Carel humiFog User manual

humiFog - UA
Pressure Atomizing Multi-Point
Zone Control Panel
User manual
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THESE INSTRUCTIONS

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WARNINGS
BEFORE INSTALLING OR HANDLING THE HUMIDIFIER PLEASE CAREFULLY READ AND FOLLOW THE INSTRUCTIONS AND
SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ON THE LABELS ATTACHED TO THE humiFog.
CAUTION: ALWAYS DISCONNECT THE MAIN POWER BEFORE OPENING OR SERVICING THE HUMIDIFIER!
This appliance has been designed exclusively to directly humidify in ducts and AHUs through the atomizing rack.
The quality of the water used affects the operation of this unit, so the humiFog must be supplied with treated water (Reverse
Osmosis or Deionized). The installation, use, and maintenance operations must be carried out according to the instructions
contained in this manual and on the labels applied internally and externally.
IMPORTANT: BEFORE beginning installation:
Check for shipping damage to carton. Mark the shipping waybill accordingly.
Open cartons and check for any hidden damage. Mark the shipping waybill accordingly.
Check packing slip to ensure all items have been received. Notify CAREL of any shortages or damaged parts. You must
notify CAREL within 5 working days of any shortages.
The conditions of the environment and the power supply voltage must comply with the specified values listed on the data
label in the humidifier.
All other uses and modifications made to the humidifier that are not authorized by the manufacturer are considered
incorrect, and the manufacturer assumes no liability for the consequences of any such unauthorized use.
Please note that the humidifier contains powered electrical devices and high pressure components.
All service and/or maintenance operations must be performed by qualified personnel who are aware of the necessary
precautions and are capable of performing the operations correctly.
Disconnect the humidifier from the main power supply before accessing any internal parts.
The humidifier must be installed in accordance with all local and national standards.
WARNING: Your humidifier requires water to operate. Do NOT mount it above materials or machinery that could be
damaged if a leak occurs. CAREL assumes no responsibility for consequential or inconsequential damage as a result of any
leaks.
Disposal of the parts of the humidifier: The humidifier is made up of metallic and plastic parts. All parts must be disposed of
according to the local standards on waste disposal.
Warranty on materials: 2 years (from the date of production, excluding the consumable parts).

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TABLE OF CONTENTS
1.HOW THE humiFog WORKS .................................................................................................................4
2.COMPONENTS.......................................................................................................................................5
2.1Main pumping station........................................................................................................................................5
2.2Microprocessor control system.......................................................................................................................5
2.3Atomizing nozzles..............................................................................................................................................6
2.4Distribution.........................................................................................................................................................6
2.5Zone Control Panels..........................................................................................................................................6
2.6Zone Control PaneL Dimensions and weights................................................................................................7
2.7zone control cabinet components....................................................................................................................8
3.MODELS ................................................................................................................................................8
3.1Zone Control PANEL CODING GUIDE..............................................................................................................8
4.ZONE CONTROL CABINET POSITIONING AND MOUNTING................................................................9
4.1Zone Control Positioning and Mounting NOTES.............................................................................................9
4.2Zone Control PANEL CLEARANCES................................................................................................................9
4.3Zone Control drilling template........................................................................................................................10
5.ELECTRICAL WIRING...........................................................................................................................10
5.1Wiring Connection Layouts (UAZN***108).....................................................................................................10
5.2Wiring Connection Layouts (UAZN***109).....................................................................................................11
5.3DETAILS OF (2) AND (3) TERMINAL BLOCKS (UAZN***108) .......................................................................12
5.4DETAILS OF (2)(TBS1) AND (3)(TBS3,TBS4) TERMINAL BLOCKS (UAZN***109) ......................................12
5.5Electrical Wiring...............................................................................................................................................13
5.6Control signals from external voltage-free contact (humidistat)(UAZN***108).................................................14
5.7Modulating control signal(UAZN***108) .........................................................................................................15
5.8control signal Wiring (UAZN***109) ................................................................................................................16
5.9Solenoid Valve connection For Distribution System (UAZN***108).............................................................17
5.10Solenoid Valve connection For Distribution System (UAZN**109)..............................................................18
5.11Cumulative alarm relay (J15)..............................................................................................................................19
5.12Inputs from external devices..............................................................................................................................19
5.13Supervisor Network.........................................................................................................................................19
5.14Pumping Station to Multi Zones .....................................................................................................................20
5.15Duplex Control Wiring / Multiple zones per Air HandleR..............................................................................21
6.START-UP ............................................................................................................................................22
6.1Startup Checklist..............................................................................................................................................22
6.2Re-addressing the Controllers and Displays for Multi-zone or Duplex Systems.......................................22
6.3Re-addressing PCO3 controller......................................................................................................................23
6.4Re-addressing PGD display............................................................................................................................23
7.THE humiFog CONTROLLER...............................................................................................................24
7.1MULTI-ZONE IN SINGLE ahu SETUP OVERVIEW..........................................................................................25
7.2SYSTEM STATUS.............................................................................................................................................25
7.3Main Menu ........................................................................................................................................................26
7.4Service menu....................................................................................................................................................28
7.4.1Service Settings Submenu............................................................................................................................................................29
7.4.2Manual Management Submenu...................................................................................................................................................30
7.5Manufacturer Submenu...................................................................................................................................30
8.REPLACEMENT PARTS ........................................................................................................................32
8.1See specific material list(s) provided with unit. ............................................................................................32
9.WIRING DIAGRAM ..............................................................................................................................33
10.WARRANTY .........................................................................................................................................37

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1. HOW THE humiFog WORKS
The humiFog humidification system is a high pressure atomizing system designed to produce a fine mist that readily
evaporates to raise the relative humidity. The atomizing humidifier is an efficient humidification system that is especially
suitable for larger installations, where high flow-rates of water are required without the necessity of excessive energy
expenditure. When the humidity value in the environment is less then the desired value, as measured by a probe or external
controller, the controller starts the volumetric piston pump, which sends the “treated” water to the nozzles.
The treated water; using a reverse osmosis or deionizer system, is pumped at a pressure of 1000psi (75bar) and sent via the
connection pipes to the atomizing nozzles. The nozzles then reduce the jet of water into a multitude of very fine water
droplets (10-20 microns). Because of the fine droplet size, the water can then easily change its state and vaporize. The energy
required for this transformation is supplied by the ambient air; at a rate of 690 W per liter/hour. Consequently, there is a
decrease in temperature in the environment being humidified, and this process may be useful in many applications (adiabatic
transformation).
The humiFog unit must be supplied with treated water, for the following reasons:
To reduce the introduction into the environment of dust due to the mineral salts found in the untreated water.
To minimize the clogging of the nozzles.
PUMPING STATION
A
TOMIZING MANIFOLDS
800-1,000 psi
Mist Eliminator
A
A
TOMIZING NOZZLES
Fig. 1.a
A - Duct/AHU Distribution
B - Ambient/Room Distribution
(Direct manifolds)
B

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2. COMPONENTS
A humiFog system is made up of the following components:
Pumping station, containing the electrical panel and the volumetric piston pump.
Microprocessor control system.
Distribution system with the atomizing nozzles; for ducts/AHUs or rooms.
Zone control panels for controlling the distribution staging in each zone or AHU.
2.1 MAIN PUMPING STATION
The main pumping station features an energy efficient combination of an advanced Inverter Duty Motor and a Variable Frequency
Drive. This combination allows for the precise control of the volume of outlet water from the positive displacement pump. The
positive displacement pump is a reliable component that is designed for long life and minimal maintenance. By adjusting the
speed of the pump, the pressure and the flow rate of the nozzles are precisely modulated according to the requirements of the
application. The station also incorporates a user friendly display, allowing the user to visually change set points, and other user-
modified fields.
The main pumping station controls the water output using “Constant Pressure” principles. This type of control allows a single
pumping station to supply humidification to multiple ducts/AHUs or rooms. In this setup, the humiFog controller manages the
speed of the pump according to the “Constant Pressure” set point, increasing the speed if the pressure decreases (opening more
zones/branches of the circuit) and decreasing the speed if the pressure increases (closing one or more branches of the circuit).
With this configuration, the humiFog controller can manage the humidity control and distribution directly (one zone/AHU); or the
distribution control is managed by an additional external zone controller (multiple zones/AHUs).
2.2 MICROPROCESSOR CONTROL SYSTEM
No. Description
1 Electric motor
2 Piston pump
3 Electrical cabinet
4 Controller-display
5 Low pressure hydraulics
6 Motor/pump drive assembly
7 Low pressure water inlet
8 High pressure water outlet
9 Drain water outlet-thermal valve
10 Drain water outlet-relief valve
11 Water filter
Fig. 2.b
The humiFog control system is based on the latest, state of the art, CAREL pCO
programmable controller. This controller operates a Variable Frequency Drive to
modulate water pressure and water flow according to requirements. Control can be
stand-alone using humidity and temperature sensors, or the system can be controlled by
a DDC signal. Modbus, BACnet, Echelon and TCP/IP protocol interface is available. A LAN
(Local Area Network) connection allows up to 32 systems to be connected to share sensor
information, or even operate redundantly.
Tab.2.a

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Fig. 2.c Fig. 2.d
2.3 ATOMIZING NOZZLES
The humiFog atomizing nozzles are constructed of stainless steel and are available in three capacities: 3.3, 6.2
& 8.8 lbs/hr (1.5, 2.8 & 4.0 kg/hr). Working on the centrifugal/whirljet principle, they have no targets to drip or
require adjustment. An internal 60 micron filter is used to prevent jamming of the nozzle, and a special
internal valve closes the orifice to avoid dripping and prevent any ambient contamination when the nozzle is
off. The nozzles are mounted uniformly in the distribution manifolds.
2.4 DISTRIBUTION
The following diagrams illustrate the typical applications in ducts (Fig. 2.c) or directly in the rooms (Fig. 2.d).
The ambient humidity is measured by a probe (1), or receives a command signal from an external controller, and is read by the
controller contained in the humiFog pumping station (6). The controller then compares the humidity measured in the room
against the humidity set point, starting, when necessary, the production of the pump. The demineralized water produced by the
water treatment system (7) is brought to high pressure by the humiFog pump (6), sent to the manifolds for distribution into the
duct or directly into the room (5), and then atomized by the nozzles (4). The percentage of water fog evaporated depends on the
temperature and speed of the air, as well as on the relative humidity reached. In duct applications, any non-evaporated droplets
are separated by a mist eliminator filter or cooling coil (2), collected in the bottom tank (3) and immediately discharged. The
control system built into the pumping station controls the banks of nozzles supplied with solenoid “zone” valves.
2.5 ZONE CONTROL PANELS
The humiFog Zone Control Panels utilize the latest state-of-the-art CAREL pCO programmable controller. This controller
operates the distribution system, by interfacing with the selected control system, and then controlling the water solenoid valves
for appropriate modulation. Control can be stand-alone using humidity and temperature sensors, or the system can be controlled
by a DDC signal. Modbus, BACnet, Echelon and TCP/IP protocol interface is available. A LAN (Local Area Network) connection
allows up to 32 Controller devices to be connected to share sensor information, or even operate redundantly. The zone control
cabinets are also used to control each zone, in a multi-point humiFog system. In this type of system, all of the zone control panels
communicate to each other, and to the pumping station panel, by a pLAN network.
Multi zone setup configuration may involve multiple zones within the same air handler. There are two primary methods
of how to distribute water through a multi zone setup, parallel or staged control. With parallel control, each zone connected to
the pumping station will be activated simultaneously and operate at the same output level. Staged control will run one zone to its
maximum capacity before activating the next zone. This choice will affect the zone demand display of the zone control cabinets,
as described in the section 7.1 of this manual.
Duct or AHU Ambient

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2.6 ZONE CONTROL PANEL DIMENSIONS AND WEIGHTS
Weight Table, UAZN***108
weight installed
lbs / kg 53 / 24
weight packaged
lbs / kg 66 / 30
Weight Table, UAZN***109
weight installed
lbs / kg 142 / 64.1
weight packaged
lbs / kg 190 / 86.2
3.5" [89.6mm]
1.6" [39.7mm]
3.3" [82.6mm]
5.9" [150.0mm]
1.2" [30.0mm]
2.4" [59.7mm]
7.6" [193.4mm]
2.4" [62.2mm]
ON / OFF SWITCH
PROBE CABLE INLETS
19.7" [500.3mm]
22.9" [580.5mm]
4.8" [122.5mm]
8.8" [223.0mm]
2.1" [52.3mm]
8.8" [223.0mm]
2" [51.0mm]
4.8" [122.5mm]

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2.7 ZONE CONTROL CABINET COMPONENTS
3. MODELS
3.1 ZONE CONTROL PANEL CODING GUIDE
Zone Control Panels
UA ZN 0 YYYY U
humiFog Zone Control
Cabinet Type of Cabinet Available – Sequencing Number Custom
0 = Standard U= USA
Key (UAZN***108)
1 terminal rear view
2 transformer B
3 main switch G
4 power supply terminal block
5transformer primary fuse carrier (TRA:F1,F2;TRB:F3,F4)
6transformer B secondary fuse carrier (F8)
7 transformer A
8 electronic controller
9 control terminal block with fuses
Key(UAZN***109)
1 PGD
2 main switch G
3 Transformer A
4 Transformer B
5 Transformer C
6 Transformer A fuse carriers (F1,F2)
7 Transformer B fuse carriers (F4,F5)
8 Transformer C fuse carriers (F9,F10)
9 Fill and Drain fuse carriers (FU7, FU8, FU11, FU12)
10 Controller Wiring fuse carrier (FU6)
11 Customer Power, Sensor and Alarm Terminal Blocks (TBS1)
12 Power Supply Terminal Blocks (TBS2)
13 Fill/Drain Solenoid Terminal Blocks (TBS3, TBS4)
14 Solenoid Valve Relays (RD1-9,RF1- 9,RV1)
15 electronic controller
6
275
8
9
1
4
3

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UNIT CLEARANCES (UAZN***108)
FACE OF UNIT DIM (IN) DIM (MM)
FRONT (D) 24 610
LEFT SIDE (B) 4 102
RIGHT SIDE (A) 4 102
TOP (C) 12 305
Tab. 4.b
UNIT CLEARANCES (UAZN***109)
FACE OF UNIT DIM (IN) DIM (MM)
FRONT (A) 24 610
LEFT SIDE (B) 4 102
RIGHT SIDE (C) 4 102
TOP (D) 12 305
Tab. 4.b
4. ZONE CONTROL CABINET POSITIONING AND MOUNTING
4.1 ZONE CONTROL POSITIONING AND MOUNTING NOTES
The humiFog zone control cabinets are designed to be wall mounted. There are appropriate holes in the back of the
cabinet, for mounting to the wall. Use appropriate fasteners for supporting the weight of the cabinet and its components. Maintain
clearances around the cabinet as noted below. This allows for proper ventilation, maintenance and user operation of the cabinet.
The cabinet should be placed locally centered to the pumping station, and distribution zone points. For ducted systems, the zone
control cabinet should be close to the duct/AHU. For ambient systems, the zone control cabinet should be mounted centrally to
the zone areas.
IMPORTANT NOTE: The maximum distance between the zone control cabinet and the rack/distribution is 50ft
(15meters). It is recommended that the unit be fixed in position so that the electrical connections do not become damaged.
All connecting wiring is done by installer. Certain clearances must be maintained around the unit for safety and
maintenance.
The cabinet can be placed wherever the following conditions are met:
Cabinet protection index: IP20 / Nema Type 1 (unless specified otherwise)
Operating conditions: 20-80% RH non condensing, 34-104ºF (1-40ºC)
Storage conditions: 10-90% RH non condensing, 34-122ºF (1-50ºC)
4.2 ZONE CONTROL PANEL CLEARANCES
AB
D
C

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4.3 ZONE CONTROL DRILLING TEMPLATE
5. ELECTRICAL WIRING
5.1 WIRING CONNECTION LAYOUTS (UAZN***108)
Drilling Hole Conversion Table
Dimension mm in
Upper Horizontal 440 17.32
Lower Horizontal 200 7.87
Vertical Space Between Horiz. 390 15.35