Carel gaSteam-UG User Manual
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Carel gaSteam-UG User Manual

Carel gaSteam-UG User Manual

Gas-fired humidifier
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USER MANUAL
gaSteam - UG
Gas-fi red humidifi er
gaSteam - UG
+0300122EN - ENG
Up to date version available on
www.carel.com
NO POWER
& SIGNAL
CABLES
TOGETHER
READ CAREFULLY IN THE TEXT!
ENG

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Summary of Contents for Carel gaSteam-UG

  • Page 1 - UG Gas-fi red humidifi er USER MANUAL NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT! gaSteam - UG +0300122EN - ENG Up to date version available on www.carel.com...
  • Page 3 All other The liability of CAREL in relation to its products is specifi ed in the CAREL uses and modifi cations made to the appliance that are not authorised by general contract conditions, published on the website www.carel.com...
  • Page 4 Warranty on materials: 2 years (from production date, excluding consum- ables). Approval: the quality and safety of CAREL products are guaranteed by the ISO 9001 certifi ed design and production system, as well as the marks.
  • Page 5 Index 1. PURPOSE OF THE MANUAL ........7 12. User menu and unit confi guration ...... 67 12.1 Main menu......................67 2. How to read the manual .......... 7 12.2 Menu: E. Settings .................... 69 12.3 Menu E. Settings - a. Control ..............69 3.

  • Page 7: Purpose Of The Manual

    Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 e-mail: carel@carel.com - www.carel.com 2. HOW TO READ THE MANUAL The manual is divided into chapters and paragraphs. Each paragraph is a sub-level of the corresponding chapter. References to headings or paragraphs are indicated by the abbreviation “Chap.

  • Page 8: Intended Use

    3. GENERAL SAFETY INFORMATION AND INSTRUCTION Intended use The humidifi er is designed and built exclusively to humidify rooms through distribution systems (ducts). Any other use may be a source of danger that is not contemplated in this manual and is therefore considered improper and therefore is prohibited by the manufacturer, which declines all liability in such cases.

  • Page 9: Personal Protective Equipment

    Notice: the liability of the manufacturer in relation to its products is specifi ed in the general contract conditions, pub- lished on the website www.carel.com and/or by specifi c agreements with customers; specifi cally, to the extent where allowed by applicable legislation, in no case will the manufacturer, its employees or subsidiaries/affi liates be liable for any lost earnings...

  • Page 10: Description Of The Humidifi Er

    4. OVERVIEW Description of the humidifi er The gaSteam (UG) humidifi ers are gas-fi red isothermal humidifi ers for the distribution of steam, and are equipped with a graphic touch display for easy interaction with the user. Models available (identifi ed by the part number shown on the packaging label and on the rating plate): UG045, UG090, UG150, UG180, UG300, UG450 with steam production capacity up to 450 kg/h (992 lb/h).
  • Page 11 27 26 Fig. 4.b Key: 1. disconnect switch 16. 115-230V transformer (DIN version) 2. lock 17. gas valve 3. fi ll solenoid valve 18. combustion air intake pipe 4. fi ll shut-off valve 19. heater (accessory for CE version, supplied with UL ver- 5.

  • Page 12: Packaging Contents

    Packaging contents IMPORTANT Before removing the packaging, move the humidifi er to the site of installation, following the instructions shown in Chap. 5 - Transport and handling and in par. 4.5 - Positioning. Upon opening the packaging, check the humidifi er components (Fig. 4a) and the material supplied (par. 4.7). Notice: if anything is missing when opening the package, contact the manufacturer immediately to agree on the appro- priate procedures to be adopted.

  • Page 13: Dimensions By Model - Mm (In)

    Dimensions by model - mm (in) 4.4.1 Indoor models UG 45-90-150 1442 (56.8) indoor 1282 (50.5) 1122 (44.2) 573(22.5) 107 (4.2) 57 (2.2) 147 (5.8) 82 (3.2) 222 (8.7) Fig. 4.d Ref. Description Ref. Description Flue gas outlet Tank drain Steam outlet Drain column Water inlet...
  • Page 14 UG 180-300 1443 (56.8) 936 (36.8) indoor 715 (28.1) 340 (13.4) 180 (7.1) 106 (4.2) 519 (20.4) 80 (31.5) 55 (2.2) 140 (5.5) 222 (8.7) Fig. 4.e Ref. Description Ref. Description Flue gas outlet Tank drain Steam outlet Drain column Water inlet Combustion air intake Drain tempering (accessory)
  • Page 15 4.4.2 Outdoor models 1610 (63.4) UG 45-90-150 1442 (56.8) outdoor 207 (8.1) 292 (11.5) 107 (4.2) 57 (2.2) 147 (5.8) 82 (3.2) 870 (34.2) 262 (10.3) Fig. 4.f Ref. Description Ref. Description Flue gas outlet Water drain (CE version) Steam outlet Water drain (UL version) Water inlet (CE version) Tank drain...
  • Page 16 1608 (63.3) 1442 (56.8) UG 180-300 1232 (48.5) outdoor 669 (26.3) 108 (4.2) 293 (11.5) 517 (20.3) 57 (2.2) 82 (3.2) 730 (28.7) 380 (14.9) 509 (20) 240 (9.4) Fig. 4.g Ref. Description Ref. Description Flue gas outlet Water drain (CE version) Steam outlet Water drain (UL version) Water inlet (CE version)
  • Page 17 1564 (61.6) UG450 outdoor 741 (29.2) 105 (4.1) 532 (20.9) 686 (27) 321 (12.6) 589 (23.2) 376 (14.8) 302 (11.9) 313(12.3) 307 (12.1) 65 (2.5) 298 (11.7) 148 (5.8) 369 (14.5) 279 (11) 229 (9) Fig. 4.h Ref. Description Ref. Description Flue gas outlet Water drain (CE version)
  • Page 18 Positioning The humidifi er must be positioned so as to allow the following operations: • opening the front panel; • accessibility to the electrical panel; • accessibility to the internal parts for checks and maintenance; • connection to the feedwater line; •...

  • Page 19: Opening The Front Panel

    Opening the front panel Unscrew the screws using a suitable tool (A - Fig. 4.j), grasp the handles and slide the panel slightly downwards to remove it. Fig. 4.k Notice: in the outdoor models, the front panel handles are supplied disassembled. These should be assembled before opening the humidifi er front panel.

  • Page 20: Material Supplied

    Serial No. Date Rev. Part No. MADE IN ... CAREL INDUSTRIES Via dell'Industria, 11, 35020 Brugine (Padova) Italy Fig. 4.m Notice: tampering, removal or absence of the rating plate or anything else that does not allow certain identifi cation of the humidifi er will make any installation or maintenance operations diffi cult and void the warranty.

  • Page 21: Transport And Handling

    5. TRANSPORT AND HANDLING DANGER: always place the humidifi er on surfaces that are suitable to support its weight. WARNING: transport operations must be carried out by trained personnel using certifi ed equipment in good con- dition. Transport equipment and tools must be suitable for the weight and characteristics of the humidifi er. WARNING: make sure that there are no unauthorised persons or things that could obstruct the lifting and trans- port operations in the area where these are performed.
  • Page 22 Table of residual risks and PPE for handling operators PPE required: • Protective gloves • Non-slip safety footwear • Safety hard hat • Instruction manual Residual risk Procedure to be adopted Risk of cutting or abrasion due to sharp edges or surfaces. Wear gloves to protect against physical agents and a hard hat before entering the work area.

  • Page 23: Installation Notes

    6. INSTALLATION NOTES System layouts Below are some typical installations of gaSteam units for AHU/duct applications. gaSteam layout with ultimateSAM steam distributor RETURN AIR ARIA IN USCITA OUTLET AIR ARIA DI RIPRESA min 3xA (min 3m/9.8 ft) ARIA DI RECIRCULATION RICIRCOLO EXTERNAL AIR OUTLET AIR...
  • Page 24 gaSteam layout with DP series steam distributor ARIA IN USCITA ARIA DI RIPRESA OUTLET AIR RETURN AIR min 3xA (min 3m/9.8 ft) ARIA DI RECIRCULATION RICIRCOLO EXTERNAL AIR OUTLET AIR ARIA ESTERNA ARIA DI MANDATA Limit set point 90% 11 10 14 13 Fig.
  • Page 25 gaSteam layout for outdoor installation with connections at the bottom (US market only) OUT OF THE BIULDING ESTERNO DELL'EDIFICIO Cordolo di supporto per il rialzo dell'unità Unit support curb Solaio copertura dell'edificio Building covering fl oor Ingresso alimentazione elettrica 115V 60 HZ Carico acqua Electric power input INTERNO DELL'EDIFICIO...
  • Page 26 If the Main/Secondary system comprises three or more units, a network switch is required. Main Secondary 1 ...Secondary 19 Fig. 6.e The Ethernet port is available on the humidifi er’s c.pHC controller: Fig. 6.f Notice: use a CAT-5 STP Ethernet cable with a maximum length of 100 m. To connect the shield, use the earth connector provided on the controller.
  • Page 27 Type of “Main & Secondary” installation The Main/Secondary system features one Main humidifi er, which manages operation of the Secondary units. The external signal or probe connections, depending on the set control type, are made to just one of the humidifi ers in the system. The unit that the signal is connected to will automatically be identifi ed as the Main.

  • Page 28: Unit Hardware Backup

    This will guarantee service even in the event of probe malfunctions. Supervisor protocols and confi guration The humidifi er can be connected to a supervisor via serial (BMS) or Ethernet network. The Carel, ModBus and BACnet protocols are supported as standard by the units.

  • Page 29: Built-In Web Server

    DigitalHUM service registration The system can be connected to the DigitalHUM service, the cloud portal for remote monitoring of Carel humidifi ers. Digital- HUM allows remote control of the units, with complete diagnostics for analysis of system operating conditions and effi ciency.

  • Page 30: Wireless Probe Installation

    IMPORTANT: the controller is not accessible directly on the internet as a fi rewall guarantees remote access only via a secure connection (Carel tERA cloud or encrypted VPN connection). 6.10 Wireless probe installation For installations where standard wired probes can not be used, (for example, modifi cations to existing systems), wireless probes can be used.
  • Page 31 gaSteam/access point connection: To connect the humidifi er to the access point, use the Fieldbus connection on terminal M3 (M3.1: Tx/Rx-, M3.2: Tx/Rx+, M3.3: GND): Notice: the devices have a range of around a hundred metres in a free space, i.e. without any obstacles.

  • Page 32: Installation

    7. INSTALLATION Piping connections The humidifi er requires a connection to the gas and water supply and water drain pipes. The feedwater supply can be connect- ed using a hose with a minimum inside diameter (recommended) of 6 mm. Install a shut-off valve to allow the appliance to be disconnected during maintenance.

  • Page 33: Drain Water Characteristics

    7.1.1 Water circuit connection diagram IMPORTANT: the drain pipe must not be obstructed, must not have back pressure and must be fi tted with a drain trap immediately downstream of the connection to the humidifi er. Ref. Description shut-off valve fi lter (not supplied by the man- ufacturer) feedwater...

  • Page 34: Air Intake And Fl Ue Connections

    7.1.4 Air intake and fl ue connections Notice: the abbreviations that identify the various confi gurations for installation refer to the EN 1749:2020 standard (clas- sifi cation of gas appliances according to the method of supplying combustion air and of evacuation of the combustion prod- ucts).
  • Page 35 Both the fl ue gas outlet and the combustion air intake can be moved using the accessories available, based on installation re- quirements, with reference to the pressure drop values shown in Tables 7.e, 7.f and 7.g. Notice: the data shown in Tables 7.e, 7.f and 7.g refer to aluminium or stainless steel ducts. Unit UG45 max.

  • Page 36: Steam Distribution

    8. STEAM DISTRIBUTION Steam distribution To achieve optimal humidifi er effi ciency, the steam produced must be introduced into the room uniformly, in order to prevent the formation of droplets and condensation. This is achieved using linear steam distributors. The right steam distributor must be chosen according to the place where the steam is to be introduced.
  • Page 37 Mounting instructions (Fig. 8.c): • drill a series of holes in the wall of the pipe, using the drilling jig of the distributor (found in the packaging of the distributor); • insert the distributor with the steam outlet holes facing upwards; •...
  • Page 38 8.1.3 Linear distributor models and typical installations gaSteam humidifi er outlet Ø mm 2 x 80 2 x 80 3 x 80 (3.1”) (3.1”) (2 X 3.1”) (2x 3.1”) (3x 3.1”) humidifi er capacity kg/h minimum width distributor inlet (ØA) max distributor of duct/AHU mm part number...
  • Page 39 Vertical installation of DP series steam distributors. Bracket for vertical mounting of DP* series linear steam distributors. DP00VM3000 bracket for distributors with Ø 30 mm steam inlet (DP***D30R*); DP00VM4000 bracket for distributors with Ø 40 mm steam inlet (DP***D40R*); Tab. 8.g H≥250 mm Fig.

  • Page 40: Steam Hose

    8.1.4 Steam hose Warnings: • use CAREL hoses (max length = 4 m / 3.3 ft, see par. 8.1.5); • avoid the formation of pockets or traps (these cause condensate accumulation); • avoid choking the hose with sharp bends or twists;...

  • Page 41: Condensate Drain Pipe

    8.1.6 Condensate drain pipe During operation of the humidifi er, part of the steam may condense, causing a decline in effi ciency and noise (gurgling). To drain the condensate, connect to the distributor (Fig. 8.g) drain spigot (Fig. 8.f ) a drain pipe with a trap and a minimum slope of 5°. The condensate drain pipe must be connected to the drain water pipe.
  • Page 42 The tables therefore show the diameters of the pipes to be installed (not supplied by Carel) and the corresponding estimated condensate formation according to the distance to be covered.
  • Page 43 Condensate Pipe inside diameter Non-insulated pipe Insulated pipe Insulation thickness [mm] [inches] [kg/h/m] [lbs/hr/ft] [kg/h/m] [lbs/hr/ft] [mm] [inches] 1”1/2 0.27 0.59 0.02 0,044 1.96 0.32 0.70 0.03 0,066 1.96 steel or copper 2”1/2 0.38 0.83 0.03 0,066 1.96 pipe 0.46 1.00 0.03 0,066...

  • Page 44: Electrical Connections

    Notice: to avoid unwanted interfer- ence, the power cables should be kept sepa- rate from the probe signal cables. to the transformer (connection by Carel) Fig. 9.c IMPORTANT: connect the yellow-green wire to the earth terminal (GND). gaSteam +0300122EN rel. 1.0 - 01.12.2021...

  • Page 45: Power Supply

    9.1.3 Power supply The humidifi er power line must be fi tted by the installer with a disconnect switch and protection fuses. The table shows the recommended size of the power cable and fuse ratings. These data are purely indicative; local regulations must always prevail. power supply rated characteristics produc-...

  • Page 46: Auxiliary Circuit Transformer

    power supply rated characteristics line fuses current A power W produc- cable size mm temperature no. of A - type mod. voltage V tion kg/h °C (°F) heater heaters line heater line (lbs/h) UG line heater line UG line line line line heaters...
  • Page 47 c.pHC control board 1 2 3 J17C J17L Ethernet Unit Alarm RS485 Serial status relay Control signal relay Fig. 9.e Terminal Function Electrical specifi cations M1.1 GND (G0) M1.2 Controller power supply 24Vac +10%/-15% 50/60Hz M2.1 Main room probe input 0 to 1V, 0 to 10V, 2 to 10V, 0 to 20mA, 4 to 20mA, NTC 10 kΩ...

  • Page 48: Steam Production Control Signals

    Steam production control signals Depending on the type of signal used, steam production can be enabled and/or managed in diff erent ways (ON/OFF or mod- ulating). IMPORTANT the probe inputs are protected against short-circuits, and the maximum current delivered (3U) is 50 mA. Despite this, it is recommended to confi gure the “Control type”...

  • Page 49: Control With Humidity Probes

    EXTERNAL PROPORTIONAL CONTROLLER and REMOTE CONTACT (modulating operation) • connect terminals 1U and 2U (production request) to a humidistat; • connect inputs 7U and 8U (enable) to a remote contact (e.g.: switch, timer,...); • to enable control, set: 1U 2U 3U 4U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U...
  • Page 50 CONTROL WITH ONE HUMIDITY PROBE • short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U – 8U to a remote contact (e.g.: switch, timer,...); • connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); •...

  • Page 51: Control With Temperature Probes

    Notice: when using 0-10 V probes, connect the probe power supply +(G) to terminal “14” on the terminal block “T” inside the electrical panel, rather than terminal 3U. 1U 2U 3U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U The following probes can be connected: probes for rooms DPWC111000...
  • Page 52 CONTROL WITH ONE TEMPERATURE PROBE AND LIMIT PROBE • short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U – 8U to a remote contact (e.g.: switch, timer,...); • connect the main active room probe to terminals 1U, 2U (GND) and 3U (+12Vdc); •...

  • Page 53: Alarm Contact

    CONTROL WITH ONE NTC TEMPERATURE PROBE (passive) • short-circuit terminals 7U and 8U (jumper) to enable production; alternatively connect terminals 7U – 8U to a remote contact (e.g.: switch, timer,...); • connect the main NTC room probe to terminals 1U and 2U; •...

  • Page 54: Production Request Analogue Output

    Production request analogue output The humidifi er controller is fi tted with an analogue output (0-10 V signal) that refl ects the production request. The production request output (0-10 V max 10 mA) is connected to terminals 11U, 12U. 1U 2U 3U 4U 5U 6U 7U 8U 9U 10U 11U 12U 13U 14U Key:...

  • Page 55: StartUp And User Interface

    11. STARTUP AND USER INTERFACE 11.1 Commissioning After having connected power using the main disconnect switch (ON), switch the appliance on by moving the switch on the front panel (1 - Fig. 11.a) to “ON”. The activation sequence will start, which includes an initial phase, an autotest phase and fi nally actual operation. Each step in the activation sequence is identifi ed by a diff erent display.
  • Page 56 11.3 Diff erent types of gas supply IMPORTANT: the appliances are delivered calibrated and tested to operate on natural gas (methane). The humidifi er can be supplied by the following types of gas: • Natural gas (G20-G25 methane - factory setting). •...
  • Page 57 11.3.4 Burner calibration at maximum output Force the burner to operate at maximum output by setting the fan to the maximum speed and analysing the fl ue gas. UG45/90/180 UG150/300/450 Fig. 11.c Fig. 11.d Procedure: After opening the front door and identifying the fan-valve assembly: using a T25 Torx screwdriver: using a 4 mm hex key: •...
  • Page 58 11.3.5 Burner calibration at minimum output Force the burner to operate at minimum output, by setting the fan to the minimum speed. Procedure for both models: Using a T40 Torx screwdriver: • remove the cap to access the adjustment screw; UG45/90/180 UG150/300/450 Fig.

  • Page 59: Graphic Terminal

    11.4 Shutdown To avoid stagnation, drain the water from the boiler using the manual procedure. Then move the switch to 0, “OFF”. 11.5 Graphic terminal The 4.3” touch graphic terminal has a graphic interface with coloured and animated icons. The contents of the display can be scrolled up and down simply and intuitively.

  • Page 60: Scheduler Settings

    11.6.2 Scheduler settings The Scheduler menu is used to activate and set the time bands for switching on the humidifi er. After enabling the scheduler (1 - Fig. 11.m), six on/off time bands can be set for each day. Use the copy button to copy the set time bands from one day to the next.

  • Page 61: Set Point Setting

    11.6.5 Set point setting The Setpoint tab is used to set the set point (1 - Fig. 11.q), the proportional band (2 - Fig. 11.q) and the maximum production (3 - Fig. 11.q). Fig. 11.q 11.6.6 System information The System information tab shows information on the status and activity of the humidifi er, as well as on the software and hard- ware.

  • Page 62: Complete Programming Tree

    11.7 Complete programming tree Below is the complete tree of the settings menu. The screen index at the top right (Fig. 11.s) corresponds to the sequence in each menu in order to reach the specifi c page. There are two levels of access: Installer and Service. To login to the settings menu, use the follow- Regulation Ea01...
  • Page 63 Menu E. Settings(password) Menu Index Description Level a. Control Control type Ea01 Set the type of control Installer Weights Ea02 Set the weight of the two probes Installer Control proportional Ea03 Set the hysteresis, minimum production and max production Installer to external signal External ON/OFF Ea04...
  • Page 64 Menu Index Description Level No. of evaporation cycles before Ec11 Set the number of evaporation cycles between two drain cycles Installer drain No. of evaporation cycles before Ec11a Set the number of evaporation cycles between two drain cycles Installer draining (for the secondary unit, if present) Variation in fi ll and drain time Ec12...

  • Page 65: Operation And Control

    Menu Index Description Level g. Initialisa- Wizard Eg01 Start the wizard for initial unit confi guration Service, tion Set whether to display the wizard when next restarting Installer Language Eg02 Set the language Service, Installer Unit of measure Eg03 Set unit of measure (International or Imperial). Select the language Installer and language when starting when starting...

  • Page 66: Autonomous Control With Humidity Probes

    11.8.3 Proportional to an external signal (modulating control) Steam production is proportional to the value of an external signal Y (selectable by programming one of the following standards: 0-1Vdc; 0-10Vdc; 2-10Vdc; 0-20mA; 4-20mA). The maximum production Pmax corresponds to the maximum value of the external signal Y and will be the humidifi er’s rated output.

  • Page 67: User Menu And Unit Configuration

    12. USER MENU AND UNIT CONFIGURATION The following paragraphs describe the gaSteam programming menus. The screen index at the top right (Fig. 11.s) corresponds to the sequence in each menu in order to reach the specifi c page. 12.1 Main menu 12.1.1 Clock menu The Clock menu is used to set the time (4 - Fig.12a), the date (3 - Fig.12a), the date display format (1 - Fig.12a) and the time zone (2 - Fig.12a).

  • Page 68: Scheduler Menu

    To access this tab, enter the system menu and then click the “alarm thresholds” icon (3 - Fig. 11.l): Parameter Description Alarm thresh- Set alarm thresholds olds Low humidity/temperature alarm threshold High humidity/temperature alarm threshold Limit humidity/temperature alarm threshold Default: low humidity/temperature 0% rH / 0°C(32°F);...

  • Page 69: Menu E. Settings - A. Control

    12.2 Menu: E. Settings The Settings menu (Fig. 12.h) can be used to: • modify the humidifi er settings and control (1 - Fig. 12.h); • set the reference units of measurement (2 - Fig. 12.h); • manually drain the water in the boiler (3 - Fig. 12.h).
  • Page 70 12.3.2 Weighted average of the probes (Installer menu) If using two temperature probes or two humidity probes, the humidifi er controller will calculate the weighted average of the probe readings. In this way, two probes can be used, for example humidity probes, at opposite ends of the room, calculating the average.
  • Page 71 12.3.7 Limit probe confi guration (Installer menu) A second probe can be connected as a limit probe at the outlet. This probe has the purpose of preventing the relative humidity downstream of the steam distributor from exceeding a set value, confi gured by the user. As this probe has a modulating action, the diff erential can also be set.

  • Page 72: Menu E. Settings - B. Functions

    There are also two types of activation: • PARALLEL: the steam request is divided equally between the burners so that steam production is the same; • SERIES (also called “sequential”): if the steam request is less than 50% of the rated production, only one burner is operated. Only if the request exceeds 50% does the other burner start.
  • Page 73 12.4.2 Fill cycles in PWM mode after drain to dilute cycles and high level/foam (Installer menu) After a drain to dilute cycle or high level/foam, the fi ll valve is opened to replenish water up to the maximum level of the fl oat. The addition of fresh water aff ects steam production, as it decreases the average water temperature inside the boiler: to reduce the negative impact of fresh water on steam production, the user can activate PWM mode for the fi ll cycles after drain to dilute cycles and due to high level/foam.
  • Page 74 Digital outputs M5 and M6 can be confi gured as follows: • production • main probe broken or disconnected alarm • failed autotest alarm • limit probe broken or disconnected alarm • high conductivity warning • pre-heating probe broken or disconnected alarm •...

  • Page 75: Frost Protection

    12.4.8 Save alarm log The alarm log can be saved to USB pen drive. To export the fi le, plug the USB pen drive into the c.pHC and go to screen Eb10, then set “YES” for the “Export?” parameter. Index Parameter Description Eb10...
  • Page 76 12.5.2 Limit probe (or second probe - Installer menu) The limit probe (if present) can be confi gured on the screen with index Ec02. Index Parameter Description Ec02 Limit probe/2nd probe Limit probe confi guration; Default: Enable: enabled (depending on the type of control) Type: 0-10 V Minimum: 0% rH Maximum: 100% rH...
  • Page 77 12.5.5 Duration of the fi ll and drain to dilute cycles settable by the user (Installer menu) On screen Ec12, the duration of the fi ll time after the evaporation cycle and the duration of the drain to dilute cycle can be set in relation to the default parameter values.
  • Page 78 12.5.7 No feedwater setting (Installer menu) In the event of no feedwater, the corresponding “No water” alarm is displayed. After the alarm has been displayed and the “no feedwater time” has elapsed, the controller attempts a new fi ll cycle. At each attempt, the “no feedwater time” is multiplied by the number of times it has already been carried out.

  • Page 79: Fan Speed Setting

    12.5.11 Fan speed setting Set the fan speed for minimum and rated production. These values are set by default to ensure the correct air/gas mix with the natural gas Pre-purge speed. The pre-purge speed is indicated in “RPM” and is normally set by the manufacturer based on the characteristics of the combustion system and the gas.
  • Page 80 12.6 Menu E. Settings - d. Main/Secondary 12.6.1 Main/Secondary system network settings (Installer menu) To increase total production capacity when one single unit is not suffi cient, the Main/Secondary function can be used to con- nect up to 20 units together in just one system. To set and enable the individual units in the system, go to the “Network” menu, specifi cally starting from screen Ed01.

  • Page 81: Menu E. Settings - E. Backup

    12.7 Menu E. Settings - e. Backup 12.7.1 Enable backup unit (Installer menu) In some critical applications where relative humidity control is very important, it may be essential have a backup unit available in the event of malfunctions on the main unit. To enable the backup unit, go to screen Ee01: Index Parameter Description...
  • Page 82 12.9.6 Software update from USB pen drive The update package can be downloaded from ksa.carel.com. The unit’s software can be updated using a USB pen drive plugged directly into the c.pHC controller. In the pen drive’s root directory, create an UPGRADE directory and copy the software update fi le to this directory.
  • Page 83 Address is the device’s supervision address on the BMS port. Enabling or disabling the parameters “On/Off from SV” and “Control from SV” activates or deactivates the response to the corresponding signals from the supervisor. For other supervisor protocols, select Carel protocol and use the Carel external gateway (supernode for humidifi cation). 12.10.2 BMS port (Installer menu) Screen Eh02 is used to set supervisor communication on the BMS port.
  • Page 84 “Update?” parameter to “YES”. IMPORTANT: the controller is not accessible directly on the internet as a fi rewall guarantees remote access only via a secure connection (Carel tERA cloud or encrypted VPN connection). 12.10.5 Supervisor settings for ModBus or BACnet on TCP/IP (Ethernet port) (In- staller menu) Both Modbus and BACnet are available on the Ethernet port;...

  • Page 85: Menu E. Settings - I. Logout

    12.10.7 Monitoring service settings Monitoring service refers to a system that does not have the ability to manage/act on the unit, but rather simply monitor its operation. The parameters relating to the management of an external monitoring service are shown on screen Eh09. However, a unit pause signal from an external source can be managed and disabled by activating the corresponding bypass.
  • Page 86 13. MAIN/SECONDARY SYSTEM 13.1 System confi guration Systems set up in this way will be able to cover the humidifi cation requirement. In this specifi c case, the Main unit will always be the unit with the lowest IP address of those connected to the signal/probes. If necessary, an additional humidifi er (backup) can be installed to cover request in the event of malfunctions on one of the units in the system.

  • Page 87: Software Backup

    13.1.4 Disconnecting a unit To remove a unit from the Main/Secondary system, thus reducing the number of units available in the system, use the “Discon- nect unit” function on screen Ed06. This can be done on any of the humidifi ers in the system. Notice: once the unit has been disconnected, this will no longer be visible in the Main/Secondary system, as its IP address will be removed from the list.

  • Page 88: Web Server Functions

    Info Unit info: information on the unit model and software version. Select language and unit of measure. Resources: useful links (Carel website, gaSteam manuals and pages on Carel website). Guide & FAQ: general information on using the web server. Notice: to avoid incorrect settings, some of the main unit operating parameters can only be modifi ed via the web server when the unit is off (off from keypad).

  • Page 89: Supervisor Network

    The variables shown in the list are a set of all the internal variables on the gaSteam humidifi er. DO NOT CONFIGURE ANY VARIABLES THAT ARE NOT SHOWN IN THE TABLES, OTHERWISE HUMIDIFIER OPERATION MAY BE AFFECTED. 15.1.1 Table of Carel variables The variables used for the Carel protocol are shown below. RW= Read/Write Type Add. Variable name Description Def.
  • Page 90 Type Add. Variable name Description Def. Access Analogue 58 PreheatOff set_Hum Set humidity diff erence with reference to humidity set point 20.0 PercentRelative- for activation of preheating (preheating off set) Humidity Analogue 59 ManMode_Fan1_PWM Fan 1 speed setting in manual mode Fan_1_cfg.
  • Page 91 Type Add. Variable name Description Def. Access Boolean Alrm_NetUnit_17.Active Alarm ALN17: Problems on network unit 17 Boolean Alrm_NetUnit_18.Active Alarm ALN18: Problems on network unit 18 Boolean Alrm_NetUnit_19.Active Alarm ALN19: Problems on network unit 19 Boolean Alrm_NetUnit_20.Active Alarm ALN20: Problems on network unit 20 Boolean Alrm_WirelessPrb_1_ Alarm ALP05: Wireless probe 1 low battery...
  • Page 92 Type Add. Variable name Description Def. Access Boolean 157 DilDrainCfg.Daily- Drain to dilute - Daily scheduler (Monday) - enable TRUE Sched[1].Enable Boolean 158 DilDrainCfg.Daily- Drain to dilute - Daily scheduler (Tuesday) - enable TRUE Sched[2].Enable Boolean 159 DilDrainCfg.Daily- Drain to dilute - Daily scheduler (Wednesday) - enable TRUE Sched[3].Enable Boolean...
  • Page 93 Type Add. Variable name Description Def. Access Integer Month Current month Months Integer Current day Days Integer Hour Current time Hours Integer Minute Current minute Minutes Integer SetTimezone Time zone set Integer SV_Command Reset command (1=cancel alarms; 2=reset cylinder produc- tion hours, reset after 5 seconds) Integer SV_SWVer...
  • Page 94 Type Add. Variable name Description Def. Access Integer 125 DilDrainCfg.Daily- Drain to dilute - Daily scheduler Hours Sched[2].Start_h (Tuesday) - hours Integer 126 DilDrainCfg.Daily- Drain to dilute - Daily scheduler Minutes Sched[2].Start_min (Tuesday) - minutes Integer 127 DilDrainCfg.Daily- Drain to dilute - Daily scheduler Hours Sched[3].Start_h (Wednesday) - hours...
  • Page 95 15.1.2 Table of Modbus variables The variables used for the Modbus protocol are shown below RW= Read/Write Type Add. Occ. Variable name Description Def. Access Coil OnBySV Unit On/Off signal from supervisor Coil WHardnessTyp Set water hardness management mode (0 = TRUE AUTO;...
  • Page 96 Type Add. Occ. Variable name Description Def. Access DiscreteInput Alrm_CylFull.Active Alarm ALW02: Cylinder full DiscreteInput Alrm_ConductPrb.Active Alarm ALA04: Conductivity meter DiscreteInput Alrm_HighConductWr.Active Warning ALW03: High conductivity DiscreteInput Alrm_RetMem.Active Alarm ALR01: Retain memory DiscreteInput Warn_Autotest.Active Warning ALW04: Autotest log only DiscreteInput Warn_LevSen.Active Warning ALW05: Level sensor log only DiscreteInput...
  • Page 97 Type Add. Occ. Variable name Description Def. Access DiscreteInput Alrm_MissingModel_S.Active Alarm ALP24: No secondary model DiscreteInput Alrm_WMiss_S.Active Alarm ALP25: Secondary no water DiscreteInput Alrm_Foam_S.Active Alarm ALM21: Secondary foam warning DiscreteInput Alrm_LowProd_S.Active Alarm ALB03: Secondary low production DiscreteInput Alrm_LevSen_S.Active Alarm ALC05: Secondary level sensor broken DiscreteInput Alrm_Autotest_S.Active Alarm ALC06: Secondary autotest failed...
  • Page 98 Type Add. Occ. Variable name Description Def. Access HoldingRegister 60 RegulationCfg.PwrCorrec- Unit control parameters - Correction factor (0 = 29.0 50.0 tionFactor no correction) HoldingRegister 62 Scheduler.SchedDayToSet Scheduler - Day to confi gure (a value > 0 enables editing mode) HoldingRegister 63 SchedDayCfg[0].StartHr Scheduler - Time band start time (Monday)
  • Page 99 Type Add. Occ. Variable name Description Def. Access HoldingRegister 128 DilDrainCfg.PeriodicDilDrain- Set number of hours between two periodic drain Thrsh to dilute cycles if micro-fi lling mode active HoldingRegister 130 DilDrainCfg.DailySched[1]. Drain to dilute - Daily scheduler (Monday) - Start_h hours HoldingRegister 131 DilDrainCfg.DailySched[1].
  • Page 100 Type Add. Occ. Variable name Description Def. Access InputRegister WirelessPrbInfo_4.RadioSig- Wireless probe 4 - Radio signal level in dBm+100 nalLev (8-15 = LOW; 15-30 = MEDIUM, >30 = EXCEL- LENT) InputRegister UnitStatus Unit status* InputRegister CurrProdPh Current production NomProd 0.1[kg/h]/ [lb/h] InputRegister WorkHr...
  • Page 101 15.1.3 Table of Bacnet variables The variables used for the Bacnet protocol are shown below RW= Read/Write Type Add. Variable name Description Def. Access AnalogInput WirelessPrbVal_1.Hum Wireless probe 1 - Humidity value in %rH (for SA and SI probes only) AnalogInput WirelessPrbVal_1.Temp Wireless probe 1 - Temperature value in °C AnalogInput...
  • Page 102 Type Add. Variable name Description Def. Access AnalogValue Temp_Fumes_1 Flue gas temperature - Probe 1 reading Degrees Celsius AnalogValue Temp_Fumes_2 Flue gas temperature - Probe 2 reading Degrees Celsius AnalogValue Temp_Fumes_MB_3 Flue gas temperature - Probe 3 reading Degrees Celsius AnalogValue Fan1_PWM Fan 1 speed set point...
  • Page 103 Type Add. Variable name Description Def. Access BinaryValue Warn_LowProd.Active Warning ALW06: Low production log only BinaryValue Alrm_WirelessPrb_1_ Alarm ALP01: Wireless probe 1 offl ine Offl ine.Active BinaryValue Alrm_WirelessPrb_2_ Alarm ALP02: Wireless probe 2 offl ine Offl ine.Active BinaryValue Alrm_WirelessPrb_3_ Alarm ALP03: Wireless probe 3 offl ine Offl ine.Active BinaryValue Alrm_WirelessPrb_4_...
  • Page 104 Type Add. Variable name Description Def. Access BinaryValue Alrm_SVOffl ine.Active Alarm ALP21: Supervisor offl ine BinaryValue Alrm_MissingModel_S. Alarm ALP24: No secondary model Active BinaryValue Alrm_WMiss_S.Active Alarm ALP25: Secondary no water BinaryValue Alrm_Foam_S.Active Alarm ALM21: Secondary foam warning BinaryValue Alrm_LowProd_S.Active Alarm ALB03: Secondary low production BinaryValue Alrm_LevSen_S.Active Alarm ALC05: Secondary level sensor broken...
  • Page 105 Type Add. Variable name Description Def. Access Positive MainPrbCfg.UITyp Main probe confi guration - Probe type IntegerValue Positive LimitPrbCfg.UITyp Limit probe confi guration - Probe type IntegerValue Positive WHardnessMan Set water hardness value, if manual mode IntegerValue (0=0-10°F; 1=10-20°F; 2=20-30°F; 3=30-40°F;...
  • Page 106 Type Add. Variable name Description Def. Access Positive WirelessPrbInfo_ Wireless probe 3 - Radio signal level in IntegerValue 3.RadioSignalLev dBm+100 (8-15 = LOW; 15-30 = MEDIUM, >30 = EXCELLENT) Positive WirelessPrbInfo_ Wireless probe 4 - Battery level from 0 to 3600 IntegerValue 4.BattLev mV (below 2800 mV the battery level is low)
  • Page 107 Type Add. Variable name Description Def. Access Positive DilDrainCfg.Daily- Drain to dilute - Hours IntegerValue Sched[3].Start_h Daily scheduler (Wednesday) - hours Positive DilDrainCfg.Daily- Drain to dilute - Minutes IntegerValue Sched[3].Start_min Daily scheduler (Wednesday) - minutes Positive DilDrainCfg.Daily- Drain to dilute - Hours IntegerValue Sched[4].Start_h...

  • Page 108: Alarm Table

    16. ALARM TABLE Any active alarms will be shown on the corresponding screen with direct access from the display. The Alarm icon starts fl ashing; pressing the Alarm button once displays the type of alarm. In the event of potentially dangerous alarms, the humidifi er auto- matically stops steam production.
  • Page 109 Alarm Cause Possible solution Reset Action ALW01 Foam warning Entrainment of foam in the boiler • The entrainment of foam is generally due to the pres- Automatic Signal during boiling ence of surfactants in the water (lubricants, solvents, only detergents, water treatment or softening agents) or an excessive concentration of dissolved salts.
  • Page 110 Alarm Cause Possible solution Reset Action ALP25 Secondary no No feedwater • Check that the supply pipe to the humidifi er and the Stop with Stop produc- water internal tubing are not blocked or choked and that manual reset tion there is enough pressure (0.1-0.8 MPa, 1-8 bars) •...
  • Page 111 Alarm Cause Possible solution Reset Action ALA15 Main unit offl ine Main unit offl ine ALA16 Frost protection Frost protection Temperature below • check the temperature inside and outside of the hu- force pre- 10°C, preheating activated to protect midifi er. Increase the temperature inside the humidi- heating the humidifi er fi er by fi tting heaters where necessary...

  • Page 112: Boiler Maintenance

    17. MAINTENANCE DANGER: always wear protective gloves during maintenance operations. DANGER: poor maintenance, removal or modifi cation of safety devices and/or the use of non-original spare parts can cause serious or fatal injuries to operators or third parties and humidifi er malfunctions. DANGER: before all operations: •...
  • Page 113 To remove the heat exchanger, proceed as follows: • disconnect the cables from the burner electrodes (the detection electrode must be disconnected from the burner control board, see the A - Fig. 17.b); • remove the fan manifold by removing the screws B (Fig. 17.b) and remove the burner combustion head (Fig. 17.c); Fig.

  • Page 114: Cleaning The Burner

    17.2 Cleaning the burner The burner must be checked by authorised and qualifi ed personnel once or twice a year, according to use. Before performing any maintenance on the burner, check its general condition, carrying out the operations listed below: •...

  • Page 115: General Features And Models

    18. GENERAL FEATURES AND MODELS Models for indoor installation: INDOOR models UG045 UG090 UG150 UG180 UG300 rated supply voltage (Vac) 230V 50Hz (ver. UG***HD005) / 115V 60Hz (ver. UG***H1105) steam connection (Ø mm) 1x80 1x80 1x80 2x80 2x80 steam outlet pressure limits (Pa) 0-2000 (0-0.30 PSI) Feedwater connection...

  • Page 116: Heating-Water Circuit Specifi Cations

    18.1 Heating-water circuit specifi cations UG045 UG090 UG150 UG180 UG300 UG450 heat input rated kW (BTU/h) 33 (112596) 62.5 (213250) 105 (358260) 125 (426500) 210 (7165209) 315 (1074780) minimum 7.8 (26614) 14.7 (50156) 24.7 (84276) 14.7 (50156) 24.7 (84276) 24.7 (84276) heat input rated 34.8 (118737) 65 (221780)

  • Page 117: Electrical Panel

    19. ANNEX Annex A: wiring and connection diagrams Electrical panel J17C J17L J24 J19 3 2 1 Fig. 19.a gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...
  • Page 118 Wiring diagram for UG045 - UG090 - UG150 J17C J17L J6L J6C 3 2 1 Fig. 19.b gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...
  • Page 119 Wiring diagram for UG180 - UG300 J17C J17L J6L J6C 3 2 1 Fig. 19.c gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...

  • Page 120: Wiring Diagram For Ug450

    Wiring diagram for UG450 Ref. 62C759A406/R J17C J17L 3 2 1 Fig. 19.d gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...
  • Page 121 J17C J17L 3 2 1 Fig. 19.e Wiring diagram key Ref. Description Ref. Description Base Selectable fuse carrier Two-pole ON/OFF switch cPHC Main board + expansion card K.MINIMA Safety thermostat (outdoor only) Diff erential pressure switch (180/300/450 kg/h) TRPS2 115-230 V transformer (UG180-300) 3-pin through connector F1-F2 Power fuses...
  • Page 122 Electrical panel Fig. 19.f Annex B: Accessories and spare parts kits 1 Water circuit Fig. 19.g gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...
  • Page 123 Key: Part number Description Ref. fi gure Quantity per humidifi er UGKBL00091SP UG45-90 “boiler + cover + nuts” kit UGKBL00181SP UG180 “boiler + cover + nuts” kit UGKBL000C6SP UG150 “boiler + cover + nuts” kit UGKBL0004CSP UG300 “boiler + cover + nuts” kit UGKSC00001SP stainless steel heat exchanger kit for UG045 UGKSC00002SP...

  • Page 124: Burner Assembly

    2 Burner assembly Fig. 19.h Quantity per Part number Description Ref. fi gure humidifi er UGKBRUC445SP combustion assembly kit. assembled and calibrated - UG045 UGKBRUC490SP combustion assembly kit. assembled and calibrated - UG090-180 UGKBRUC2C5SP combustion assembly kit, assembled and calibrated - UG150-300-450 50Hz UGKBRUC3C5SP combustion assembly kit, assembled and calibrated - UG150-300-450 60Hz UGKCH00045SP combustion head for UG45 UGKCH00090SP combustion head for UG90-180...
  • Page 125 3 Electrical panel Fig. 19.i Part number Description Ref. fi gure Quantity per humidifi er MCKTR00000SP panel transformer UGKAD00040SP unit main control board HCTXGCR000SP pGDX graphic touch display UGKVENT001SP cooling fan kit gaSteam +0300122EN rel. 1.0 - 01.12.2021 Annex...
  • Page 126 20. CONFORMITY gaSteam +0300122EN rel. 1.0 - 01.12.2021 conformity...
  • Page 128 CAREL INDUSTRIES - Headquarters Via dell’Industria, 11 - 35020 Brugine - Padova (Italy) Tel. (+39) 049.9716611 - Fax (+39) 049.9716600 gaSteam +0300122EN rel. 1.0 - 01.12.2021 e-mail: carel@carel.com - www.carel.com...

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