Carel gaSteam 45 HD003 User manual

High Efficiency Solutions
gaSteam 45/90/180 HD003
45/90/180 HD103
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
hardware
User manual
Manuale d’uso

3
ENG
“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
IMPORTANT WARNINGS
The CAREL humidifiers are advanced products, whose operation is specified
in the technical documentation supplied with the product or can be
downloaded, even prior to purchase, from the website www.carel.com. Each
CAREL product, in relation to its advanced level of technology, requires setup/
configuration/programming/commissioning to be able to operate in the
best possible way for the specific application. The failure to complete such
operations, which are required/indicated in the user manual, may cause the
final product to malfunction; CAREL accepts no liability in such cases.
The customer (manufacturer, developer or installer of the final equipment)
accepts all liability and risk relating to the configuration of the product in
order to reach the expected results in relation to the specific final installation
and/or equipment. CAREL may, based on specific agreements, acts as a
consultant for the installation/commissioning/use of the unit, however in no
case does it accept liability for the correct operation of the humidifier and the
final installation if the warnings or suggestions provided in this manual or in
other product technical documents are not heeded. In addition to observing
the above warnings and suggestions, the following warnings must be heeded
for the correct use of the product:
DANGEROF ELECTRICSHOCK
The humidifier contains live electrical components. Disconnect the mains
power supply before accessing inside parts or during maintenance and
installation;
DANGEROF WATERLEAKS
The humidifier automatically and constantly fills/drains certain quantities of
water. Malfunctions in the connections or in the humidifier may cause leaks;
DANGEROF BURNS
The humidifier contains high temperature components and delivers steam
at 100°C/212°F.
In the event where there is no demand for steam production for a period
exceeding 24 hours, the unit will automatically empty the cylinder, so as to
avoid stagnation of the water inside. It is recommended to manually empty
the cylinder before switching off the unit at the main switch.
The conditions of the environment, the fuel and the power supply voltage
must comply with the specified values.
All other uses and modifications made to the appliance that are not authorised
by the manufacturer are considered incorrect.
Liability for injury or damage caused by the incorrect use of the appliance lies
exclusively with the user.
Please note that the appliance is connected to the gas mains, contains live
electrical devices and hot surfaces.
All service and/or maintenance operations must be performed by specialist
and qualified personnel who are aware of the necessary precautions and are
capable of performing the operations correctly and in accordance with the
safety standards and legislation in force, with specific reference to:
1. Italian law 1083/71: “Safety standards relating to the use of gaseous fuel”;
2. Italian Law no. 46/90:“Safety standards relating to systems in buildings”;
3. Italian Presidential Decree no. 447, December 6, 1991: “Regulations for the
enforcement of law no. 46, dated March 5, 1990, on safety relating to systems
in buildings”;
4. Italian Law 10/91: “Regulations for the enforcement of the national plan for
energy savings and the development of renewable sources of energy”.
Il settaggio di tutte le unità (sottostanti alla normativa UL - 998) per
funzionamento da Gas naturale (settaggio di fabbrica) a gas GPL dovrà essere
effettuato esclusivamente da personale Carel o Service Carel.
Disconnect the appliance from the mains power supply before accessing any
internal parts. The local safety standards in force must be applied in all cases.
Warning
Warning:
The installation of the product must include an earth
connection, using the special yellow-green terminal
available in the humidier.
The environmental and power supply conditions must conform to the values
specified on the product rating labels.
The product is designed exclusively to humidify rooms either directly or
through distribution systems (ducts).
Only qualified personnel who are aware of the necessary precautions and able
to perform the required operations correctly may install, operate or carry out
technical service on the product.
Only water with the characteristics indicated in this manual must be used for
steam production.
All operations on the product must be carried out according to the instructions
provided in this manual and on the labels applied to the product. Any uses
or modifications that are not authorised by the manufacturer are considered
improper. CAREL declines all liability for any such unauthorised use. Do not
attempt to open the humidifier in ways other than those specified in the
manual.
Observe the standards in force in the place where the humidifier is installed.
The appliance is not intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or lack of experience
and knowledge, unless they have been given supervision or instruction
concerning use of the appliance by a person responsible for their safety.
Do not install and use the product near objects that may be damaged when
in contact with water (or condensate). CAREL declines all liability for direct or
indirect damage following water leaks from the humidifier.
Do not use corrosive chemicals, solvents or aggressive detergents to clean
the inside and outside parts of the humidifier, unless specifically indicated in
the user manual.
Do not drop, hit or shake the humidifier, as the inside parts and the linings
may be irreparably damaged.
CAREL adopts a policy of continual development. Consequently, CAREL
reserves the right to make changes and improvements to any product
described in this document without prior warning.The technical specifications
shown in the manual may be changed without prior warning.
The liability of CAREL in relation to its products is specified in the CAREL general
contract conditions, available on the website www.carel.com and/or by
specific agreements with customers; specifically to the extent where allowed
by applicable legislation, in no case will CAREL, its employees or subsidiaries
be liable for any lost earnings or sales, losses of data and information, costs of
replacement goods or services, damage to things or people, downtime or any
direct, indirect, incidental, actual, punitive, exemplary, special or consequential
damage of any kind whatsoever, whether contractual, extra-contractual or
due to negligence, or any other liabilities deriving from the installation, use or
impossibility to use the product, even if CAREL or its subsidiaries are warned
of the possibility of such damage.
DISPOSAL
The humidifier is made up of metal parts and plastic parts. In reference to
European Union directive 2002/96/EC issued on 27 January 2003 and the
related national legislation, please note that:
1. WEEE cannot be disposed of as municipal waste and such waste must be
collected and disposed of separately;
2. the public or private waste collection systems defined by local legislation
must be used. In addition, the equipment can be returned to the
distributor at the end of its working life when buying new equipment;
3. the equipment may contain hazardous substances: the improper use or
incorrect disposal of such may have negative effects on human health
and on the environment;
4. the symbol (crossed-out wheeled bin) shown on the product or on the
packaging and on the instruction sheet indicates that the equipment
has been introduced onto the market after 13 August 2005 and that it
must be disposed of separately;
5. in the event of illegal disposal of electrical and electronic waste, the
penalties are specified by local waste disposal legislation.
Warranty on the materials: 2 years (from the date of production, excluding
consumables).
Approval: the quality and safety of CAREL products are guaranteed by the
ISO 9001 certified design and production system, as well as by the . and
mark.

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
Content
1. MODELS AND DESCRIPTION OF THE COMPONENTS 7
1.1 Models ................................................................................................................. 7
1.2 Description of the components ...................................................................... 7
2. ASSEMBLY 8
2.1 Receipt and storage............................................................................................ 8
2.2 Positioning and dimensions ............................................................................ 8
2.3 Removal and reassembly of the front cover................................................ 8
3. WATER CONNECTIONS 9
3.1 Characteristics of the supply water................................................................. 9
3.2 Characteristics of the drain water ................................................................... 9
3.3 Pipe connections................................................................................................ 9
3.4 Diagram of water connections........................................................................ 9
3.5 Air inlet and flue connections ..................................................................... 10
3.6 Checks................................................................................................................. 11
3.7 Gas connections............................................................................................... 12
3.8 Venting Requirements for CAREL gaSteam units...................................... 12
4. STEAM DISTRIBUTION 14
4.1 Steam distribution in ducts - linear distributors ...................................... 14
4.2 Positioning the linear distributors in the air ducts................................... 14
4.3 Installation of the steam hose...................................................................... 15
4.4 Installation of the condensate drain pipe.................................................. 15
4.5 Checks ............................................................................................................... 15
5.4 Connection diagram, UG45-90.................................................................... 16
5.5 Connection diagram, UG180.........................................................................17
5.6 Adjusting the humidifier to different types of gas................................... 18
6. MAINTENANCE 20
6.1 Boiler maintenance.........................................................................................20
6.2 Cleaning the burner ....................................................................................... 21
6.3 Operating anomalies - checking the ionisation current......................... 21
6.4 Flue gas temperature sensor ....................................................................... 21
6.5 Water temperature sensor............................................................................ 21
6.6 Fuses ................................................................................................................. 21
6.7 Cooling fan ...................................................................................................... 21
7. OPERATING PRINCIPLE AND OTHER FUNCTIONS 22
7.1 Operating principle..........................................................................................22
8. TECHNICAL SPECIFICATIONS 23
8.1 Thermal-gas supply characteristics..............................................................23
8.2 Flue gas values according to the heat input .............................................23
8.4 Weights..............................................................................................................24
8.3 Dimensions ......................................................................................................24
8.5 Rating plate.......................................................................................................25

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
1. MODELS AND DESCRIPTION OF THE COMPONENTS
1.1 Models
The code that marks the model of humidifier is made up of 10 characters
(Fig. 1.a).
Example: the code UG180HD003 identifies a gas-fired humidifier (UG)
with:
• rated steam production 180 kg/h (180);
• modulating control (H);
• 230 Vac single-phase power supply (D).
UG xxx x x x 0 3
1 2 3 4 5 6 7
Fig. 1.a
1 family prefix
2 rated instant steam production in kg/h: 045; 090 and 180
3 type of control: H= modulating*
4 type:
power supply voltage: D= 230 - 1~N
5 options: 0= 50 Hz version; 1= 60 Hz version
6 not used
7 internal updating use
*= includes the following types of operation: ON-OFF, proportional, humidity
and temperature.
1.2 Description of the components
Fig. 1.b
1 water on-off tap
2 fill solenoid valve
3 foam detection electrode
4 steam outlets
5 boiler
6 flue gas
7 electrical panel
8 flue gas temperature sensor (2 ea. for UG180)
9 level sensor
10 preheating temperature sensor
11 heat exchanger (2 ea. for UG180)
12 air inlet
13 gas line
14 gas on-off tap
15 gas burner (2 ea. for UG180)
16 drain and pre-fill valve
17 filter
18 drain pump
19 drain network
20 conductivity meter
21 drain pipe
22 water line
23 safety thermostat
24 botton tank drain pipe

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
2. ASSEMBLY
2.1 Receipt and storage
• Check that the humidifier is intact upon delivery and immediately
notify the carrier, in writing, of any damage that may be due to careless
or improper transport;
• Move the humidifier to the site of installation before removing it from
the packaging, holding the neck only from below the base;
• Open the cardboard box and pull out the humidifier, remove the layer
of protective material and move the humidifier from the pallet to
the support surface, keeping it vertical at all times; only remove the
protective bag when installing the unit.
Fig. 2.a
2.2 Positioning and dimensions
• For installation choose the most suitable position for the steam
distribution, that is, the position that minimises the length of the steam
outlet pipe (see STEAM DISTRIBUTION). The unit has been designed for
installation on a floor that must be able to support the weight of the
unit in normal operating conditions (see DIMENSIONS AND WEIGHTS).
• The metal casing of the humidifier heats up during operation, and the
top may reach temperatures of over 50°C (122 °F); check that this does
not cause any problems.
• Make sure the humidifier is level, and that the minimum spaces are
respected as indicated in Fig. 2.b, to allow room for maintenance
operations.
WARNING:make sure that the cooling fan outlet grill is not blocked or
covered.
1000 mm min.
(40 inch)
1000 mm min.
(40 inch)
1000 mm min.
(40 inch)
1000 mm min.
(40 inch)
Fig. 2.b
2.3 Removal and reassembly of the front
cover
To remove the front cover of the humidier, proceed as follows (Fig.
2.c):
1. open the side door A;
2. remove the screws (part V) using a screwdriver;
3. hold cover B by the sides, tilt it until it is released from the side supports,
lift it around 2 centimetres and remove it from the hooks on the side
supports;
4. remove the cover.
To close the appliance, proceed as follows (Fig. 2.c):
1. slightly tilt cover B, slide it onto the hooks on the side supports at the
base of the panel;
2. tilt the cover back to vertical, and lightly press it into the side
supports;
3. fasten the locking screws using a screwdriver (part V);
4. close door A.
Fig. 2.c

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
3. WATER CONNECTIONS
Before making the connections, ensure that the unit is disconnected
from the mains power supply.
3.1 Characteristics of the supply water
The water used to supply the humidifier must be legal-standard drinking
water, as the steam produced is used to humidify air that is breathed.
For the optimum operation of the unit, the use of demineralised
water is recommended, and specifically the use of a reverse osmosis
demineralisation system.
Ingeneral,andif nottreatedand subsequentlyanalysed,thecharacteristics
of the supply water must not exceed the limits listed in the Table 3.a.
IMPORTANT WARNING:water treatment using softeners or
polyphosphate metering devices does not reduce the quantity of
dissolved salts and may lead to foam forming, potentially shutting down
operation and causing corrosion of the heating elements.
If such water cannot be avoided, it should be diluted with mains water in
such a proportion as to reduce hardness to a minimum of 40% of the initial
value, and no less than 5°f. In addition, follow the instructions provided in
paragraph 5.1.1 of the control manual - (cod. +030220930).
Water treatment by reverse osmosis demineralisation is allowed; in this
case, follow the procedure described in paragraph 5.1.1. of the control
manual - (cod. +030220930).
It is NOT allowed:
1. the use of well water, industrial water or water from cooling circuits
and, in general, any potentially chemically or bacteriologically
contaminated water;
2. the addition to the water of disinfectants or corrosion inhibiters, as
these are potential irritants.
Warning:
• noreliablerelationshipexistsbetweenthehardnessandtheconductivity
of the water;
• if the water supply comes from an external reverse osmosis system, the
installation must guarantee an instant flow-rate of 20 l/min (5,28 Gal/
min).
Hydrogen ions pH da 6.5 a 8.5
Specific conductivity at 20°C σR,20 °C - μS/cm 1500
Total hardness TH - mg/l CaCO3500
Iron + Manganese - mg/l Fe+Mn 0,2
Chlorides - Mg/l Cl- 50
Silica - mg/l SiO220
Residual chlorine - mg/l Cl20,2
Calcium sulphate - mg/l CaSO4100
Tab. 3.a
A G3/4male fitting is used.
3.2 Characteristics of the drain water
Inside the humidifier the water boils and is transformed into steam,
without the addition of any substances.
The drain water, as a result, contains the same substances that are
dissolved in the supply water, yet in greater quantities, depending on the
concentration in the supply water and the set draining cycles, and may
reach temperatures of 100°C(212 °F) and an instant ow-rate of 32
l/min. (6,60 Gal/min); not being toxic, it can be drained into the sewage
system.
3.3 Pipe connections
The installation of the humidifier requires connection to the gas supply,
water supply and drain pipes.
Fig. 3.a shows the side views of the unit.
The supply water may be connected using a pipe or hose with a minimum
recommended inside diameter of 6 mm. This must be fitted with a shut-
off tap to allow the appliance to be disconnected during maintenance
operations.
It is recommended to use Carel hoses (code FWH3415000).
A mechanical filter should be installed to trap any solid impurities.
The drain water is connected using a section of non-conductive plastic
pipe (preferably) resistant to 100°C (212 °F), with a recommended outside
diameter of 50 mm.
The connection to the gas supply is made using a metal hose (with
vibration-damping joint) supplied, connected to a tap (manual shut-off
valve), with a 1”G fitting for the gaSteam 45 and 90, and a 1” 1/4G fitting
for the gaSteam 180.
In the USA, use the installation kit code UGKINST*.
1
2
3 4
Fig. 3.a
1 gas tap
2 water inlet tap
3 drain fitting
4 drain connection Ø = 20mm
Note: for North American and Canadian Market, see paragraph 3.7.
3.4 Diagram of water connections
IMPORTANT WARNING:the drain pipe must be free, without
backpressure and with a drain trap immediately downstream of the
connection to the humidifier.
1
2
3
4
5
6
Fig. 3.b
1 tap
2 filter
3 supply
4 reverse osmosis water treatment system, if used
5hoses (code FWH3415000) NOT SUPPLIED
6hoses Ø 3/4 not supplied (drain tempering option)

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
3.5 Air inlet and flue connections
The gaSteam humidifier is an approved type C appliance (room-sealed
appliance).
The air intake pipes / flues should be connected according to the
diagrams below.
For further requirements, see the flue accessories available on the
market.
The air intake pipes and flues must be installed and positioned in
compliance with the corresponding legislation and standards in force, as
well as with any national or local provisions (for example, in Italy, the UNI-
CIG 7129, UNI-CIG 7131 standards and their subsequent amendments),
and therefore the validity of the diagrams below should always be
checked.
The maximum lengths indicated in the following installations have been
calculated using CAREL ducting.
3 openings are available for the air intake and flue gas outlet (6 on the
UG180):
• 2 on the top of the humidifier (4 on the UG180);
• 1 at the rear (2 on the UG180).
The humidifier is factory-fitted as follows:
• flue gas outlet from the top of the humidifier;
• air intake from the rear;
• supplied with an inspection section (2 for the UG180), 135 mm long;
• condensate suction 135 mm long.
The condensate section supplied must be assembled and the lateral hole
must be connected to a pipe that acts as a condensate drain, so as to
prevent condensate from causing the burner to malfunction.
Both the flue gas outlet and the air intake can be moved according to the
installation requirements.
dia. of connection (in aluminium or
stainless steel)
Gasteam 45 DP d=80mm d=100mm d=120mm
section of linear pipe l= 1m Pa 2,5 0,85 0,4
90° bend ø80 mm r/d=0,5 Pa 5,6 2,2 1,0
90° bend ø80 mm r/d=1 Pa 2,2 0,9 0,4
45° bend ø80 mm r/d=0,5 Pa 3,3 1,3 0,6
flue terminal ø80 mm Pa 6,6 2,6 1,2
condensate T collection Pa 6,6 2,6 1,2
Expansion of the section Pa 6,6 2,6 1,2
dia. of connection (in aluminium or
stainless steel)
Gasteam 90 DP d=80mm d=100mm d=120mm
section of linear pipe l= 1m Pa 7,7 2,5 1,0
90° bend ø80 mm r/d=0,5 Pa 19,1 7,6 3,6
90° bend ø80 mm r/d=1 Pa 7,4 2,9 1,4
45° bend ø80 mm r/d=0,5 Pa 11,2 4,5 2,1
flue terminal ø80 mm Pa 22,5 8,9 4,2
condensate T collection Pa 22,5 8,9 4,2
Expansion of the section Pa 22,5 8,9 4,2
dia. of connection (stainless steel)
Gasteam 180 DP d=120mm d=150mm
section of linear pipe l= 1m Pa 3,2 1,1
90° bend ø80 mm r/d=0,5 Pa 14,3 5,6
90° bend ø80 mm r/d=0,5 Pa 8,4 3,3
45° bend ø80 mm r/d=1 Pa 5,6 2,2
flue terminal ø80 mm Pa 16,8 6,6
condensate T collection Pa 16,8 6,6
Expansion of the section Pa 16,8 6,6
Tab. 3.b
air
fumes
alternative air inlet/fumes outlet
min. 100 mm with back side
suction
C33
C43
C33C53
C13
A
B
Fig.3.c.a
X
Fig.3.c.b

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
Flue accessories available from CAREL:
Ref. Description Code
1 Stainless steel flue gas outlet grill, Ø80 mm EXHZ080000
2a 1000 mm extension Ø80 mm EXHP080100
2b 500 mm extension, Ø80 mm EXHP080500
3 90° bend Ø80 mm EXHC080080
4 Stainless steel intake grill, Ø80 mm EXHX080000
5 Inside/Outside gasket Ø80 mm EXHQ080000
6 Tile for sloped roof Ø80 mm EXHNI00125
7 Flat tile Ø80 mm EXHN080000
8 Condensate collection section Ø80 mm L= 135mm EXHS0A0011
9 T connection, Ø80 mm EXHD080000
10 Plug EXHG000000
11 Condensate drain trap with pipe EXHDS00000
12 Silicon gasket for flue gas Ø=80mm EXHW000080
13 Flanged section Ø 80 mm, L= 57 mm EXHL080056
14 Flanged section Ø 80 mm, L= 120 mm EXHT080120
15 Inspection section Ø 80 mm, L = 135 mm EXHI080025
16 Flanged section Ø 80 mm, L= 100 mm EXHT080100
Tab. 3.c
Fig. 3.d
5
6
7
15
9
10
3
2a-2b
8
1
11
12
13
14-16
4
3.5.1 Installation of the appliance with air intake from
the room (type B)
The gaSteam humidifiers may be also installed as type B appliances, that
is, with the air intake from the room where the appliance is installed, as
long as this complies with the legislation and standards in force.
The maximum pressure drop allowed along the 80 mm diam. air intake
pipes/flues is:
- for the gaSteam 45: -50…90 Pa (-0,50…0,90 mbar / -0.007…0.013 PSI);
- for the gaSteam 90: -50…82 Pa (-0,50…0,82 mbar / -0.007…0.012 PSI);
- for the gaSteam 180: -50…95 Pa (-0,50…0,95 mbar / -0.007…0.012 PSI).
To calculate the maximum possible length of the pipes, refer to the values
in Table 3.b.
IMPORTANT WARNING:a condensate collection section (part 6) or an
appropriate drain (part 9) must be installed in flues longer than 2 m.
3.5.2 Pressure switch (UG180)
the pressure switch is used to check that there is no flue gas return when
using a shared chimney (see“outlet with flue manifold”).
3.6 Checks
The following conditions represent correct water connections:
• installation of a shut-off tap in the supply water line;
• presence of a mechanical filter in the supply water line;
• water temperature and pressure within the allowed values;
• drain hose resistant to operating temperatures of 100°C (212 °F);
• minimum inside diameter of the drain hose 40 mm (1 1/2 inch);
• minimum slope of the drain hose greater than or equal to 5°;
• adding the inspection section with condensate drain connection.
IMPORTANT WARNING:when installation is completed, flush the supply
pipe for around 30 minutes by piping the water directly into the drain
without sending it into the humidifier. This will eliminate any scale or
processing residues that may cause foam when boiling.
independent outlets UG180
independent outlets UG45-90
Fig. 3.e

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IMPORTANT: FOR NORTH AMERICAN and
CANADIAN MARKET
3.7 Gas connections
Installation piping must be in accordance with local codes, and
ANSI Z233.1, “National Fuel Gas Code”, in the United States or CAN/
CGA-B149 Installation Codes in Canada.
Should overheating occur, or the gas supply fails to shut off, shut off
the manual gas valve to the appliance before shutting off the electrical
supply.
The gas inlet pipe sizes are as follows: UG045, UG090 – 1”Male Gas thread,
UG180 - 1”1/4 Male Gas thread.
The gas connection may either be made by piping directly to the gas
inlet, or by using the supplied flexible, vibration dampening pipe.
The appliance must be isolated from the gas supply piping system by
closing its individual manual shut-off valve during any pressure testing of
the gas supply system at test pressures equal to or greater than 14”w.c.
(½ psig,3.5 kPa).
Provide an adequate size gas supply line.
A 1/8-inch NPT plugged tapping, accessible for test gage connection,
must be installed immediately upstream of the gas supply connection
to the appliance.
When specified by codes, a sediment trap must be located ahead of the
humidifier gas controls.
The external shut-off gas valve, supplied with the unit, must be installed
outside of the unit.
NOTE:You must provide support to the gas connection during hookup
to avoid loosening internal connections of the gas line!
WARNING: Never use an open flame to check for gas leaks. If a leak
does exist, a fire or explosion could occur, resulting in damage, injury or
death.
The appliance and its individual shut-off valve must be disconnected
from the gas supply piping system during any pressure testing of that
system.
Dissipate test pressure from the gas supply line before reconnecting the
humidifier and its manual shut off valve to the gas supply line.
3.8 Venting Requirements for CAREL
gaSteam units
CAUTION: The humidifier shall not be connected to a chimney flue
serving any other appliance.
The unit has 4 holes for the air intake and gas vent outlet (8 for the
UG180):
• 2 on the top of the humidifier (4 on the UG180).
• 2 at the back of the unit (4 on the UG180).
The humidifier is configured from the factory as follows:
• exhaust vent through to the top of the humidifier;
• air intake from the back;
Note: Both the exhaust vent and air intake can be moved, according to
the installation requirements.
Note: Fit the exhaust vent pipe so that the section with the inspection
hole is always the first section.
When installing the exhaust or intake pipes in the rear of the unit,
a rear clearance of 12” must be maintained. If the included exhaust
vent pipe does not have a pre-installed“test plug/inspection hole”, the
provided one must be installed to applicable standards.
IMPORTANT: Vent materials must be approved for use for Category IV
gas-burning appliances.
These materials are designed to be both air and watertight. You cannot
use PVC for the exhaust because the gas temperatures are too high.
However, the air intake may be safely run in PVC or any other approved
conduit, as long as the ID of the tubing is at least 3”.
The maximum distance the vent and intake can be run is 120 equivalent
combined feet or a maximum pressure drop of 90 Pa (0.36”w.c.), whichever
is more restrictive.
Use the National Fuel Gas Code and the vent pipe manufacturer’s
technical data to determine the venting length.
The vent pipe must be drained of condensate if it is run longer than 6
feet in any direction. When using a condensate drain, a standard loop
or p-trap must be used to prevent exhaust gases from venting into the
drain. Prior to using the appliance, ensure that the trap is filled with
water and that the drain terminates in accordance with local or national
plumbing codes.
The vent adapter provided with the humidifier is designed to interface
with standard 3”, single wall stainless steel exhaust pipe.
Caution: The air intake must never be blocked or obstructed in any way.
The vent system must be installed and terminate so that proper clearances
are maintained as cited in local codes or the latest edition of the National
Fuel Gas Code, whichever is more restrictive.
The following are possible parts for outside vent terminations:
- 7390TEE Heat-Fab Inc.
- 02SVSTTX03 Z-Flex Inc.
- SRTT-03 Flex-L International Inc.
Example of air intake for the outside
Gas Valve supplied with the unit
Installation/materials from gas supply to shut-o valve and
from the shut-o valve to the unit are not supplied.
Sediment trap
C33
C43
C33C53
C13
A
B
Exhaust
Intake
Fig. 3.f
Fig. 3.g

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
gaSteam exhaust and intake configurations
independent outlets UG180 independent outlets UG45-90
Outlets with flue manifold UG180 (EXHM80B120)
Fig. 3.h
Metric Exhaust/Intake Adapters (only for units: UG***HD103):
For 80mm to 3”:
EXHR08030I – Item shown below. This item is included in the UGKINST090
Gas connections kit for UG045 and UG090
Gas connections kit for UG180

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
4. STEAM DISTRIBUTION
To achieve optimal humidifier efficiency, the steam produced must be
introduced into the room uniformly, in order to prevent the spraying
of drops and notable condensation. This is best achieved using steam
blowers or linear distributors. The right steam distributor must be chosen
according to the place where the steam is to be introduced.
4.1 Steam distribution in ducts - linear
distributors
For steam distribution into air ducts, the steam distributor must be sized
according to the output of the humidifier and the cross-section of the
ducting. Figure 4.a provides the dimensions of the CAREL linear steel
distributors. Table 4.a specifies the minimum number and the model of
the distributors recommended for the type of humidifier used.
Humidifier fitting dia. mm 2x40 2x40 4x40
Humidifier capacity kg/h (lbs/h) 45 (100) 90 (200) 180 (400)
Distributor f itting Max. distributor capacity kg/h Length mm Code UG045 UG090 UG180
40 25 834 DP085D40R0 2
40 35 1015 DP105D40R0 2 (4)**
40 45 1222 DP125D40R0 2 2 4
40 45 1636 DP165D40R0 2 2 4
40 45 2025 DP205D40R0 2 2 4
Tab. 4.a
**: 40x40x40 “Y” kit for branching the steam hose available from 01/01/2005.
N.B.: if the duct is not wide enough for the distributor, two shorter
distributors can be used (numbers in brackets), by branching off the
steam hose.
Assembly of the linear distributors (see Fig. 4.a):
• make a series of holes in the wall of the duct according to the drilling
template indicated in Fig. 4.a;
• insert the distributor with the steam holes facing upwards;
• fasten the flange of the distributor using 4 screws. i.
dimensions mm:
Ø AØ BØ YØX
40 10 89 60 99
To allow the return of condensate using the drain connection (see
Installation of the condensate drain pipe), mount the distributor (Fig.
4.a) with the inlet connection closer than the closed end, which, for this
reason, must be adequately supported (the support surface already has
the right slope).
1 steam inlet
2 condensate drain
3 flange gasket
4 fasten the support where required
5 max. screw diameter“M5”
6 L (see Table 4.a)
7 hole on the wall
8 use the fastening support supplied so as to ensure the slope determined
by the shape of the flange
Tab. 4.b
70 mm
min. 200 mm
1
1/3 H
H > 250 mm
2
1/3 H
200 mm
H > 250 mm
3
1/5 H
2/5 H
200 mm
H > 350 mm
4
1/5 H
2/5 H
H > 400 mm
5
1/7 H
2/7 H
2/7 H
H > 600 mm
7
1/7 H
2/7 H
2/7 H
H > 500 mm
6
8min 200 mm
=
=
9H > 200 mm
=
=
1/2 H
10 H > 300 mm
=
=
=
=
11 H > 500 mm
=
1/3 H
1/3 H
=
Fig. 4.a - assembly distributor
As allowed by the dimensions of the air duct, the distributor must be
as long as possible and located away from curves, branches, changes in
cross-section, grills, filters and fans.
The minimum recommended distance between the steam distributor
and the nearest obstacle is around 1-1.5 metres, yet this greatly depends
on the operating conditions; this distance it in fact increases with:
• an increase in the air speed in the duct;
• an increase in the relative humidity of the air before and, above all, after
humidification;
• a decrease in turbulence.
Follow the indications and the distances between the distributor and the
walls of the ducting and/or between two distributors, as indicated in the
figures below (distances in mm).
Fig. 4.b
4.2 Positioning the linear distributors in the air ducts

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
4.3 Installation of the steam hose
• The humidifier must be connected to the distributor using a hose
suitable for this purpose, such as the CAREL flexible hose.
• The use of unsuitable pipes or hoses may cause weakening and cracking
and consequently steam leaks.
• The layout of the hose must be such as to avoid the accumulation
of condensate, with consequent noise (gurgling) and reduction in
efficiency; the path of the hose must exploit gravity to drain the
condensed steam back to the boiler or to the distributor.
• Pockets or traps must thus be avoided, in that the condensate may be
trapped; attention should also be paid to avoid choking the hose due
to sharp bends or twisting (see Fig. 4.c).
• Using screw clamps, tightly fasten the ends of the hose to the humidifier
and steam distributor fittings, so that they do not slide off due to the
effect of the temperature
• According to the position of the steam distributor, one of two following
solutions may be adopted for the path of the hose:
1. rise upwards with a vertical section of at least 300 mm (12 inch),
followed by a curve with a minimum radius of 300 mm (12 inch) and
finally a downwards section with a constant slope of no less than 5°
(see Fig. 4.d);
2. for short paths (less than 2 m (80 inch)), curves with a minimum
radius of 300 mm (12 inch), followed by a rising section with a slope
of no less than 20° (see Fig. 4.e).
IMPORTANT WARNING: the backpressure exerted by the steam hose
should not exceed half of the maximum allowable for the humidifier.
Generally this means a hose with a length of around 4 metres; for special
applications, contact CAREL.
Fig. 4.c
4.4 Installation of the condensate drain pipe
• Due to the re-condensation of the steam produced, condensate forms
inside the steam hose and the distributor that must be removed to avoid
gurgling and a reduction in efficiency.
• The condensate is drained by gravity using a hose that is suitable for
the purpose. The use of unsuitable tubing may cause weakening and
cracking with consequent steam leaks.
• To avoid the release of non-condensed steam from the condensate
hose, a drain trap must be made by looping part of the drain hose.
• The end of the condensate hose can be connected to the nearest drain
pipe, with a minimum slope of 5° to assist correct downflow (see Fig.4.d/
4.e).
WARNING:for the unit to operate correctly, the drain trap must be filled
with water before starting the humidifier.
As per the UNI11071 standard.
Fig. 4.d
4.5 Checks
The following conditions represent correct installation of the steam
hose:
• the position of the steam distributor complies with the instructions
provided in this chapter, the steam outlet hoses are aimed upwards and
the distributor has an upwards slope of at least 2°;
• the ends of the hoses are fastened to the fittings using metal hose
clamps with fastening screws;
• the curves in the hoses are sufficiently wide (radius > 300 mm (12 inch))
so as to not cause bending or choking;
• the steam hose has no pockets or traps for condensate to form;
• the paths of the steam and condensate hoses comply with the
instructions provided in this chapter;
• the length of the steam hose should not exceed 4 m; for special
applications, contact CAREL;
• the slope of the steam hose is sufficient to allow correct dragging of
the condensate (> 20° for the upward sections, > 5° for the downward
sections);
• the slope of the condensate hose is at least 5° at every point;
• the condensate hose always follows a downward path and features a
drain trap (filled with water before starting operation) to prevent steam
being released.
Fig. 4.e

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
5.4 Connection diagram, UG45-90
MORSETTI AUSILIARI
MORSETTI DI POTENZA
LEGENDA
G= 24 Vac
G0 = 0V
J17.
M2.
M7.
M8.
M1.
M4.
.1
.2
.3
.4
.5
.1
.2
.3
.4
.5
.6
.7
.8
.1
.2
.1
.2
.1
. 2
1U
2U
3U
4U
5U
6U
7U
8U
9U
10U
11U
12U
13U
14U
7O
8O
9O
12T
13T
J20.
.1
.2
.3
.4
.5
.6
5S
6S
CE
CONTROL SENSOR
EXTERNAL
SIGNAL
REMOTE
ON-OFF
G0 -
G
G
G0
G0
G+
DEHUMIDIF.
RELAY
ALARM
RELAY
GND
GND
+ 15V
10mA
HI LIMIT SENSOR
WATER
TEMPERATURE NTC
FILL SOLENOID
VALVE
RD
TLAN
M3.
J16.
.3
.2
.1
.1
.2
pLAN
pGD
.1
.2
M5.
.1
.2
.1
.2
.3
AB 3
2
1
3
2
1
A
B
J7
J3
J5
GND -GREEN
HIGH -YELLOW
MIDDLE -RED
LOW -WHITE
+15Vcc -BLUE
LEVEL
SENSOR
*
NTC 1
FLUE GASES
J14
G
G0
G0
G
GND
GND
F4
75 VA
230 V
0V
.2
.1
.3
.2
.1
.5
.4
.3
.2
.1
C
3
2
1
D
321
J1.
.1
.2
.3
.4
J2.
.1
.2
.3
.4
J8.
.1
.2
.3
.4
J15.
.1
.2
.3
.4
J11. .1
.2
J14..1
.2FB1
6T
7T
1T
2T
3T
4T
5T
8S
9S
10S
11S
12S
10T
11T
+
TACH
PWM
-
6Y
P8T
9T
KLIXON 1
0
24 V
TO CLIP 4Y 0 TO CLIP 5Y 230
GND
BLOWER 1
SHILDING
TO CLIP
J11.2
V1
V2
FENWALL 1
CONTROL BOARD
F1
F3
RD
2O
MS TR
5O
6O
4O
1Y 2Y
*
3Y
F2
COOLINGFAN
3O
L1
L2
GND
1O
FB1
0V BLOWER 1 230 V BLOWER 1
5Y4Y
GND
HIGH_Level
MIDDLE_Level
LOW_Level
+15Vcc BLUE
WHITE
RED
YELLOW
GREEN
1S
2S
3S
4S
FERRITE
CONDUCIBILITY
SENSOR
FOAM SENSOR
G0 T+
1248
Serial Address J3 - tLANJ1
J4
GND
G
ID2ID3ID4IDCID1
TO GAS VALVE
1A 2A
DRAIN PUMP
230 VacGND
DRAIN
TEMPERING
VALVE
14S
13S
RELAY P
BRIDGE
Fig. 5.b

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
5.5 Connection diagram, UG180
MORSETTI AUSILIARI
MORSETTI DI POTENZA
LEGENDA
G= 24 Vac
G0 = 0V
J17.
M2.
M7.
M8.
M1.
M4.
.1
.2
.3
.4
.5
.1
.2
.3
.4
.5
.6
.7
.8
.1
.2
.1
.2
.1
. 2
1S
2S
1U
2U
3U
4U
5U
6U
7U
8U
9U
10U
11U
12U
13U
14U
7O
8O
9O
3S
4S
12T
13T
J20.
.1
.2
.3
.4
.5
.6
5S
6S
FERRITE
CONDUCIBILITY
SENSOR
CONTROL SENSOR
EXTERNAL
SIGNAL
REMOTE
ON-OFF
G0 -
G
G
G0
G0
G +
DEHUMIDIF.
RELAY
ALARM
RELAY
GND
GND
+ 15 V
10 mA
HI LIMIT SENSOR
FOAM SENSOR
WATER
TEMPERATURE NTC
FILL SOLENOID
VALVE
RD
TLAN
M3.
J16.
.3
.2
.1
.1
.2
pLAN
pGD
FB2
.1
.2
M5.
.1
.2
.1
.2
.3
AB 3
2
1
3
2
1
A
B
J7
J3
J5
NTC 1
FLUE GASES
P
PRESS
13S
14S J14
G
G0
G0
G
GND
GND
F4
75 VA
230 V
0 V
.2
.1
.3
.2
.1
.5
.4
.3
.2
.1
C
3
2
1
D
3 2 1
J1.
.1
.2
.3
.4
J2.
.1
.2
.3
.4
J8.
.1
.2
.3
.4
J15.
.1
.2
.3
.4
J11. .1
.2
J14. .1
.2 FB1
6T
7T
1T
2T
3T
4T
5T
10T
11T
+
TACH
PWM
-
6Y
P8Z
9Z
KLIXON 2
P8T
9T
KLIXON 1
TO CLIP 4Y 0 TO CLIP 5Y 230
GND
BLOWER 1
SHILDING
TO CLIP
J11.2
6Z
7Z
1Z
2Z
3Z
4Z
5Z
+
TACH
PWM
-
9Y
TO CLIP 7Y 0 TO CLIP 8Y 230
GND
BLOWER 2
SHILDING
TO CLIP J11.2
TO CLIP 5Z - 5T
NTC 2
FLUE GASES
10Z
11Z
F1
F3
RDFB2
2O
MS
TR
5O
6O
4O
1Y 2Y
3Y
F2
COOLING FAN
DRAIN PUMP
230 Vac
0 V BLOWER 2 230 V BLOWER 2
3O
L1
L2
GND
GND
1O
8Y7Y
FB1
0 V BLOWER 1 230 V BLOWER 1
5Y4Y
M6.
LEVEL
SENSOR *
8S
9S
10S
11S
12S
*
GND - GREEN
HIGH - YELLOW
MIDDLE - RED
LOW - WHITE
+15Vcc - BLUE
BLUE
WHITE
RED
YELLOW
GREEN
GND
HIGH_Level
MIDDLE_Level
LOW_Level
+15Vcc
0
24 V
V1
V2
FENWALL 2
CONTROL BOARD
0
24 V
V1
V2
FENWALL 1
CONTROL BOARD
G0 T+
1248
Serial Address J3 - tLANJ1
J4
GND
G
ID2 ID3 ID4 IDCID1
TO GAS VALVE
TO GAS VALVE
4A 1A 3A 2A
DRAIN
TEMPERING
VALVE
Fig. 5.c

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
Fig. 5.e
5.6.5 Calibrating the burner at minimum output
Operate the burner at the minimum output setting the fan speed to the
minimum level, as described previously, and check by analysing the flue
gas that the CO2value is 8.4% ±0.5%.
If the values measured are different, proceed as follows:
1. open the front door;
2. remove the cap from the gas valve pressure regulator and adjust
the pressure regulator A (see Fig. 5.e) using a no. 40 Torx key: turn
clockwise to increase the CO2value, anticlockwise to decrease it
(make small adjustments, as the screw is very sensitive);
3. wait until the value of CO2correct is stable, if necessary, repeat the
operations.
4. replace the cap on the regulator.
WARNING: Once the calibration at MINIMUM output has been
performed, check the MAXIMUM calibration again, as it may have been
affected by the MINIMUM calibration; if necessary, repeat the operations
described in Calibrating at MAXIMUM output. Then restart the automatic
operation of the burner.
To check the correct position of the burner electrodes, see “Cleaning the
burner”.
IMPORTANT: make sure that the CO values in steady operation do not
exceed 100 ppm.
5.6 Adjusting the humidifier to different
types of gas
Important: The appliances are delivered calibrated and tested to operate
on natural gas
The humidifier can be supplied with the following types of gas:
• Natural gas (G20-G25 natural gas - factory default);
• Propane-butane (GPL G30-G31).
A number of parameters on the electronic controller need to be set for
correct operation (see the controller manual - cod. +030220930) and
combustion adjusted by checking the CO2 (%vol) and CO (ppm) values
in the flue gas:
NATURAL GAS CALIBRATION
UG45 UG90 UG180
n. giri min max min max min max
G20-G25 1450 4700 1700 5050 2000 5300
Tab. 5.b
Important note: the humidifier is factory-fitted for a maximum
production equal to the 70% of the rated output.To change the maximum
production see the controller manual - cod. +030220930.
5.6.1 Calibrating the gas burner
The burner is pre-calibrated in the testing phase by the manufacturer
for natural gas utilized; nonetheless, combustion should be checked and
adjusted if necessary.
5.6.2 Preparing for analysis of the combustion
If the flue is positioned horizontally or vertically:
1. remove the T cap from the flue inspection section on the humidifier
(see Fig. 5.d);
2. insert the flue gas analysis probe;
3. analyse the flue gas.
When analysis is completed, replace the T cap on the inspection section.
Fig. 5.d
5.6.3 Types of calibration
Two types of burner calibration are available:
A. Guided
B. Manual
The step-by-step Guided procedure automatically provides the user all
the information needed to complete calibration.
For the manual procedure, on the other hand, see the instructions below.
(For further info see the controller manual P/N +030220930)
5.6.4 Calibrating the burner at maximum output
Operate the burner at maximum output as shown in Table 5.b, setting the
fan speed to the maximum level, and check by analysing the flue gas that
the CO2value is 9.1% ±0.5%;
If the values measured are different, proceed as follows:
1. open the front door;
2. adjust the gas flow regulator B (see Fig. 5.e) using a flat blade
screwdriver or a 4 mm Allen key: turn anticlockwise to increase the
CO2value, clockwise to decrease it;
3. wait for the correct CO2value to stabilise; if necessary, repeat the
operations.

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
PROPANE/ BUTANE/LPG CALIBRATION
IMPORTANT: Do not start the burner (delivered with default calibration
for natural gas!) supplied on propane or LPG until having turned the
maximum gas flow control screw (B) around 2.5-3 turns clockwise.
The heat value of propane in fact is around three times higher than
natural gas, therefore the maximum gas flow must be reduced before
igniting the burner.
After having reduced the gas flow as above, ignite the burner and then
calibrate the gas flow by analysing the flue gas, as described in paragraphs
5.6.5 – 5.6.6.
UG45 UG90 UG180
n. giri min max min max min max
G30-G31 1650 4200 1850 4450 2000 5150
Tab. 5.c
5.6.6 Calibrating the burner at maximum output
Operate the burner at maximum output as shown in Table 5.c, setting the
fan speed to the maximum level, and check by analysing the flue gas that
the CO2 value is10.5% ±0.5%.
If the values measured are different, proceed as follows:
1. open the front door;
2. adjust the gas flow regulator B (see Fig. 5.e) using a flat blade
screwdriver or a 4 mm Allen key: turn anticlockwise to increase the
CO2 value, to decrease it;
3. wait for the correct CO2 value to stabilise; if necessary, repeat the
operations.
5.6.7 Calibrating the burner at minimum output
Operate the burner at minimum output, setting the fan speed to the
minimum level, and check by analysing the flue gas that the CO2value
is 9.9% ±0.5%.
If the values measured are different, proceed as follows:
1. open the front door;
2. remove the cap from the gas valve pressure regulator and adjust
the pressure regulator A (see Fig. 5.e) using a no. 40 Torx key: turn
clockwise to increase the CO2value, anticlockwise to decrease it
(Important: make small adjustments, as the screw is very sensitive);
3. wait for the correct CO2value to stabilise; if necessary, repeat the
operations.
4. replace the cap on the regulator;
WARNING: Once the calibration at minimum output has been performed,
check the MAXIMUM calibration again, as it may have been affected by
the MINIMUM calibration; if necessary, repeat the operations described
in Calibrating at maximum output. Then restart automatic operation of
the burner.
To check the correct position of the burner electrodes, see “Cleaning the
burner”.
IMPORTANT: make sure that the CO values in steady operation do not
exceed 100 ppm.
5.6.8 Shutdown
During seasonal shutdown or shutdown for maintenance of the electrical
parts and/or the water circuit, the humidifier should be placed out-of-
service (see the controller manual - cod. +030220930).

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
6. MAINTENANCE
BEFORE ALL OPERATIONS:
• disconnect the appliance from the mains power supply;
• close the mains water and gas taps;
• drain the water circuit using the manual electric pump function, or
drain. it is necessary to connect a pipe to drain out the water to avoid
internal flooding.
IMPORTANT WARNINGS:
• do not use detergents or solvents to clean the plastic components.
• descaling can be performed using a 20% acetic acid solution, then
rinsing with plenty of water.
6.1 Boiler maintenance
Access the boiler as described in “Removing and reassembling the front
cover”.
Remove panels A, B and C as follows (Fig. 6.a):
• remove the boiler steam hose, T;
• undo screws V and V1;
• undo the inside and outside screws that secure panel B;
• remove panels A, B and C.
To remove the exchanger, proceed as follows (Figs. 6.a and 6.b):
• disconnect the cables from the burner electrodes (the detection
electrode should be disconnected from the burner control board, Fig.
6.c position “A”);
• remove the fan manifold by undoing the screws B (Fig. 6.c) and remove
the burner combustion head (Fig. 6.d);
• disconnect the cables from the foam detection electrode F(Fig. 6.b);
• unscrew and remove the fastening nuts G;
• remove the boiler cover;
• undo the nuts Efrom the side of the burner;
• remove the heat exchanger Hand clean it using a 20% acetic acid
solution, removing any deposits using implements that do not scratch
the lining on the exchanger (e.g. wood or plastic material). At the end
of this activity rinse out copiously.
• disconnect the power cable and all the pipes connected to the electric
pump and the panel O;
• undo the panel fastening nuts and remove the panel, making sure not
to damage the gasket L;
• unscrew screws Mto free the steel filter Nand clean it using a 20%
acetic acid solution;
• using a wooden or plastic scraper, scrape the inside of the vaporiser
chamber and clean it using a 20% acetic acid solution.
IMPORTANT WARNING:after having replaced or checked the parts in
the water circuit, make sure that the connections have been completed
correctly and are tight. Start the unit again and run a number of fill and
drain cycles (2 to 4), after which, applying the safety procedure, check for
any water leaks.
A B
Fig. 6.c Fig. 6.d
C
TPart. V+V1
V
V1
B
A
Fig. 6.a Fig. 6.b

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
6.2 Cleaning the burner
The burner must be checked by authorised and qualied personnel
once or twice a year, according to use.
Before performing any maintenance on the burner, check its general
condition, carrying out the operations listed below:
•remove the burner head as described previously;
•using a brush, clean the inside of the burner head; make sure not to
crush the metal mesh (Fig. 6.e);
•remove all gas and electrical connections from the burner assembly;
•check for dust deposits on the fan and if necessary remove the parts
required to clean it (Fig. 6.f).
•clean the fan using a brush (Fig. 6.g).
WARNING:to avoid damaging the fan, never use a jet of compressed air
when cleaning it.
When reassembling the parts, check:
•the condition of the gaskets (replace if necessary);
•that the position of the electrodes corresponds to Fig. 6.c.
Fig. 6.e
Fig. 6.f
Fig. 6.g
1
Fig. 6.h
6.3 Operating anomalies - checking the
ionisation current
The ionisation current is checked by placing a microammeter set to 10 μA
full scale (direct current) in series with the flame detection electrode.
The wrong positioning of the electrode may lead to a decrease in the
ionisation current and shut the burner down due to incorrect flame
detection. In this case, check the correct position and condition of the
electrode, its electrical connections, and the earth connection of the
burner. The ionisation current is normally 5 μA.
For details of the spare parts, see the SPARE PARTS manual.
Min 0,9 µA
12
1 microammeter with 10 μA full scale
2 test equipment
Fig. 6.i
6.4 Flue gas temperature sensor
The flue gas temperature sensor is located in the flue and does not
require periodical maintenance.
If the sensor needs to be replaced due to a fault, proceed as follows:
•stop the humidifier by moving the rocker switch on the control panel
to 0 and then checking that the display is off;
•open the electrical compartment to access to the panel;
•loosen terminals 10T and 11T (or 10Z and 11Z) (see the wiring diagram)
on the terminal block in the bottom of the electrical panel and the
probe holder nut on the adapter joint (see the spare parts manual) and
then remove the probe and the electrical cable.
Then replace the sensor by following the same procedure in reverse.
6.5 Water temperature sensor
This does not require periodical maintenance.
To replace the sensor, proceed as follows:
•stop the humidifier by moving the rocker switch on the control panel
to 0 and then checking that the display is off;
•open the panels to access the water circuit (Fig. 6.a);
•remove the sensor to the inox support inside the level sensor in the
forntal part;
•loosen terminals 12T and 13T (see the wiring diagram) on the terminal
block in the bottom and remove the probe.
Then replace the sensor by following the same procedure in reverse.
6.6 Fuses
Fuses 1, 2, 3 measure 10.3x38 mm and are contained inside the fuse
carrier; while fuse 4 measures 6.3x20 mm; to check the fuses, test
continuity using a tester.
Use fuses with the ratings indicated in Table 7.a.
model UG045, UG090, UG180
fuses 1 and 2 Slow-blow, 2 A
fuse 3 Fast-blow, 1A
fuse 4 Slow-blow, 3.15A
Table 6.a
6.7 Cooling fan
The cooling fan starts when the unit is switched on, and is used to keep
the operating temperature of the electrical panel and the electronics
within the designed limits.
If the fan is faulty, after to have removed pannel B - Fig. 6.a:
•disconnect the electrical connections;
•replace the fan after having unscrewed the fastening screws.
N.B:being thermally protected, the fan may switch off temporarily if it
overheats, and then will start again after having cooled down.

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“gaSteam HARDWARE”+030220940 -rel. 1.6 - 06.12.2013
7. OPERATING PRINCIPLE AND OTHER FUNCTIONS
7.1 Operating principle
In a gas humidifier the production of steam is obtained inside a boiler
containing water that is heated to and then held at boiling temperature.
The heat required to boil the water is provided by a heat exchanger,
heated by a type C pre-mix modulating room-sealed gas burner
(standards compliant), which takes in air for combustion and discharges
the flue gas to the outside through suitable piping.
This unit is therefore suitable for environments where there is not
sufficient fresh air.
The operation of the burner is completely automatic and does not use
a pilot flame.
All the operating phases of the burner are controlled by an electronic
board, which also constantly checks the presence of the flame by
ionisation.The output of the burner continuously responds to the request
for heat, according to an ample modulation ratio (1:4).
The variable speed fan (managed by the control board), together with
the proportional gas valve, allows the output to be modulated (the flow-
rate of gas is proportional to that of the air required for combustion).
The water that evaporates over time is automatically replaced with water
from the mains supply.
In stable operating conditions, the level of production required is
automatically controlled by adjusting the thermal output of the burner.
The salts introduced by the automatic refilling of the water are partly
deposited as lime scale inside the boiler, contributing to the progressive
depletion of the cylinder, and partly remain dissolved in the water. To
avoid excessive accumulation of salts, a quantity of water is periodically
and automatically drained and then replaced with renewal water.
For further information on operation, see the controller manual - cod.
+030220930.

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“gaSteam HARDWARE”+030220940 - rel. 1.6 - 06.12.2013
8. TECHNICAL SPECIFICATIONS
models UG045 UG090 UG180
rated power supply voltage (Vac) 230 50 Hz (*003 version) / 230 60 Hz (*103 version)
steam connection (dia. mm) 2x40 4x40
steam outlet pressure limits (Pa) 0…2000 (0…0.30 PSI)
supply water
connection 3/4” G
temperature limits °C (°F) 1…40 (33.8....104)
pressure limits (MPa) 0,1…0,8 (1…8 bar) (14,5÷166 PSI)
instant flow-rate (l/min) carico 18 (4.76 gall US/min)
drain water
connection dia. mm (in) 50 (1.97)
typical temperature °C (°F) ≤100 (212)
instant flow-rate (l/min) acqua drenaggio 32 (6,60 gall/min)
operating conditions 1T40 °C (33T104 °F); 10...90% rH non condensing
storage conditions -10T70 °C (14T158 °F), 5…95% rH
index of protection IP20
auxiliary voltage/frequency (V - Hz) 24 / 50…60
maximum auxiliary power (VA) 25
instant steam production (1) kg/h (lbs/h) 45 (100) 90 (200) 180 (400)
power input at rated voltage (W) 110 140 190
(1) the average steam production is affected by factors such as: room
temperature, water quality, the steam distribution system.
8.1 Thermal-gas supply characteristics
UG045 UG090 UG180
heat output rated Kw (BTU/h) 33,02 (112,763) 62,5 (213,449) 125,0 (426,897)
minimum 7,82 (26,705) 14,7 (50,203) 14,7 (50,203)
heat input rated 34,76 (118,712) 65,0 (221,987) 130,0 (443,973)
minimum 8,69 (29,678) 16,25 (55,497) 16,25 (55,497)
steam production rated kg/h (lbs/h) 45 (100) 90 (200) 180 (400)
minimum 11,25 (25) 22,5 (50) 22,5 (50)
maximum steam temperature º C (°F) 105 (221) 105 (221) 105 (221)
water content in stable operation l 120 120 198
NOx emissions classe 5(<70 mg/Kw/h 5(<70 mg/Kw/h) 4 (< 100 mg/kWh)
CO2 natural gas (G20) % vol 9,4 9,4 9,4
natural gas (G25) 9,3 9,3 9,3
propane (G31) 11,2 11,4 11,2
butane (G30) 11,6 11,6 12,0
CO mg/kWh * <25 * <60 * <60
flue diameter *** mm 80 (3”) 80 (3”) 2xØ80 (3”)
air intake duct diameter *** 80 (3”) 80 (3”) 2xØ80 (3”)
steam hose diameter 2x Ø40 2x Ø40 4xØ40
natural gas flow-rate (G20) rated m3St/h ** 3,68 6,87 13,4
minimum 0,90 1,75 1,67
natural gas flow-rate (G25) rated 4,2 8,7 17,5
minimum 1,02 1,98 1,98
propane flow-rate (G31) rated 1,43 2,68 5,36
minimum 0,48 0,68 0,68
butane flow-rate (G30) rated 1,10 2,06 4,12
minimum 0,37 0,545 0,545
gas supply pressure natural gas (G20) Pa/mbar/PSI 2000/20/0.9 2000/20/0.9 2000/20/0.9
natural gas (G25) 2000/20/0.9 2000/20/0.9 2000/20/0.9
propane (G31) 3000/30/0.44 3000/30/0.44 3000/30/0.44
butane (G30) 3000/30/0.44 3000/30/0.44 3000/30/0.44
max pressure drop allowed in the air intake duct and flue Pa/mbar/PSI 90/0.90/0.013 82/0.82/0.012 95/0.95/0.014
Tab. 8.b
* value referred to combustion with natural gas (G20);
** m3St = dry gas at 15°C and an atmospheric pressure of 1013.25 mbar;
*** using the specific KITINSTALL for USA.
8.2 Flue gas values according to the heat
input
type of fuel natural gas (G20) natural gas (G25) propane (G31) Butane (G30)
UG045 UG090 UG180 UG045 UG090 UG180 UG045 UG090 UG180 UG045 UG090 UG180
rated heat output (kW/h/BTU) 34,76/
118,712
65,00/
221,987
130,0/
443,973
34,76/
118,712
65,00/
221,987
130,0/
443,973
34,76/
118,712
65,00/
221,987
130,0/
443,973
34,76/
118,712
65,00/
221,987
130,0/
443,973
flue gas flow-rate (kg/s) 0,0163 0,0303 0,0606 0,0167 0,03115 0,0623 0,0154 0,0283 0,0566 0.0147 0,0276 0,0551
flue gas temperature °C (°F) 135 (253) 170 (338) 165 (329) 123 (253) 175 (347) 163 (325) 123 (253) 175 (347) 165 (329) 123 (253) 175 (347) 163 (325)
percentage of CO2in the flue
gas (%)
9,4 9,4 9,4 9,3 9,3 9,3 11,2 11,4 11,2 11,6 11,6 12,0
Tab. 8.a
Tab. 8.c