Stulz STULZ Ultra Series Owner's manual

STULZ Ultra-Series Controller
®
For STULZ Ultrasonic Humidifiers
Installation, Operation & Maintenance
IOM
Retrofit & Conditioning
Humidification
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STULZ Ultra-Series Controller
(© Feb, 2008)
Air Technology Systems, Inc.
Notice
This document contains information protected by copyright. All rights are reserved. The owner of the
equipment for which this manual is written may photocopy the contents of this manual for internal use
only. No part of this document may be photocopied, reproduced, or translated into another language for
use by anyone other than the owner of the equipment for which this manual is written without the prior
written consent of STULZ Air Technology Systems, Inc. (STULZ).
This document contains confidential and proprietary information of STULZ. Distributing or photocopying
this document for external distribution is in direct violation of United States copyright laws and is strictly
prohibited without the express written consent of STULZ.
Unpublished rights reserved under the copyright laws of the United States and of other countries.
Other brands and trade names are trademarks of their respective owners.
© 2011 STULZAir Technology Systems, Inc.
Printed in the United States of America.
All rights reserved.
STULZ Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704
USA
FOR INITIAL STARTING,
SEE SECTION 3.0
IMPORTANT NOTE
This document applies to STULZ Ultra-Series Controllers with
Revision 1.05 or higher software and communicating with
humidifiers equipped with Revision 3.0.7 or higher software.

STULZ Ultra-Series Humidifier Controller
(April 2013) i
Table of Contents
1.0  GENERAL INFORMATION........................1 
1.1  Forward ......................................................1 
1.2  Safety Summary.........................................1 
1.3  Warnings & Cautions .................................1 
1.4  Product Warranty .......................................2 
2.0  DESCRIPTION........................................... 3 
2.1  General.......................................................3 
2.2  Features .....................................................3 

BMS Interface............................................. 3  2.2.1
 Field Configurable ......................................3  2.2.2
 Password Protection ..................................3  2.2.3
 Timed Drain Cycle...................................... 4  2.2.4
 Restorable Set Points ................................4  2.2.5
2.3  User Interface Display Panel......................4 

Function Keys............................................. 4  2.3.1
 Alarms ........................................................4  2.3.2
2.4  Controller Nomenclature ............................5 
2.5  Controller I/O Module .................................6 

Controller I/O Module Layout .....................6  2.5.1
2.6  Auxiliary Terminals.....................................6 

Control Sensors..........................................6  2.6.1
 Alarm Contacts........................................... 6  2.6.2
 Water Conductivity Probe .......................... 7  2.6.3
 Air Velocity Sensor..................................... 7  2.6.4
 Air Proving Switch ...................................... 7  2.6.5
 Water Leak Detector .................................. 7  2.6.6
 Remote On/Off ...........................................7  2.6.7
 Multiple Humidifier Grouping...................... 7  2.6.8
 BMS Operation........................................... 8  2.6.9
3.0  INSTALLATION.......................................... 9 
3.1  Uncrating and Inspection ...........................9 
3.2  Mounting.....................................................9 
3.3  Wiring Connections ....................................9 

AC Input .....................................................9  3.3.1
 DC Output to Humidifier(s)......................... 9  3.3.2
 Control Wiring to Humidifiers .....................9  3.3.3
 Sensors .................................................... 10  3.3.4
 Water Conductivity Probe ........................ 10  3.3.5
 Remote On/Off .........................................11  3.3.6
 Remote Alarm Signal Contacts ................ 11  3.3.7
 Water Leak Detector ................................ 11 3.3.8
4.0
 OPERATION ............................................12 
4.1  General Theory of Operation ...................12 

Humidification Control .............................. 12  4.1.1
 Operating Modes......................................12  4.1.2
 P/I- Proportional/Integral Control.............. 13  4.1.3
4.2  Navigating Controller Screens .................14 

Menu Selection......................................... 14  4.2.1
 Menu Loops..............................................14  4.2.2
4.3  Password Authorization ...........................16 

Password Protected Screens...................16  4.3.1
 Wrong Password ......................................16  4.3.2
 Setting the Passwords..............................16  4.3.3
4.4  Start-up / Commissioning.........................17 

Main Info Screen ......................................18  4.4.1
 Saving & Restoring Set points .................18  4.4.2
4.5  Controller Features...................................18 

Alarms ......................................................18  4.5.1
 Remote On/Off .........................................19  4.5.2
 Automatic Drain Cycle..............................19  4.5.3
 Manual Drain ............................................19  4.5.4
 Communication with the Controller ..........20  4.5.5
 Loading New Software .............................20  4.5.6
5.0  MENU SCREENS ....................................21 
5.1  Main Menu................................................21 
5.2  Information Menu .....................................21 

Main Info Screen ......................................21  5.2.1
 Control Sensor .........................................22  5.2.2
 Limit Sensor ............................................. 22  5.2.3
 Conductivity..............................................22  5.2.4
 Control Points...........................................22  5.2.5
 Cabinet Temperature ...............................22  5.2.6
 NTC Temperature Sensors ......................22  5.2.7
 Air Speed (optional)..................................23  5.2.8
 Humidifier Information (Loop)...................23  5.2.9
 About Screen............................................23  5.2.10
5.3  Alarm Log .................................................23 

Alarms ......................................................24  5.3.1
 Non-Critical Alarms ..................................24  5.3.2
 Critical Alarms ..........................................24  5.3.3
 Alarm Screen Messages ..........................25  5.3.4
5.4  Control Menu............................................26 

Set Point Screens..................................... 26  5.4.1
 Alarm Set Point Screens ..........................27  5.4.2
(August, 2013)

STULZ Ultra-Series Humidifier Controller
ii (August, 2013)
 Clock Screen ............................................ 28  5.4.3
 Version Screen......................................... 29  5.4.4
5.5  Service Menu ...........................................29 

Humidifier Configuration........................... 30  5.5.1
 Alarms ......................................................35  5.5.2
 Sensors .................................................... 35  5.5.3
 Options Menu Loop.................................. 36  5.5.4
 Digital In ................................................... 38  5.5.5
 Run Hours ................................................ 38  5.5.6
 BMS Communication ............................... 39  5.5.7
 Factory Configuration............................... 40  5.5.8
 Sys Configuration ..................................... 40  5.5.9
 Save Configuration...................................40  5.5.10
5.6  Factory Configuration...............................41 
5.7  Sys Configuration.....................................44 

Basic System Configuration ..................... 44  5.7.1
 Humidifiers and Cabinet Fan.................... 45  5.7.2
 Drain, BMS and Integration...................... 45  5.7.3
 Input Configuration................................... 45  5.7.4
 Digital Input Configuration........................46  5.7.5
 Output Configuration ................................46  5.7.6
 Sensor Options......................................... 46  5.7.7
 Measurement Units .................................. 46  5.7.8
 Screens Visible Only by Config Password.....46  5.7.9
5.8  Factory Default Set Points .......................47 
6.0  MAINTENANCE ....................................... 49 
6.1  General.....................................................49 
7.0  TROUBLESHOOTING ............................. 49 
7.1  General.....................................................49 
7.2  Control I/O Module Signal LED's .............50
8.0
 REPAIR PROCEDURES..........................51 
8.1  General.....................................................51 
8.2  Component Replacement ........................51 
9.0  PRODUCT SUPPORT .............................51 
9.1  Technical Support ....................................51 
9.2  Obtaining Warranty Parts.........................51 
9.3  Obtaining Spare/Replacement Parts........52 
10.0  APPENDIX A - BMS Parameters .............53 
10.1  Signed Values .........................................53 
10.2  Unsigned Values .....................................54 
10.3  Boolean Values ........................................55 
10.4  Alarm Packed Bit Variables......................56 
10.5  Input Packed Bit Variables .......................57 
10.6  Output Packed Bit Variables ....................57 
11.0  APPENDIX B - Input/Output..................... 58 
LIST OF FIGURES
Figure 1 - Ultra-Series Control Box............................3

Figure 2 - User Interface Display Panel .....................4 
Figure 3 - Control Box Internal Layout .......................5 
Figure 4 - Controller I/O Module.................................6 
Figure 5 - Multiple Humidifier Groups ........................7 
Figure 6- Humidifier Grouping....................................8 
Figure 7 - Serial Interface Ports .................................8 
Figure 8 - Supervisory Control of Humidifiers ............8 
Figure 9 - RJ45 Connector.......................................10 
Figure 10 - Locating Wall Mount Sensor..................10 
Figure 11 - Control Inputs and Outputs....................12 
Figure 12 - Control Logic..........................................13 
Figure 13 - Main Menu Selections ...........................14 

STULZ Ultra-Series Humidifier Controller
(August, 2013) 1
1.0 GENERAL INFORMATION
1.1 Forward
Congratulations, this microprocessor based, Ultra-Series
Humidifier controller is designed and manufactured by
STULZ Air Technology Systems, Inc. (STULZ) utilizing the
latest, state-of-the-art control technology. Recognized as a
world leader, STULZ provides humidification systems and
controllers manufactured with the highest quality
craftsmanship using the finest materials available in the
industry. The controller will provide years of trouble free
service if it is installed, operated and maintained in
accordance with this manual. Damage to the unit from
improper installation, operation or maintenance is not
covered by the warranty.
This manual contains information for the installation,
operation, troubleshooting, maintenance and repair of the
controller. STUDY the instructions contained in this
manual. They must be followed to ensure proper operation
of the equipment. Spare parts are available from STULZ to
ensure continuous operation. Using substitute parts or
bypassing electrical components in order to continue
operation is not recommended and will VOID THE
WARRANTY.
Ultra-series controllers are designed primarily to precisely
operate, control and monitor STULZ Ultrasonic
humidification systems. Any use beyond this is deemed to
be not intended. STULZ is not liable for any damage
resulting from improper use. All Ultra-series controllers are
designed for indoor use.
1.2 Safety Summary
Read and understand all instructions in this manual
relating to the specific function prior to starting the task.
Carefully read and understand all notes, cautions and
warnings contained in this manual that pertain to the task
to be performed. Warnings indicate potential threat to
personnel safety. Cautions indicate potential threat of
damage to equipment.
Carefully read and understand all WARNING and/or
CAUTION plates located on the unit.
1.3 Warnings & Cautions
STULZ uses NOTES along with CAUTION and WARNING
symbols throughout this manual to draw attention to
important operational and safety information.
A bold text NOTE marks a short message in the
information alerting to an important detail.
A bold text CAUTION safety alert appears with information
that is important for protecting of the equipment and
performance. Be especially careful to read and follow all
cautions that apply to your application.
A bold text WARNING safety alert appears with
information that is important for protecting personnel from
harm and the equipment from damage. Pay very close
attention to all warnings that apply to the particular
application.
A safety alert symbol accompanies a general WARNING
or CAUTION safety statement.
A safety alert symbol accompanies an electrical shock
hazard WARNING or CAUTION safety statement.
CAUTION
Prior to performing any installation, operation,
maintenance or troubleshooting procedure read
and understand all instructions, recommendations
and guidelines contained within this manual.
CAUTION
All maintenance and/or repairs must be performed
by a qualified technician.
NOTE
We recommend consulting the STULZ customer
service department for the adjustment and
maintenance of the controller or the humidification
system.
WARNING
Never operate the unit with any cover, guard,
screen, panel, etc., removed unless the
instructions specifically state otherwise, then do so
with extreme caution to avoid personal injury.
WARNING
Always disconnect the main power supply to the
equipment at the main power disconnect switch
before beginning work on the equipment. A
lockout tag-out procedure should be followed to
ensure that power is not inadvertently
reconnected.
CAUTION
Air vent openings must be completely free of
obstructions.

STULZ Ultra-Series Humidifier Controller
2 (August, 2013)
1.4 Product Warranty
2-Year Standard Limited Warranty:
STULZ Air Technology Systems, Inc., warrants to the original buyer of its products that
the goods are free from defects in material and workmanship. STULZ Air Technology
Systems, Inc.’s obligation under this warranty is to repair or replace, at its option, free of
charge to the customer, any part or parts which are determined by STULZ Air
Technology Systems Inc. to be defective for a period of 24 months from date of shipment
when a completed start-up form has been submitted to STULZ Air Technology Systems,
Inc. within 90 days from shipment. In the event that a completed start-up form is not
received by STULZ Air Technology Systems, Inc. within 90 days from shipment, the
company’s obligation will be for a period of 12 months from date of shipment. Parts
repaired or replaced under this warranty are shipped FOB Factory, and warranted for the
balance of the original warranty period or for 90 days from the date of installation,
whichever is greater.
STULZ Air Technology Systems, Inc.’s warranty does not cover failures caused by
improper installation, abuse, misuse, misapplication, improper or lack of maintenance,
negligence, accident, normal deterioration (including wear and tear), or the use of
improper parts or improper repair.
Purchaser’s remedies are limited to replacement or repair of non-conforming materials in
accordance with the written warranty. This warranty does not include costs for
transportation, costs for removal or reinstallation of equipment or labor for repairs or
replacement made in the field.
If any sample was shown to the buyer, such sample was used merely to illustrate the
general type and quality of the product, and not to represent that the equipment would
necessarily conform to the sample.
This is the only warranty given by the seller, and such warranty is only given to buyers for
commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is
paid in full.
THE FOREGOING SHALL CONSTITUTE STULZ’S ENTIRE LIABILITY AND YOUR
EXCLUSIVE REMEDY. IN NO EVENT SHALL STULZ BE LIABLE FOR ANY DIRECT,
INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES,
INCLUDING LOST PROFITS (EVEN IF ADVISED OF THE POSSIBILITY THEREOF)
ARISING IN ANY WAY OUT OF THE INSTALLATION, USE OR MAINTENANCE OF
THE EQUIPMENT. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR
FITNESS FOR A PARTICULAR PURPOSE.

STULZ Ultra-Series Humidifier Controller
(August, 2013) 3
2.0 DESCRIPTION
2.1 General
The microprocessor based, Ultra-Series controller is a
highly versatile and flexible humidification controller. It is
designed primarily for STULZ Ultrasonic Humidifiers with
variable humidity output. The controller is equipped with
factory configured software designed to precisely control
the operation of this Ultrasonic Humidifier.
The Ultra-Series controller is factory programmed therefore
most applications will require no additional field setup
except for the addressing of the humidifiers. However, the
set points and their ranges are easily adjusted from the
user interface display panel. The program and operating
parameters are permanently stored in FLASH-MEMORY in
case of power failure. The Ultra-Series controller may be
configured to monitor and control a complete humidification
system consisting of multiple ultrasonic humidification units.
Depending on the Humidifier capacity, a full size Ultra-
Series controller may hold output power supplies for up to 8
STULZ Ultrasonic Humidifiers. When controlling groups of
Humidifiers, auxiliary control boxes, containing additional
Humidifier output power supplies, may be utilized to
achieve up to 16 humidifiers on a system. Auxiliary control
boxes contain no controller or interface display panel. They
are powered independently of the controller allowing them
to be installed near the Humidifiers they operate, resulting
in reduced wire lengths and wire size.
Figure 1 - Ultra-Series Control Box
A smaller space saving "Trim" control box is also available
for powering smaller groups of humidifiers consisting of four
units or less. The Ultra-Series control box and auxiliary
control box are provided with a door interlocked, main
power disconnect switch with a lockable handle. The switch
must be turned "Off" to open the door of the box. The
disconnect switch isolates power only from the Humidifiers
connected to that box.
The Ultra-Series controller is designed to manage humidity
or dew point levels to a user defined set point via
proportionally controlled output signals to the Humidifier(s).
Control set points are established to maintain the necessary
level of humidification needed to achieve the room's design
conditions. The controller has the ability to monitor the
conditions (such as humidity, temperature, supply air
velocity) via sensors or BMS control inputs. The internal
logic determines if the room conditions require
humidification. The controller communicates with the
Humidifiers the percentage output they need to be
delivering in response to the demand for humidification. The
controller responds accordingly to changes in conditions
and proportionally varies the output(s) controlling humidity
production to maintain humidity levels to the control set
point.
2.2 Features
BMS Interface 2.2.1
The controller may incorporate a communication port that
can be field connected through a serial interface to a
Building Management System via Modbus, BACnet, SNMP
or HTTP protocol.
Field Configurable 2.2.2
Ultra-Series controllers are field configurable, allowing the
operator the capability of selecting control set points
specific to the application. Operator interface for the
controller is provided via an attractive, user interface display
panel. The display panel has a backlit LCD display and
function keys allowing the user to scroll through and enter
various menu loops. The menu driven loop structure is user
friendly with operator prompts making it easy to navigate
through the various screens.
Monitoring of room conditions and system operation is
allowed without entering a password. Modifications to the
control set points may be made with the use of a password.
Password Protection 2.2.3
Access to the Information menu and Alarms log is allowed
without the use of a password. The controller is
programmed to recognize predetermined security levels
before allowing access to display screens containing critical
variables. Only authorized personnel who possess a
thorough understanding of the system should make

STULZ Ultra-Series Humidifier Controller
4 (August, 2013)
changes to Control and Service menu settings. These
screens must have accurate variables entered, otherwise
erratic operation may occur. The secured menu levels
support unique passwords that must be entered to access
the menu screens so only authorized personnel may
perform modifications to the settings. See Password
Authorization, Section 4.3.
Timed Drain Cycle 2.2.4
The Ultra-Series controller is programmed to enable timed
drain cycles when the Humidifier(s) have been idle to help
ensure proper water quality in the reservoir.
Restorable Set Points 2.2.5
Upon initial start-up the system operates using the set
points programmed by the factory. The set points for the
system may be re-adjusted in the Control menu at any time.
The customer may enter new operating parameters in the
Control>Set points and Control>Tuning menus and the
system will operate accordingly. If it becomes necessary,
the customer may restore the set points back to saved
customer parameters or to the original factory (primary)
parameters.
2.3 User Interface Display Panel
Figure 2 - User Interface Display Panel
The user interface panel features an easy to read, backlit
liquid-crystal alphanumeric display giving a quick-glance
operational overview of the humidification system. The
display is equipped with LED illuminated function keys
allowing the operator complete control and monitoring
capability of the humidification system. The screens
available on the interface display panel present data that
originates from the controller I/O module. The controller is
operated via a 6-key menu-driven windows type loop
structure providing the ability to scroll through and enter
various menus (Information, Control, and Service). These
menus permit the user to easily view, control and adjust
operating parameters for the humidification system. (See
Menu Selections, Figure 13.)
Function Keys 2.3.1
KEY FUNCTION
Accesses active alarm screens
Silences audible alarms
Resets active alarms
Prg
Displays the main menu
Esc
Returns to the next menu level up
Cancels a changed entry
Steps back to the previous screen in a menu loop
Increases the value of a modifiable numeric field
"Enter Key"- Accesses the menu loops
Moves the cursor into a modifiable field
Accepts the current value of a modifiable field
Steps to the next menu screen in a menu loop
Decreases the value of a modifiable numeric field
2.3.1.1 Contrast Adjustment
Press and hold the Alarm ( ) and (Prg) keys; then
repeatedly press the Up (↑) and Down (↓) keys to adjust the
contrast.
Alarms 2.3.2
Alarm conditions activate a red LED indicator that
backlights the alarm function key. As an option, an alarm
condition may also be enunciated by an audible alarm
signal. An alarm is acknowledged by pressing the alarm
key. This calls up alarm display screen(s) that provide a text
message detailing the alarm condition(s). After an alarm
condition is corrected, the alarm may be cleared by
pressing the alarm key.
2.3.2.1 Alarm Log
The alarm log provides a history of the alarms in sequential
order with a time and date stamp. To access the alarm log,
press the (Prg) key, then press the Down (↓) arrow key until
the "
ALARM LOG " screen is reached.
Press the Enter (←) key to access the loop. When access
is gained to the Alarm Log, use the Up and Down arrow
keys to scroll through the log for additional alarm
messages.

STULZ Ultra-Series Humidifier Controller
(August, 2013) 5
2.4 Controller Nomenclature
The Ultra-Series controller box contains the main operating components. The control box layout, shown in Figure 3, is a
typical layout showing power supplies for up to eight individual Humidifiers. One power supply is provided for each
Humidifier to be controlled. The higher the Humidifier capacity is, the larger the power supply for it must be. Depending on
the number of Humidifiers that need to be controlled (up to 16), the number of power supplies required may not fit inside
the Ultra-Series enclosure. In that case auxiliary control boxes are utilized to house additional power supplies as needed.
Figure 3 - Control Box Internal Layout
The item numbers below coincide with the call outs in Figure 3.
1. Controller I/O module (Figure 4)
2. Expansion I/O module (for conductivity sensor)
3. Humidifier power supplies (8 maximum)
4. Controller transformer
5. Vent Fan
6. Sensor averaging board (optional)
7. Power supply circuit breakers (8 maximum)
8. Humidifier output relays
9. Water detector control module (optional)
10. Service disconnect switch (*see note)
11. Cabinet ground lug
12. Knock-out for power cable
13. Humidifier(s) output terminal block
14. Knock-outs for Humidifier cables (8 max)
15. Knock-out for control wires
16. Control interface terminal blocks
17. Humidifier circuit breakers (8 maximum)
*Note: The service disconnect switch removes power from the Ultra-Series controller and only the Humidifiers connected
directly to it. Auxiliary boxes power the Humidifiers they are connected to, but the Humidifiers will time out and shutdown if
the control signal is interrupted by turning off the Control Box disconnect switch or if the control signal is lost over the
Modbus. Auxiliary Boxes must have their service disconnect switch turned off to stop the operation of the Humidifiers
connected to them while other Humidifiers are continuing to run off the Control Box and other Auxiliary Boxes.

STULZ Ultra-Series Humidifier Controller
6 (August, 2013)
2.5 Controller I/O Module
The Ultra-Series controller is equipped with a microprocessor based controller I/O module (see Figure 4). The controller I/O
module contains the software that manages the operating parameters of the humidification system.
Figure 4 - Controller I/O Module
Controller I/O Module Layout 2.5.1
The controller I/O module contains the logic and
input/output terminals. See Figure 4 for details of the I/O
module layout. The item numbers below coincide with the
call-outs in Figure 4.
1. RJ11 Telephone connector (J10) for display
2. Hatch for BMS serial interface port
3. Power on LED (1- yellow)
4. Signal LED's (3- red, yellow, and green)
5. Hatch for RS485 connector for network control bus
6. Power connector (J1)
2.6 Auxiliary Terminals
The Ultra-Series controller is equipped with customer
interface positions on terminal blocks located in the control
box. For auxiliary device wiring connections, refer to the
electrical drawing(s) provided with the unit.
Control Sensors 2.6.1
The controller is equipped with terminal positions for the
connection of sensors (temperature, or relative humidity).
If customer supplied, the sensor(s) may be a 4 to 20mA, a
0-1V, a 0-10V or a 0-5V signal to the system controller.
Parameters inside the controller need to be set
appropriately before connecting the sensors. Sensor(s) may
be duct mounted to monitor return or supply air and/or wall
mounted to monitor the room air to determine the
humidification demand against the control set points for
automatic control of humidity production. A wall mounted
sensor or return duct mounted sensor is typically used to
control room conditions. A duct mounted supply humidity
sensor is typically used as a high humidity limit sensor.
Alarm Contacts 2.6.2
Dry relay contacts (N/O or N.C.), are available for remote
monitoring of alarm conditions. The alarm contacts are
rated for a resistive load at 250VAC/ 8 Amps.
2.6.2.1 Summary Alarm
A summary alarm dry-contact is provided for remote
notification of an alarm condition. As programmed into the
system controller, an alarm condition activates the
summary alarm logic which energizes a summary alarm
relay and audible alarm if enabled.
2.6.2.2 Custom Alarm
In addition to the summary alarm, dry contact relays may be
optionally provided for remote annunciation of customer
selected alarm condition(s). Any alarm may be programmed
in the controller to activate the user configurable custom
alarm logic.

STULZ Ultra-Series Humidifier Controller
(August, 2013) 7
Water Conductivity Probe 2.6.3
To ensure proper demineralized water supply quality, the
controller is equipped with terminal positions for the
connection of a conductivity probe. The conductivity probe
is shipped loose with a 10 ft. long cable. The conductivity of
the demineralized water is monitored via the sensor (probe)
mounted in the pipe supplying water to the Humidifier (see
Section 3.3.5). The controller alerts the operator with a
"High Conductivity Pre-alarm" if the water conductivity rises
to between 5 and 20 microSiemens. Above 20
microSiemens, the controller shuts down Humidifier
operation following a 5 minute time delay and signals a
"High Conductivity" alarm.
Air Velocity Sensor 2.6.4
This controller is equipped with terminal positions for the
connection of an optional Air Velocity Sensor/Transmitter to
allow monitoring of the air flow in ductwork. The system
controller displays a “Low Airflow” or a "High Airflow" alarm
when the measured air velocity is outside the established
range (too high or too low). The system controller is
programmed to recognize an "Air Velocity" alarm condition
as a Non-Critical alarm. This alerts the operator of the
alarm condition but allows the Humidifier(s) to continue
operating.
Air Proving Switch 2.6.5
The controller is equipped with terminal positions for the
connection of an optional Air Proving Switch for use as a
safety feature. The switch contacts close when there is
sufficient airflow in the ductwork. The contacts open upon
loss of Airflow, triggering an alarm. The controller displays a
“Loss of Airflow” alarm when this occurs. Additionally, the
system controller is programmed to provide a “Summary
Alarm” indication. The system controller is programmed to
recognize a “Loss of Airflow” alarm condition as a “Critical
Alarm” and shut the Humidifier(s) down. The system will
automatically resume operation when airflow is restored.
Water Leak Detector 2.6.6
The controller is equipped with terminal positions for the
connection of optional Water Leak Detector(s). The water
leak detector(s) may be a spot or cable (20 ft.) type sensor.
The system controller is programmed to recognize a "Water
Leak" alarm condition as a critical alarm. Upon sensing a
water leak, the system controller shuts down Humidifier
operations and displays a “Water" alarm message. It
remains shut down until the cause has been determined
and corrected. Once corrected, the alarm can be reset.
Remote On/Off 2.6.7
If the controller is configured for the Remote On/Off option,
terminal positions are provided to connect a remotely
located, On/Off switching control device. If the Humidifier is
turned on and the Ultra-Series controller receives a remote
input signal to turn it off, the controller disables all controller
outputs and provides a status message "Off by Remote
Shutdown". The humidification system is automatically re-
enabled when the remote On/Off signal calls for the unit to
turn back on.
Multiple Humidifier Grouping 2.6.8
The Ultra-Series controller can be configured to operate two
individual groups of Humidifiers (Figure 5) via a common
Modbus.
Figure 5 - Multiple Humidifier Groups
The 2 groups can be configured with duty assignments:
Rotating, Capacity-Assist, and Bank Select.
2.6.8.1 Group Rotation
In Rotating mode, controller will rotate duty between the
Humidifier groups to promote equal run time. The rotation
time period is typically 1 week, however it may be set by the
user via the Factory menu. Call STULZ Product Support for
assistance when accessing the Factory menu.
2.6.8.2 Capacity Assist
In Capacity Assist mode, the system can be used to
maximize efficiency for conservation of energy and to allow
more precise control of humidity production during periods
of low demand. The Capacity-Assist option enables one
group of Humidifiers to proportionally handle the demand
for humidification up to their maximum capacity. If the
output of the first group of Humidifiers reaches 100%
capacity and they are unable to satisfy the demand, the
controller enables the second group of Humidifiers to
operate, controlling their output proportionally while the first
group continues to operate at 100% capacity. As humidity
conditions approach set point, the controller scales back the
proportional output control signal to the second group
accordingly until they are no longer required. At this point

STULZ Ultra-Series Humidifier Controller
8 (August, 2013)
the Humidifiers in the second group are turned off and the
Humidifiers in the first group return to proportional control.
Rotation of which group is the lead group occurs as in the
Rotate mode.
2.6.8.3 Bank Select
Bank select is controlled by a digital input from an external
source. It selects which group will operate. The other group
does not assist. If customer provided, the bank select
control contacts must be sized appropriately. The contacts
must have a minimal rating of 24 VAC.
2.6.8.4 Proportional Humidifier/Duct Limitation
The Proportional Limitation option limits humidity production
of a group of Humidifiers based on humidity or dew point to
prevent condensation from forming on cold surfaces. For
example, Humidifiers that may be positioned near the
ceiling or floor of an AHU, where condensation may occur,
can be configured as a group with a threshold applied to
limit humidity production. In this case, the limited
Humidifiers will be in Group A (see Figure 6) and limited by
the Limit Sensors. Group A would be selected to be limited.
The Humidifiers in Group A and B operate up to their full
rated output capacity based on the demand for
humidification. As the user selected limit humidity or limit
dew point temperature limit set point is reached, the
Humidifiers in Group A start scaling output back humidity
output proportionally until it is zero output. Limitation can be
set for either Group, but based on only one limit sensor.
The enables for Proportional limitation are set in the Service
Option Loop>Startup Menu.
Figure 6- Humidifier Grouping
BMS Operation 2.6.9
The Ultra-Series controller may be equipped with a serial
communication port (Figure 7) that can be interfaced to a
Building Management System (BMS) via Modbus, BACnet,
SNMP or HTTP protocol as configured by the factory. A
controller interfaced to a network must be configured for
BMS communication.
Multiple Humidifier controllers can be connected to a BMS or
central control terminal allowing the communication of data
and information to the BMS. Instead of sensors, control
signals from an Ethernet interface may be used to mimic
sensors used by the Ultra-Series controller to manage
humidity levels. The controller develops and transmits
control output signal(s) to the Humidifiers based on those
input signals.
Modbus RTU
BACnet IP, BACnet Ethernet BACnet MS/TP
HTTP, SNMP & Modbus IP
Figure 7 - Serial Interface Ports
Each controller added to the network must be configured for
BMS communication and assigned an address.
Figure 8 - Supervisory Control of Humidifiers

STULZ Ultra-Series Humidifier Controller
(August, 2013) 9
3.0 INSTALLATION
3.1 Uncrating and Inspection
The controller has been tested and inspected prior to
shipment. Perform a visual inspection of the packaging
immediately upon delivery to ensure the equipment has
been delivered in excellent condition. If there is visible
shipping damage, it must be noted on the freight carrier's
delivery forms BEFORE signing for the equipment. Any
freight claims MUST be done through the freight carrier.
STULZ ships all equipment FOB factory. STULZ can assist
in the claim filing process with the freight carrier.
Carefully remove all protective packaging, open the
controller access door and thoroughly inspect for any signs
of transit-incurred damage. Should any such damage be
present, notify STULZ prior to attempting any repairs. Refer
to the last section of this manual for instructions.
NOTE
The controller should always be stored indoors in a
dry location prior to installation. A Data Package
has been sent with the unit. It contains this manual,
an IOM for the Humidifier, system drawings and
any other applicable instructions based on the
configuration and options furnished with the unit.
These documents should be kept with the unit for
reference.
NOTE
Shipped loose items such as sensors are shipped
separately unless specified otherwise by the
customer. Remove and store these items in a safe
place unless they are being installed immediately.
3.2 Mounting
The control box is designed for indoor installation only.
Mount the control box within 10 feet of the supply water
source for the STULZ supplied water conductivity probe to
reach. Avoid installing the controller in locations where
ambient temperatures are above 90°F or where the relative
humidity is above 90%. Do not install the controller where it
will be subjected to strong vibrations or bumps. Avoid
mounting in areas exposed to direct sunlight or with wide
and rapid temperature fluctuations. The control box may be
mounted to an equipment rack, a wall or a flat surface.
Secure the enclosure through the 4 mounting holes taking
care not to damage the internal components. Ensure the
mounting surface is capable of supporting the total weight
of the unit. Ensure that the areas around the enclosure
vents are free of obstructions that may impede Airflow.
CAUTION
When the unit is operating, the enclosure vent
openings must be completely free of obstructions.
3.3 Wiring Connections
The controller is provided with terminals for all required
field-wiring connections. Refer to Figure 3 for the location of
the interconnect terminals and see the electrical drawing(s)
supplied with the unit for all field wired power and control
connections. It is important to identify the options that were
purchased with the unit in order to assure which field
connections are required.
WARNING
Verify power is turned off before making
connections to the equipment.
AC Input 3.3.1
It is important that the controller nameplate be examined to
determine the operating voltage, frequency and phase of
the system. The supply voltage measured at the unit must
be within ±10% of the voltage specified on the system
nameplate. The unit nameplate is located inside the
controller enclosure. The nameplate also provides the full
load amps (FLA), the current that the unit will draw under
full design load, the maximum fuse size for circuit
protection, and the minimum circuit ampacity (MCA) for wire
sizing.
When the main power wires are connected, the electric box
has power to the main power non-fused service switch.
A separate equipment ground lug is provided within the
electrical box for termination of an earth ground wire.
DC Output to Humidifier(s) 3.3.2
Consult the wire sizing table in the Humidifier IOM to
determine the correct wire gauge, by Humidifier model, for
the length of wire to be run. Insufficient wire gauge will
result in excessive voltage drop between the controller and
Humidifier(s). Distances over 75 feet are not recommended.
STULZ recommends the use THHN or NTW, stranded
conductor (not solid conductor) wire.
Control Wiring to Humidifiers 3.3.3
CAT 5e cable, with RJ45 connector terminations; connect
the controller to the Humidifier(s) in a daisy chain fashion
(See Figure 5). Do not exceed 1,000 feet in total length.
Ensure the termination resistor (shipped loose) is plugged
on the last Humidifier in the string as shown in the electrical
drawing(s). Older systems use shielded 3 conductor cable.
Ask STULZ Product Support for instructions on wiring these
systems.

STULZ Ultra-Series Humidifier Controller
10 (August, 2013)
EIA/TIA-568B wiring Standard shall be used. Figure 9 is the
pin side of the connector (tab on the other side).
Figure 9 - RJ45 Connector
A Jack is mounted in the control box to connect to the
humidifiers. The wires marked Shield are not connected to
the humidifiers, but passes through all units as a generic
shield. It is connected to chassis ground in the Control Box.
Pin Color Name
1 Orange/White DC Ground
2 Orange DC Ground
3 Green/White RS-485 +
4 Blue RS-485-
5 Blue/White RS-485+
6 Green RS-485-
7 Brown/White Shield
8 Brown Shield
Sensors 3.3.4
The Ultra-Series control box is equipped with a terminal
block for the connection of a humidity sensor and/or an
optional temperature/humidity or dew point sensor. A
sensor/transmitter is required regardless of the control
mode selected. If provided by STULZ, sensors and
transmitters are shipped loose for installation by the
customer. Interconnecting field wiring should be installed in
accordance with NFPA 70 of the National Electrical Code
(N.E.C.). The wiring connections for sensors must be made
using shielded cable with a minimum AWG 22 (0.5 mm
2
cross section) for each lead. Trim the length of the sensor
cables where possible to minimize wire resistance and
avoid wrapping the cable around power devices.
A remote sensor must be located so that it will properly
sense the conditions to be controlled. Refer to Sections
3.3.4.1 or 3.3.4.2 when mounting sensor(s). Refer to Figure
3 for the location of the controller interface terminals and to
the electrical drawing for wiring details.
NOTE
All wiring should conform to local and national
electrical code requirements. Use of copper
conductors only is required. Wiring terminations
may become loose during transportation of the
equipment. Therefore, it is required to verify that all
wiring terminations are secure.
3.3.4.1 Room Temperature/Humidity Sensors
Mount a room control sensor/transmitter in the center of the
room where air circulation is good. The sensor should not
be mounted near a doorway or an area where it would be
exposed to direct sunlight. Wall-mounted control devices
should typically be mounted 4-5 feet up from the floor in the
conditioned space (see Figure 10). Care should be taken
not to install the sensor in an area with excessive changes
in humidity and temperature.
Figure 10 - Locating Wall Mount Sensor
Make the wiring connections to the controller interface
terminal block as shown in the electrical drawing(s).
CAUTION
Do not damage the exposed temperature/humidity
sensors on the PC board while screwing in the
cover fastening screw. The circuitry can be
damaged if handled improperly.
3.3.4.2 Duct Mounted Sensors
Cut a hole in the side of the duct and mount the sensor,
(temperature, humidity and or air velocity) to the duct using
the screws provided. Position the supply air sensors
approximately 10 feet down stream of the Humidifier outlet.
Each supply air sensor is to be field connected to the
controller at the terminal positions designated in the
electrical drawing.
Water Conductivity Probe 3.3.5
The Ultra-Series control box monitors water quality via a
probe (sensor) shipped loose. It is to be field installed in the

STULZ Ultra-Series Humidifier Controller
(August, 2013) 11
demineralized water supply piping to sense water quality
entering the Humidifier. The length of control cable provided
is 10 feet long. Do not cut the control cable or add to its
length because a change in wire resistance will affect the
sensor's calibration. Because the conductivity circuit is
sensitive to electromagnetic interference, the control cable
should not be run near high voltage wires. Connect the
leads from the conductivity sensor to the designated
terminal positions in the controller as shown in the electrical
drawing.
Remote On/Off 3.3.6
A remote on/off control device may be an On/Off switch,
thermostat or a humidistat. If customer provided, the remote
On/Off control contacts must be sized appropriately. The
Remote On/Off contacts must have a minimal rating of 24
VAC. Refer to the electrical drawing(s) included with the
unit for wiring details.
Remote Alarm Signal Contacts 3.3.7
The Summary Alarm and Custom (user configured)
Alarm(s) have dry contact relay interface terminals inside
the controller. The customer may connect a 2 conductor,
alarm signal cable to each relay for remote annunciation of
alarm conditions. The alarm contact positions are
NO/C/NC, rated at 250VAC / 8 Amps.
Water Leak Detector 3.3.8
Optional remote water detector(s) are normally placed on
the floor or in a customer supplied drain pan located
beneath the Humidifier(s). The detector(s) may be secured
using double sided tape or cable ties with mounting pads.
Prepare the surface before applying the tape. Apply tape to
the bottom of the detector and secure it in place.

STULZ Ultra-Series Humidifier Controller
12 (August, 2013)
4.0 OPERATION
4.1 General Theory of Operation
This Ultra-Series controller is designed to control the output
of an ultrasonic humidification system in a space or process
application to humidity levels as defined by the user.
Humidified air is supplied to the conditioned space as
needed to maintain the relative humidity or dew point
control set point. The controller may also be networked with
a group of Humidifiers to manage their outputs as a system.
The controller I/O module includes inputs and outputs as
depicted in Figure 11:
Figure 11 - Control Inputs and Outputs
Humidification Control 4.1.1
The method of operation depends on the controller's
programmed operating mode. Control takes place by
means of the controller analyzing signal inputs from
sensor(s) and/or from an external supervising controller or
Building Management System (BMS).
4.1.1.1 Humidity Control
The controller responds to relative humidity sensor signal
input(s) to manage humidity production against a relative
humidity control set point.
4.1.1.2 Dew Point Control
The controller calculates dew point based on signal inputs
from temperature and humidity sensor(s) to manage
humidity production against a dew point control set point.
4.1.1.3 Proportional Control
The controller uses an external input signal representing 0
to 100% output to control humidity production.
Operating Modes 4.1.2
There are 6 operating modes for the controller depending
on how many and what types of inputs are used. The
operating mode has been pre-set by the factory and should
not require adjustment. BMS Signal indicates the input is
sourced by the serial BMS interface. Sensor indicates the
input is a physical signal and may originate from a sensor
or a voltage/current generated by another control system.
Mode Input 1
(Control)
Input 2
(Limit) Function
1 BMS Signal None Room Control
2 Control Sensor None
3 BMS Signal BMS Signal Return duct
monitoring with
proportional high
limit
4 Control Sensor Limit Sensor
5 BMS Signal Limit Sensor
6 Control Sensor BMS Signal
4.1.2.1 Room
Control
The controller may be configured for room installations with
only one control input. In room installations the controller
maybe configured to manage humidity production based on
a control signal from a return air humidity sensor or
optionally from a relative humidity and temperature sensor
for dew point control or, a signal from an external controller
or BMS can be used (Modes 1 & 2).
4.1.2.2 Return Air Duct Monitoring (DAH Units)
When used for duct installed, DAH Humidifiers in air
handling units, two inputs may be utilized. Input 1 is the
control for the humidity in the return air duct and input 2 as
a proportional high limit signal downstream of the
Humidifier. The inputs may be from a BMS/external
controller and/or remote sensors (Modes 3 - 6).

STULZ Ultra-Series Humidifier Controller
(August, 2013) 13
P/I- Proportional/Integral Control 4.1.3
The controller calculates proportional control output
signal(s) based on the analysis of sensor input signals,
which determines the amount of humidification needed (see
Figure 12).
Figure 12 - Control Logic
Signal 1 represents the return air humidity and is calculated
by the controller as a percentage value compared to the
maximum control set point value for input 1, taking into
account the prop band. Signal 1 is compared to the
maximum control set point value for input 1 resulting in a
control value that will be proportional to signal 1. Signal 2
represents the limit humidity and is calculated as a
percentage value for input 2 taking into account the prop
band. Signal 2 is compared to the maximum control set
point value for input 2 resulting in a control value that will be
proportional to signal 2. The control output signal to the
Humidifier(s) will be directly proportional to the combined
input signals by the following process:
Signal 1 x Signal 2
100
If input 2 is not used, the controller only works with
reference to signal 1. The effect of integral on the control
signal (Signal 1) has been neglected from the above
calculation for simplification. With integral control, the
added element of time is factored into the Humidifier output
algorithm. The integral value is used to gradually adjust the
proportional output when the calculated output does not
move the process variable closer to set point in a given
period of time. Decreasing the integral value decreases the
interval for the output corrections (speeding the rate of
adjustment). Increasing the integral value increases the
interval for corrections (slowing the rate of adjustment). The
P/I control factors are hard coded in the controller and
cannot be user adjusted.

STULZ Ultra-Series Humidifier Controller
14 (August, 2013)
4.2 Navigating Controller Screens
Menu Selection 4.2.1
The Ultra-Series controller provides five user selectable menus needed to view operating data and enter set points for the
system (see Figure 13). These menus may be accessed by pressing the Program (Prg) key to reveal the Main Menu
screens. Scroll between adjacent menu selections within the Main Menu by use of the Up (↑) and Down (↓) arrow keys.
When the desired menu is centered in the screen with bold capital letters and an arrow symbol pointing towards the Enter
(←) key, press the Enter (←) key to access that menu loop. The user can access the menu loop screens located within the
designated menu selection using the Up (↑) and Down (↓) arrow keys. Access to some menus may be protected by a built
in security protocol and may require the use of a password to gain access (see Section 4.3).
Menu Loops 4.2.2
Press the Program (Prg) key from any screen to select from among the five menu loops shown in Figure 13.
Figure 13 - Main Menu Selections

STULZ Ultra-Series Humidifier Controller
(August, 2013) 15
Alarm Set
CLOCK
Version
Time: █00:00
Date: 00/00/0000
Day: XXXXXXXX
Time: █00:00
Date: 00/00/0000
Day: XXXXXXXX
4.2.2.1 Display Variables
The user interface display panel provides screens with
three (3) different forms of both the read only and the
modifiable variables:
Numbers are displayed as positive (+) or negative (-)
integers.
Dual-State can be toggled between two (2) values i.e.
On/Off, Yes/No.
Word Variables have a unique text message for each
of the variable's possible choices.
4.2.2.2 Cursor Position in Screens
The following display screen is shown as an example after
accessing a new menu loop display screen using the
function keys. The name of the menu loop is the line in the
upper-most field of the screen. A flashing window also
appears in the left of the uppermost field.
Flashing
Window
From this position the Up (↑) and Down (↓)arrow keys may
be used to access additional selections within the current
display menu.
Each screen supports a specific functional requirement.
Pressing the Enter (←) key allows access to the selected
display screens to adjust any of the modifiable fields. If a
screen with modifiable values is accessed, Use the Enter
key to insert a flashing cursor in the modifiable fields within
that screen.
Flashing
Cursor
If the flashing cursor is located in a modifiable field, the
value of the field will be changed with the use of the Up (↑)
and Down (↓)arrow keys. When the Enter (←) key is
pressed the cursor moves to the next modifiable field.
After entering the last modifiable field within a screen,
pressing the Enter key removes the cursor and the flashing
window reappears in the left-hand corner of the upper-most
field of the current screen. From here advancement to the
next adjacent menu loop screen will occur when the Up or
Down key is pressed. Successive use of the Enter key will
advance the cursor through the various modifiable fields of
the display screen eventually returning to the first field.
Values that are already correct may simply be skipped by
using the Enter (←) key without modification of the variable.
The current value, if not changed, will be retained after
pressing the Enter (←) key. Values for fields being adjusted
will automatically wrap when adjusted beyond the high or
low limit established for that field.
Whenever the flashing cursor is located in a modifiable
field, pressing the Escape (Esc) key one time returns the
user to the next menu up. Each successive use of the
Escape key returns to the next menu level up until the
Main screen is reached.
4.2.2.3 Modifiable Variables
Modifiable
Variable
For the purpose of this manual the examples of user
modifiable variables within display screens will be denoted
by bold text. (Please note the actual display may not use
bold text.) Pressing the Enter (←) key accepts the value
displayed and advances the cursor to the next modifiable
field. The Up (↑) or Down (↓) key may be used to modify the
values of these fields.
If the modifiable field is a positive (+) number, the positive
value is indicated by the absence of a (+) or (-) symbol in
front of it. The (-) negative symbol will be displayed to the
left of the first digit for negative numbers.
CONTROL MENU
▬
→
SET CLOCK
←
SET CLOCK

STULZ Ultra-Series Humidifier Controller
16 (August, 2013)
█
Enter Password: 0
JD 0 Level:0
** WRONG PASSWORD **
4.3 Password Authorization
Access to a menu loop may be requested from the main
menu. Modifiable control screens have variables that affect
system performance. Improper settings may result in erratic
operation and possible system failure or damage. Anyone is
allowed direct access to the Info and Alarm log display
menus with no security password.
Only authorized personnel who possess a thorough
understanding of the system operation should perform
modifications to secured menu settings (Control, Service
and Factory). These menus are configured with password
protection, thus requiring a higher level of authority to
access them. The screens must have accurate variables
entered otherwise erratic operation may occur.
Password Protected Screens 4.3.1
Upon first attempting to select a secure menu in a given
session, the "Enter Password" screen will be displayed. This
screen displays the current security level authorized.
(Current
Security
Level)
Enter Password Screen
A session is defined as from the time access is gained to a
secure menu until 60 seconds elapses with no key activity.
Security access will be terminated at this point and the
password will have to be reentered to gain access. The
menus that may be password protected by the user are the
Control and Service menus. The Factory level menu
screens are also password protected, however the
password is set at the factory to limit access.
It is intended that access to the Factory menu screens only
be established while the user is working with the guidance
of STULZ Product Support (see Section 9.0). Incorrect
settings made at the Factory level could unintentionally
damage the equipment.
Operators, who are allowed access to the Service menu
(level 2) for example, must know the password to enter that
level. If the entered password equals or exceeds the level
requested during a given session, the operator is allowed to
access the requested loop. For example, if the entered
password allows access to level 2 and the Control menu
(level 1) is requested, access will be allowed. If the entered
password authority level is lower than the level requested,
the words "WRONG PASSWORD" will appear for several
seconds at the bottom of the screen.
Wrong Password 4.3.2
The “WRONG PASSWORD” message is displayed any time
an incorrect password has been entered and the Enter (←)
key has been pressed. If the “Wrong Password” message
appears, use of the Enter (←) key will return the operator to
the “Enter Password” field.
A requested menu screen is displayed any time a valid
password has been entered and the Enter ( ) key has been
pressed.
NOTE
If the Control menu is requested and the Service
menu password is entered, access to both is
granted.
Setting the Passwords 4.3.3
The initial password for the Control menu (Level 1) and
Service menu (Level 2) are factory set. Upon entering the
Service menu, the operator is allowed to change the
passwords for the menus (see Section 5.5.10.1). If
changed, from that point on access may only be gained to
that menu by personnel who know the password.
MENU PASSWORD
Control 1
Service 2
Factory Consult STULZ
Product Support
█
Enter Password: 0
Level:0
←