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ELECTRONICALLY CONTROLLED STEAM HUMIDIFIER

DESIGN SERIES “E”

INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
CARNES COMPANY, 448 S. Main St., P. O. Box 930040, Verona, WI 53593-0040 - Phone: 608/845-6411 - Fax: 608/845-6470 - [email protected] - www.carnes.com

External Disconnect Water Shutoff Valve

or Circuit Breaker (Not Provided by Carnes)
(Not Provided by Carnes)

Make-Up
Solenoid
Valve
Door
Interlock
Steam Hose

Steam Output
Rate Meter
Overflow
“On” Lamp Sensor

“Abnormal”
Lamp
Steam Output Terminal
Control Connectors

On-Off-Drain
Switch Steam
Cylinder

Optional
Circuit Cylinder
Breakers Retaining
Band

Brass Cylinder Drain Solenoid

Power
Fittings Valve
Contactors

Photo A
(Model HBHE Shown)

FORM 16699
REVISED: 05-96
INSTALLATION
WATER SUPPLY CONNECTION
UNPACKING AND INSPECTION Use ordinary tap water (20 to 120 psi) - DO NOT use hot
1. An envelope attached to the outside of the cabinet water, deionized water, or water that has been treated
contains one cabinet key. by a water softener without consulting the factory. A
2. Open the cabinet and check for concealed shipping 3/8” FPT fitting is provided at the top of the humidifier for
damage. Report any damage immediately to the connection to tap water supply. A shutoff valve, not provid-
carrier who delivered the shipment. ed by Carnes, must be installed just ahead of this fitting.
3. The following components are packed in a shipping
carton for connection when installing humidifier. DRAIN LINE CONNECTION
A. Distribution pipe. 1. Remove the large nut and plastic gasket located on
B. Steam hose. the fitting on the bottom of the cabinet. (Photo B). The
C. Condensate return line. nut and gasket may be used with standard type drain
4. Optional accessories may be packed with the cabinet fitting if an air gap fitting is not required by local
or in the same shipping carton. Large accessories codes.
may ship in separate cartons. 2. Connect the air gap drain fitting to the cabinet drain
5. Inside the cabinet is an envelope containing the connection. It may be necessary to cut off some of
following items: the air gap fitting depending on available space.
A. Steam hose clamps. 3. Connect the drain or air gap fitting to S or P trap. Use
B. Condensate return line clamps. plumbing material capable of handling hot water.
C. Air gap drain fitting. Note: If the drain water pump accessory package is
D. Installation instructions. used, follow instructions included with the drain water
pump package.
MOUNTING THE HUMIDIFIER
Mount the humidifier cabinet securely on a level and plumb
surface near the ductwork. Allow 6” or more on each side
for proper ventilation and minimum of 16” from the bottom
of the cabinet to the floor to allow space for the drain con-
nection. The humidifier must never be mounted outside
or where it may be exposed to freezing temperatures.
Maximum operating weights for the humidifier are shown
below.

Table 1 - MAXIMUM OPERATING WEIGHT

Model Pounds
HBAE, HCAE 80
HBDE, HCDE 85
HBGE, HCGE 105
HBHE, HCHE 185
Drain Line
Connection

Photo B

Table 2 - FASTENER RECOMMENDATION

6 FASTENERS REQUIRED (Models HBAE, HCAE, HBDE, HCDE)

TYPE OF WALL 8 FASTENERS REQUIRED (All Other Models)
Wood Studs or Solid Wood 1/4” Lag Screw, 1” Minimum Length
Hollow Plaster 1/4” Molly Bolts or Toggle Bolts, 3” Minimum Length
Sheet Metal 1/4” Thread Forming Screws, 1/2” Minimum Length
Cement or Masonry 1/4” Lead Type Anchor and Bolts, 1-1/2” Minimum Length

2
STEAM DISTRIBUTOR PIPE LOCATION The maximum length of steam hose that may be installed
Each steam cylinder in two-cylinder units require a separate as shown in Figure A is 12 feet. For a steam hose length
steam distributor pipe, steam hose, and condensate return over 12 feet refer to Figure B.
line. A drain “T”, as shown in Figure B, must be used to remove
In a typical installation, the humidifier is located below the condensation that occurs in steam hose lengths over 12
duct as shown in Figure A. It is recommended that the feet. It is preferable to have the steam hose rise vertically
length between the humidifier cabinet and the steam dis- from the cabinet and the slope toward the distributor pipe as
tributor pipe in the duct be the minimum possible distance. shown. If sufficient head room is not available, it is possible
Refer to Table 3 for maximum lengths that may be installed. to install with an upward slope to the hose.

Figure B

Figure A

3 If airflow is vertical, the steam distributor pipe should be

installed horizontally (Figure C).

Figure C

In two-cylinder units the pipes should be staggered as

shown (Figure D).

Figure D

MAXIMUM STEAM HOSE LENGTH

(Table 3)
Duct Static
0 1 2 3 4 5
Pressure “wg”
Maximum Steam 40 35 30 25 15 10
Hose Length (Ft.)

3
STEAM DISTRIBUTOR PIPE LOCATION (Continued) If it is difficult to install the steam hose to prevent sags, it
Steam distributor pipes must be located on a plumb surface. is recommended that copper tube be used as a substitute.
This is required so the condensate which forms in the dis- If copper tube is used, a minimum of one inch of insulation
tributor pipe will drain to the return line and back to the unit. must be applied to prevent excess condensation. A short
Steam distributor pipes should be mounted in the duct to length of steam hose should be used to connect to the cyl-
insure even distribution of steam across the center portion inder in the humidifier and another short length to connect
of the duct. The condensate return line must always be kept to the steam distributor pipe. Size 3/4” copper tube should
on the bottom. A minimum clearance of 4” must be main- be used with steam cylinders having output rates up to 30
tained between top of the duct and distributor pipe. pounds of steam per hour. Size 1-1/2” copper tube should
The steam distributor pipe should be located in the sup- be used with steam cylinders over 30 pounds per hour. The
ply air stream, downstream of the fan. When installed in condensate return line which connects the outlet on the
packaged units (central station air handlers, multizone steam distributor pipe to the inlet on the top of the humidifier
units, make-up air units, etc.) the distributor pipe should also must be supported to prevent sags that would restrict
be mounted just downstream of the fan discharge in the the flow of water.
primary air stream.
In multizone applications it is preferable to have a separate INSTALL STEAM DISTRIBUTOR PIPE
humidifier serving each zone. However, steam can be intro- EACH CYLINDER REQUIRES SEPARATE STEAM
duced into the hot deck upstream of the zone dampers. In HOSE, CONDENSATE RETURN LINE, AND STEAM
this case, good distribution of steam across the entire hot DISTRIBUTOR PIPE.
deck is very important. 1. Steam distributor pipe must be mounted on a plumb
The steam distributor pipe may be located below the humid- surface. When on a plumb surface the standard
ifier if the installation is made in accordance with Figure E. distributor pipe is inclined upward. This is required so
A trap must be installed as shown to prevent steam from the condensate which forms in the distributor pipe
flowing back through the condensate return line. will drain to the return line and back to the unit.
2. Insert distributor pipe into duct and secure with four
sheet metal screws, not provided by Carnes.
3. Special distributor pipes are shipped with specific
instructions on how to mount them.
4. If the optional fan distribution unit is to be used,
follow the instructions included with the unit.

CONNECT THE STEAM HOSE

COPPER OR BRASS TUBE IS THE ONLY ACCEPTABLE
SUBSTITUTE FOR CARNES STEAM HOSE OR
CONDENSATE HOSE.
1. The steam hose should be installed so there is a
continuous rise from the humidifier to the distributor
pipe. Support the steam hose at intermediate points
to prevent dips or pockets.
Figure E 2. Any turns should have a minimum radius of 8” to
prevent the hose from kinking.
3. Fasten the steam hose to the distributor pipe with one
of the hose clamps provided.
It is preferable to locate the steam distributor pipes down- 4. Push the steam hose through the opening on the top
stream from any obstructions in the ductwork so that air can of the humidifier cabinet and slip over the outlet stub
absorb moisture before it impinges on a surface and accu- on the top of the cylinder. Fasten the hose clamp
mulates. There must be a minimum of six feet between the provided.
steam distributor pipes and any fans, coils, filters, zone
dampers, elbows or outlets which may be installed down- CONDENSATE RETURN LINE
stream of the distributor pipe. However, in all cases, the 1. Fasten the condensate return line to the distributor
steam distributor pipes should be located as far upstream pipe with the hose clamp provided.
from any such obstruction as possible. 2. Follow the steam hose to the humidifier cabinet and
It is very important that the steam hose is installed so that secure the return line to the steam hose.
sags in the hose are prevented. Because the steam is at 3. Connect the return line to the condensate return inlet
very low pressure it cannot overcome resistance caused with hose clamp provided.
by water standing in the steam hose. The steam hose is 4. If it is impossible to maintain a drop to the top of the
flexible so it must be supported adequately to prevent any cabinet, it is necessary to run the condensate return
low point from occurring. The steam hose and condensate line directly to the air gap drain fitting or some other
return line must have a continuous pitch so that standing drain.
water will not develop.

4
ELECTRICAL DATA
Table 4
Opt. NOTES:
Max. Line Disc. Circuit Steam “Model” and “Opt. Circuit Breaker” col-
Model Lb/Hr. K.W. Ph. Volt Amp Size Breaker Cylinder umns designate presence, quantity and amp
120 14.4 20 1-20 1-AX220 rating of optional circuit breakers. All models
208 8.3 15 1-15 1-AX380 preceded by “HC” have overload protection
5 1.7 1 230 7.5 15 1-15 1-AX380 provided by the electronic circuit board. In
277 6.2 15 1-15 1-AX380
460 3.7 15 1-15 1-AX700
addition, as an option, internally mounted,
575 3.0 15 1-15 1-AX700 switchable on-off, circuit breakers are avail-
HCAE 120 28.7 40 1-40 1-AX220 able in models preceded by “HB”.
208 16.6 25 1-25 1-AX380
10 3.4 1 230 15.0 20 1-20 1-AX380 “Max Lb./Hr.” designates maximum capacity
277 12.4 20 1-20 1-AX380 of humidifier. Units are shipped from the fac-
460 7.5 15 1-15 1-AX700 tory preset at the maximum rate. The output
575 6.0 15 1-15 1-AX700 rate may be easily reset after installation any-
208 33.1 45 1-45 1-B500
230 29.9 40 1-40 1-B500
where between 100% and 25% of maximum
20 6.9 1 277 24.9 35 1-35 1-B500 capacity.
460 15.0 20 1-20 1-B700
575 12.0 15 1-15 1-B700 “KW” ratings shown is at maximum output
208 19.1 25 1-25 1-B500 rate. If a unit is reset for less than maximum
230 17.3 25 1-25 1-B500 output, the KW is reduced proportionally.
HCDE 20 6.9 3 460 8.6 15 1-15 1-B700
575 6.9 15 1-15 1-B700 “PH ” and “Volt” designate available phase
208 28.7 40 1-40 1-B500
230 25.9 35 1-35 1-B500
and nominal voltages. Single phase units may
30 10.3 3 460 13.0 20 1-20 1-B700 be operated from two legs of a three phase
575 10.4 15 1-15 1-B700 supply but the load will be unbalanced.
208 49.7 70 2-35 1-C62
230 44.9 60 2-30 1-C62 “Line Amp” and “Disc. Size” are amp rat-
30 10.3 1 277 37.3 50 2-25 1-C62 ings shown for use in selecting electrical ser-
460 22.5 30 1-30 1-C65 vice requirements.
575 18.0 25 1-25 1-C65
208 38.2 50 2-25 1-C62
230 34.6 45 2-25 1-C62
“Steam Cylinder” columns shows the quan-
40 13.8 3 460 17.3 25 1-25 1-C65 tity and the model of steam generating cylin-
575 13.8 20 1-20 1-C65 ders mounted in the humidifier. Each cylinder
208 47.8 70 2-35 1-C62 requires its own steam distribution pipe, steam
230 43.2 60 2-30 1-C62 hose and condensate return line.
HCGE 50 17.2 3 460 21.6 30 1-30 1-C65
575 17.3 25 1-25 1-C65 ELECTRICAL CONNECTIONS
208 57.4 80 2-40 1-C62
230 51.9 70 2-35 1-C62 POWER MUST BE OFF BEFORE MAKING
60 20.7 3 460 25.9 35 1-35 1-C65 ANY ELECTRICAL CONNECTIONS
575 20.8 30 1-30 1-C65
80 27.5 3 460 34.6 50 2-25 1-C12
575 27.7 40 2-15 1-C12 Check unit electrical characteristics on label
460 43.2 60 2-25 1-C12 outside of cabinet. It must agree with power
100 34.4 3
575 34.6 45 2-20 1-C12 provided to the unit. If it does not, contact your
80 27.5 3 208 76.5 100 4-25 2-C62 Carnes Representative.
230 69.2 90 4-25 2-C62 A fused disconnect or circuit breaker not
100 34.4 3 208 95.6 125 4-35 2-C62 provided by Carnes, MUST be installed per
230 86.4 125 4-30 2-C62
208 119.5 175 4-30 2-C62
local and national codes. See Table 4 for rec-
230 108.0 150 4-35 2-C62 ommended circuit ratings. The optional circuit
125 43.0 3
HBHE 460 54.0 70 4-15 C-C12 breaker switch in the humidifier is NOT for use
HCHE 575 43.2 60 4-15 C-C12 as a disconnect switch.
150 51.7 3 460 64.8 90 4-15 2-C12 1. Remove screws securing lower electrical
575 51.9 70 4-20 2-C12 cover panel for access to wiring.
175 60.3 3 460 75.6 100 4-25 2-C12 2. An opening is provided on the bottom of
575 60.5 80 4-20 2-C12
460 86.4 125 4-35 2-C12 the electrical section. Bring electrical
200 68.9 3 power lines through this opening and
575 69.2 90 4-25 2-C12
connect to electric power terminals.
3. Connect cabinet ground terminal to an
independent ground. DO NOT use the
neutral of a four-wire power supply.
4. Replace electrical cover panel.

5
CONTROLS
CONTROL OPTIONS - Figure F
CONTROL HUMIDISTAT AIR FLOW DETECTION CONDENSATION
PROTECTION

WALL HUMIDISTAT
PROPORTIONAL
CONTROL
CARNES MODEL HXHBG

OR PRESSURE
DIFFERENTIAL
SWITCH
WALL HUMIDISTAT HIGH
CARNES MODEL HXAAE
ON-OFF LIMIT
CONTROL HUMIDISTAT
OR
CARNES MODEL HXHAA CARNES MODEL HXHAD
AIR
OR FLOW
SWITCH
DUCT HUMIDISTAT CARNES MODEL HXAAF
PROPORTIONAL
CONTROL
CARNES MODEL HXHBH

OR

DUCT HUMIDISTAT
ON-OFF
CONTROL
CARNES MODEL HXHAB

OR

DUCT HUMIDISTAT
WITH
AIR FLOW SWITCH
CARNES MODEL HXHAC

CONTROL HUMIDISTAT AIR FLOW DETECTION

If an on-off humidistat is used the humidifier will generate The humidifier control circuit should include some method
steam at the preset output rate and cycle on or off as nec- to determine air flow. If the steam distributor pipe is located
essary to satisfy the conditioned area requirements. All in a duct where there is no air flow and the control humidi-
humidifiers are preset at the factory for the maximum rating stat is calling for humidity, steam would be discharged into
of the unit. The output may be easily reset in the range of the duct where it would immediately condense. Air flow
25-100% by adjusting the control located on the front of the may be detected by several methods. The humidistat circuit
electronic control module.
may be interlocked by using a fan relay if the fan is direct
If Carnes proportional humidistat is used the humidifier will
driven. A fan relay is not recommended if a belt driven fan
automatically vary the steam output rate in the range of
25-100% of the humidifiers maximum rating in response is used as a broken belt would stop air flow even though the
to the signal from the humidistat. The steam output control fan relay was closed.
mentioned above may also be used to limit the maximum Among the alternatives are the use of a pressure differen-
output desired. Proportional control provides less cycling of tial switch that determines air flow by sensing a pressure
the humidifier. differential caused by air movement in the duct. A paddle
Either a wall humidistat or duct mounted humidistat in the type switch is also available to determine air flow. The pres-
return air may be used. The wall mounted humidistat is the sure differential switch is normally the preferred device as it
most common as it allows the setting to be easily changed is less susceptible to erratic operation caused by improper
to accommodate changing requirements or to lower the positioning in the duct system. Paddle switches require
relative humidity in the space to prevent condensation on careful positioning in the duct to insure sufficient air flow
windows during extremely cold weather. In applications to activate the switch. A combination return air duct on-off
where it may be desirable to prevent the occupants of a humidistat and sail switch is available but care must be
space from changing the setting, a duct mounted humid- taken during installation to insure proper operation.
istat in the return may be used. This is normally mounted
in the equipment room or in the duct where it is accessible
only to maintenance personnel.

6
 CONTROLS
CONDENSATION PROTECTION A 12 volt DC signal is supplied to terminals 10 and 12
A third device may be desirable to provide condensation whenever the humidifier is operating and is used to activate
protection in the duct system. A high limit humidistat may an electronic relay to start the fan motor in Carnes optional
be installed ten feet downstream from the steam distributor fan distribution unit. Maximum current available at terminals
pipe. This humidistat is normally set to 90-95% RH and 10 and 12 is 25 mA.
opens the circuit if the humidity level in the duct exceeds
the set point. Use of this device is recommended particular- EXTERNAL CONTROL SIGNALS
ly when the humidifier is used in applications where cooling Carnes humidifiers can also accept a 0-10 volt DC signal
air is being humidified or where a VAV system may throttle to modulate the output of the humidifier. Selection of this
back to a point where air flow is insufficient to absorb the type of signal is made by switch S2 on the humidifier circuit
steam being introduced. board. In the standard position any on-off humidistat can
be used. In the alternate position, signified by “V” in the
CONTROL CONNECTIONS humidifier model number, a 0-10 volt DC signal may be
FIELD WIRING TERMINAL BOARD supplied to terminals 11 and 13. Polarity must be observed
and terminal 11 is a chassis ground. Input impedance
Figure G
is 100K ohms. The position of switch S2 may be easily
changed anytime if a change in control systems is desired.
Recalibration for input voltages other than 0-10 volt is pos-
sible. Consult the factory for ranges and calibration proce-
dure. If a 4-20 mA. input signal is provided to the humidifier
a 470 ohm resistor must be installed across terminals 11
and 13.

HUMIDIFIER CIRCUIT BOARD

Figure H

CONTROL CONNECTIONS
An on-off humidistat is connected to terminals 11 and 13
IMPORTANT: TURN OFF POWER AT EXTERNAL
on the field wiring terminal board. The (+) and (-) markings
DISCONNECT BEFORE MAKING ANY CONNECTIONS
are not significant unless a signal is being supplied by an
TO PREVENT POSSIBLE DAMAGE TO ELECTRONIC
external humidity transmitter. The air flow detection control
CIRCUIT BOARD.
should be connected to terminals 1 and 2. If a high limit
humidistat is used it should be connected to terminals 3 1. A 7/8”opening is provided on the top of the cabinet.
and 5. If it is not used a jumper must be installed. The control wiring should pass through the opening to
the terminal strip (Figure G).
A 24 volt AC signal is provided by the humidifier circuit
board to terminals 4 and 6 to indicate the need for service. NOTE: A built-in transformer provides power for the
This signal is provided whenever the output is less than control circuit. No outside power supply is required for
50% of the desired rate. Maximum current available at ter- the control circuit.
minals 4 and 6 is 1/2 Amp. It is not necessary to connect 2. If an air flow switch or high limit humidistat is not used
any device to these terminals but a jumper must never be jumpers must be installed before the humidifier will
connected. operate.

7
OPERATION
Carnes state of the art electronic circuit board controls all
Figure I
functions within the humidifier to provide the highest ener-
gy efficiency available. The circuit board is mounted in a STEAM
control module containing a steam output meter calibrated DISTRIBUTOR
directly in pounds per hour, an “on” light, and “abnormal” PIPE
operation light that indicates the need for maintenance.

MAKE-UP WATER
SOLENOID VALVE
STEAM
HOSE
AIR GAP
STAND FROM POWER
PIPE CONTACTOR

CYLINDER

VERTICAL
ELECTRODES

DRAIN
SOLENOID
VALVE

STEAM TO DRAIN
Upon a signal from an external humidistat the circuit board WATER
opens a make-up water solenoid valve, allowing water to
flow across an air gap into a standpipe. The standpipe
provides a column of water to be fed into the cylinder using
gravity. The air gap prevents back flow into the water supply
and prevents the cylinder from becoming a pressure vessel.
As mineral deposits build up within the cylinder the water
The steam cylinder operates at a pressure of approximately
1/2 psi. level will slowly rise to uncovered electrode surfaces to
The circuit board also closes a power contactor allowing maintain the desired steam output rate. When mineral
current to flow to vertical electrodes sealed inside the cyl- deposits have covered all available electrode surface
inder. Current flows between the electrodes using minerals areas, current flow will be reduced to a level where the
in the water as a conductor. The water is heated to boiling desired steam output cannot be reached and the abnormal
and converted to steam which leaves the cylinder through light will signal the need for maintenance. When the cylin-
the flexible steam hose which is connected to the steam der is filled with minerals it is easily changed in less than
distributor pipe. five minutes.
The circuit board reacts to current flow between the elec-
trodes and automatically opens the make-up solenoid valve
when more water is required to maintain the desired output
rate, and closes when the desired rate is reached. The
operation of the drain solenoid valve is automatically con-
trolled by the circuit board which responds to any changes
in water conditions and drains the required quantity of water
to provide stable operation and long cylinder life.
Current flow in each leg of a three phase circuit is monitored
and in the event of overcurrent the contactor is opened
to disconnect power to the cylinder. The drain solenoid is
opened automatically to reduce water and current levels
and the humidifier resets for normal operation. If current lev-
els are not reduced to normal levels the circuit board opens
the contactor and indicates the over-current condition by
flashing the abnormal light.
8
START UP 2. The timer runs for a predetermined time until 90% of
While the external disconnect switch is off, be sure terminal setpoint is reached.
connectors are firmly secured to the top of the cylinder.
3. If rate of change of current occurs too rapidly, the drain
1. Open all water supply valves external to unit. solenoid will open to drain mineral rich water from the
cylinder.
2. Turn external disconnect switch to “ON” position.
4. Fill valve will automatically reopen to refill cylinder to
3. In units with optional circuit breakers, turn circuit proper current level.
breaker(s) to “ON” position.
ADJUSTING STEAM OUTPUT RATE
4. For safety, door interlock disconnects power to Steam output is regulated by adjusting steam output control
cylinder(s) when door is open. Humidifier may be (Photo C).
operated for service purposes when door is open
by pulling out white button located above the meter. To change steam output:
CAUTION: High Voltages Are Present.
1. Drain water from cylinder by turning “On-Off-Drain”
5. Turn “On-Off-Drain” switch to “ON” position. Green switch to “Drain” position.
“ON” light should now be on.
2. Turn steam output rate control fully clockwise.
6. Unit will now be in operation if humidistat is calling for
humidity. If Humidistat is not calling for humidity, 3. Turn “On-Off-Drain” switch to “On” position. Steam
adjust humidistat control upward to check operation. output rate will gradually increase as shown on
steam output rate meter. When desired output is
7. When humidistat is calling for humidity, water will reached, slowly turn counter clockwise until inlet
slowly flow into cylinder. Steam output meter will water valve closes and stops incoming water.
slowly rise as water enters cylinder.

8. The “ABNORMAL” light will remain on until sufficient

water has entered cylinder to provide 50% of set Steam Output Control
output. NOTE: Unit has been preset at factory for
maximum output as shown on label on bottom left
side of humidifier.

9. When high level or full output is reached, the fill

solenoid valve will close.
NOTE: When starting unit with new cylinder, the
“Abnormal” light may come on and the drain solenoid
valve and contactor may open for brief periods until
water has come to full boil.

LOW CONDUCTIVITY OPERATION

In areas where water conductivity is low, full output may not
be reached until humidifier has conditioned water.

1. If water comes in contact with the overflow sensor,

the fill valve will automatically close.

2. Water will boil and the fill solenoid valve will reopen.

3. Process will continue to occur until sufficient minerals

have accumulated to allow full output.

AUTOMATIC DRAIN CYCLE

The electronic circuit board controls the drain solenoid
valve to drain a portion of water from the steam cylinder.

1. As water boils away in the cylinder, a timer (indicated

by “BD “ lighted) is activated as current falls to 95% of
setpoint.
Photo C

9
TROUBLE SHOOTING MANY ITEMS CAN CAUSE ARCING

SYMPTOM: Water In Duct 1. Incoming water high with conductivity.

Conductivity, the ability to conduct current, is measured
POSSIBLE SOLUTIONS: This is usually an installation in “micromhos”. In any electrode type humidifier there
problem. First step is to determine if water is spitting from are maximum values of conductivity that may be used
the steam distributor pipe or if steam is condensing on in the humidifier. Maximum conductivities are shown in
some object in the duct or on the duct itself. Carnes Catalog HB-02.
If the water has been treated by a water softener, it’s
If water is spitting from the steam distributor pipe there may conductivity will be higher than if it is untreated. Soft
be several causes: water may be too high in conductivity to operate with-
out arcing.
1. The hose and condensate return lines MUST have
continuous slopes without ANY sags or pockets that 2. Build up of conductivity of water inside cylinder.
could accumulate water. If water accumulates in the Arcing can occur if incoming water conductivity is
steam hose, it may suddenly be pushed into the acceptable but other problems allow the conductivity
distributor pipe and the condensate return line may be inside the cylinder to increase beyond its design
unable to handle the large volume. capabilities. This may be caused by:
2. Make sure the condensate return line is not obstructed
in any way. Water should flow freely, through the return A. Drain lines that have become restricted by mineral
line. deposits prevent proper drain rates. This allows miner-
3. The mounting plate on the steam distributor pipe must als to concentrate inside the cylinder which causes low
be plumb on the duct to obtain the proper pitch on the water levels and therefore arcing. Drain lines should
portion inside the duct. If the portion inside the duct is be inspected when cylinders are changed and
tilted downward condensate cannot flow away from the thoroughly cleaned if necessary.
duct.
4. If the condensate return line has a very small pitch B. A defective solenoid valve will prevent proper drain-
down from the distributor pipe to the humidifier cabinet, ing. Disassemble and clean. The solenoid coil should
(less than 1 foot) it may be better to go to a drain be checked to verify its condition. If the “drain” switch
below the cabinet rather than connecting at the top of is placed in the drain position both the fill solenoid and
the cabinet. drain valves should open.

If the water is condensing on an object in the duct or on the C. A defective component or wiring harness may pre-
duct itself, it will be necessary to take other steps: vent the solenoid from operating. If the drain valve
operates in the manual drain position the wiring
1. The distributor pipe must be mounted AT LEAST 6 feet harness is good but the circuit board may be defec-
from any elbow, split, coil, turning vane, grille or dif- tive. If the drain valve won’t operate in the drain
fuser. The lower the air temperature is in the duct the position either the valve or wiring harness may be at
further upstream the pipe must be located. If the air fault. Check crimped on connectors for good connect-
temperature is 55O it may be necessary to have 10 ions. The best method to check the circuit board is to
feet between the pipe and any obstruction. substitute a board known to be good.
2. It may be that the air simply can’t hold the volume of
steam that is being introduced into it. Normally the only D. Insufficient quantity of incoming water will cause
practical solution is to reduce the steam output of the arcing by causing low water levels. In electronically
humidifier as it usually not feasible to increase the air controlled units a drain is never initiated until a set-
temperature or quantity. point is reached. Therefore, if low water pressure at the
unit (Below 20 PSI) or a clogged water strainer re-
SYMPTOM: “Arcing” or “Sparking” In Steam Cylinder stricts the flow of water, arcing will result. High back-
pressure caused by an obstruction in the steam hose,
POSSIBLE SOLUTIONS: An occasional arc is not a or excessive duct static pressure will also prevent the
problem. When a cylinder is restarted after a period of cylinder from reaching its setpoint and initiating a
time arcing may occur as chunks of mineral flake of the drain.
electrode surface. During a drain cycle arcing may occur
if water is very low in the cylinder. Arcing is a problem if it E. Frequent cleaning of the cylinder can dislodge flakes
occurs almost constantly and causes dark discoloration in that will cause blockage and prevent draining. It is not
the cylinder recommended that the cylinder be removed except for
replacement.

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 TROUBLESHOOTING
SYMPTOM: Drains Continuously
- (S2) switch in wrong position (See page 7,
POSSIBLE SOLUTIONS: The first step is to determine Figure H)
whether water is overflowing from the fill cup or flowing a. Secondary options
through the drain solenoid valve. It’s important to check - Door interlock switch can be jumpered
closely since both conditions appear identical but have - Miswire or bad connection in module
much different causes. harness
- Harness not plugged into board properly
1. The most common cause is to have a piece of - Defective control board
sediment in the drain solenoid valve that prevents the
valve from closing properly. By turning the unit back
and forth between “ON” and “DRAIN” it may be SYMPTOM: Humidifier Won’t Fill
possible to dislodge the sediment. In extreme cases
it may be necessary to disassemble drain lines to I. Verify fill and drain activate with switch in DRAIN
clean them. position.
II. Verify red (HL) LED is off.
2. If dirt in the valve is not causing the problem, dis- A. If LED is on, check
connect one of the wires connected to the solenoid 1. Water level too high in cylinder
coil. If draining stops this indicates the circuit board a. Water conductivity very low
is causing the valve to operate. The circuit board is b. Cylinder needs replacing
defective if it is sending an improper signal to drain c. Miswire of high voltage electrode wires
and should be replaced. d. Foaming water (flush out cylinder)
2. Defective high level circuit
3. If water continues to drain with the wire to the sole- a. Defective high level sensor
noid - Disconnect low voltage wire (blue), and
disconnected the valve is defective and should be verify fill
cleaned or replaced. - Verify no miswire on board -
wait 2 minutes
4. If water is flowing to the drain from the overflow tube b. Defective control board
coming from the fill cup it is usually caused by an
obstruction in the water line between the fill cup and
cylinder or in the steam hose from the cylinder to the SYMPTOM: Humidifier Won’t Satisfy Space
steam distributor pipe. All lines and steam hoses I. Unit capacity too small
should be checked to eliminate any obstructions. II. High limit humidistat too close to distribution pipe
resulting in tripping
III. Duct air capacity or temperature too low resulting in
trip of high limit
SYMPTOM: Humidifier Won’t Turn On IV. Customer steam potentiometer set too low.
V. Clogged drain system may result in less than 100%
I. Verify Power is supplied to unit. output.
A. Verify green “on” light is lit.
1. If no light check
- Incoming high voltage and circuit breaker
- 24 VAC on secondary of power transformer
- Fuse (F2) on control module
a. Secondary options
- Lamp burned out
- Miswire or bad connection in module harness
- Harness not plugged into board properly
- Bad ON-OFF switch
- Defective control board
B. Verify (HS) LED is lit
1. If no LED, check
- High limit humidistat can be jumpered
- Air flow switch can be jumpered
- Humidistat can be jumpered
- Fuse (F1) on control module

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 UNAUTHORIZED MODIFICATION OF THIS HUMIDIFIER OR USING UNAUTHORIZED
! WARNING REPLACEMENT PARTS MAY CAUSE MALFUNCTION WITH RISK OF SERIOUS
PERSONAL INJURY AND WILL VOID ALL PRODUCT WARRANTIES.
MAINTENANCE “HL” Red light indicates water has activated overflow
NOTE: It is advisable to inspect the humidifier visually at sensor. May be on during initial startup. May
approximately two week intervals. also be on when cylinder is full of minerals and
needs replacement.
UNIT MAINTENANCE
CLEANING WATER STRAINER
1. For safety, door interlock disconnects power to
cylinder(s) when door is open. Humidifier may be
1. Turn “On-Off-Drain” switch to “Off”.
operated when door is open by pulling out white
2. Turn circuit breakers to “Off”. (Optional circuit breaker
button located above the steam output meter.
units only).
CAUTION: HIGH VOLTAGES ARE PRESENT!
3. Shut off water supply valve ahead of unit.
4. Remove brass nut by turning counter-clockwise (A
2. Green “On” light should be on whenever power is
small amount of water will drain when nut is removed.
supplied to the humidifier, and “On-Off-Drain” switch
Use small container to catch this water.
is in “On” or “Drain” position. If green light is NOT on
5. Rinse strainer screen to remove deposits.
check the following:
6. Reinstall screen, nut, and gasket in strainer housing.
a. If unit has optional internal circuit breakers they
7. Return unit to service.
must be in “On” position.
b. Check each incoming power wire for proper
CHANGING STEAM CYLINDERS
voltage as shown on humidifier plate.
1. Turn “On-Off-Drain” switch to “Drain”. Completely
CAUTION: HIGH VOLTAGES ARE PRESENT!
drain cylinder.
c. Check green “On” light bulb (24 volt) using volt-
2. Turn circuit breakers to “Off’ (Optional circuit breaker
meter.
units only).
3. Slip off cylinder terminal connectors.
3. When amber “Abnormal” light is continually on check
4. Remove steam hose.
the following items: NOTE: Abnormal light will occa-
5. Loosen cylinder retaining band.
sionally be on for short periods of time during opera-
6. Remove cylinder by turning counter-clockwise on
ation such as initial startup, during drain cycle and
cylinders with threaded connection. Lift cylinders up
whenever the switch is in “Drain” position.
on cylinders with unthreaded connection.
a. Clean water strainer.
7. Replace cylinder using teflon tape or pipe dope on
b. All valves in water supply must be open and water
cylinders with threaded connection. Make sure the
pressure above 20 psi.
new “O” ring is installed on the cylinder base and
c. Check drain to be sure water is not constantly
insert cylinders into holder with enough pressure to
draining. Disassemble and clean drain if necessary.
seat the “O” ring on cylinders with unthreaded
d. Replace cylinder if desired output cannot be reached.
connections.
e. Check incoming power wire for proper voltage as
8. Tighten cylinder retaining band.
shown on humidifier rating plate. CAUTION: HIGH
9. Reconnect steam hose and tighten clamp.
VOLTAGES ARE PRESENT!
10. Reconnect terminal connectors. NOTE: Match
f. Check voltage at fill solenoid valve. Replace if 24
numbers on terminal connectors with numbers on
volts are present but valve is not open.
cylinders.
g. Check steam hose for any restriction.
11. Turn circuit breakers to “On.” (Optional circuit breaker
units only).
4. When amber “Abnormal” light is flashing it indicates
12. Turn “On-Off-Drain” switch to “On.”
that excessive current has occurred.
13. “Abnormal” light will remain on until water fills cylinder.
a. Turn “On-Off-Drain” switch to “Drain” position.
If water does not drain from cylinder disassemble
After replacing humidifier cylinder, order a replacement immedi-
and clean drain.
ately. This will insure having a spare cylinder on hand when the
b. If water drains from cylinder turn switch back to
next change is required. Order model number shown on cylinder
“On” position and allow unit to operate.
label.
c. Mineral build-up in the cylinder may have caused
a short. If this has occurred, replace cylinder.
MISCELLANEOUS
5. Lights on electronic control module above the
If humidification is not going to be required for a long period of
“Increase Steam” control are labeled as follows:
time, e.g. during summer cooling cycle in a comfort application, it
“BD” Used for factory calibration only.
is recommended the steam cylinders be completely drained before
“HS” If the green light is on it indicates that the
switching off power and closing water supply valve.
humidistat and other external controls are
closed and are calling for humidification.
“SP” Used for factory calibration only.

“Due to ongoing research and development CARNES reserves the right to change specifications without notice.”
Copyright © 1996 Carnes Company - All Rights Reserved

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