Carel heaterStream-UR User manual

heaterSteam - UR
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THETEXT!
electrical heater humidifier
User manual

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heaterSteam +030222011 - rel. 2.1 - 21.05.2010
IMPORTANT WARNINGS
BEFORE INSTALLING OR HANDLING THE APPLIANCE PLEASE CAREFULLY READ AND FOLLOW THE
INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ILLUSTRATED ON THE
LABELS ATTACHED TO THE MACHINE.
This humidifier produces non-pressurised steam using heating elements immersed in the water con-
tained in the cylinder (hereafter cylinder); the steam produced is used to humidify environments or
industrial processes, through special distributors.
The quality of the water used does not affect the evaporation process, and as a result the appliance can
be supplied with untreated water, as long as such water is fit for drinking, demineralised or softened (see
Supply water characteristics); the evaporated water is automatically replaced using a refill valve.
To achieve uniform distribution of the heat flow, the heating elements, which are electrically insulated
from the water, are covered in an aluminium casting, and are also available with a special non-stick
coating to prevent and aid the removal of lime scale.
This appliance has been designed exclusively to directly humidify rooms or ducts, through distributors.
It has been developed for this purpose, as long as: the installation, use and maintenance of the unit are
carried out according to the instructions contained in this manual and on the labels applied, internally
and externally, to the unit.
The environmental conditions and the voltage of the power supply must correspond to those specified.
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 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.
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. We 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).
Certification: the quality and safety of CAREL products are guaranteed by CAREL’s ISO 9001 certified
design and production system, as well as CE or ETL mark.
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THETEXT!
WARNING: separate as much as possible the probe and digital input signal cables from the cables carrying inductive
loads and power cables to avoid possible electromagnetic disturbance.
Never run power cables (including the electrical panel wiring) and signal cables in the same conduits.
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.

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heaterSteam +030222011 - rel. 2.1 - 21.05.2010
CONTENT
1. MODELS 7
1.1 Accessories.......................................................................................................................................................................................................................... 7
2. DESCRIPTION OF THE MAIN COMPONENTS AND FUNCTIONS 8
2.1 Level control.......................................................................................................................................................................................................................10
2.2 Overfill device.................................................................................................................................................................................................................... 10
2.3 Control of steam production..........................................................................................................................................................................................10
2.4 Measurement of supply water conductivity- alarm...................................................................................................................................................10
2.5 Automatic draining........................................................................................................................................................................................................... 10
2.6 Foam elimination procedure.......................................................................................................................................................................................... 11
2.7 Safety thermostat (Motor Protector) ............................................................................................................................................................................ 11
2.8 Autotest procedure...........................................................................................................................................................................................................11
2.9 Measurement of the water temperature and pre-heating (not available in the version with type C control module) ............................11
2.10 Dehumidification request signal (not available in the version with type C control module)........................................................................11
2.11 Procedure for cleaning the drain valve (UR 2 to 10kg/h/4.4 to 22lbr/h)............................................................................................................. 11
3. CONTROL PRINCIPLES 12
3.1 ON/OFF control (control module C)............................................................................................................................................................................12
3.2 Modulating control (control module H)......................................................................................................................................................................12
3.3 Setting the alarm thresholds (type H or T control module) ................................................................................................................................... 13
4. ASSEMBLY 14
4.1 Receipt and storage ........................................................................................................................................................................................................... 14
4.2 Dimensions and weights.................................................................................................................................................................................................14
4.3 Removing and replacing the front casing ................................................................................................................................................................... 14
5. POSITIONING THE UNIT 15
5.1 Fastening.............................................................................................................................................................................................................................15
6. WATER CONNECTIONS 16
6.1 Supply water characteristics ............................................................................................................................................................................................16
6.2 Characteristics of the drain water.................................................................................................................................................................................. 16
6.3 Technical specifications .................................................................................................................................................................................................. 17
6.4 Checks................................................................................................................................................................................................................................. 17
7. ELECTRICAL CONNECTIONS 18
7.1 Power supply voltages ....................................................................................................................................................................................................... 18
7.2 Main control board ........................................................................................................................................................................................................... 19
7.3 Description of the terminal block and connections (functions and electrical specifications).......................................................................... 19
7.4 Auxiliary connections........................................................................................................................................................................................................ 19
7.5 Other auxiliary contacts .................................................................................................................................................................................................. 21
7.6 Checks...................................................................................................................................................................................................................................21
7.7 Wiring diagrams for the connection of the heating elements ................................................................................................................................22
7.8 Single-phase wiring diagram for 2-4kg/h (4.4-8.8lbr/h) humidifiers with type C control module..........................................................................................23
7.9 Single-phase wiring diagram for 2-4kg/h (4.4-8.8lbr/h) humidifiers with type H or T control module........................................................ 24
7.10 Single-phase wiring diagram for 6kg/h (13.2lbr/h) humidifiers with type C control module........................................................................ 25
7.11 Single-phase wiring diagram for 6kg/h (13.2lbr/h) humidifiers with type H or T control module........................................................................................26
7.12 Three-phase wiring diagram for 6-10Kg/h (13.2-22lbr/h) humidifiers with type C control module.....................................................................................27
7.13 Three-phase wiring diagram for humidifiers with type H or T control module ................................................................................................ 28
7.14 Three–phase electrical diagram for 20 (44lbr/h) ( 208-230-400-460-5756V) 27-40Kg/h (59.5-88lbr/h) (400-460-575V)
humidifiers with type C control module 400-460-575 V................................................................................................................................................. 29
7.15 Three–phase electrical diagram for 20 (44lbr/h) ( 208-230-400-460-5756V) 27-40Kg/h (59.5-88lbr/h) (400-460-575V)
humidifiers with type H control module 400-460-575 V................................................................................................................................................. 30
7.16 Three–phase electrical diagram for 60Kg/h (132.2lbr/h) humidifiers with type C control module 400-575 V........................................ 31
7.17 Three–phase electrical diagram for 60Kg/h (132.2lbr/h)humidifiers with type H control module 400-575 V.......................................... 32
7.18 Three–phase electrical diagram for 27Kg/h (59.5lbr/h)humidifiers with type H control module at 208 - 230 V..................................... 33
7.19 Three–phase electrical diagram for 27Kg/h (59.5lbr/h) humidifiers with type H control module at 208 - 230 V.................................... 34
7.20 Three-phase electrical diagram for 60kg/h (132.2lbr/h) humidifiers with type H control module at 460 V............................................. 35
7.21 Three-phase electrical diagram for 60kg/h (132.2lbr/h) humidifiers with type C control module at 460 V.............................................. 36

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8. STEAM DISTRIBUTION 37
8.1 Ambient steam distribution: ventilated steam distributors...................................................................................................................................... 37
8.2 Steam distribution in cold rooms.................................................................................................................................................................................. 37
8.3 Ducted steam distribution: linear and concentrated jet distributors (OEM)....................................................................................................... 38
8.4 Concentrated jet steam distribution (OEM) (only for humidifiers up to 10 Kg/h/22 lbr/h) ........................................................................... 39
8.5 Positioning linear distributors in the air duct.............................................................................................................................................................. 39
8.6 Installation of the steam pipe......................................................................................................................................................................................... 40
8.7 Installing the condensate return pipe .......................................................................................................................................................................... 40
8.8 Checks................................................................................................................................................................................................................................. 40
9. START-UP 41
9.1 Preliminary checks ............................................................................................................................................................................................................41
9.2 Removing the heating element centring spring (only for three-phase models)................................................................................................ 41
9.3 Start-up................................................................................................................................................................................................................................41
10. THE HUMIDIFIER CONTROLLER 42
10.1 Type C control module, with indication LEDs and ON/OFF action..................................................................................................................... 42
10.2 Type H or T control module, numeric LED display, modulating action ............................................................................................................. 43
11. READING AND PROGRAMMING THE PARAMETERS OF THE TYPE H OR T CONTROL MODULE 45
11.1 Reading and programming the set point ..................................................................................................................................................................45
11.2 Display of SW release..................................................................................................................................................................................................... 45
11.3 Reading and programming the control parameters - reading the measurements .........................................................................................45
11.4 Reading and programming the configuration parameters ................................................................................................................................... 46
11.4 Validity of the modifications to the parameters ...................................................................................................................................................... 49
11.5 Recalling the default parameters (factory settings)................................................................................................................................................. 49
11.6 Resetting the hour counter .......................................................................................................................................................................................... 49
11.7 Displaying and modifying the unit of measure ....................................................................................................................................................... 49
11.8 Automatic total drain for inactivity...............................................................................................................................................................................50
11.9 User-adjustable duration of dilution drain ................................................................................................................................................................ 50
11.10 User-adjustable max. allowed no. of evaporation cycles between 2 dilution drains..................................................................................... 50
11.11 Reduced fills to restore water level after evaporation........................................................................................................................................... 51
11.12 PWM fills after dilution and high-level/foam drains.............................................................................................................................................. 51
12. THE REMOTE CONTROL (OPTIONAL ACCESSORY) 52
12.1 Description of the remote control...............................................................................................................................................................................52
12.2 Programming from the remote control..................................................................................................................................................................... 53
12.3 Exiting the programming phase.................................................................................................................................................................................. 54
13. SHUTTING DOWN THE UNIT 55
14. MAINTENANCE 56
14.1 Maintenance of the cylinder-cylinder......................................................................................................................................................................... 56
15. ALARMS AND TROUBLESHOOTING 58
15.1 Alarm summary table..................................................................................................................................................................................................... 58
15.2 Autotest Retry procedure (Fault tolerance) .............................................................................................................................................................60
15.3 Troubleshooting ............................................................................................................................................................................................................. 60
16. HUMIDIFIER TECHNICAL SPECIFICATIONS 61
17. SPARE PARTS 62
17.a Maintenance of the other plumbing components................................................................................................................................................... 65
17.2 Replacing the components............................................................................................................................................................................................ 66
17.3 Spare parts ........................................................................................................................................................................................................................ 68
17.4 Disposal of the parts of the humidifier....................................................................................................................................................................... 68

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UR xxx x x x 0 *
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1. MODELS
The code designating the model of electric heater humidifier is made up of 10 characters, with the
following meaning (Fig. 1a).
Example: the code UR010CL101 identifies an electric heater humidifier (UR) with:
• rated steam production of 10kg/h (22lbr/h) (010);
• ON/OFF control module (C);
• 400 Vac, three-phase power supply (L);
• full optional version (1).
NOTE: Not all the combinations are possible.
Fig. 1.a
1 ID prefix;
2 rated instant steam production
in kg/h / lbr/h:
mod. production
002 2/4.4
004 4/8.8
006 6/13.2
010 10/22
020 20/44
027 27/59.5
040 40/88
060 60/132.2
3 type of control: C= ON/OFF
H= modulating
T= for steam baths;
4 type - power supply: type V
U= 208 1~N
D= 230 1~N
W= 208 3~
K= 230 3~
L= 400 3~
M= 460 3~
N= 575 3~
5 option: 0= base version
1= full optional version
6 customisations
7Sfor UR020
Table 1.a
1.1 Accessories
Table 1.b lists the accessories fitted on the humidifiers, in the various configurations.
type of control
C
(ON/OFF)
H
(modulating)
T
(for steam baths)
options 0: base 1: full
optional
0: base 1: full
optional
0: base 1: full
optional
water temperature probe
and pre-heater
--- --- incl. incl. incl. incl.
external thermal lining on
cylinder
--- incl. --- incl. --- incl.
elements coated with non-
stick film
--- incl. --- incl. --- incl.
lime collection film * --- incl. --- incl. --- incl.
Remote control --- --- optional optional optional optional
Humivisor --- --- optional optional optional optional
Table 1.b
*: not present on the full option version of the 20-27-40-60 kg/h (44-59.5-88-132.2 lbr/h) units;
---: not available;
incl.: accessory included.

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1
2
3
4
6
9
10
11
12
13
7
8
5
15
16
17
14
1
11
4
9
2
5
6
3
10
12
7
8
15
16
1419
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2. DESCRIPTION OF THE MAIN COMPONENTS AND FUNCTIONS
n. description
1 Klixon (motor overload – in models where featured)
2 Solid state relay (SSR) (in models where featured)
3 Motor protector
4 Fuse carrier base
5 Remote control switch
6 Transformer
7 Relay board
8 ON-OFF and manual drain switch
9 Power cable terminal block
10 Power cable gland
11 Fan (in models where featured)
12 Control module
13 Drain electrovalve
14 Fill electrovalve
15 Cylinder
16 Level controller
17 Locking lever
18 conveyor
19 drain pump
Table 2.a
Fig. 2.a Fig. 2.b

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1
11
4
9
2
5
6
3
10
1213
7
8
1516
17
18
19
20
21
22
23
24
14
27
25 26
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Fig. 2.c Fig. 2.d
Humidifiers up to 10 kg/h /22 lbr/h Humidifiers from to 20-27-40-60 kg/h (44-59.5-88-132.2 lbr/h )
n. description
1 fill electrovalve
2 flow limiter
3 supply pipe
4 refill pipe
5 overflow pipe
6 connection pipe
7 level gauge housing
8 level control - level switch (following: level switch)
9 equaliser pipe
10 conductivity measurement electrodes
11 fill tank
12 fill diaphragm
13 overfill diaphragm
14 high level electrodes
15 steam outlet pipe
16 cylinder cover
17 thermal lining on the boiler (optional))
18 water temperature sensor (optional)
19 overheating sensors
20 lime collection film
21 heating elements
22 cylinder housing
23 bottom filter
24 drain electrovalve
25 drain pump
26 Drain column
27 Conductivity meter
28 water temperature sensor (optional)
Table 2.b

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2.1 Level control
Steam is produced with the heating elements completely immersed in water, whose level is controlled
by a sensor made up of two independent and overlapping float switches, that is, the working level switch
and safety level switch.
2.1.1 Level control
It is composed of a float contained in a plastic pipe. Constrained to the level control case, an electronic
board detect the float position and display the levels through three LEDs:
green working level, yellow charge level, red safety level. The signals, working and safety level, are
detailed in the paragraphs 2.1.2, 2.1.3.
2.1.2 Working level switch
This switch, which activates the fill electrovalve, introduces water through the special pipe into the fill
tank, from where, dropping from a fill diaphragm, it refills the level inside the cylinder; the fill electroval-
ve is fitted with a flow limiter, maintaining the flow basically constant on changes in mains pressure.
2.1.3 Safety level switch
This switch shuts off power to the elements, activating the alarm in the case where the level is insuffi-
cient.
2.2 Overfill device
This is a device used to avoid water exiting the cylinder over the safety level, due for example to the
malfunctioning of the control module (for more details, see THE HUMIDIFIER CONTROLLER) or to
leaking from the fill electrovalve.
The fill tank is fitted with an overfill diaphragm which diverts the excess inlet water, discharging it
through special pipe.
The overfill diaphragm is lower than the fill diaphragm to avoid back flow through the supply pipe.
2.3 Control of steam production
Steam production can be controlled either:
• By step, alternating steam production with standby using a
humidistat or external contact; steam production can be controlled in four steps with pseudo-modu-
lation from 30% to 100% of rated power, cyclically activating the remote-control switch (humidifier
with type C control module).
• By continuous modulation from 0% to 100% of rated power, using solid-state relays (SSR); the
control logic is PWM (pulse width modulation) with programmable base times (humidifier with type
H or T control module).
2.4 Measurement of supply water conductivity- alarm
To optimise the functionality of the humidifier by suitably portioning the automatic draining cycles (see
Automatic draining), when the fill electrovalve is opened the conductivity of the inlet water is measured
using the special electrodes in the tank.
Two high conductivity thresholds can be set to activate respectively a pre-alarm and an alarm (with the
shut-down of the appliance) when these thresholds are exceeded for at least 60 minutes, or instantly if
the value measured is greater than three times the set value.
2.5 Automatic draining
The automatic draining function is managed by the control module. Part of the water contained in the
cylinder is drained automatically, being replaced by fresh water to prevent an excessive salt concentra-
tion following the evaporation process.
The drain pump/electrovalve is operated for a pre-set time at intervals that vary automatically as a
function of the steam production and the content of solids dissolved in the supply water, detected using
the conductivity measuring electrodes.
Irrespective of the concentration of salt in the supply water, at least one drain cycle is performed within
a maximum interval based on the quantity of steam produced; this is also true for demineralised supply
water.