drain solenoid valve, smooth operation and 100% seal when normally closed. If necessary, remove solenoid valve, disassemble and clean or replace as necessary.

6. Visually check the cylinder for extreme amounts of residue on the inside surface. Very high levels of water or the unit unable to provide full capacity may be an indication that the cylinder is at the end of its life. Do not attempt to clean out with chemicals; do not stick screwdrivers or other objects into cylinder to clean out sediment. These cylinders are made to be replaced at end of life cycle. Life cycle of a cylinder is often determined by the condition of the water used in the unit, especially hardness, % of max output, or run time (24/7, 8 hr./day, etc.). Refer to this IOM or main humidifier catalog for more information.

7. Visually and manually check all wires and connections inside the unit. Include inspecting the wire connections to the top of the cylinder. If a red 90° connector is used, be sure to check the inside of the connector for a set screw. This screw needs to be checked for tightness. Make sure control wires at the J16, J17 and J18 terminal connections, bottom of the circuit board, are tight.

8. Monthly - remove drain air gap and check for any sediment buildup that may block any free flow of water. These check points for the “H” series humidifier are basic, but significantly covers the entire unit.

Keeping a preventative maintenance record would be recommended to show maintenance performed and any observations made during inspection.

Page 45

EXTENDED SHUTDOWN/STARTING AFTER EXTENDED SHUTDOWN:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

EXTENDED SHUTDOWN

During long periods of humidification downtime, the cylinder should be completely drained and emptied.

1. Manually push the On/Off rocker switch to drain.

2. Wait until the humidifier is completely drained of water.

3. Turn the On/Off rocker switch to the “OFF” position.

4. Shut off the main external power to the humidifier unit.

5. Turn the supply water off at the shut-off valve.

CARNES RECOMMENDS THAT THE CYLINDER REMAIN EMPTY DURING EXTENDED SHUTDOWN

NOTE:

STARTING AFTER EXTENDED SHUTDOWN

1. Inspect the humidifier for any damage. Check to make sure the mounting and installation has not been altered.

2. Turn on the main external power to the humidifier unit.

3. Turn the On/Off rocker switch to the “ON” position.

4. Review and follow the startup procedure in the IOM.

PERIODS. THIS WILL PREVENT THE POSSIBILITY OF CORROSION OF THE ELECTRODES AND THE ACCUMULATION OF ALGAE AND BACTERIA GROWING IN THE CYLINDER.

Page 46

REPLACEMENT CYLINDER:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

The label on the existing cylinder identifies the cylinder model. When ordering, please quote the 7, 8 or 9 digit model number from the cylinder label. You will also need to provide the humidifier model number and serial number (located on the sticker on the front of the unit).

Electrode Pin

Connect number coded

cylinder plugs to the

corresponding

numbered pins.

Steam Outlet

Secure steam hose

outlet with hose clamp.

Cylinder Label

This label identifies

the cylinder model and

ordering information.

CARNES RECOMMENDS THAT THE CYLINDER REMAIN EMPTY DURING EXTENDED SHUTDOWN

NOTE:

PERIODS. THIS WILL PREVENT THE POSSIBILITY OF CORROSION OF THE ELECTRODES AND THE ACCUMULATION OF ALGAE AND BACTERIA GROWING IN THE CYLINDER.

Page 47

REMOVING THE CYLINDER:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

• Disconnect power (external shut-off) before servicing.

WARNING

1. Completely drain the existing cylinder (flip On/Off rocker switch to “Drain).

2. Turn off water supply at the shut-off valve.

3. Turn the humidifier off (flip On/Off rocker switch to “OFF”).

4. Turn main power “Off” at the external shut-off.

5. Remove all terminal plugs from the cylinder.

6. Loosen the steam hose clamp and remove the steam hose from the cylinder.

7. (Using a flat head screwdriver) Remove the cylinder strap, keeping the cylinder in place.

8. A and B sized cylinders are threaded. Unscrew the cylinder (counter clockwise) and lift up and out.

9. C sized cylinders are seated into the brass plumbing with an O-ring. Just lift up and out.

• CAUTION: cylinder may be hot.

• Compartments contain high voltage wiring.

Fill Cup

Lock

Steam Hose Electrode Connector

Drain Valve

On-Off-Drain Switch

LCD

Door Interlock Switch

Circuit Breakers

Cylinder

Cylinder Fitting

Page 48

INSTALLING THE CYLINDER:

Unit Serial #: _____________________ No. of Humidiﬁ ers: ______________________________________________

Model #: _________________________________ Voltage: _______ V/ ___ Ph. Steam Output: _______ lb./hr.

Customer/Job: ___________________________ Address: ______________________________________________

• Keep power off (external shut-off) until cylinder is in place and

1. Insert cylinder into brass cylinder fitting.

2. A and B style cylinders are threaded. Verify there is Teflon tape on the threads and do not over tighten.

3. C sized cylinders have no threading, verify the two O-rings are present and set the cylinder fully.

4. Secure the cylinder with the white cylinder straps (not labeled).

5. Do not over tighten as this may damage the cylinder.

6. Connect the terminal wires to the electrodes so that the numbers match those on the cylinder. Push the plugs onto the pins to ensure the electrode plugs are firmly in place.

7. Place the steam hose onto the steam outlet and tighten the steam hose clamp.

8. Turn main power “On” at the external shut-off.

9. Turn on the water supply at the shut-off valve.

10. Turn the humidifier on (flip On/Off rocker switch to “ON”).

WARNING

reconnected.

• Compartments contain high voltage wiring.

Fill Cup

Lock

Steam Hose Electrode Connector

Drain Valve

On-Off-Drain Switch

LCD

Door Interlock Switch

Circuit Breakers

Cylinder

Cylinder Fitting

Page 49

WARNING

“AX” Cylinder

“B” Cylinder

UNAUTHORIZED MODIFICATION OF THIS HUMIDIFIER OR USING UNAUTHORIZED REPLACEMENT PARTS MAY CAUSE MALFUNCTION WITH RISK OF SERIOUS PERSONAL INJURY AND WILL VOID ALL PRODUCT WARRANTIES.

REPLACEMENT CYLINDER ORDER FORM

Name: ___________________________________________________

Company: ________________________________________________

Address: _________________________________________________

City: ____________________State/Province: _____ Code: ________

Phone: __________________ Email: __________________________

Part # Cylinder Humidiﬁ er Speciﬁ cations Quantity

HXCBAX145 “AX” Contact Carnes Rep for more info.

HXCBAX220 “AX” 005/010 lb./hr. 120V 1 Ph.

HXCBAX380 “AX” 005/010 lb./hr. 208-277V 1 Ph.

HXCBAX500 “AX” Contact Carnes Rep for more info.

HXCBAX600 “AX” 005/010 lb./hr. 415-380V 1 Ph.

HXCBAX700 “AX” 005/010 lb./hr. 460-575V 1 Ph.

HXCBB380 “B” Contact Carnes Rep for more info.

HXCBB500 “B” 020/030 lb./hr. 208-277V 1 & 3 Ph.

HXCBB600 “B” 020/030 lb./hr. 380-415V 1 Ph.

HXCBB700 “B” 020/030 lb./hr. 460-575V 1 & 3 Ph.

HXCBC12 “C” 080/200 lb./hr. 380-575V 3 Ph.

HXCBC6F “C” Contact Carnes Rep for more info.

HXCBC6X “C” Contact Carnes Rep for more info.

HXCBC61 “C” Contact Carnes Rep for more info.

HXCBC62 “C” 030/100 lb./hr. 208-277V 1 & 3 Ph.

HXCBC63 “C” Contact Carnes Rep for more info.

HXCBC64 “C” Contact Carnes Rep for more info.

HXCBC65 “C” 030/060 lb./hr. 380-575V 1 & 3 Ph.

Cylinders can be ordered directly from your local agent. You can also fill out this form and email it directly to Carnes at [email protected]. We will have

“C” Cylinder

“Due to ongoing research and development CARNES reserves the right to change specifications without notice.”

your agent contact you. Thank you for choosing Carnes Humidifiers.

MODEL LBS/HR

SERIAL NO. CODE

POWER SUPPLY VAC HZ PH. AMPS

Requested information is located on a label on the outside of the humidifier cabinet on the lower left corner.

Page 50

REPLACEMENT PARTS

SEE TABLE 2 FOR STEAM CYLINDER SELECTION

3 4

TYPE “AX” TYPE “B” TYPE “C”

Page 51

REPLACEMENT PARTS (Table 8)

Item # Description Models Where Used Part #

1 CIRCUIT BOARD WITH TOUCHSCREEN DISPLAY ALL SEE TABLE 10 2 ON-OFF-DRAIN SWITCH ALL H-999-7331 3 POWER TRANSFORMER ALL SEE TABLE 9 4 CONTACTOR ALL SEE TABLE 9 5* CIRCUIT BREAKER (optional) HT MODELS ONLY SEE TABLE 9 6 FILL SOLENOID VALVE WITH COIL AND STRAINER ALL H-999-7488 7 MOLDED FILL CUP ALL H-690-4138 8* DOOR PIVOT RELEASE ALL H-999-9143 9 METAL HOSE CLAMP ALL H-999-7165 10 HIGH WATER SENSOR SUB-ASSEMBLY ALL H-690-1355 11 WATER FILL TUBE SUB-ASSEMBLY (Single Cylinder) 11 WATER FILL TUBE SUB-ASSEMBLY (Dual Cylinder)

H_AH, H_DH, H_GH H_HH

H-690-1672

H-690-1671

12 CLEAR HOSE 5/8” ID ALL HXLA 13* PLASTIC ELBOW 5/8” HOSE TO 5/8” HOSE ALL H-999-9690 14 DRAIN SOLENOID VALVE H_GH H-999-7448 14 DRAIN SOLENOID VALVE H_HH H-690-1091 R. H. 14 DRAIN SOLENOID VALVE

H_AH, H_DH, H_HH

H-690-1092 L. H. 17 “AX” CYLINDER FITTING H_AH H-998-5703 17 “B” CYLINDER FITTING H_DH H-998-5715 17 “C” CYLINDER FITTING H_GH, H_HH H-998-5716 18

BRASS ELBOW 3/8” NPT TO 5/8” HOSE BARB

ALL H-999-3869 19* PLASTIC “T” 5/8” HOSE TO 5/8” HOSE TO 5/8” HOSE ALL H-999-3863 20* TERMINAL CONNECTOR WITH WIRE** ALL SEE TABLE 9 21 WATER INLET FITTING ALL H-999-4055 22 POWER DISTRIBUTION BLOCK ALL SEE TABLE 9 23 CURRENT SENSING TRANSFORMER ALL H-999-9429 24 DOOR INTERLOCK SWITCH ALL H-801-7801 25 LOW VOLTAGE WIRING HARNESS 25 LOW VOLTAGE WIRING HARNESS

H_AH, H_DH, H_GH (purchased after 9/1/15) H_AH, H_DH, H_GH (purchased prior to 9/1/15)

H-998-7024

H-998-7025 25 LOW VOLTAGE WIRING HARNESS H_HH H-998-7029 26* STRAIGHT BRASS FITTING 3/8” NPT WITH BARB H_AH H-999-4058 27* PLASTIC “U” TUBE H_AH, H_DH, H_GH H-998-5699 27* PLASTIC ELBOW H_HH H-998-5700 28* DRAIN FITTING TUBE ALL H-999-6469 29 DOOR LOCK WITH KEY ALL H-999-9141 30* FLEXIBLE CLEAR PLASTIC 5/8” ELBOW ALL H-999-9833 31* FLEXIBLE CLEAR PLASTIC 5/8” “U” TUBE ALL H-999-9834

* = Not Shown

REPLACEMENT PARTS (Table 9)

Max.

Model

Lb./Hr. Ph. Volts

H_AHA 5 1 120 AX220 998-9537 999-7389 690-3019 999-7406 999-8035 H_AHB 5 1 208 AX380 998-9537 999-7389 690-3019 999-7405 999-8035

H_AHD 5 1 230 AX380 998-9537 999-7389 690-3019 999-7406 999-8035

H_AHF 5 1 277 AX380 998-9535 999-7389 690-3019 999-7405 999-8035 H_AHL 5 1 380 AX600 998-9535 999-7389 690-3019 999-7405 999-8035

H_AHQ 5 1 415 AX600 998-9535 999-7389 690-3019 999-7405 999-8035

Steam

Cylinder

Power

Transformer

Item #3

Contactor

Item #4

Terminal Connector with Wire*

Item #20

Circuit

Breaker

Item #5

Power

Distribution

Block

Item #22

Page 52

REPLACEMENT PARTS (Table 9) - Continued

Power

Model

Max.

Lb./Hr. Ph. Volts

Steam

Cylinder

Transformer

Item #3

Contactor

Item #4

H_AHM 5 1 460 AX700 998-9537 999-7389 690-3019 999-7405 999-8035

H_AHN 5 1 575 AX700 998-9539 999-7389 690-3019 999-7412 999-8035 H_AHA 10 1 120 AX220 998-9537 999-7480 690-3019 999-7409 999-8035 H_AHB 10 1 208 AX380 998-9537 999-7389 690-3019 999-7407 999-8035 H_AHD 10 1 230 AX380 998-9537 999-7389 690-3019 999-7407 999-8035

H_AHF 10 1 277 AX380 998-9535 999-7389 690-3019 999-7406 999-8035 H_AHL 10 1 380 AX600 998-9535 999-7389 690-3019 999-7405 999-8035

H_AHQ 10 1 415 AX600 998-9535 999-7389 690-3019 999-7405 999-8035

H_AHM 10 1 460 AX700 998-9537 999-7389 690-3019 999-7405 999-8035

H_AHN 10 1 575 AX700 998-9539 999-7389 690-3019 999-7412 999-8035 H_DHB 20 1 208 B380 998-9537 999-7480 690-3019 999-7410 999-8035 H_DHD 20 1 230 B380 998-9537 999-7480 690-3019 999-7407 999-8035 H_DHF 20 1 277 B380 998-9535 999-7389 690-3019 999-7409 999-8035

H_DHL 20 1 380 B600 998-9535 999-7389 690-3019 999-7408 999-8035 H_DHQ 20 1 415 B600 998-9535 999-7389 690-3019 999-7407 999-8035 H_DHM 20 1 460 B700 998-9537 999-7389 690-3019 999-7406 999-8035

H_DHN 20 1 575 B700 998-9539 999-7389 690-3019 999-7412 999-8035 H_DHC 20 3 208 B500 998-9537 999-7389 690-3019 999-7407 999-8035 H_DHE 20 3 230 B500 998-9537 999-7389 690-3019 999-7407 999-8035

H_DHT 20 3 380 B600 998-9535 999-7389 690-3019 999-7405 999-8035 H_DHW 20 3 415 B600 998-9535 999-7389 690-3019 999-7405 999-8035 H_DHG 20 3 460 B700 998-9537 999-7389 690-3019 999-7405 999-8035

H_DHH 20 3 575 B700 998-9539 999-7389 690-3019 999-7412 999-8035

H_DHC 30 3 208 B500 998-9537 999-7480 690-3019 999-7409 999-8035

H_DHE 30 3 230 B500 998-9537 999-7389 690-3019 999-7409 999-8035

H_DHT 30 3 380 B600 998-9535 999-7389 690-3019 999-7407 999-8035 H_DHW 30 3 415 B600 998-9535 999-7389 690-3019 999-7406 999-8035 H_DHG 30 3 460 B700 998-9537 999-7389 690-3019 999-7406 999-8035

H_DHH 30 3 575 B700 998-9539 999-7389 690-3019 999-7412 999-8035

H_GHB

30 1 208 C62 998-9537 999-7389 (2) 690-3019 999-7401 999-8035

H_GHD 30 1 230 C62 998-9537 999-7480 690-3046 999-7411 999-8035

H_GHF 30 1 277 C62 998-9535 999-7480 690-3046 999-7410 999-8035

H_GHL 30 1 380 C62 998-9535 999-7480 690-3046 999-7409 999-8035 H_GHQ 30 1 415 C62 998-9535 999-7389 690-3019 999-7409 999-8035 H_GHM 30 1 460 C62 998-9537 999-7389 690-3019 999-7408 999-8035 H_GHN 30 1 575 C62 998-9539 999-7389 690-3019 999-7414 999-8035 H_GHC 40 3 208 C62 998-9537 999-7480 690-3046 999-7411 999-8035

H_GHE 40 3 230 C62 998-9537 999-7480 690-3046 999-7410 999-8035

H_GHT 40 3 380 C65 998-9535 999-7389 690-3019 999-7408 999-8035

H_GHW 40 3 415 C65 998-9535 999-7389 690-3019 999-7408 999-8035

H_GHG 40 3 460 C65 998-9537 999-7389 690-3019 999-7407 999-8035 H_GHH 40 3 575 C65 998-9539 999-7389 690-3019 999-7413 999-8035 H_GHC 50 3 208 C62 998-9537 999-7389 (2) 690-3019 999-7409 (2) 999-8035

H_GHE 50 3 230 C62 998-9537 999-7480 690-3046 999-7401 999-8035

H_GHT 50 3 380 C65 998-9535 999-7480 690-3046 999-7409 999-8035

H_GHW 50 3 415 C65 998-9535 999-7389 690-3019 999-7409 999-8035

H_GHG 50 3 460 C65 998-9537 999-7389 690-3019 999-7408 999-8035 H_GHH 50 3 575 C65 998-9539 999-7389 690-3019 999-7414 999-8035

H_GHC H_GHE

60 3 208 C62 998-9537 999-7480 (2) 690-3046 999-7401 (2) 999-8035

60 3 230 C62 998-9537 999-7389 (2) 690-3019 999-7401 (2) 999-8035

H_GHT 60 3 380 C65 998-9535 999-7480 690-3046 999-7410 999-8035

H_GHW 60 3 415 C65 998-9535 999-7480 690-3046 999-7409 999-8035

H_GHG 60 3 460 C65 998-9537 999-7389 690-3019 999-7409 999-8035

*H-690-3019 INCLUDES #10 WIRE. FOR RED CONNECTOR ONLY ORDER H-998-1256. H-690-3046 INCLUDES #8 WIRE. BLACK CONNECTOR ONLY IS NOT AVAILABLE.

* = Circuit Breaker is REQUIRED per NEC 48 amp guidelines.

Terminal

Connector

with Wire*

Item #20

Circuit

Breaker

Item #5

Power

Distribution

Block

Item #22

Page 53

REPLACEMENT PARTS (Table 9) - Continued

Model

Max.

Lb/Hr Ph. Volts Code

Steam

Cylinder

Power

Transformer

Item #3

Contactor

Item #4

Terminal

Connector

with Wire*

Item #20

Circuit

Breaker

Item #5

Power

Distribution

Block

Item #22

H_GHH 60 3 575 7060 C65 998-9539 999-7389 690-3019 999-7414 999-8035 H_GHC*80 3 208 2080 C62 998-9537 999-7480 (2) 690-3046 999-7403 (2) 999-8035 H_GHE

80 3 230 4080 C62 998-9537 999-7480 (2) 690-3046 999-7402 (2) 999-8035

H_GHT 80 3 380 3380 C12 998-9535 999-7480 690-3046 999-7411 999-8035

H_GHW 80 3 415 4380 C12 998-9535 999-7480 690-3046 999-7411 999-8035

H_GHG 80 3 460 6080 C12 998-9537 999-7480 690-3046 999-7410 999-8035

H_GHH 80 3 575 7080 C12 998-9539 999-7389 690-3019 999-7415 999-8035 H_GHC*100 3 208 2100 C62 998-9537 999-7480 (2) 690-3046 999-7403 (2) 999-8035 H_GHE*100 3 230 4100 C62 998-9537 999-7480 (2) 690-3046 999-7403 (2) 999-8035

H_GHT*100 3 380 3300 C12 998-9535 999-7389 (2) 690-3046

Contact Factory

999-8035

H_GHW 100 3 415 4300 C12 998-9535 999-7389 (2) 690-3019 999-7409 (2) 999-8035

H_GHG 100 3 460 6100 C12 998-9537 999-7480 690-3046 999-7411 999-8035

H_GHH 100 3 575 7100 C12 998-9539 999-7480 690-3046 999-7416 999-8035 H_HHC*125 3 208 2125 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7401 (4) 999-8035

H_HHE*125 3 230 4125 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7401 (4) 999-9524

H_HHT*125 3 380 3325 C12 (2) 998-9535 999-7480 (2) 690-3046 999-7402 (2) 999-8035 H_HHW*125 3 415 4325 C12 (2) 998-9535 999-7480 (2) 690-3046 999-7402 (2) 999-8035 H_HHG*125 3 460 6125 C12 (2) 998-9537 999-7480 (2) 690-3046 999-7401 (2) 999-8035

H_HHH 125 3 575 7125 C12 (2) 998-9539 999-7389 (2) 690-3019 999-7414 (2) 999-8035

H_HHC*150 3 208 2150 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7402 (4) 999-9524

H_HHE*150 3 230 4150 C62 (2) 998-9538 999-7480 (4) 690-3046 999-7401 (4) 999-9524

H_HHT*150 3 380 3315 C12 (2) 998-9535 999-7480 (2) 690-3046 999-7402 (2) 999-8035 H_HHW*150 3 415 4315 C12 (2) 998-9535 999-7480 (2) 690-3046 999-7402 (2) 999-8035 H_HHG*150 3 480 6150 C12 (2) 998-9537 999-7480 (2) 690-3046 999-7402 (2) 999-8035 H_HHH*150 3 575 7150 C12 (2) 998-9539 999-7389 (2) 690-3019 999-7414 (2) 9998-8035 H_HHC*175 3 208 2175 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7403 (4) 999-9524

H_HHE*175 3 230 4175 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7403 (4) 999-9524

H_HHT*175 3 380 3317 C12 (2) 998-9535 999-7480 (4) 690-3046

Contact Factory

999-9524 H_HHW*175 3 415 4317 C12 (2) 998-9535 999-7480 (2) 690-3046 999-7403 (2) 999-9524 H_HHG*175 3 460 6175 C12 (2) 998-9537 999-7480 (2) 690-3046 999-7403 (2) 999-8035 H_HHH*175 3 575 7175 C12 (2) 998-9539 999-7480 (2) 690-3046 999-7416 (2) 999-8035 H_HHC*200 3 208 2200 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7403 (4) 999-9524

H_HHE*200 3 230 4200 C62 (2) 998-9537 999-7480 (4) 690-3046 999-7403 (4) 999-9524 H_HHT*200 3 380 3321 C12 (2) 998-9535 999-7480 (4) 690-3046

H_HHW*200 3 415 4321 C12 (2) 998-9535 999-7480 (4) 690-3046

Contact Factory Contact Factory

999-9524

999-9524 H_HHG*200 3 460 6200 C12 (2) 998-9537 999-7480 (2) 690-3046 999-7403 (2) 999-8035 H_HHH*200 3 575 7200 C12 (2) 998-9539 999-7480 (2) 690-3046 999-7416 (2) 999-8035

* = Circuit Breaker is REQUIRED per NEC 48 amp guidelines.

CIRCUIT BOARD (Table 10)

Model Series Type Power Output Capacity Options 1 2 3 4 5 6 7 8 9 10

H X N A C G 0 5 0

H - Humidifier

X - Accessory

Design Board Nominal Steam

N - Circuit Board

A - H690-0080 B - H690-0106 C - H690-0107

VOLTAGE A - 115V, 1 Ph. B - 208V, 1 Ph. C - 208 V, 3 Ph. D - 230V, 1 Ph. E - 230V, 3 Ph. F - 277V, 1 Ph. G - 460V, 3 Ph. H - 575V, 3 Ph. M - 460V, 1 Ph. N - 575V, 1 Ph.

Lb/Hr 005 - 5#/Hr 010 - 10#/Hr 020 - 20#/Hr 030 - 30#/Hr 040 - 40#/Hr 050 - 50#/Hr 060 - 60#/Hr 080 - 80#/Hr 100 - 100#/Hr 125 - 125#/Hr 150 - 150#/Hr 175 - 175#/Hr 200 - 200#/Hr

A - BACnet MS/TP C - Modbus RTU D - Metasys N2 E - Siemens FLN

Page 54

WARRANTY

Seller warrants products manufactured by it and supplied hereunder to be free from defects in materials and workmanship under normal use and proper maintenance for a period of twelve months from date of shipment. If within such period any such products shall be proved to Seller’s reasonable satisfaction to be defective, such products shall be repaired or replaced at Seller’s option. Seller’s obligation and Buyer’s exclusive remedy hereunder shall be limited to such repair and replacement and shall be conditioned upon Seller’s receiving written notice of any alleged defects no later than 10 days after its discovery within the warranty period and, at Seller’s option, the return of such products to Seller, f.o.b. its factory, when such return is feasible. Seller reserves the right to satisfy its warranty obligation in full by reimbursing Buyer for all payments it makes hereunder, and Buyer shall thereupon return the products to Seller. Seller shall have the right to remedy such defects.

THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES (EXCEPT TO TITLE) INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, PERFORMANCE, OR OTHERWISE, and in no event shall the Seller be liable for claims (based upon breach of express or implied warranty, negligence, product liability, or otherwise) for any other damages, whether direct, immediate, incidental, foreseeable, consequential, or special.

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