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INSTALLATION INSTRUCTIONS & OWNER MANUAL
FIELD CONTROLS ELECTRONIC STEAM UNIT - POWER HUMIDIFIER
MODELS S2000 (120VAC) and S2020 (240VAC)
Application: Forced Air Ducted Furnaces, Heat Pumps and Air Handlers
The Steam Humidifier you have purchased has been designed to be simple to install, operate and maintain. Read this manual before you install the humidifier.
Figures 1 and 2 will assist you in installing and maintaining your Steam Humidifier. This product should be installed according to local and national codes and standards.
FIG 2
Parts included in Steam Humidifier package are: |
Options and additional parts recommended: |
1. Self-piercing Saddle Valve |
1. Water Hammer Arrester |
2. Installation Instructions and Owner’s Manual |
2. Anode |
3. Mounting Templates x2 |
3. Decorative Under Duct Cover |
4. Installation Hardware Package |
4. Gasket Material to seal flanges (installer provided) |
5. Insulation and Tape |
5. Model APD Current Sensing Switch, or other Airflow Proving Switch. |
6. Automatic Drain Assembly (Shipped loose) |
6. Steam Treament Water Cartridge |
7. Humidistat - Model #072000 (if ordered) |
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8. 1/2” I.D. Drain Hose - 8 ft |
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9. Anode #Z100 (located on lower flange of tank baffle) |
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Electronic Steam Unit - Power Humidifier
Table of Contents |
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Specifications ................................................................................................................................ |
2 |
Simplified Installation Instructions ........................................................................................ |
3 |
Detailed Installation Instructions ........................................................................................... |
3 |
Control Wiring Solutions .................................................................................................. |
5, 6, 9 |
Dimensional Data ........................................................................................................................ |
7 |
Air Ramp ......................................................................................................................................... |
8 |
Variable Speed Wiring Diagram ............................................................................................. |
9 |
Relative Humidity Chart ............................................................................................................ |
9 |
Initial Start-Up Sequence ........................................................................................................ |
10 |
Start-Up/Service Indicators ........................................................................................ |
10, 11, 12 |
Service and Replacement Parts ............................................................................................ |
13 |
Model 07200Smart Digital Humidistat ............................................................................ |
14 |
OAS - Outside Air Sensor ................................................................................................... |
16-19 |
Anode Assembly (Z100)........................................................................................................... |
20 |
Decorative Cover (SC100)....................................................................................................... |
21 |
Water Hammer Arrester (WH-100)........................................................................................ |
22 |
Water Conditioning System (WC-25).................................................................................... |
23 |
Air Proving Device (ADP) ........................................................................................................ |
24 |
Inside Duct Mounting Bracket (IDB).................................................................................... |
25 |
Under Duct Mounting Bracket (UDB)................................................................................. |
26 |
Water Level Probe Replacement ......................................................................................... |
27 |
Water Fill Valve Replacement ............................................................................................... |
28 |
page 2
SIMPLIFIED INSTALLATION INSTRUCTIONS
1.Inspect water probe assembly
2.Assemble and install drain valve assembly.
3.Insulate the water reservoir. See Figure 3.
4.Select the mounting location on the duct and tape on the mounting template.
5.Drill the (8) 1/8” mounting holes.
6.Cut out the humidifier opening in the duct.
7.Insert the humidifier into the opening and screw in place.
8.Connect the drain line.
9.Flush and connect the water line.
10.Make 24VAC electrical connections to achieve fan operation and Interlock circuit.
11.Install and connect to humidistat.
12.Plug power cord into a grounded dedicated 120VAC, 20 amp outlet for S2000 (240VAC, 15amp for S2020).
DETAILED INSTALLATION INSTRUCTIONS
1.CHECK WATER PROBE ASSEMBLY
Before installing drain valve assembly, inspect water probe assembly. Heater element should be ¼” away from the brass water temperature sensor. The wire probe must be vertical (pointing towards bottom of reservoir). Check for alignment of probe assembly prior to installation. Probe may have been shifted in position or become loose during shipping. Probe assembly must be tight and should not rotate. If loose, remove cover and tighten water probe nut. Refer to probe supplement insert on page 28.
2.ASSEMBLE/INSTALL DRAIN VALVE ASSEMBLY (See figure 18)
Before assembling the drain valve assembly, apply water
tight sealant to all metal to metal connections. Connect the drain cock valve to the “T” adapter, then the “T” adapter to the solenoid. Connect the barbed tee to the solenoid and then connect the overflow tube. After installation, insert the
Molex plug into the right side of the |
steam |
humidifier |
control panel socket. |
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3. INSULATE WATER TANK RESERVOIR |
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With insulation foil side down, remove |
adhesive |
backing. |
Align humidifier so that front side of unit meets long edge of insulation. Fold insulation up onto sides of humidifier and press firmly. Apply 5 continuous strips from the tape provided to seal the foil as shown. The tape will prevent the sharp duct edges from damaging the foil. Use additional foil tape to repair damage to the foil. The Insulation MUST be applied to the tank regardless of the mounting location.
FIG 3
INSULATION (FOIL SIDE OUT)
USE TAPE TO SEAL THE FOIL TO THE FRONT
MOUNTING PLATE
(3 PLACES-SIDE AND BOTTOM) 
USE TAPE TO SEAL OUTSIDE EDGE OF THE FOIL (2 PLACES)
4. LOCATION - Required Criteria
DO NOT INSTALL this unit in an attic period. Do Not Install this unit in any area that may fall below 35 degrees F.
Installing unit in area 35°F or less will void your warranty!
The steam humidifier can be installed in either the warm air supply or the cold air return ducts; however the preferred location would be in the warm air supply duct of the system. This humidifier does not require warm air to evaporate the water in order to provide humidity, but it will operate more efficiently in the warm air duct and condensation is less likely to occur on the surrounding cold surfaces. Efficiency is lost in a return air duct location.
When selecting a location on the duct, be certain that there is enough room in the duct for the water reservoir. There should be at least five (5) inches above the reservoir and the reservoir should not occupy more than about 25 percent of the duct space. If this criteria cannot be met, you should install the unit under the duct by means of the tank flange. See Figure 13 and UDB supplement insert on page 27.
If a suitable means of gravity draining the unit is not available or cannot be provided, the unit will work with the drain valve electrically disconnected. Call the Technical Support Hotline for Instructions.
It is highly recommended but not required that the use of Fiberglass duct-board with this product includes an antimicrobial treatment.
5.WEIGHT - Required Criteria
Providing Adequate Structural Support for this unit is the responsibility of the Installer. It is recommended to reinforce the cut openings with folded lengths of sheetmetal to provide rigidity to the duct opening.
Now the screws must pass through 3 layers of metal when inserted. DO NOT install this unit into fiberglass duct without adequate structural support! Both models weigh approximately 9 lbs. empty and 15 lbs when full of water.
6. MOUNTING TEMPLATES
Two mounting templates are provided. Choose the correct template for your mounting method. Tape the mounting template to the duct. The template must be leveled using the top of the cutout on the template.
The template should be located so that the bottom of the
page 3
reservoir cut-out is flush with the inside of the bottom of the duct for horizontal duct mount. Most ducts are insulated allow for additional space, about one (1) inch, must be accounted for when determining the location for the bottom of the reservoir cut-out. If you are mounting it under the duct, make sure the duct is level.
7.DRILL HOLES AND CUT OPENINGS
Safely predrill eight 1/8” diameter mounting holes in the duct. These can be drilled through the template at the locations indicated on the template.
Safely remove the air duct material by cutting along the mounting template cut lines.
Insert and/or mount the Humidifier and secure it to the duct with the provided screws.
FIG 4
CUT ON LINE
MOUNTING TEMPLATE
MODEL S2000 & S2020
1. TAPE TEMPLATE IN LEVEL POSITION.
2. DRILL (8) HOLES FOR SHEET METAL SCREWS SHOWN ON TEMPLATE (DO NOT DRILL LARGER THAN 1/8” DIAMETER.
3.USE SOLID LINE TO CUT OUT OPENING FOR HUMIDIFEIR
4.MOUNT HUMIDIFIER PER INSTRUCTION.
CUT ON LINE
/N0 94021B0037
8.WATER SUPPLY - Required Criteria
A.WATER SUPPLY USING THE SADDLE VALVE FURNISHED WITH UNIT.
Installation instructions for the saddle valve are printed on the plastic bag containing the saddle valve and its components. Tap into a 1/2” or 3/4” domestic cold water line. Avoid connecting to water lines from a Reverse Osmosis system or De-ionized water systems. The supply water must read a minimum of 25 ppm in order for the Steam unit to reliably sense the water.
NOTE: Never install the saddle valve on the bottom of the water pipe. Sediment in the water pipe may clog the saddle valve. Flush the line before connecting to the unit. When tightening the hex compression nut, tighten only enough to assure there are no leaks.
NOTE: Saddle valves do not meet plumbing codes in some areas. A “T” fitting with a valve may be required to meet code or, if low water pressure causes frequent water alerts on the steam humidifier.
NOTE: Flush the new water line before connecting it.
NOTE: The use of City water or Municipal water is preferred. Softened water is preferred over untreated well water. Specify the Optional WC-25 disposable water filter for treating any water supply that is very high in mineral content. Refer to water conditioning system supplement insert information on page 24.
NOTE: Use optional water hammer arrester (WH-100) if water spikes occur (pipes bang) during fill ups. Refer to water hammer arrester supplement insert information on page 23.
B. OVERFLOW & DRAIN LINES - Required Criteria
The use of an overflow line and drain line is always required. Use the supplied 1/2” ID high temperature hose. Slip the hose over the 1/2” OD “T” drain fitting and use a hose clamp to secure. Route the hose to a suitable drain, avoiding kinks, traps and sharp objects. DO NOT route the hose above the humidifier. Failure to install all necessary drain lines may result in water leaks during normal operating conditions, and voids all warranties.
When routing the S2000 drain hose into a condensate pump, be sure to cut the end of the hose at a sharp angle to prevent the hose from bottoming out in the pan. It could result in poor draining or no draining at all. Failure to do so may result in water backing up into the S2000 reservoir and eventual overflow. See Figure 5.
CORRECT DRAIN HOSE INCORRECT
COMPENSATE
PUMP
FIG 5
9. MOUNTING THE STEAM HUMIDIFIER
Use gasket material to seal where the front plate or tank flange contacts the duct-work. Place the humidifier reservoir into the opening in the duct and secure with eight
(8) sheet metal screws. Refer to page 8 and 9 for additional humidifier mounting location information.
NOTE: If the duct-work will not support the unit in a level position with the reservoir full of water, the duct-work must be reinforced. Both steam models weigh approximately 9 lbs. empty and approximately 15 Lbs. when full of water.
10. STEAM OPERATION - Required Criteria
Because of the high humidity output of the steam humidfier, it must not be operated without proper fan operation. The steam humidifier is designed to be "Dominant" over the HVAC System Blower. The "System" Blower will be operated by the humidifier when the water tank temperature reaches 170° F. A minimum of 800 cfm @ 800-900 fpm is required for proper operation of the steam humidifier. Lower velocities may result in excessive condensation inside the duct. See Air Proving Feature under section 11 B. See Variable Speed on Page 9.
A temperature sensor is mounted in the water reservoir of the humidifier. As the water temperature increases to about 170° F, the computer closes a set of blower relay contacts to start the HVAC system fan. When the water cools to about 140° F, the computer will open the relay contacts to shut off the fan. This operational sequence drastically decreases the chances of condensation occurring inside the duct-work.
page 4
11. WIRING THE STEAM HUMIDIFIER |
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Heat Only System and |
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IMPORTANT: Dedicated fused circuits and outlets of the |
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Steam Humidifier with standard |
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dry contact Humidistat |
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proper voltage and current ratings must be provided. Use a |
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NEMA 5-20R receptacle for the S2000 and a NEMA 6-15R |
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S2000 & S2020 Humidifier |
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receptacle for the S2020. All wiring must conform to local |
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Low Voltage Terminal Block |
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and national codes. |
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Heat |
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Failure to do so will void all warranties. |
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ONLY |
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R G2 H |
H |
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Thermostat |
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DO NOT cut off the grounded plug and/or hard wire this unit |
at R |
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to line voltage! DO NOT use extension cords to operate this |
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unit! Doing so will void all warranties. |
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Factory |
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A. INSTALLINGAND WIRING THE HUMIDISTAT |
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Jumper will |
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stay in place |
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A humidistat, such as the Model #072000 is required to |
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unless a field |
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installed Air |
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control the Steam Humidifier. The humidistat may be |
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Proving Device |
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R W |
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is used. |
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installed on the wall in the living space or on the return air |
Typical |
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Dry Contact |
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duct. NOTE: Continuous fan operation should be initiated |
Furnace |
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Humidistat |
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if the humidistat is installed on the return air duct! |
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062000 Humidistat |
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Instructions for installation are packaged with each |
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humidistat. Follow wiring instructions carefully! |
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DO NOT connect any foreign voltage to the “H” terminals |
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of the humidifier! The Humidifier supplies its own control |
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voltage. Simply connect the two “H” terminals straight to |
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any dry contact humidistat terminals. |
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If you are using a 3rd party Humidistat that has powered |
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terminals, you must use an isolating relay to operate the |
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Steam Humidifier. Failure to do so will result in circuit |
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board failure and will void all warranties. |
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B. |
FIELD WIRING |
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Schematics on the following pages describe the |
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suggested interlock wiring arrangement for different |
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HVAC systems. Interlocking may be performed on systems |
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that provide a 24VAC NEC Class 2 terminal block for system |
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control. |
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AIR PROVING FEATURE: The Steam Humidifier has an |
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integrated air proving feature that allows the user to install |
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a current sensing switch, airflow proving switch and/or |
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high humidity switch in the duct and easily achieve fail safe |
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shutdown in the event of fan/blower failure. This feature |
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prevents the Steam Humidifier from operating unless |
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adequate airflow is proven thereby avoiding a saturated |
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duct condition. Refer to Air Proving Device Current Sensing |
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Switch Supplement insert information on page 25. |
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WARNING: It is highly recommended to use an airf low |
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proving device. In particular Duct-Board applications |
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should always use an airflow proving device. |
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A factory jumper wire is provided and must be removed |
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when connecting the safety switch or other field supplied air |
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flow proving device. Leave the jumper in place if you |
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decide not to use the airflow proving feature. |
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IMPORTANT NOTE: If the Steam Humidifier is removed and |
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disconnected from the system, the blower interlock circuit |
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must be restored to its original configuration. Failure to do |
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so may result in loss of blower operation during cooling |
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mode. |
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page 5
CONTROL WIRING SOLUTIONS FOR VARIOUS HVAC SYSTEMS
Additional diagram shown on page 5
The latest improvement to the Field Controls humidifiers is the new “Airflow Interlock Feature” provided on the low voltage terminal block. Due to popular demand we have made it easier for you to achieve fail safe lockout in the event the fan or blower on the HVAC system does not operate when called upon. A high humidity or airflow proving device is necessary.
You must still determine the type of proving device you want to use. We recommend our new Model APD switch, (P/N: 090558A0001). Refer to APD Application Note contained in this manual. But then all you have to do is connect two low voltage wires from your air proving device straight to the Steam Humidifier’s “A” terminals. No additional field relays or components are needed.
The Steam Humidifier monitors the airflow circuit anytime it is operating the blower on the HVAC system. If the Steam Humidifier detects a loss of airflow longer than 1 minute, it will shutdown the heating element and stop producing eam to avoid saturating the duct.
You must test the air proving device when you install it to make sure it will function properly.
WARNING: DO NOT perform this test with the wires connected to the Steam Humidifier. Temporarily disconnect them. Refer to Figure 11.
AIR PROVING DEVICE TEST:
1.After installing the air proving device, test for continuity across the normally open contacts with the fan/blower off. You should read infinity (nocontinuity) when the fan/blower is off.
2.Turn on the fan/blower at the thermostat and test for continuity across the normally open contacts with the fan/blower running. You should now read continuity (a complete circuit) when the fan/blower is running.
page 6
12. HUMIDIFIER MOUNTING LOCATION
Figure 12 reflects the basic dimensions of the S2000 or S2020 Steam Humidifier. This data is useful in determining the room needed to install the unit in a certain location. The data can also be used to determine the minimum duct size the Steam Humidifier can be inserted into. The Steam Humidifier should not obstruct more than 25% of the cross sectional area of the selected duct. For Example: The humidifier tank measures 8 inches wide (including the flange) times the length of 11.6 inches=92.8 square inches. We are only concerned with the obstruction on a flat plane. Which is why the flange is taken into account but not the depth of the tank. This assumes an up-flow configuration. If the configuration is horizontal, then the Steam Humidifier will obstruct approximately 70 square inches of duct area. The tank flange is no longer a factor.
At 92.8 square inches, the smallest duct plenum that can accommodate the Steam Humidifier mounted internally would be approximately 20” by 19”. 20x19=380 square inches multiplied by .25 = 95 square inches.
Steam Humidifier square inches of obstruction= 92.8 square inches. Up-flow configuration. 25 percent of 20x19 duct= 95 square inches.
Steam Humidifier square inches of obstruction= 69.6 square inches. Horizontal-flow configuration. 25 percent of 12x24 duct=72 square inches.
In either case, avoid installing the Steam Humidifier on any duct size where the unit will consume more than 25% of the cross sectional area of the duct at the point of insertion. Doing so may result in turbulent airflow, lower velocities and condensation inside the duct. Avoid all of these conditions by selecting an “under the duct” location and specify the SC100 decorative tank cover to give it a finished look.
page 7
AIR RAMP
Improves velocity
AIR RAMP (FOR UNDERDUCT MOUTNING ONLY)
-FABRICATE FROM CORROSION-RESISTANT SHEET METAL (CUTOUT FROM METAL DUCT TO BE USED)
- ATTACH TO UPSTREAM EDGE OF CUTOUT
-DO NOT OBSTRUCT MORE THAN 25% OF THE DUCT AREA
Suitable locations to install your Steam Humidifier on an Up-flow or horizontal HVAC System. Notice that some of the locations are X’d
out. These are poor locations for the Steam Humidifier and may result
in lower capacity output and/or excessive condensation. Try to avoid mounting the unit within 2 feet of any 90 degree turns. Allow at least 5 inche s of clearance above the tank. The unit should not be installed within 5 feet of an Electronic Air Cleaner, 4-5 inch thick Media filters, or a UV Lamp.
Caution: UV lamps may destroy cer- tain plastics/rubber unless shielding is applied to those surfaces.
DO NOT install the Steam Humidifier on a Down-flow HVAC system. Avoid Fiberglass Duct-Board as it cannot support the weight of the Steam unit when full of water. DO NOT install the Steam Humidifier in an attic or crawl space exposed to freezing temperatures.
Remember to insulate the water reservoir with supplied insulation. under extreme velocities it m ay be necessary to double wrap the tank and/or the tank flange to prevent excessive heat loss. Also remember to use gasket material on duct opening to prevent metal to metal heat loss and to prevent against condensation and air leakage.
page 8
14.SETTING THE HUMIDISTAT
It is recommended that humidistat settings of 30-45% not be exceeded. If condensation is noticed on windows during very cold outside temperatures, the humidistat setting should be lowered.
The maximum recommended relative humidity for your home depends upon many factors such as outdoor air temperature, type and placement of insulation, vapor barriers, effectiveness of weather stripping, type of windows and doors (including frames and jambs) and whether or not storm windows and doors are used. With all these variables it is nearly impossible to recommend a proper humidity setting. The best humidistat setting is one that you are most comfortable with. Also, as the outdoor temperature fluctuates, it may be necessary to adjust the humidity level of your system a few times during the heating season.
Refer to the “Relative Humidity Chart” as a starting point for your proper humidistat setting. Generally, in a tighter and better insulated house, the humidistat may be set higher than in a drafty, un-insulated house.
IMPORTANT: If the humidifier is installed in the return air plenum the humidistat must be located at least five (5) feet upstream from the humidifier. Fan should be operated in continuous mode when the humidistat is mounted in the return air plenum. Mounting the humidistat on an interior wall is always preferable to mounting on the return duct. But mounting the humidistat on an interior wall takes more time, material and labor than a return duct location. Sometimes it may be impossible to mount a humidistat on an interior wall and the return duct location is the only solution.
Variable Speed WIRING DIAGRAM
FIG 15
RELATIVE HUMIDITY CHART
13. VARIABLE SPEED
The diagram above should be followed if it is required to operate the fan system at high speed during the humidify operation. Such a requirement may be necessary if condensation occurs inside the duct-work due to the lower velocities of a variable speed system when only the fan is running.
The “Y” circuit must be wired exactly as shown to achieve the correct operation. This wiring configuration may result in the loss of the “enhanced” latent effect operations of your variable speed HVAC system. If you do not want this to happen, you should consider installing a different type of whole house humidifier that does not require dominance over the HVAC fan and full CFM capacities while operating.
Variations on this diagram are available. Contact Field Controls Technical Support Hotline.
page 9
INITIAL START-UP SEQUENCE OF OPERATION SERVICE “LED” INDICATORS
15. START-UP & OPERATING SEQUENCE
Once the Steam Humidifier has been installed and the water, drain, humidistat and blower interlock connections completed, the humidifier may be started.
A.Disconnect the water line. Turn on the water supply and flush the line into a bucket. Reconnect the water line.
B.Set the humidistat to a setting higher than the room RH level.
C.Plug the S2000 Humidif ier line cord into a 120 VAC, 20 amp source. (240VAC, 15amp for S2020).
D.The Green "POWER" LED should blink rapidly and the drain valve will open momentarily upon initial startup. The "FILL" LED will illuminate and water should begin to fill the Water Pan. The Power LED will now blink slowly.
E.When the water has reached the probe level the "FILL" lamp and fill valve will be turned off, and the "HEATER" LED and heater element will be turned on. The “POWER” LED will blink slow and steady.
F.Once the water reaches 170 deg. F. the "BLOWER" LED will illuminate and the system blower should start up.
G.If the above steps have been successfully completed, the humidifier is operating properly.
16.SERVICE “LED” INDICATORS
A.POWER: In normal standby mode, when the humidistat is not calling for humidity and the power cord is plugged in, the "POWER" LED should be blinking slowly. If the green "POWER" LED is not flashing when there is power to the unit, the CPU and/or circuit board may have failed.
B.FILL: When the humidistat closes, on a call
for humidity, the "FILL" LED is illuminated, the Solenoid Valve is open and the water reservoir is filling.
C.HEATER: When the water reaches its proper level the valve closes, the "FILL" LED goes out, the "HEATER" LED is illuminated, and the Heater begins to heat the water.
NOTE: If the humidifier is unplugged while in steaming operation and then plugged back in, a rapid flashing of the “POWER” LED will occur and all other functions will stop! The unit wants to perform a water probe test, but cannot perform this test until the water cools down. Simply wait until the unit cools down and it will resume normal operations. To accelerate a cool down, simply turn the HVAC system fan on via the thermostat.
D.BLOWER: When the water in the reservoir reaches approximately 170 deg. F. the "BLOWER" LED will be illuminated and the interlock wiring should turn the system blower on. Depending upon the water and ambient temperatures, it may take anywhere from four to twelve minutes for the water to heat to 170 deg. F. If the humidistat remains closed the "HEATER" and "BLOWER" LED's will both be illumi nated at the sametime and the "POWER" LED will be blinking slowly.
E.The "FILL" LED will illuminate and the water reservoir will refill at irregular intervals, depending on the boil off rate. The "HEATER" LED should remain illuminated unless the humidistat opens or the humidifier enters a drain cycle or failure mode.
F.DRAIN: This LED will be illuminated when the microprocessor cycles the humidifier into a Mainte nance Mode. After a fan forced cool down period, the water is allowed to drain at 140 degrees F. The drain valve will then close and the fill valve will open to refill the reservoir and resume normal operation. This mode will last about one hour and the micro processor will automatically restart the unit after wards, if there is a call for humidity. This drain cycle will occur once every 8-12hours, to reduce the min eral concentration in the tank and let the heater cooldown. That will shed most deposits that have built up on the heater.
NOTE: The "POWER" LED will blink rapidly during Maintenance mode.
NOTE: A unique feature of the “S” series humidifiers is called “Fill on Request”. The unit will not refill with water after a maintenance cycle, unless there is a demand for humidity from the humidistat. This ensures that the unit will not sit idle with standing water, which can stagnate over time.
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