SATA STEAMaster+ SERIES Instruction manual

(10/04)
STEAMaster + SERIES
Installation, Operation & Maintenance Manual
ELECTRODE STEAM HUMIDIFIERS
Frederick, Maryland, U.S.A.
STEAMaster+ SERIES
Installation, Operation
& Maintenance Manual
Installation, Operation
& Maintenance Manual

(10/04)
STEAMaster+ SERIES
Installation, Operation & Maintenance Manual
IMPORTANT
BEFORE INSTALLING OR HANDLING THE HUMIDIFIER 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-pressurized steam by means of electrodes immersed in the water contained in the
cylinder-boiler (hereafter called the cylinder). The electrodes pass current through the water, which also provides
resistance, heating the water into steam, which is used to humidify environments or industrial processes, using
special distributors.
The quality of the water used affects the process of evaporation, so the humidifier may be supplied with untreated
water, as long as this is drinkable and not softened or demineralized; the evaporated water is automatically
replaced using a fill valve. This humidifier has been designed exclusively to directly humidify rooms or ducts, using
a distribution system. The installation, use and maintenance operations must be carried out according to the
instructions contained in this manual and on the labels applied internally and externally.
The conditions of the environment and the power supply voltage must comply with the specified values.
All other uses and modifications made to the humidifier that are not authorized by the manufacturer are
considered incorrect.
Liability for injury or damage caused by the incorrect use of the humidifier lies exclusively with the user.
Please note that the humidifier 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.
Disconnect the humidifier from the main power supply before accessing any internal parts.
The humidifier must be installed in accordance with the local standards in force.
The local safety standards in force must be applied in all cases.
The humidifier is made up of metallic and plastic parts. All parts must be disposed of according to the
local standards on waste disposal.
Warranty on materials: 2 years (from the date of installation, excluding the consumable parts, such as the cylinder
and electrodes).
Certification: the quality and safety of SATS products are assured by SATS’ ISO 9001 certified design and
production system, as well as listings from UL, cUL, CE, TUV and others.

(10/04)
STEAMaster + SERIES
Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
i
Models And Description Of The Components ....................................................................................................... 4
How The STEAMaster+ Works ............................................................................................................................ 5
Installation ........................................................................................................................................................... 6
Positioning ...................................................................................................................................................... 6
Removing the front cover .............................................................................................................................. 7
Fastening to the wall ................................................................................................................................... 7
Plumbing ......................................................................................................................................................... 8
Water supply ............................................................................................................................................... 8
Water drain ................................................................................................................................................. 8
Steam distribution .......................................................................................................................................... 10
Duct injection ............................................................................................................................................ 10
Room distribution blower units .................................................................................................................. 12
Power wiring .................................................................................................................................................. 13
Control wiring ................................................................................................................................................. 15
ASWH / ASDH – ASDH / ASDC Wall – Duct Temperature/Humidity Sensors ........................................... 17
HC-101 and HC-201 Wall and Duct Humidistats ....................................................................................... 18
PC-301 Air Proving Switch ......................................................................................................................... 19
Start-Up .............................................................................................................................................................. 20
Startup Checklist ........................................................................................................................................... 20
The HumiControl Controller ............................................................................................................................ 21
Start-up Procedure ......................................................................................................................................... 21
Starting with a new cylinder ....................................................................................................................... 21
Operation ........................................................................................................................................................... 22
Display Information ........................................................................................................................................ 22
Changing The Set Point ................................................................................................................................. 22
Activating Manual Drain ................................................................................................................................. 22
Accessing/Changing Configuration Parameters ............................................................................................. 22
Notes about special parameters .................................................................................................................... 25
Standard Factory Settings ............................................................................................................................. 26
Seasonal Shut Down ..................................................................................................................................... 27
The Remote Control ....................................................................................................................................... 27
Resetting the Hour Counter ........................................................................................................................... 28
Alarms ........................................................................................................................................................... 28
Trouble-Shooting ............................................................................................................................................ 32
Resetting Factory Defaults ........................................................................................................................ 33
Maintenance ...................................................................................................................................................... 34
Periodic checks ............................................................................................................................................. 34
Cylinder maintenance .................................................................................................................................... 34
Replacing the cylinder ............................................................................................................................... 34
Maintenance of the other plumbing components ....................................................................................... 35
Replacement Parts ........................................................................................................................................ 36
Single Phase Humidifiers .......................................................................................................................... 36
Three Phase Humidifiers ............................................................................................................................ 37
Wiring Diagrams ................................................................................................................................................ 39
Technical Specifications ..................................................................................................................................... 43
IMPORTANT: BEFORE beginning installation:
••
••
•Check for shipping damage to cartons. Mark the shipping waybill accordingly
•Open cartons and check for any hidden damage. Mark the shipping waybill accordingly.
•Check packing slip to ensure all items have been received. Notify SATS of any shortages or damaged
parts. You must notify SATS within 5 working days of any shortages.

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STEAMaster+ SERIES
Installation, Operation & Maintenance Manual
4
Models And Description Of The Components
Model Selection
SMP 025 H D 000 U 1
=STEAMaster Capacity (KG) H Control Power Version USA Cylinder Type
Plus 001 = 3.3 lbs/hr For use with: U = 208/1 Internal use only
003 = 6.6 lbs/hr On/off D = 230/1
1 = Disposable
Standard Conductivity
005 = 11 lbs/hr or W = 208/3
008 = 17.6 lbs/hr Modulating K = 230/3
2 = Disposable
Low Conductivity
009 = 20 lbs/hr or M = 460/3
010 = 22 lbs/hr DDC N = 575/3
015 = 33 lbs/hr
025 = 55 lbs/hr
035 = 77 lbs/hr
045 = 99 lbs/hr
065 = 132 lbs/hr
SMP 001 through SMP 015
No. Description
1 Steam generator cylinder
2 Water drain valve
3 Power contactor
4 Fuses
5 Power transformer
6 Relay board
7 On/Off and Manual drain switch
8 Wiring terminal block
9 Water fill valve
SMP 025 through SMP065
No. Description
1 Steam generator cylinder
2 Water drain pump
3 Water fill valve
4 Amperage transformer
5 Power contactor
6 Power transformer
7 Relay
8 Fuses
9 Wiring terminal block
10 Cable raceway
11 On/Off and Manual drain switch

((06/06)
STEAMaster + SERIES
Installation, Operation & Maintenance Manual
5
How The STEAMaster+ Works
STEAMaster+ is an electrode humidifier. It produces steam for humidification by passing electrode
current through the water in the steam generator cylinder between metal electrodes. There are no
heater elements. Steam output is directly proportional to the conductivity of the water, and the amount
of electrode immersed in the water.
On a call for humidity, the STEAMaster+ controller will open the water fill valve (1) and allow water to enter the system. A
flow restrictor (2) prevents the unit from filling too quickly or with too much pressure. The water flows up the fill tube (3)
and into the fill cup (7), where it flows over the conductivity probes (6), which feed the water conductivity back to the
controller for analysis. Water then flows over the dam in the fill cup (7), which creates a 1" air gap to prevent backflow of
contaminated water into the feed lines, and through the fill tube (4) and into the bottom of the steam cylinder (11).
As the water fills the cylinder, it will reach the electrodes (10) and current will begin to flow. As the water continues to fill
the cylinder, the current will increase, and this is monitored by an amperage transformer placed on one of the power wires
(9). When the desired current is reached, the fill valve will close (1) and the water will then begin to warm and produce
steam. If the water reaches the cylinder full probes (8) prior to reaching the desired current level, the fill valve (1) will be
closed to prevent overflow. If the current rises too much as the water fills the cylinder, the drain valve or pump (13) will be
activated to drain away some water and reduce the current flow.
Periodically, based on the incoming water conductivity, the unit will drain some water to reduce the mineral concentration.
A strainer (12) in the cylinder helps to prevent mineral debris from jamming the drain valve (13).
If there is no water in the cylinder, there will be no current flow and no steam production. The electrodes do not burn out,
but they will eventually become comletely coated with mineral and the cylinder will then need to be replaced or cleaned.

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STEAMaster+ SERIES
Installation, Operation & Maintenance Manual
6
Installation
Positioning
The STEAMaster+ has been designed for wall mounting
(although it can be placed on a stand) and, since it is an
atmospheric steam humidifier, should be placed close to
the point where the steam will be used, to minimize the
steam hose length (and condensate). Certain clearances
must be maintained around the unit:
A B C D E F
Minimum
Dimension
(inches)
12 8 8 16 28 0.5°
With room blower units, other clearances are needed:
A B C D E F H
Minimum
dimension
(inches)
20 72 72 24 20 72 24
Model - SMP
001-008 009-015 025-045* 045**-065
A 15 15 22 26
B 11 11 15 18
Dimensions
(inches) C 25 28 35 38
packaged 36 44 86 113
empty 30 38 75 97
Weight
(lbs) installed 42 60 134 207
* = SMP045 for 460-575/3 Vac
* = SMP045 for 460-575/3 Vac

(06/06)
STEAMaster + SERIES
Installation, Operation & Maintenance Manual
7
Mounting
Removing the front cover
The front cover is secured by a capture screw located underneath the SATS
logo. Twist the SATS logo to reveal the screw, and use a phillips head
screwdriver to remove it. Then simply lift the front cover and pull out to
remove it. Return it in reverse order.
Fastening to the wall
Using the screws and anchors supplied, fasten the mounting bracket to the
wall. Be sure that the screws anchor firmly into studs or supports. Note
the unit installed weights from the Positioning section.
Once the mounting bracket is secured to the wall, hang the unit on the bracket. Fasten the remaining capture
screws through the bottom holes in the unit to secure it to the wall
Model SMP
001-008 009-015 025-045 065
X 8.67 8.67 12.21 15.75
Y 19.69 23.23 28.55 30.91
Z 4.53 1.5
Z’ 4.41

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STEAMaster+ SERIES
Installation, Operation & Maintenance Manual
8
Plumbing
Water supply
The STEAMaster+ must be supplied with water (not softened) having the following characteristics:
Water drain
The STEAMaster+ also requires connection to a drain. The drain water characteristics are:
Model SMP
001-008 009-015 025-045 65
Instant flow rate 0.2 gpm 0.3 gpm 1 gpm 1.9 gpm
Connection 1/4" O.D. Compression 3/8" O.D. Compression
Temperature limits 34 to 104°F
Pressure limits 15 to 116 psi
Hardness limits <= 400 ppm CaCO3
Conductivity range 125 to 1250 µS/cm (micromhos)
Model SMP
001 003 005 008 009 010 015 025 035 045 065
Drain rate per hour 0.7 gph 2.2 gph 3.7 gph 5.9 gph 6.6 gph 7.3 gph 11 gph 18.3 gph 25.7 gph 33 gph 47.7 gph
Instant drain rate 1.3 gpm 6 gpm
Connection 1-1/2" nominal diameter
Typical temperature 212°F

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STEAMaster + SERIES
Installation, Operation & Maintenance Manual
9
Water supply and drain connections are made according to the following diagram.
NOTE: Drain line must be trapped under the unit to prevent flash steam from condensing in the unit cabinet.
Physical location of the supply and drain connections are located as shown below.
SMP 010-015 SMP 025-065
NOTE: SATS can provide a drain tempering system which limits the water drain to no more than 140°F.
NOTE: Softened water should NOT be used as it is generally corrossive to the electrode plating.

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STEAMaster+ SERIES
Installation, Operation & Maintenance Manual
10
Steam distribution
Duct injection
If your STEAMaster+ humidifier was supplied with duct steam
distributor pipes, they must be mounted completely level in the
duct with the steam outlet holes facing up as shown to the right.
Support the end of longer distributor pipes if needed.
Distributor pipes should be mounted per the diagrams shown
below, with a minimum of 6" from the center of the distributor
pipe to the top of the duct and 3" minimum to the bottom.
Generally the distribu-
tor pipes should be
mounted in the center
of the air stream.
Multiple pipes need to
be staggered on a
diagonal to prevent
the steam discharge
from the lower pipes
from impinging on the
upper ones.
In vertical ducts, the distributor pipes are mounted in the center
with the holes facing up as shown at right. The airflow may be up or
down, but when the airflow is down, maximum velocity is 1,500
fpm.
To install the distributor pipes:
1. Cut a key shaped hole in the side of the duct to match the steam pipe and
condensate return.
2. Apply silicone sealant to the mounting plate and insert the pipe through the
hole and secure it with 4 sheet metal screws.
3. Connect the steam and condensate hoses using the hose clamps supplied.
IMPORTANT: Allow 2 feet of straight duct downstream of the distributor pipes when the air temperature will be
>55oF. Allow 3 feet of straight duct if the air temperature will be <50oF. Always allow 2 feet upstream. Turbulent
air flow may require longer lengths.