Amerec AI18 User manual
COMMERCIAL STEAM GENERATOR
WITH COOLFLUSH™ AUTO DRAIN OPTION
BOILERS FOR LARGE STEAM ROOMS
INSTALLATION INSTRUCTIONS
MODELS AI 12, AI 18 AI 24, AI 30, AI 36, AI 42 & AI 48
208 and 240V 1 & 3 phase, and 480V 3 phase
WITH COOLFLUSH™ AUTO DRAIN OPTION
INDEX
SECTION PAGE
WARNINGS 3
GENERAL INFORMATION 6
WATER QUALITY REQUIREMENTS 6
BOILER RATINGS 7
DIMENSIONS 8
INSTALLATION 9
GENERATOR 9
PLUMBING 9
WATER LINE 9
STEAM LINE 10
SAFETY VALVE 10
DRAIN 10
ELECTRICAL SERVICE 11
ROOM CONTROLS 11
TEMPERATURE SENSOR 12
THERMOSTAT 12
I60 ROOM SWITCH 13
REFRESH SWITCH 13
WIRING DIAGRAM AI12-AI24 14
WIRING DIAGRAM AI30-AI48 15
STARTING THE GENERATOR 16
OPERATING INSTRUCTIONS 17
BOILER START 17
STEAM ROOM OPERATION 17
THE I60 SWITCH 18
THE REFRESH™ SWITCH 18
LIGHTS AND SWITCHES 18
ROUTINE MAINTENANCE 19
WATER LEVEL CONTROL 19
BLOWDOWN/ CoolFlush™ Auto Drain option 19
BLOWDOWN/MANUAL DRAIN 21
APPENDIX 1: RUN CLOCK AND AUTOBLOWDOWN CLOCK 22
APPENDIX 2: PRESSURE CONTROL ASSEMBLY 23
APPENDIX 3: LOW WATER CUTOFF INSTRUCTIONS 24
SAVE THIS MANUAL
A MANUFACTURER’S REPORT: CONTROLS AND SAFETY DEVICES is supplied with each generator.
You may be required to present this form to a state, provincial or other inspection agency.
Secure this document in a safe location.
Thank you for purchasing your new AMEREC steam generator.
If we can be of any assistance do not hesitate to call our Technical Support at 1-800-363-0251.
POST "WARNING LABEL OUTSIDE STEAMBATH FOR SAFETY WARNINGS. REQUIRED POSTING ON
DOOR OF STEAM ROOM OR ADJACENT TO DOOR FOR ALL COMMERCIAL INSTALLATIONS.
FOR THE SAFETY OF YOU AND YOUR FAMILY OR CUSTOMERS, PLEASE READ FOLLOWING
WARNINGS AND ALL INSTRUCTIONS BEFORE USING YOUR STEAMBATH.
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS.
1. WARNING - To reduce the risk of injury, do not permit children to use this product unless they are closely
supervised at all times.
2. WARNING - To reduce the risk of injury:
a. The wet surfaces of steam enclosures may be slippery. Use care when entering or leaving.
b. The steam head is hot. Do not touch the steam head and avoid the steam near the steam head.
c. Prolonged use of the steam system can raise excessively the internal human body temperature and
impair the body’s ability to regulate its internal temperature (hyperthermia). Limit your use of steam
to 10 - 15 minutes until you are certain of your body’s reaction.
d. Excessive temperatures have a high potential for causing fetal damage during the early months of
pregnancy. Pregnant or possibly pregnant women should consult a physician regarding correct
exposure.
e. Obese persons and persons with a history of heart disease, low or high blood pressure, circulatory
system problems, or diabetes should consult a physician before using a steambath.
f. Persons using medication should consult a physician before using a steambath since some
medication may induce drowsiness while other medications may affect heart rate, blood pressure
and circulation.
3. WARNING - Hyperthermia occurs when the internal temperature of the body reaches a level several degrees
above the normal body temperature of 98.6 °F. The symptoms of hyperthermia include an increase in the
internal temperature of the body, dizziness, lethargy, drowsiness and fainting. The effects of hyperthermia
include:
a. Failure to perceive heat:
b. Failure to recognize the need to exit the steambath:
c. Unawareness of impending risk:
d. Fetal damage in pregnant women:
e. Physical inability to exit the steambath: and
f. Unconsciousness.
4. WARNING - The use of alcohol, drugs or medication can greatly increase the risk of hyperthermia
SAVE THESE INSTRUCTIONS
WARNING
Electric Shock Hazard - High voltage exists within this equipment. Disconnect all electrical power before
servicing the generator. All installation and service to this equipment should be performed by qualified
licensed personnel in accordance with local and national codes. There are no user serviceable parts in
this equipment.
Electrical grounding is required on all AMEREC steambath generators. The generator is designed for
hookup with copper wire only, 75°C or better.
Wire the controls exactly as described. Do not connect any additional wiring or power supplies to the
controls or their terminals in the generator.
All plumbing must be installed by a licensed plumber in accordance with all applicable local and national
codes.
Install indoors only. Protect from freezing. Generator must be level side to side and end to end.
The pressure relief valve and generator drain must be installed in such a fashion that the risk of scalding
is reduced to a minimum. Draining these outlets into the steam room may present a scald hazard and
may damage materials used to construct the room.
Avoid traps and valleys in the steam line where water could collect and cause a steam blockage. The hot
steam line must be insulated against user contact.
Be certain that steambath enclosures are properly sealed to avoid water damage from escaping steam. It
is recommended that 100% silicone caulk be used to seal all pipes and fittings. Steam must be
prevented from escaping into the wall cavity. Centering the steam pipe is critical in rooms made of
plastic, acrylic, resin, fiberglass or similar materials. Allowing the steam pipe to touch materials not
rated 240°F or higher will result in damage to these materials.
Do not install the steam head near bench(es) or where steam may spray or where condensation will drip
on the user as this will present a scald hazard.
Be careful when entering a steambath. Escaping steam from an overheated steam room may cause
injury.
Scald Hazard: Do Not Touch the steam head or trim during operation as they are HOT. Stay at least 12
inches away from the hot steam escaping from the steam head.
Children should only use the steambath under close adult supervision.
Do not exceed 30 minutes in a steambath. Excessive exposure can be harmful to your health. Excessive
exposure can produce a rapid pulse, light-headedness, weakness or fainting. If you become
uncomfortable or experience any of the above conditions exit the steambath immediately.
Steambaths can put undue stress on the body. Therefore a steambath should be used only under a
doctor's direction if you:
Are in generally poor health Are pregnant
Are under the care of a physician Have a heart condition
Have circulatory problems Have high blood pressure
Have diabetes Are using medication
DO NOT use the steam bath if you are under the influence of drug or alcohol!
GENERAL INFORMATION:The AI Commercial Steam Generator is a low pressure heating boiler,
UL/CUL Listed, built to NEC requirements and with an ASME “H” stamped certified and National Board
registered pressure vessel.
The generator has all steel construction with powder coated finish on visible surfaces and stainless steel
mounting feet to minimize the risk of corrosion. The mounting feet hold the generator one inch above the floor to
allow cleaning the floor below it and to further prevent corrosion. This also allows the generator to sit directly on
a combustible surface without additional protection. The feet extend beyond the sides of the generator chassis
and have clearance holes to allow securing the generator in place using ¼” bolts.
AI Commercial Steam Generators are factory assembled and tested and ready to install. All generators are
plumbed for a ½” potable water feed inlet, a ¾” drain discharge and a ¾” pressure relief valve discharge.
Generators are available for connection to 208VAC or 240VAC single or three phase, or 480VAC in three phase
only. All models require the appropriate full power electrical service plus ground. Models in 208V and 240V also
require a 14 gauge minimum Neutral for the control circuit; 480V models require a separate 120VAC+N service
for the control circuit. Use 75° minimum copper wire for all service connections. A ¾”-1”-1½”-2”
combination knockout is provided in the generator’s electrical box for the main service conduit and an additional
½”-¾” knockout is provided for the 480V models’ 120V control service.
The generator’s control circuit is protected by a 250VAC 3A non-time-delay fuse installed in the front panel of the
generator’s electrical box. A 100mA time-delay fuse mounted on the generator’s circuit board protects the
board’s low voltage circuitry. No other fusing is installed in the steam generator.
Room controls (ON/OFF, thermostat, temperature sensing and steam Refresh™) are connected during generator
installation using factory supplied wire or cables. Room controls operate on a low voltage Class 2 circuit. An
access hole and knockouts, ½” trade size, are provided for room control wiring. The thermostat must be
mounted outside the steam room, the temperature sensor must be mounted inside the steam room, the optional
Refresh™ switch mounts inside the steam room, the optional I60 Bath On/Off switch is available for mounting
outside the steam room. Temperature sensors require factory supplied cables for connection to the generator,
all other controls require 3 conductors, 18 to 24 AWG copper, 75° 300V minimum (25 foot long cables are
provided).
Standard equipment:
Manual operation (generator mounted RUN switch and manual ball valve drain) and single steam room (one
steam valve, one temperature sensor, one thermostat with integral steam bath ON/OFF switch and bath-on
indicator light, two steam heads). Switches allowing manual heat and water control during routine service,
lights indicating heat and valve operating status and self-check fault codes.
Optional equipment:
Second steam room (second steam valve, thermostat and temperature sensor) factory installed only!
RUN CLOCK (7-day or 24 hour clock or 7-day programmable digital clock for generator ON/OFF scheduling).
CoolFlush™ Auto Drain (24 hour clock plus electronic drain valve).
Steam bath
ON/OFF switch: commercial (mounts to single gang switch box in a dry location only, automatic
timeout 60 minute bath time, integral bath-on indicator light).
Steam bath
ON/OFF switch: residential (membrane switch, may be mounted in steam room, automatic
timeout 60 minute bath time, integral bath-on indicator light).
Steam Refresh™ (membrane switch for mounting inside steam room, status indicator light).
Manual reset low water cut-off (check your local codes for requirements)
Water Quality Requirements:
The nature of a steambath generator requires testing of the feedwater to avoid potential high concentrations of
impurities which can cause a deposit or scale to form on the internal surfaces. This deposit or scale can interfere
with the equipments proper operation and even cause premature generator failure. Concentration of impurities is
generally controlled by treating the feedwater and/or “blowing down” the generator when it is not heating. The
“blow down” process involves removing a portion of the tank water with high solid concentration and replacing it
with makeup water.
To reduce corrosion and element damage risks, always flush feedwater lines thoroughly to eliminate flux residue
and avoid sodium based water softeners. The ASX-200 filter system available from Amerec provides very good
protection in most installations and should be connected to a cold water supply. Feedwater temperature must be
no hotter than 100°F if the ASX-200 is installed!
To insure proper operation, the water supply should be tested prior to operating the equipment. There are
several treatment processes which can be used if you have a problem with hard water. A local reliable water
treatment company can recommend the appropriate treatment if required. The recommended feedwater quality is
listed below.
Feedwater Quality
Hardness, ppm 10 – 30 (.5 – 1.75 gpg)
T-Alkalinity, ppm 150 – 700 (8.75 – 40.8 gpg)
Silica, ppm 15 – 25 (.875 – 1.45 gpg)
PH (strength of alkalinity) 10.5 – 11.5
IMPORTANT! Regular maintenance will help your steamer work properly for a long time. Check for leaks, loose
or damaged wires, signs of corrosion and calcium build up in the tank and on the level probe.
This is particularly important in areas with high calcium levels and other water quality problems. Calcium buildup
can cause poor steamer performance and damage the heating elements!
Some water filtration equipment is available through Amerec. Contact us for further information.
AMEREC AI BOILER RATINGS
CATALOG#
UL MODEL#
WATTS
VOLTS
PHASE
AMPS MAX ROOM
SIZE (CU FT) STEAM
LB-HR DIMENSIONS
(INCHES)
L W H
AI 12
12-208
12-208
12-240
12-480
12,000
208
208
240
480
1
3
1
3
59
34
51
15
550 36 20 x 22 x 24 ½
AI 18
18-208
18-208
18-240
18-480
18,000
208
208
240
480
1
3
1
3
88
51
76
22
900 54 20 x 22 x 24 ½
AI 24
24-208
24-208
24-240
24-480
24,000
208
208
240
480
1
3
1
3
116
68
101
29
1200 73 20 x 22 x 24 ½
AI 30 30-208
30-240
30-480 30,000 208
240
480
3
3
3
85
73
36 1500 91 20 x 28 x 24 ½
AI 36 36-208
36-240
36-480 36,000 208
240
480
3
3
3
101
88
43 1800 109 20 x 28 x 24 ½
AI 42 42-208
42-240
42-480 42,000 208
240
480
3
3
3
118
102
51 2100 127 20 x 28 x 24 ½
AI 48 48-240
48-480 48,000 240
480 3
3 117
58 2400 145 20 x 28 x 24 ½
Notes:
All models: no internal heating circuit fuses are needed, panel mounted 3A fuse provided for 120V control circuit
All models use 120VAC control circuits.
208V and 240V models supply 120V to control circuit internally, 480V models require a separate 120V service.
oFor 208V and 240V models, run power wires + Ground and a 14AWG Neutral for controls.
oFor 480VAC units, run 3 power wires + Ground and run a 120V service for the 3A control circuit.
Use only copper wire, rated 75°C or better.
Install all wiring per local codes.
DESCALANT
ACCESS
241
2
23
20
FILL
21
4
51
2DRAIN
0
GAGE
GLASS
2
9
ROOM TEMPERATURE
6
8
754
3
STEAMBATH
BATH
10
ON
1
OFF
OPTIONAL RUN
& DRAIN CLOCKS
VAC
ASME MARKINGS LOCATED ON SHELL
MAX. WORKING PRESSURE: STEAM, 15 psi
CERTIFI ED AND MANUFACTURED BY:
SAUNATEC, INC., WOODINVILLE, WA, USA
ELECTRONIC DRAI N (OPTIONAL)
CAUTION: Imprope rly opening drain may release da ngerously
hot water or steam. Refer to OperatingMaintenence Instructions.
BLOWDOWN/FLUSH BOILER DAILY
Blowdown/flu sh boiler at least once a d ay for commercial/hard -use installations and
in areas of hard w ater. Failure to proper ly maintain boiler can cause equipment
failure and may v oidw arranty. Refer t o Operating Maintenence Instructions.
30
10
5
15
20
25
HAMMER
ARRESTOR
STEAM
28
203
4
161
2
20
OPTIONAL BOILER
MOUNTED
THERMOSTAT
171
2
RUN CLOCK
181
2
ELECTRICAL
POWER ENTRY ELECTRICAL SHOCK HAZARD
FOR ASSI STANCE CALL
DISCONNECTPOWER SUPPLY
BEFORE REMOVINGTHIS COVER
NO USER SERVICEABLEPARTSWITHIN
1-800-331-0349
SERVICE O NLY BY AUTHO RIZED PERSONNEL
SERIAL No.
MODEL
lb.s PER HOUR
MAX. CAPACITY
MAX. kW
!
C
L
O
C
K
YEAR BUILT
ELECTRIC BOILERS
US LISTED
PHASE
50/60Hz
CUL
AMPS
69XJ
MANUAL
OPEN
DRAIN
VALVE
OPEN
ROOM STATUS
BOILER OPERATION
IF LIGHTSARE
BLINKINGREFER
TO OPERATING
INSTRUCTIONS
ROOM1 LOCKOUT
ROOM2 LOCKOUT
FEEDWATER
LEVEL PROBE
ACCESS
DRAIN CLOCK
N
O
R
M
A
L
N
O
R
M
A
L
N
O
R
M
A
L
HEAT
(OPTIONAL)
CLOCK RUN
R
O
O
M
1
BOILER
HEATING
O
F
F
WATER
VALVE
OPEN
STOP
FILL
STEAM
VALVE
OPEN
V
A
L
V
E
MANUAL
RUN BOILERON
STEAM
VALVE
OPEN
C
L
O
S
E
R
O
O
M
2
FOR ASSISTANCECALL
DISCONNECTPOWER SUPPLY
BEFORE REMOVINGTHIS COVER
NO USER SERVICEABLEPARTS WITHIN
1-800-331-0349
SERVICEONLY BY AUTHORIZEDPERSONNEL
ELECTRICAL SHOCK HAZARD
CONTROLS
3A 250VAC
ASME - NB
PLATE BEHIND
THIS COVER
CHECK
VALVE
PRESSURE SWITCHES
ACCESS FROM FAR SIDE PRESSURE RELIEF
CAUTION: Improperl y opening drain may release da ngerously
hot water or steam. Refer to Operating MaintenenceInstructions.
C
L
O
C
K
MANUAL
OPEN
DRAIN
VALVE
OPEN
ROOM STATUS
ROOM2 LOCKOUT V
A
L
V
E
N
O
R
M
A
L
O
F
F
N
O
R
M
A
L
FEEDWATER
N
O
R
M
A
L
STOP
FILL
HEAT
BOILER
HEATING
WATER
VALVE
OPEN
STEAM
VALVE
OPEN
MANUAL
RUN
(OPTIONAL)
CLOCK RUN
ROOM1 LOCKOUT C
L
O
S
E
BOILER OPERATION
R
O
O
M
1
IF LIGHTSARE
BLINKINGREFER
TO OPERAT ING
INSTRUCTIONS
BOILER O N
STEAM
VALVE
OPEN
R
O
O
M
2
FOR ASSI STANCE CALL
DISCONNECTPOWER SUPPLY
BEFORE REMOVINGTHIS COVER
NO USER SERVICEABLEPARTSWITHIN
1-800-331-0349
SERVICE ONLY BY AU THORIZED PERSONNE L
ELECTRICAL SHOCK HAZARD
CONTROLS
3A 250VAC
LEVEL PROBE
ACCESS
22
143
4
ELECTRONIC DRAIN(OPTIONAL)
BLOWDOWN/FLUSH BOILER DAILY
Blowdown/flu sh boiler at least once a da y for commercial/hard -use installations and
in areas of hard wa ter. Failure to proper ly maintain boiler can cause equipment
failure and may vo idw arranty. Refer t o Operating Maintenence Instructions.
PHASE
SERIAL No.
MAX. CAPACITY
SAUNATEC, INC., WOODINVILLE, WA
CERTIFI ED AND MANUFACT URED BY:
MAX. WORKING PRESSURE: STEAM, 100 psi
lb.s PER HOUR
NATIONAL BOAR D NUMBER LOCATED ON SHELL
VAC
UL FILE
E70764 UL C
UL
AMPS
YEAR BUILT
MAX. kW
!
030
10
525
15
20
AI30, AI36, AI42, AI48AI12, AI18, AI24
ALL MODELS ALL MODELS
Shown with optional boiler mounted thermostat. All dimensions in inches.
INSTALLATION
GENERATOR
AI Steam Generators must be installed by a licensed plumber and electrician to local and national codes.
AI Steam Generators are intended for indoor use only.
Install upright and level side to side and front to back.
Not for space heating purposes.
Protect from freezing.
The steam generator is designed to sit directly on a hard level surface.
The mounting location must be suitable to safely support your boiler.
Models AI12-AI24 may weigh more than 165lb and models AI30-
AI48 may weigh more than 220lb. The generator must be mounted
upright and level and prevented from moving. Ensure that the generator is mounted high enough above the
drain receptacle to allow proper drain flow. The weight of the generator is generally sufficient to prevent
movement. Use ¼” bolts through the holes provided in the generator’s feet to secure it in place on the floor if
necessary.
The generator’s back end (nearest the water gauge) may be installed 1” or further from a wall or combustible
surface. Use the lift handle to set the minimum clearance by placing the generator so the handle just touches the
adjacent surface. Keep combustibles at least 1” away from left side, 8” from right side plumbing and 6” from top
of switches and steam valve. Do not store solvents, paints or other flammables near the generator.
All electrical access is from the left side
and front end (as viewed at right). Up
to 480VAC may be exposed during
servicing. Leave space for service
access: at least 18” to front and left
side, 6” above the pressure switches
and valves.
Install per code: your local codes
may require even greater clearances.
Left Front
Leave sufficient space between the
right (plumbing) side and adjacent
surfaces to allow servicing the
plumbing when needed. Provide at
least 8” clearance from the piping for
access.
CAUTION: Exposed plumbing may
be over 200°F during normal
operation and can present a severe
burn hazard. Be sure to protect
people from accidental contact!
PLUMBING All valves are factory equipped with a short pipe nipple in their outlet. When attaching plumbing,
hold these nipples while tightening. Do not tighten plumbing by using a wrench on the brass valve bodies
as this can damage the valve! Brass or copper lines are recommended for all plumbing.
1. INSTALL WATER LINE
Run a ½” potable water feed line between the nearest cold water line and the WATER INLET fitting on the
generator. Cold feedwater is required for proper operation of the CoolFlush™ Auto Drain system. Special water
treatment may be required in your area – see Water Quality section on pages 6 and 7 for further details. Install a
shut-off valve near the generator. When tightening the water fittings, always use two wrenches so there will be
no strain on the water inlet valve. The water shut off valve must remain open during generator operation! We
recommend feedwater pressure between 20 and 50 psi. A water hammer prevention device is installed on your
boiler. Excessive water hammer can damage a water valve, preventing it from shutting off the water supply to
the generator!
Flush water supply line thoroughly before final hookup. Debris such as flux residue can prevent the inlet valve
from fully closing and may cause corrosion damage to the water valve or heating elements. A grit filter is factory
installed on the generator to trap large debris such as sand. Shut the water supply off and remove and clean the
filter periodically as dictated by local water conditions.
A check valve is installed in the boiler’s feedwater line. An additional customer supplied back-flow prevention
device may be required in your area. Check local codes. To prevent water level sensing errors, backflow
prevention is necessary in installations where the steam generator’s water supply is shared with another
generator or other nearby high usage connection.
2. INSTALL STEAM LINE
AI generators come equipped with ¾”NPT steam outlets. Do not place a shutoff device in the steam line! Locate
steam heads so bathers do not come into contact with a steam head and so steam may not exhaust directly on
any part of a bather’s body. Steam and steam heads are very hot and can cause severe burns!
Run a ¾” copper steam line from the generator to the steam room. The steam line should enter the steam room
18" above the floor.
IMPORTANT: the steam line should be pitched away from the generator so any condensate will drain from the
steam line. For best results, the generator should be installed as close to the steam room as possible, with its
steam outlet valve higher than the steam heads in the steam room and the steam line run straight to the steam
heads with a pitch of at least ¼” per foot to drain into the room. Do not allow sags, dips or other low sections in
the steam line: these may block the steam flow or cause spitting of very hot water into the steam room.
As with any steam bath steam generator, spitting, reduced steam and other problems can occur if too many
elbows or tees are placed in the steam line, if the line is too long, if the line has large rises or if there are low area
or traps in the line. The effects depend on the number and size of these practices in a particular installation.
To reduce noise or improve the distribution of steam in larger rooms, additional steam heads may be installed.
Two steam heads are supplied with each generator. Space steam heads at 6” intervals, minimum. The steam
heads should be located to ensure they do not discharge steam or drip condensate where the user may come in
contact with the hot moisture – contact may cause injuries from scalding to severe burns!
At the steam room: drill/prepare a 15/8" hole at each steam head location for steam line entry 15 to 18” above the
floor. Terminate the steam line from the generator with a tee at the steam room then plumb each side of the tee
to a steam head location and through the wall. Center the 3/4” copper steam pipe in the 15/8" hole. Terminate the
steam line with a 3/4” NPT male adapter. Stub the line out into the room 3/8” from the finished surface. Secure the
steam lines to structural members.
Install steam heads so vent opening is pointed
towards the floor. Use Teflon thread tape to help aim
the steam head correctly if necessary. Protect the
steam head finish from damage while handling and
tightening. Seal the wall around the steam pipes and
all fixtures in the steam room with 100% silicone caulk
to avoid moisture damage within the walls.
IMPORTANT If the steam line is in an area where the
temperature will be below 40°F or if the line is more
than 20 feet long, best results can be obtained by insulating the steam pipe. Any insulation must be suitable for
temperatures of at least 250°F.
Seal rear
Of insulator
With silicone
12” min.
15 to 18”
12” min. 12” min.
6” min.
120VAC
GROUND
N
L1
L2
L3
L3
L2
L1
120VAC
GROUND
3. INSTALL SAFETY VALVE LINE All AI generators are equipped with a factory installed 15 psi pressure relief
safety valve. This must be plumbed to a ¾” indirect waste line. Do not install a shut off device in this line. Do
not reduce this line. Do not form a trap in this line! Discharge from the safety valve may be at over 240°F.Do
not plumb this line into the steam room! Plumb this waste line per local plumbing codes.
5. INSTALL DRAIN All AI generators are equipped with a factory installed manual ball valve to allow draining
the tank. An optional electronic drain may be installed after the manual valve. Plumb the drain to a ¾” indirect
waste line. If the drain is opened while the generator is under pressure, discharge from the drain may be at
over 240°F. Always plumb the drain with piping suitable for 240°F minimum. Do not plumb this line into the
steam room! Plumb this waste line per local plumbing codes. When equipped with a drain system and with
the pressure control properly set to 4 to 5psi, drain water will be at or below 140°F during the CoolFlush™
Auto Drain cycle. Local codes may require a (customer supplied) expansion tank or blowdown cooling tank if
draining water in excess of 140°F or 5 psi.
ELECTRICAL
Refer to the ID plate on the generator’s switch panel to determine voltage and current requirements.
Electrical service for all models requires two (single phase) or three (3 phase) hot
leads plus a suitable ground connection. Models operating on 208V or 240V also
require a 14 AWG Neutral for the generator controls circuit. Models operating on
480V require a separate 120V (14AWG) service for the controls circuit. Route the
copper supply wire with appropriate strain relief through the hole marked POWER
ENTRIES. A multiple knockout is provided at this point for electrical service using
up to 2” conduit. A second knockout, ½” to ¾”, is provided for the 120V controls
circuit, if needed. 1-Phase Power
Connect the control circuit’s Neutral (208/240V models) or 120V+N (480V 3-Phase Power
models) to the left side of the small terminal block provided in the generator’s
electrical enclosure. Connect the power service to the generator’s large
terminal block and the ground to the generator’s ground lug, located
near the front edge of the electrical enclosure (a copper wire clamping lug
with green screw). Ensure all wires are tightly clamped at their respective terminals.
CAUTION: Loose wire connections can cause heat damage to wires, terminal blocks and other
components and may void the warranty.
NOTE: A GFCI device is not required by UL. A GFCI may be installed if required by local codes or the owner. A
GFI device will tend to nuisance trip due to heater element aging.
ROOM CONTROLS
Each steam valve outlet is to be used for a single steam room. Each room requires one temperature sensor
mounted in the room and one thermostat control mounted outside the room. The thermostat mounts to a
standard single switch/outlet electrical box. The thermostat may be mounted directly on the generator’s electrical
enclosure using a common ½” conduit z-bracket between the box and a knockout provided in the generator’s
electrical enclosure. To reduce the risk of electrical interference between circuits, do not run the low voltage
control cables inside the same conduit as high voltage circuits. Avoid running control cables closely alongside
high voltage wiring in cable troughs and raceways.
8
Two independent control circuits are available for two steam outlets to supply two
separate steam rooms. If only one valve is installed on the steam generator, it
will be controlled by the ROOM 1 circuit with controls connected to the terminal
blocks alongside the left edge of the printed circuit board (PCA) located in the
generator’s electrical enclosure. When the (optional) second outlet is provided,
the second room’s controls connect in the same manner as the ROOM 1 circuit’s
described here. Follow all wiring and PCA jumper setting instructions closely for
proper operation.
1. TEMPERATURE SENSOR INSTALLATION The temperature sensor must be mounted in the steam room.
Cut a 7/8” diameter hole in the steam room wall to mount the sensor. It is recommended that the sensor be
mounted 6" down from the ceiling, but not directly over the steam dispersion head and not more than 7 feet
above the floor. Do not cover or enclose the sensor: if the airflow across the sensor is blocked or reduced, the
room may overheat or suffer large temperature variations.
String the sensor cable from the sensor location through 1/2" holes
in the wall studs or ceiling joists to the generator location. Leave
12" of slack at the sensor location. Route the generator end of the
sensor cable through the generator hole marked CONTROL
WIRING ENTRY using the strain relief provided.
Note: Do not staple through or otherwise damage the cable. Use a
factory supplied sensor cable only.
In the steam room: Plug the temperature sensor into the sensor cable. The cable and the sensor connectors are
designed to lock together when properly aligned. Run a bead of 100% silicone caulk around the underside of the
sensor head then carefully feed the cable and sensor through the hole and attach the sensor in place.
INSTALL ONLY IN A DRY LOCATION
FOR SERVICE CALL: 1-800-363-0251
Saunatec Inc. P.O. Box 2258
Woodinville, WA 98072
BLACK WIRE
RED WIRE
WHITE WIRE
5
6
ROOM TEMPERATURE
7
8
9
10
4
3
OFF
2
1
BATH
STEAMBATH
ON
CABLE TO
TEMPERATURE SENSOR
JP1
JP1
At the generator: Connect the sensor cable’s end plug into its socket on the generator’s control circuit board.
The socket is directly above the room’s T’STAT terminal block. Orient the cable end to match its socket and
insert it until the end locks in place. Make sure the thermostat and temperature sensor cables are connected at
the same side of the circuit board: either along the left edge (ROOM 1) or the right (ROOM2). When only one
steam outlet valve is available, always connect to ROOM 1.
2. THERMOSTAT INSTALLATION The low voltage thermostat control can be mounted up to 50 feet from the
generator and must be located outside the steam room. A 25 foot cable is provided. String the 25' cable from
the control location through ½” holes in the wall studs or ceiling joists to the generator and the switch box
installed at the desired control mounting location.
At the control: Connect the control cable to the thermostat control using wire nuts (provided). Match the
provided cable’s red and black wires to the thermostat’s red and black wires, respectively. Match the cable’s
third wire (white or green) to the thermostat’s white wire.
At the generator: Route the generator end of the control
cable through the generator hole marked CONTROL
WIRING ENTRIES using the strain relief provided. Strip the
control cable wire ends ½” and place the bare copper into
the ROOM 1 (or ROOM 2) T’STAT terminal block, putting
the black wire in the bottom hole (“3”), red in the center (“2”)
and white (or green) in the top (“1”). Use a small
screwdriver to carefully press the terminal block’s orange
tabs down to insert or remove the wire ends. When only
one steam outlet valve is available, always connect to ROOM 1.
The thermostat has an integral switch to start and stop the heating of the steam room: see operating
instructions. If an (optional) I60 switch or other switch is to be used, it will connect to the ROOM SW
terminal block as described in the following section. When using the thermostat as the Bath on/off
switch, place a jumper on only one pin of JP1 (near the center of the PCA).
The SWITCH LOCATION jumpers at the top center of the PCA must be correctly set to correspond to the switch
used. If only the thermostat will be connected place the jumper on the center and top pins. If another switch will
be connected to the ROOM SW terminal block, set the place on the center and bottom pins:
<= THERMOSTAT SWITCH OTHER SWITCH =>
3. I60 ROOM SWITCH INSTALLATION The I60 switch is a momentary type switch (closed only while pressed)
intended for installations with occasional use. When an I60 switch or equivalent is connected, the JP1 jumper
must be correctly set as shown below. The steam bath will start when the switch is pressed and stop
automatically 60 minutes later or when the switch is pressed again. If the optional second steam room is
installed, both rooms must use the same type of switch, either the thermostat or the I60!
When using an I60 switch, place a jumper on both pins of JP1 (near the center of the PCA) and place
the jumpers on the SWITCH LOCATION center and bottom pins as described above.
The (optional) I60 switch provides a low voltage control which may be mounted up to 50 feet from the generator
and must be located outside the steam room. A 25 foot cable is provided. String the 25' cable from the control
location through 1/2" holes in the wall studs or ceiling joists to the generator and the switch box installed at the
desired control mounting location. The switch location jumpers must be correctly set for proper operation.
Saunatec Inc.
INSTALL ONLY IN A DRY LOCATION
FOR SERVICE CALL: 1-800-363-0251
P.O. Box 2258
Woodinville, WA 98072
STEAMBATH
ON/OFF
BATH ON
RED WIRE
WHITE WIRE
BLACK WIRE
CABLE TO THERMOSTAT
CABLE TO TEMPERATURE SENSOR
1
3
2
CABLE TO TEMPERATURE SENSOR
CABLE TO THERMOSTAT
BLACK WIRE
WHITE WIRE
RED WIRE
At the control: Connect the control cable to the switch using wire nuts (provided). Match the provided cable’s
red and black wires to the switch’s red and black wires, respectively. Match the cable’s third wire (white or
green) to the switch’s white wire.
At the generator: Route the generator end of the switch cable
through the generator hole marked CONTROL WIRING ENTRY
using the strain relief provided. Strip the control cable wire ends ½”
and place the bare copper into the ROOM 1 (or ROOM 2) ROOM
SW terminal block, putting the black wire in the bottom hole (“3”),
red in the center (“2”) and white (or green) in the top (“1”). Use a
small screwdriver to carefully press the terminal block’s orange tabs
down to insert or remove the wire ends. When only one steam
outlet valve is available, always connect to ROOM 1.
4. REFRESH SWITCH INSTALLATION The (optional) Refresh™ switch uses a low voltage control to provide a
short burst of steam in the steam room when the switch is pressed. The switch may be mounted up to 50 feet
from the generator and must be located inside the steam room. A 25 foot cable is provided. String the 25' cable
from the control location through ½” holes in the wall studs or ceiling joists to the generator and the desired
control mounting location in the steam room.
At the control: Connect the control cable to the switch terminal block on the Refresh™
switch. Connect the switch cable to the switch and note which wire is connected to which
terminal block position. An instruction plate is provided and should be attached to the wall
alongside the Refresh™ switch in the steam room to help bathers understand the
Refresh™ operation. The instruction plate is adhesive backed for easy mounting to a clean
dry surface.
At the generator: route the generator end of the switch cable
through the generator hole marked CONTROL WIRING ENTRIES
using the strain relief provided. Strip the switch cable wire ends ½”
and place the bare copper into the ROOM 1 (or ROOM 2) REFRESH
terminal block, matching the colors to the terminal block positions
identically to the switch’s connections. When finished, the switch’s
block position 1 should be connected to the PCA’s position 1, 2 to 2
and 3 to 3. Use a small screwdriver to carefully press the terminal
block’s orange tabs down to insert or remove the wire ends. When
only one steam outlet valve is available, always connect to ROOM 1.
WIRING: AI 12, AI 18 and AI 24
ALL WIRING MUST BE INSTALLED BY A LICENSED ELECTRICAL CONTRACTOR IN ACCORDANCE WITH ALL
APPLICABLE LOCAL AND NATIONAL CODES.
ELECTRICAL GROUND REQUIRED ON ALL STEAMERS.
ELECTRIC SHOCK HAZARD – HIGH VOLTAGE EXISTS WITHIN THIS EQUIPMENT.
THERE ARE NO USER SERVICEABLE PARTS IN THIS EQUIPMENT.
DISCONNECT ALL ELECTRICAL SUPPLIES WHEN SERVICING THIS EQUIPMENT;
480V GENERATORS HAVE TWO SEPARATE SUPPLIES.
Notes: Jumper factory installed between field wiring terminal blocks to pick off 120VAC for control circuit.
Jumper is not installed for 480V models. Separate 120V+N service required for 480V models.
STEAM VALVE
OPEN LIGHT
OPTIONAL
ROOM1
REFRESH SWITCH
AUTODRAIN CLOCK
(OPTION)
MDRAIN VALVE
OPEN LIGHT
3241-02x
POWER & LEVEL CONTROL
PRINTED CIRCUIT BOARD
L
M
H
HEAT OFF
WATER ON
HEAT OKAY
WATER OFF
LEVEL PROBES
ON/OFF
AUTODRAIN
SOLENOID
(OPTION)
MANUAL OPEN DRN
ROOM
STATUS
LEDS
CONTROL
CIRCUIT
FUSE
3 AMP
NON TIME
DELAY
N
NEUTRAL
GND
120V
L1
FEEDWATER
RELAY
ON/OFF
STEAMBATH
ONBATH
OPTIONAL
ROOM1
ON/OFF SWITCH
OFF
ROOM TEMPERATURE
6
7
8
9
10
4
5
3
2
1
STEAMBATH
BATH ON
ROOM1
TEMPERATURE
SENSOR
ROOM1
THERMOSTAT
WATER VALVE
OPEN LIGHT
ROOM-1
RELAY ROOM1 LOCKOUT
CLOSE VALVE
NORMAL STM ROOM 1
STEAM
OUTLET
SOLENOID
STOP FILL NORMAL
OFF
FEEDWATER
SOLENOID
2
H 0
BOILER ON
LIGHT
BOILER
OPERATION
MANUAL
RUN
CLOCK
RUN
RUN CLOCK
(OPTION)
MNORMAL
HEAT
OPEN
ON RISE
HEAT
RELAY
OPEN
ON RISE
BOILER HEATING LIGHT
HEAT CONTACTORS
PRESSURE
SWITCH 2
PRESSURE
SWITCH 1
1-PHASE ELEMENT WIRING
3-PHASE ELEMENT WIRING
208/240/480VAC 3 PHZ
208/240VAC 1 PHZ
NOT
USED
L2
N
L1
L2
L3
ELEMENT
ASSEMBLY
1
ELEMENT
ASSEMBLY
1
23
23
120V
STEAMBATH
6
ROOM TEMPERATURE
ON/OFF
8
7
BATH
10
9
ON/OFF
4
5
3
1
ON
OFF
2
STEAMBATH
BATH ON
ROOM2
TEMPERATURE
SENSOR
OPTIONAL
ROOM2
REFRESH SWITCH
OPTIONAL
ROOM2
ON/OFF SWITCH
ROOM2
THERMOSTAT
STEAM VALVE
OPEN LIGHT
ROOM 2
STEAM
OUTLET
SOLENOID
ROOM2 LOCKOUT
ROOM-2
RELAY
DRAIN
RELAY
R
D
OFF
STM
NORMAL
CLOSE VALVE
ROOM 2 CONTROLS AND STEAMVALVE
ARE OPTIONAL AND MAY NOT BE INSTALLED
FIELD WIRING
FIELD WIRING
120V JUMPER NOT USED ON 480V MODELS
120V JUMPER NOT USED ON 480V MODELS
FIELD WIRING
L1
208VAC 3 PHZ 30kW to 42kW
240VAC 3 PHZ 30kW to 48kW
480VAC 3 PHZ 30kW to 48kW
L2
L3
ELEMENT
ASSEMBLY
12
ELEMENT
ASSEMBLY
1 2
3
3
ROOM2
TEMPERATURE
SENSOR
OPTIONAL
ROOM2
REFRESH SWITCH
OPTIONAL
ROOM2
ON/OFF SWITCH
ROOM2
THERMOSTAT
STEAM VALVE
OPEN LIGHT
ROOM 2
STEAM
OUTLET
SOLENOID
ROOM2 LOCKOUT
ROOM-2
RELAY
DRAIN
RELAY
R
D
OFF
STM
NORMAL
CLOSE VALVE
ROOM 2 CONTROLS AND STEAMVALVE
ARE OPTIONAL AND MAY NOT BE INSTALLED
AUTODRAIN CLOCK
(OPTION)
MDRAIN VALVE
OPEN LIGHT
3241-02x
POWER & LEVEL CONTROL
PRINTED CIRCUIT BOARD
L
M
H
HEAT OFF
WATER ON
HEAT OKAY
WATER OFF
LEVEL PROBES
ON/OFF
AUTODRAIN
SOLENOID
(OPTION)
MANUAL OPEN DRN
ROOM
STATUS
LEDS
CONTROL
CIRCUIT
FUSE
3 AMP
NON TIME
DELAY
N
NEUTRAL
GND
120V
FEEDWATER
RELAY
ON/OFF
STEAMBATH
ONBATH
OPTIONAL
ROOM1
ON/OFF SWITCH
OFF
ROOM TEMPERATURE
6
7
8
9
10
4
5
3
2
1
STEAMBATH
BATH ON
ROOM1
TEMPERATURE
SENSOR
ROOM1
THERMOSTAT
WATER VALVE
OPEN LIGHT
ROOM-1
RELAY ROOM1 LOCKOUT
CLOSE VALVE
NORMAL STM ROOM 1
STEAM
OUTLET
SOLENOID
STOP FILL NORMAL
OFF
FEEDWATER
SOLENOID
2
H 0
BOILER ON
LIGHT
BOILER
OPERATION
MANUAL
RUN
CLOCK
RUN
RUN CLOCK
(OPTION)
MNORMAL
HEAT
OPEN
ON RISE
HEAT
RELAY
OPEN
ON RISE
BOILER HEATING LIGHT
HEAT CONTACTORS
PRESSURE
SWITCH 2
PRESSURE
SWITCH 1
STEAM VALVE
OPEN LIGHT
OPTIONAL
ROOM1
REFRESH SWITCH
STEAMBATH
6
ROOM TEMPERATURE
ON/OFF
8
7
BATH
10
9
ON/OFF
4
5
3
1
ON
OFF
2
STEAMBATH
BATH ON
WIRING: AI 30, AI 36, AI 42 and AI 48
ALL WIRING MUST BE INSTALLED BY A LICENSED ELECTRICAL CONTRACTOR IN ACCORDANCE WITH ALL
APPLICABLE LOCAL AND NATIONAL CODES.
ELECTRICAL GROUND REQUIRED ON ALL STEAMERS.
ELECTRIC SHOCK HAZARD – HIGH VOLTAGE EXISTS WITHIN THIS EQUIPMENT.
THERE ARE NO USER SERVICEABLE PARTS IN THIS EQUIPMENT.
DISCONNECT ALL ELECTRICAL SUPPLIES WHEN SERVICING THIS EQUIPMENT;
480V GENERATORS HAVE TWO SEPARATE SUPPLIES.
Notes: Jumper factory installed between field wiring terminal blocks to pick off 120VAC for control circuit.
Jumper is not installed for 480V models. Separate 120V+N service required for 480V models.
STARTING THE GENERATOR FOR THE FIRST TIME
Before applying power to the generator for the first time: On the electrical box’s front panel set all rocker switches to
the left, their normal operating position. If installed, set the optional Run Clock so the generator is off (no orange
showing in area above pointer) and make sure the water supply is connected to the generator and turned on.
Open the valves on the glass water gauge all the way (counterclockwise).
Open the pressure gauge valve (handle horizontal). or
If the CoolFlush™ Auto Drain option is not installed, close the manual
drain ball (handle up).
If the optional electronic CoolFlush™ Auto Drain is installed, open
the manual drain ball valve as shown (handle pointing towards
electronic valve). Set the Drain Clock to an off position (no orange
showing in area above pointer).
Set the room thermostat(s) to the OFF position.
Turn on the electrical service to the boiler. All lights and valves should be off at this point.
Set the BOILER OPERATION switch to the right (red showing) or set the optional run clock to a “RUN” position
(orange area above the pointer). The BOILER ON light, both room STEAM VALVE OPEN lights and the WATER
VALVE OPEN light should turn on and the boiler will start filling with water. The water will become visible in the
water gauge a short time later. When the maximum water level is reached, the feedwater valve and its light will
turn off, the steam valve lights will turn off, the BOILER HEATING light will turn on and the heating element
contactors will close. The boiler will continue heating until it reaches its operating pressure of approx. 4 to 5 psi,
then the BOILER HEATING light and the contactors will turn off. The first time the generator fills after power is
supplied, it will fill to the maximum level then drain to just below maximum as part of its level testing. During
normal operation, the water level should always be visible in the lower half of the gauge glass.
Check for steam and water leaks. Repair any leaks before continuing.
NOTE: When the boiler is started with an empty tank, the room steam valves will open to release the air
pressure created during water fill. Once the tank has filled, the valves will operate normally, opening only when
steam needs to be released to a room to increase its temperature. Also, whenever a steam valve opens to
release steam to a room, the boiler heating is disabled for a few seconds. This is designed to increase the
elements’ working life.
Turn the thermostat(s) on to begin heating the steam room(s). If an (optional) I60 room switch is installed, set
the thermostat to the desired temperature and press the I60 switch to start the steam bath and begin heating the
room. The status LEDs on the thermostat(s), switches and boiler will light and remain on continuously when the
steam bath is on and operating normally.
OPERATING INSTRUCTIONS The AI model steam generators are based on two operating systems. The first
is the generator itself, maintaining water levels and boiling the water to create steam for use in a steam bath.
The second is the steam room control circuit, maintaining a comfortable steam bath by releasing steam from the
generator only when needed to raise the temperature in the steam room. The generator’s control circuit board is
used for both systems so the generator must be running before starting a steam bath. And the generator may
run continuously without affecting the steam room temperature. In this way the generator can be left running so
it is ready to produce steam immediately when the thermostat (or optional I60 room switch) is used to start a
steam bath.
BOILER START The generator operation may be started in one of two ways.
1. To start the generator manually, place the BOILER OPERATION switch (located on the generator’s switch
panel) to its MANUAL RUN position. The switch will show a red color at its left side to indicate that it has
been turned on and the BOILER ON light will turn on to show the generator is running. If an optional Run
Clock is installed, this manual switch will start the generator regardless of the clock setting and the
generator will continue to run until the switch is returned to the CLOCK RUN position.
2. To start the generator using the optional Run Clock, leave the BOILER OPERATION switch in its CLOCK
RUN position. Program the Run Clock to the desired on (RUN) and off periods. To determine if the clock
is switching properly, rotate the dial to the right: when an on period is reached the BOILER ON light will
turn on and the generator will fill and heat as necessary. Continue rotating the clock dial until the clock is
reset to the current time. Check the Run Clock dial later in the day to ensure it is maintaining time
correctly.
Normal generator operation controls water fill and heating using three water levels. The lowest level serves as a
low water cut-off safety level: if the water level drops too far the heating elements are turned off to prevent
damage. When the water level is near the bottom of the water gauge glass, there is enough water in the tank to
allow heating it safely. When the water level reaches near mid-glass, the water level has reached its maximum
depth and the water valve will close until the level drops to near the bottom of the glass again.
Water heating is controlled by the operating pressure switch. While there is enough water in the tank to allow
heating, the elements will be energized if the pressure in the tank is below the switch setting (about 3 psi) and
the water will be heated until enough steam pressure is generated to build up pressure in the tank to about 5 psi.
At this point the elements are turned off until the pressure drops again.
If the steam bath is not turned on, no steam will be released to the room and the generator will need to boil the
water only to make up for temperature loss from the generator itself. During a steam bath, particularly during
initial heating, the generator may need to heat continuously to compensate for the steam being released to the
steam room. The generator may not build up any pressure during this period.
When the generator is started with an empty tank, the steam outlet valve(s) will open to release air pressure
created by adding water. If not released, this air pressure could be sensed by the pressure switch, preventing
heating. The heat will turn on, the water valve will close and, if the steam bath is not turned on, the steam
valve(s) will close when the water reaches its maximum depth.
STEAM ROOM OPERATION The steam room begins heating when the thermostat or room switch is used to
“turn on” the steam bath. While the steam bath is on, steam is released to the room as needed to bring the
temperature up to the thermostat setting. When the generator supplies two rooms, the room operations are
identical but independent. Only one room will be described here.
The thermostat sets the room temperature using a 1 to 10 scale, with 1 being the coolest at about
90°F and 10 the hottest at about 124°F. These are the steam room temperatures sensed by the
temperature sensor near the ceiling. For bather safety and to prevent damage to the steam
room, never attempt to force these temperatures higher!
The thermostat has an OFF position to turn the steam bath off (prevent heating) if an I60 switch
option is not installed. When the bath is turned off, the generator’s steam valve will remain
closed and the thermostat LED, the Refresh™ switch’s LED and the corresponding ROOM
STATUS LEDs on the generator will remain turned off. When the thermostat is turned to the temperature setting
part of the dial, the steam bath is turned on and all of the corresponding LEDs will light.
For the steam bath to be on whenever the generator is running, leave the thermostat set to the desired
temperature setting. A few seconds after the generator is started, the room’s LEDs will light and it will begin
heating as soon as steam is available. Do not install an I60 option when using continuous operation. Verify the
JP1 jumper is on only one pin – refer to the Room Switch Installation section for details.
THE I60 SWITCH option is intended for steam rooms with only intermittent use. When the I60 is
installed, the thermostat’s off position is the same as the lowest temperature setting and has no
effect on the generator operation. The generator runs, holding steam under pressure until the
user is ready to start a steam bath. The thermostat should be left preset to the desired room
temperature. Press the I60 to start the steam bath. The room’s LEDs will light once the bath is
started. To stop the steam bath, press the I60 switch again or wait and it will turn off
automatically 60 minutes after it was started. If the generator supplies two rooms, both must use
the same type of switch: if one uses an I60 switch the other must as well. Verify the JP1 jumper
is on both pins – refer to the Room Switch Installation section for details.
THE REFRESH™ SWITCH option gives the bather a more immediate control over the steam bath conditions.
By pressing the Refresh™ switch during a steam bath, an extra burst of steam is added to the room regardless
of the steam room temperature. This may be used to compensate for sudden cooling caused by someone
opening the steam room door, for instance. An LED on the Refresh™ switch lights to indicate that the steam
bath is turned on and an extra burst of steam is available. Once the switch is pressed, the switch’s LED turns off
and steam is released to the room for about 10 seconds. The extra steam released to the room adds a little heat
and steam to “refresh” the steam cloud and stir the room’s air, helping to reduce cold spots. There is a 2 minute
delay after the Refresh™ switch is pressed before its LED turns on again and another steam burst is available.
This wait period is designed to prevent a bather from accidentally overheating the room. Generally, if the room
has cooled enough to need a second Refresh™ burst it will have cooled enough to require normal heating, too.
LIGHTS AND SWITCHES are provided to show generator operating status, to indicate
fault conditions and to allow manual control of generator functions for routine
maintenance and troubleshooting. During normal steam bath operation, the ROOM
STATUS LEDs on the generator will light steadily. When the optional Refresh™ switch
is installed, the bottom room status LED will turn off for two minutes while Refresh™ is
in use. These LEDs will blink in specific patterns to indicate problems with the steam
bath temperature control or generator water level control.
When the generator is operating normally, the BOILER ON light will be lit. All switches
will be set to the left except the BOILER OPERATION switch will be set to MANUAL RUN
(unless an optional Run Clock is installed).
The generator’s STEAM VALVE OPEN lights will turn on when steam is released to heat
the corresponding steam room. Set a room’s ROOM LOCKOUT switch to the CLOSE
VALVE position to prevent steam being released to that room during servicing, room
cleaning, etc.
Whenever the generator is operating, the contactors will close as needed to turn on the
heating elements, heating the generator’s water and creating steam. The BOILER
HEATING light turns on when the elements are turned on. Place the HEAT switch in the
OFF position to prevent heating, such as during manual drain/blowdown. NOTE:
whenever a steam valve opens to release steam to a room, the boiler heating is
disabled for a few seconds. This is designed to increase the elements’ working life.
C
L
O
C
K
CAUTION: Improperly opening drain may release dangerously
hot water or steam. Refer to Operating Maintenence Instructions.
BLOWDOWN/FLUSH BOILER DAILY
Blowdown/flush boiler at least once a day for commercial/hard-use installationsand
in areas of hard water. Failure to properly maintain boiler can cause equipment
failure and may void warranty. Refer to Operator Maintenence Instructions.
MANUAL
OPEN
DRAIN
VALVE
OPEN
ROOM STATUS
BOILER OPERATION
ROOM1 LOCKOUT
IF LIGHTS ARE
BLINKING REFER
TO OPERATING
INSTRUCTIONS
ROOM2 LOCKOUT
ELECTRONIC DRAIN (OPTIONAL)
N
O
R
M
A
L
N
O
R
M
A
L
N
O
R
M
A
L
FEEDWATER
HEAT
(OPTIONAL)
CLOCK RUN
R
O
O
M
1
C
L
O
S
E
BOILER
HEATING
O
F
F
WATER
VALVE
OPEN
STOP
FILL
V
A
L
V
E
STEAM
VALVE
OPEN
STEAM
VALVE
OPEN
MANUAL
RUN BOILER ON
R
O
O
M
2
CONTROLS
3A 250VAC
MAX. CAPACITY
SAUNATEC, INC., WOODINVILLE, WA, U.S.A.
CERTIFIED AND MANUFACTURED BY:
MAX. WORKING PRESSURE: STEAM, 15 psi
lb.s PER HOUR
ASME MARKINGS LOCATED ON SHELL
MODEL
SERIAL No. YEAR BUILT
VAC 50/60 Hz
MAX. kW AMPSPHASE
LISTED
BOILER
C
10 023
42208
000
368
73
When the feedwater valve opens to refill the generator, the WATER VALVE OPEN light will turn on. Set the
FEEDWATER switch to STOP FILL to prevent water fill, such as during manual drain/blowdown.
The optional electronic Auto Drain valve is normally closed, opening only when power is supplied by a Drain
Clock or by the ELECTRONIC DRAIN switch to start drain/blowdown. When the Auto Drain valve is opened, the
DRAIN VALVE OPEN light will turn on. Normal operation is controlled by a clock: Use the ELECTRONIC DRAIN
switch to open the drain without resetting the clock. This switch has no effect when the electronic drain valve is
not installed. The manual drain ball valve must be left in the open position for the electronic Auto Drain to
function. There is a delay between seeing the DRAIN light turn on and the drain valve opening. This delay could
be a minute or more.
ROUTINE MAINTENANCE The generator and controls should require very little maintenance. We recommend
checking water level control periodically and frequent draining of the tank to ensure continued safe operation.
Check for smooth, rapid flow when filling or draining the generator. Also look at the generator frequently to check
for leaks and periodically check for loose or overheated wires and for indications of corrosion.
WATER LEVEL CONTROL Your local code may require a low water cut-off test at certain intervals. This is a
good idea whether or not it is required. We recommend checking water level controls at least monthly.
CAUTION A hot generator can result in very hot water and steam being released to the drain and the operator
may be exposed to dangerously high temperatures on fittings, valves and pipes. This test may be done while the
generator is cold.
To check the water level control circuit, first start the generator using the BOILER OPERATION switch.
Set the
HEAT switch OFF. Turn on the steam bath and verify the
room’s steam valve is open (this will help the generator drain more
quickly in the following steps). Adjust the thermostat as needed to
open the steam valve.
Check the water level showing in the gauge glass: when the level rises
above the middle of the glass, the water valve should close and stop
filling the generator.
Open the generator’s drain and reset the HEAT switch to its NORMAL
position: the BOILER HEATING light will turn on and the heating
contactors will close.
Watch the water level in the gauge glass: as the level reaches a depth
of about 1/3 of the glass, the water valve will turn on again.
Set the
FEEDWATER switch to STOP FILL and the water valve will close.
Allow the water to continue to drain and watch the level in the glass.
When the water level drops to about ½” depth in the glass, the BOILER
HEATING light will turn off and the heat contactor will open. This is the
low water cut-off level.
Set the
BOILER OPERATION switch to off, close the drain and reset all
switches to their NORMAL position. Reset the thermostat to its original
position. The generator is now ready for normal operation again.
BLOWDOWN/ CoolFlush™ Auto Drain The generator is supplied with a manual drain valve and may be
equipped with an (optional) electronic Auto Drain valve. An Auto Drain valve is always a good idea to easily
schedule frequent draining. Rinsing or other cleaning of the tank is a manual operation. Draining the tank,
particularly while under pressure, is often referred to as “blowdown.” To avoid confusion, we will refer to
emptying the generator’s tank as “draining” here.
When water is changed to steam, solids may be left behind, eventually interfering with the water level sensing
and possibly causing premature element failure. Frequent draining and periodic cleaning of the tank is
necessary to help reduce the build-up of these solids (scale and sludge). Every installation is unique in its water
quality and maintenance requirements. Symptoms of excessive build up include faulty water level sensing,
gauge glass stained or water level not changing, plugged/slow running drains and early element failure. Draining
the boiler tank at least once a day is recommended even with good water, much more often could be necessary
as water quality drops. For reliable operation, your site may require water treatment.
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