Carel gaSteam 45 User manual

gaSteam 45/90/180
pHC control
User manual
LEGGI E CONSERVA
QUESTE ISTRUZIONI
READ AND SAVE
THESE INSTRUCTIONS

L’installazione del prodotto deve obbligatoriamente
comprendere la connessione di messa a terra,
usando l’apposito morsetto giallo-verde in morsettiera.
Non utilizzare il neutro come connessione a terra.
The product must be installed with the earthconnected,
using the special yellow-green terminal on the terminal
block. Do not use the neutral for the earth connection.
Le produit doit être installé avec la connexion terre
branchée, en utilisant la signalisation et les bornes
spécifiques (jaune/vert) à la mise à la terre.
Ne pas utiliser le neutre comme mise à la terre.
Das Produkt muss geerdet werden. Verwenden Sie
hierfür den gelb-grün Anschluss an der Klemmleiste.
Verwenden Sie nicht den Null-Leiter für die Erdung.
La instalación del producto debe obligatoriamente
incluir la conexión de la toma de tierra,
utilizando el borne amarillo/verde del regletero.
No utilizar el neutro como conexión a tierra.
Warning!

3gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
IMPORTANT WARNINGS
BEFORE INSTALLING OR HANDLING THE APPLIANCE PLEASE CAREFULLY READ AND FOLLOW THE
INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ILLUSTRATED BY THE
LABELS ON THE MACHINE.
This humidifier produces non-pressurised steam by means of a heat exchanger powered by a gas burner
immersed in the water contained in the boiler. The steam produced is used to humidify environments or
industrial processes, using special distributors.
The quality of the water used affects the process of evaporation, and as a result the appliance may be
supplied with untreated water, as long as this is drinkable, demineralised or treated with a softener
(see Characteristics of the supply water). The evaporated water is automatically replaced using a filling
valve.
This appliance has been designed exclusively to directly humidify rooms or ducts, using a distribution
system, as long as the installation, use and maintenance operations are carried out according to the
instructions contained in this manual and on the labels applied internally and externally.
The conditions of the environment, the fuel and the power supply voltage must comply with the speci-
fied values.
All other uses and modifications made to the device that are not authorised by the manufacturer are
considered incorrect.
Liability for injury or damage caused by the incorrect use of the device lies exclusively with the user.
Please note that the machine is connected to the gas mains, contains powered 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. Presidential Decree no. 447, December 6, 1991: “Regulations to law no. 46, dated March 5,
1990, on safety relating to systems in buildings”;
4. Italian Law 10/91: “Regulations to the national plan for energy savings and the development of
renewable sources of energy”.
Disconnect the machine from the mains power supply before accessing any internal parts.
The local safety standards in force must be applied in all cases.
Disposal of the parts of the humidifier: The humidifier is made up of metallic and plastic
parts.
In reference to European Community 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 instruc-
tion 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 materials: 2 years (from the date of production, excluding the consumable parts, such as
the cylinder).
Certification: the quality and safety of CAREL products are guaranteed by CAREL’s ISO 9001 certified
design and production system, as well as the TÜV, CE and ETL marks.

5gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
Content
1. GENERAL CHARACTERISTICS OF THE MAIN CONTROL BOARD - PHC 7
2. CONTROL SIGNALS FROM THE FIELD 8
2.1 Humidity or temperature control.......................................................................................................8
2.2 Pin strip position on the board for probe configuration..............................................................10
2.3 Using other brand probes ................................................................................................................10
3. AUXILIARY CONTACTS 11
3.1 Alarm contact..........................................................................................................................................11
3.2 Dehumidification contact ...................................................................................................................11
3.3 Remote terminal/supervisor systems ..............................................................................................11
3.4 Checks......................................................................................................................................................11
4. STARTING, CONTROL AND SHUTTING DOWN 12
4.1 Starting the appliance...........................................................................................................................12
4.2 Manually draining the boiler ..............................................................................................................14
4.3 The pGD0 graphic display (CAREL code: PGD0PH0F00) ...........................................................14
4.4 The main “menu”................................................................................................................................15
5. “MAIN “MENU” - AUXILIARY FUNCTIONS 18
“SERVICE” (“MAINTENANCE”) SUBMENU 18
5.1 “SERVICE” - information on the firmware......................................................................................18
5.2 “SERVICE” - display the operating hours........................................................................................18
5.3 Manually draining the cylinder ...............................................................................................18
5.4 Procedure for testing the electrical parts........................................................................................19
6. READING AND SETTING THE PARAMETERS 20
6.1 Reading and setting the set point.....................................................................................................20
6.2 Reading and setting the control parameters - reading the measurements............................20
6.3 “Rotation” of the steam request between the two burners (UG180 only).............................23
7. CONFIGURATION PARAMETERS 24
7.1 Reading and setting the configuration parameters - “USER” submenu...................................24
7.2 Configuring the control mode ............................................................................................................24
7.3 Humidity control with humidistat .....................................................................................................24
7.4 Unit of measure ....................................................................................................................................24
7.5 Configuring the ambient humidity (or temperature) probe ......................................................24
7.6 Configuring the limit humidity probe ..............................................................................................25
7.7 Initial auto-test........................................................................................................................................25
7.8 Setting the pre-purge speed and calibrating the fan speed........................................................25
7.9 Water supply with REVERSE OSMOSIS system.............................................................................26
7.10 Setting the maximum ratio between the water filled and the water drained for dilution..26
7.11 Preheating.............................................................................................................................................26
7.12 Antifreeze..............................................................................................................................................27
7.13 Reversing the logic of the alarm relay.............................................................................................27
7.14 Options - drain due to inactivity......................................................................................................28
7.15 Setting the production ramp .............................................................................................................28
7.16 Setting the fan speed for minimum and rated production.......................................................28
7.17 Setting the minimum production....................................................................................................29
7.18 Options .................................................................................................................................................29
8. ALARMS, TROUBLESHOOTING 30
8.1 Alarms ....................................................................................................................................................30
8.2 Alarm management and signals.......................................................................................................30
9. OPERATING PRINCIPLE, CONTROL AND OTHER FUNCTIONS 32
9.1 Operating principle..............................................................................................................................32
9.2 Control principles.................................................................................................................................32

6
ENGLISH
gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
10. OTHER FUNCTIONS 34
10.1 Measuring the conductivity of the supply water .........................................................................34
10.2 Flue gas discharge temperature measurement ..........................................................................34
10.3 Automatic draining ............................................................................................................................34
10.4 Antifoam procedure............................................................................................................................34
10.5 Dehumidification request signal .....................................................................................................34
10.6 Automatically emptying the cylinder due to extended inactivity .............................................34
10.7 Automatic reset from no water ........................................................................................................34
10.8 Repeating the humidity request.......................................................................................................35
10.9 Automatic procedure to unblock the floating level sensor........................................................35

7
U
Z
AL
O
T
S
Y
1U 2U 3U 4U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U
1T 2T 3T 4T 5T 6T 7T 8T 9T 10T 11T 12T 13T 14T
1Y 2Y 3Y 4Y 5Y 6Y 7Y 8Y 9Y
1S 2S 3S 4S 5S 6S 7S 8S 9S 10S 11S 12S 13S 14S
L1
L 2G N D
1O2O 3O 4O 5O6O 7O8O 9O
1Z 2Z 3Z 4Z 5Z 6Z 7Z 8Z 9Z 10Z 11Z 12Z
Fig. 1.a
ENGLISH
gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
1. GENERAL CHARACTERISTICS OF THE MAIN CONTROL BOARD - PHC
This is a microprocessor electronic controller based on the pGE technology developed by CAREL for the
management of all models of humidifier.
It is made up of two electronic boards, positioned one on top of the other and connected together by
pin strip.
• bottom board - “main control board”: connected to the pGE board with the microprocessor and the
clock card, as well as the serial card;
• top board, or “expansion board”.
The pHC is designed to run the control program, and is fitted with the set of terminals required for
connection to the controlled devices (for example: valves, power contactors) and to the field (probes,
external controller).
The program and the parameters are saved in FLASH MEMORY, meaning the data is safe even in the
event of a power failure (without the need for a backup battery).
The pHC can be connected to pLAN (pCO Local Area Network) and tLAN networks.
The pLAN network is made up of a series of controllers and terminals that interact with one another.
Each controller in the pLAN network can exchange information at high speed. Up to 31 units, either pHC
controllers or terminals, can be connected, for the rapid exchange of information.
tLAN communication is available with I/O expansion modules or the PST display (3 or 4 digit).
Connection to the supervisor/telemaintenance serial line on the RS485 standard is ensured by fitting the
pHC with optional cards, using the CAREL, Modbus® or ECHELON®, RS232 and GSM communication
protocols.
Terminal block

8
H
CR
CR
7U
Remote
ON/OFF
Action
ON/OFF
8U 9U 10U
a
HH
7U 8U 9U 10U
b
CR
7U 8U 9U 10U
c
Remote
ON/OFF
Action
ON/OFF
Remote
ON/OFF
Action
ON/OFF
Fig. 2.a
Fig. 2.b
R
CR
Fig. 2.c
External regulator
OUT
REF
1U
2U
3U
7U
8U
CR
Fig. 2.d
ENGLISH
gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
2. CONTROL SIGNALS FROM THE FIELD
2.1 Humidity or temperature control
The humidifier with humidity control action can be connected to a remote supervisor using optional
cards. It can be controlled in the following four different ways (for further details, see chap. 9):
a) Type C control: ON/OFF
The humidifier is operated by a mechanical humidistat H, by a voltage-free remote contact CR, or by a
combination of the two, which must be connected to terminals 7U, 8U, 9U and 10U on terminal block U
in the electrical panel.
The diagrams in Fig. 2.b show the connections to be made in the case of:
a) operation controlled by a simple enabling contact (CR);
b) operation by external mechanical humidistat (H);
c) a combination of the two.
b) Type P control:
proportional control, with signal sent by an external controller.
The steam production is managed by an external controller R, which sends the controller a humidity
request signal; the controller can be programmed to receive one of the following proportional signals
(see par. 9.2.2):
• voltage: 0 to 1 Vdc; 0 to 10 Vdc; 2 to 10 Vdc;
• current: 0 to 20 mA, 4 to 20 mA.
The reference (zero) of the external controller must be connected to the GND terminal (2U) and the
control signal to terminal B1 on terminal block U.
To avoid unstable control, the earth of the external controller must be connected to the earth of the
controller.
This type of control can also be used with an enabling contact (CR) connected to the “Remote ON/OFF”
terminal.

9
HT
CR
Fig. 2.e
CR
HT CH
Fig. 2.f
HT 1U
2U
3U
4U
5U
6U
7U
8U
out H
M
+ (G)
HT out H
M
+ (G)
CH
out H
M
+ (G)
a b
CR
1U
2U
3U
4U
5U
6U
7U
8U
CR
Fig. 2.g
TT
CR
Fig. 2.h
TT out T
M
+ (G)
1U
2U
3U
4U
5U
7U
8U
CR
Fig. 2.i
ENGLISH
gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
c) Type H control:
humidity control with ambient relative humidity probe (and outlet limit probe, if required).
With this configuration (see Fig. 2.e) the main control board, connected to a humidity probe HT,
performs a complete control action according to the humidity measured.
An outlet humidity limit probe (see Fig. 2.f) can also be connected: with this configuration, the main
control board, connected to a humidity probe HT, performs a complete control action, while also limiting
the steam production according to the relative humidity value in the outlet duct, measured by the probe
CH.
The diagrams shown in Fig. 2.g indicate the connection to be made using CAREL probes, with:
• just one relative humidity probe (a);
• an outlet humidity limit probe (b).
CAREL PROBES AVAILABLE...
...for rooms ...for air ducts ...for special applications
ASWH100000 ASDH100000 ASPC230000
ASDH200000 ASPC110000
Table 2.a
The controller can also be connected to non-CAREL probes (see paragraph 2.3.)
HT: CAREL relative humidity probe;
CH: CAREL outlet relative humidity probe.
d) Control for steam baths:
temperature control with room temperature probe
The humidifier is connected to a temperature probe TT (see Fig. 2.h), and performs a complete
control action according to the temperature measured inside the controlled environment.
Fig. 2.i shows the connection of the CAREL probe model ASET03001, with a range of measurement
-30T90°C. The recommended CAREL probes have a 0 to 1 volt output, and therefore the range
of reading must be set (see par. 7.5). The control signal must be connected to 1U, and the earth
reference is GND (2U).
The controller can also be connected to non-CAREL active probes (see par. 2.3).
TT: CAREL temperature probe.

10
1
2
3
1
2
3
JS5
JS5
JS4
JS4
3
3
1
1
2
2
Main board A in the
pHC controller
1
2
3
JS4
JS4
123
JS3
JS3
JS3
JS4
1
2
3
Expansion board B on
the pHC controller
1 2
3
4
5
6
Fig. 2.j
ENGLISH
gaSteam pHC CONTROL +030220534 - rel. 1.2 - 15.05.2006
2.2 Pin strip position on the board for probe configuration
1 room probe configuration
2 limit probe configuration
3 0 to 10 Vdc
4 all but 0 to 10Vdc
5 tachymetric 2
6 safety thermostat 2
2.3 Using other brand probes
Different brand probes can also be used, with the output signals (see par. 7.3) selectable from the
following standards:
• voltage: 0 to 1 Vdc, 0 to 10 Vdc, 2 to 10 Vdc;
• current: 4 to 20/ 0 to 20 mA.
In addition, the minimum and maximum values of the signal must be set (see par. 7.5).
A 15 Vdc power supply is available for the probes.
The control signals must be connected:
• for the control probe HT (or TT) to terminal 1U, the earth reference for which is GND (2U);
• for the limit probe CH to terminal 5U, the earth reference for which is GND (6U);
• for the current probe to terminal 4U, the earth reference for which is GND (6U).
Important warnings:
• To avoid unstable control, the earth of the probes or the external controllers must be connected to the
earth on the appliance’s controller.
• For the operation of the humidifier, the terminals corresponding to the “remote ON-OFF” signal must
be connected to an enabling contact or jumpered (default solution). If these terminals are not con-
nected, all the internal and external devices managed by the controller are disabled, with the exception
of the drain pump, limited to the drain cycle due to extended inactivity (see par. 10.5).