READ AND SAVE THESE INSTRUCTIONS TRUE TOUCHSCREEN CONTROLLED ELECTRODE STEAM HUMIDIFIER DESIGN SERIES “H” INSTALLATION, OPERATION AND MAINTENANCE MANUAL CARNES COMPANY 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 Phone: (608)845-6411 Fax: (608)845-6504 www.carnes.
TABLE OF CONTENTS Introduction - Cautions ....................................................................................................... 3 Models ................................................................................................................................ 4 Installation ...................................................................................................................... 5-8 Electrical Data Sheet and Definition......................................................
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.
HCHH HCAH HBGH HRAB HCDH 4
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. INSTALLATION UNPACKING AND INSPECTION 1. Cabinet keys are attached, by ty-rap, to side of humidifier. 2. Open the cabinet and check for concealed shipping damage. Report any damage immediately to the carrier who delivered the shipment. 3.
Figure A Outer diameter of drain pipe is 1-1/4”. Air gap fitting must be added. Photo C STEAM DISTRIBUTOR PIPE LOCATION Each steam cylinder requires a separate distributor pipe, steam hose and condensate return line. A cylinder may supply more than one distributor pipe by using an accessory “T” fitting but the output cannot be controlled separately. In a typical installation the humidifier is located below the duct as shown in Figure A.
HOSE LOCATION FOR RUNS FROM 12 FEET TO 40 FEET When hose is difficult to support within this length, straight copper tube should be used and insulation applied. Mounting plate must be plumb. If multiple pipes are used they should be staggered as shown in Figure F. Steam line must pitch down toward drain tee — NO pockets, sags or horizontal runs. Drain Tee Figure F Optional if sufficient head room is not available.
CONNECT THE STEAM HOSE COPPER OR BRASS TUBE IS THE ONLY ACCEPTABLE SUBSTITUTE FOR CARNES STEAM HOSE OR CONDENSATE HOSE. 1. The steam hose should be installed so there is a continuous rise from the humidifier to the distributor pipe. Support the steam hose at intermediate points to prevent dips, pockets, sags or horizontal runs. See Figure H. 2. Any turns should have a minimum radius of 8” to prevent the hose from kinking. Fasten the steam hose to the distributor pipe with one of the hose clamps provided. 3.
ELECTRICAL CONNECTIONS POWER MUST BE OFF BEFORE MAKING ANY ELECTRICAL CONNECTIONS. Check unit electrical characteristics on label outside of cabinet. It must agree with power provided to the unit. If it does not, contact your Carnes Representative. A fused disconnect or circuit breaker not provided by Carnes, MUST be installed per local and national codes. See Table 4 for recommended circuit ratings.
ELECTRICAL DATA AND UNIT DETAIL SHEET - Table 4 HBAH HCAH HSAH HTAH HBDH HCDH HSDH HTDH HBGH HCGH HSGH HTGH kW Line Amp Disc. Size Optional Circuit Breaker* Steam Cylinder Cyl Wire Current 1 1.725 14.4 25 1-20 Amp AX220 14.4 1 1.725 8.3 15 1-15 Amp AX380 8.3 230 1 1.725 7.5 15 1-20 Amp AX380 7.5 277 1 1.725 6.2 15 1-15 Amp AX380 6.2 380 1 1.725 4.5 15 1-15 Amp AX600 4.
ELECTRICAL DATA AND UNIT DETAIL SHEET - Table 4 (continued) HBGH HCGH HSGH HTGH HBHH HCHH HSHH HTHH Model Max Lb/Hr Voltage Phase H_GHCU H_GHEU H_GHTU H_GHWU H_GHGU H_GHHU H_GHCU* H_GHEU* H_GHTU H_GHWU H_GHGU H_GHHU H_GHCU* H_GHEU* H_GHTU H_GHWU H_GHGU H_GHHU H_GHCU* H_GHEU* H_GHTU* H_GHWU H_GHGU H_GHHU 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* H_HHCU* H_HHEU* H_HHTU* H_HHWU* H_HHGU* H_HHHU* 50 50 50
HUMIDIFIER COMPONENT LISTING - Figure J 1 23 8 2 3 7 4 6 5 9 22 10 12 11 1 13 14 20 3 21 15 HBDH 19 18 1. 2. 3. 4. 5. 6. 7. 8. On / Off / Drain Switch Circuit Board Door Interlock Switch Voltage Transformer Current Transformer Distribution Block Ground Lug Contactor 9. 10. 11. 12. 13. 14. 15. 16. 16 17 High Water Sensor Fill Cup Fill Valve Steam Hose Electrode Connector LCD - True Touchscreen Circuit Breakers (Option) Cylinder 12 17. 18. 19. 20. 21. 22. 23.
CONTROLS CONTROL OPTIONS - Figure K CONTROL HUMIDISTAT AIR FLOW DETECTION CONDENSATION PROTECTION WALL HUMIDISTAT PROPORTIONAL CONTROL CARNES MODEL HXHCG OR WALL HUMIDISTAT (NEW) PROPORTIONAL CONTROL CARNES MODEL HXHAM OR WALL HUMIDISTAT ON-OFF CONTROL CARNES MODEL HXHAA OR DUCT HUMIDISTAT PROPORTIONAL CONTROL CARNES MODEL HXHCH PRESSURE DIFFERENTIAL SWITCH CARNES MODEL HXAAE DUCT ON-OFF HIGH LIMIT HUMIDISTAT CARNES MODEL HXHAD OR OR AIR FLOW SWITCH CARNES MODEL HXAAF DUCT PROPORTIONAL HIGH LIMIT H
CONDENSATION PROTECTION Figure L A third device may be desirable to provide condensation protection in the duct system. A high limit humidistat may be installed ten feet downstream from the steam distributor pipe. This humidistat is normally set to 90-95% RH and opens the circuit if the humidity level in the duct exceeds the set-point.
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.
“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 “Component Activity” menu. 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’s.
5. Maize — 8. Steam (orange) - Explains the status of the “Steam” indicator light. The humidifier will only produce steam if the “Steam” indicator light is green. The indicator will be brown when the On/Off/Drain switch is in the “Off” position. It will turn yellow if the switch is in the “On” position, but one or more of the four basic controls are not satisfied (Control Humidistat, High Limit, Air Flow, Door Interlock). The light will turn green if all of the above switches and controls are satisfied.
continue normal operation. High water sensors can be cumulative depending on the condition of the water. The Control humidistat, which provides the Control Demand, is normally the humidistat 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 Hi-Limit Demand, is a safe-guard humidistat installed in the supply duct roughly 10-15 feet past the distribution tube.
This page adjusts the Maximum Output of the humidifier. The Maximum Output can be adjusted lower from the nominal output value of the unit (set at the factory). The unit cannot be set lower than 20% of the nominal value of the humidifier. The Maximum Output value, when changed, also changes the Max Setpoint value on the Setpoints page. “SETTINGS” Cylinder Life Counter – The Settings menu is the page where all operational values can be set.
Boil Down Timer – Setpoint Timeout – 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.
Calibration Password – The help pages consist of maize color buttons labeled with questions. When a button is pressed, information will be given answering and/or giving information about the subject in question. A basic help page consists of text and/or diagrams to help the user through basic problems. This page is where the Humidifier Unit Code, the four digit number identifying the humidifier, is programmed into the unit.
START UP & OPERATION INITIAL START UP 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. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. AUTOMATIC DRAIN CYCLE The circuit board automatically controls the operation of the drain valve to react to two situations: CONTROLLING MINERAL CONTENT: 1.
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 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.
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 humidifier 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.
STEAM DISTRIBUTOR PIPES Lengths 012-036 5” (127) 9-1/2” (241) T 3/8” N Lengths 048-120 4” (102) 4” (102) T N 3/8” Distributor Pipes for Models: HBA, HCA, HBD, HCD Distributor Pipes for Models: HBG, HCG, HBH, HCH PIPE HXPBB012S N 11-13/16 (300mm) T 7/8 HXPBB018S 17-13/16 (452mm) 7/8 PIPE HXPBC012S N 11-13/16 (300mm) T 1-5/8 HXPBB024S 23-13/16 (605mm) 7/8 HXPBC018S 17-13/16 (452mm) 1-5/8 HXPBB030S 29-13/16 (757mm) 7/8 HXPBC024S 23-13/16 (605mm) 1-5/8 HXPBB036S 35-13/16 (910mm) 7/
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.
CARNES STEAM MANIFOLDS with strong galvanized flanged frames are factory assembled to reduce installation costs. LOCATION OF MANIFOLD Figure A 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.
TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION - Table 6 SYMPTOM CAUSE ACTION Arcing *Naturally very high conductivity water. *Drain lines restricted causing low water levels. *Defective drain solenoid valve. *Insufficient flow of incoming water. Levels low. *Water may be too high in conductivity. Test water. *Inspect & clean drain & tubing regularly. *Repair, clean or replace as necessary. *Maintain 20 psi or above. Clean strainer, repair, clean or replace fill solenoid as necessary.
TROUBLE SHOOTING - SYMPTOM, CAUSE AND ACTION (Continued) SYMPTOM CAUSE ACTION No LCD display *The LCD has been dimmed. *Voltage to the humidifier is not that which is required per rating label. *3 phase voltage but not all legs have power. *Touch LCD screen. *Change humidifier or make necessary changes to confirm compatibility. *Check electrical connections and make necessary repairs or hook ups. *Close all circuit breakers. *Internal or external circuit breakers are not closed.
TROUBLE SHOOTING SYMPTOM: LCD NOT ON 1. Verify that voltage being supplied to the humidifier is the same as that listed on the rating label on the front left hand corner of cabinet. 2. If humidifier is 3-phase, verify that all legs have power. 3. If the humidifier has optional internal circuit breakers, they must be on. 4. Verify LCD is not in dimmed mode by touching it. 5. Verify that 24VAC is being supplied by the voltage transformer by taking voltage reading between TP6 and TP7 (Photo O).
SYMPTOM: DRAINS CONTINUOUSLY 1. The most common cause is to have a piece 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 re-occurring issue, make sure the “Repetitive Drain Valve” option is enabled in the settings menu. 2.
8. SYMPTOM: ARCING 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.
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.
PREVENTATIVE MAINTENANCE: 6. Visually check cylinder for extreme amounts of residue on the inside surface. Very high level of water or unit unable to provide full capacity may be an indication of end of life cycle of the cylinder. 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.
! WARNING 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 humidifier cylinders can be ordered from your local Carnes Sales Representative. Please contact them directly or fill in the information below and either mail or fax (608/845-6504) to the Carnes Company. We will then have our Sales Representative contact you.
TERMS, CONDITIONS AND WARRANTY 1. ACCEPTANCE, GOVERNING PROVISIONS AND CANCELLATION. This writing constitutes the complete and exclusive statement of the terms and conditions of sale of the products and/or services described herein, and Seller’s obligation to sell is expressly conditioned upon assent to these terms and conditions. Buyer will be deemed to have assented to these terms and conditions unless Seller receives written notice of any objection within 5 days of the date Buyer receives this writing.
