HCWH Series User`s Manual
Contents
1. INDOOR UNIT Humidifier low voltage wiring panel Required Air Proving Switch provided OUTDOOR UNIT we icomfort enabled outdoor unit Sg Alarm terminals if used not used mn QQVOOO UO I O SLP98 icomfort enabled CBX40UHV CBX32MV ONLY GND gJ not 24VAC used Humidification is controlled by the humidity sensor in the thermostat When the humidity in the space falls below the thermostat s humidity RH set point a demand message for humidification is sent to the HVAC unit control board The demand message starts the indoor blower and sends a 24 volt signal from the H terminal on the furnace control to the humidifier isolation relay coil The isolation relay contacts close to complete the circuit from GND and IN terminals on the humidifier controller When the indoor blower achieves sufficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidity demand is satisfied When the RH set point is reached the thermostat removes the demand to the furnace board which removes the 24 volt output from the H terminal and opens the isolation relay circuit and in turn opens the circuit between GND and IN on the humidifier controller stopping steam production The indoor bl2. Power source failure blown fuse tripped breaker Transformer failure Remote ON OFF contact open The humidistat has not been connected correctly Humidistat failure Control signal not compatible with the type set Value measured by the humidistat sensor s higher than the corresponding RH set point Low conductivity water High steam back pressure Fill valve strainer clogged Mineral buildup in the fill cup The steam nozzle is not installed correctly too near the top of the duct or the condensate return is blocked Air flow rate is too low Humidifier active when the fan in the duct is off The humidifier drain is blocked The supply water or overflow circuit has leaks The condensate drain pipe does not bring the water back to the drain pan The steam hose is not properly fastened to the cylinder Minerals in the cylinder have over concentrated and are deteriorating the electrodes The feed water contains large amounts of Iron Copper or other conductive contaminants Mineral has bridged between the electrodes There is back pressure from the steam hoses or duct The flow regulator in the fill valve is broken or out of place Water conductivity is very high Water is foaming excessively Page 20 Check the safety devices upstream from the humidifier and the presence of power Close the switch on the panel position l ON Check t
3. Recommended Periodic Checks e After one hour of operation Check that there are no water leaks e Every fifteen days or no more than 300 operating hours Check operation that there are no water leaks and the general condition of the cylinder Check that during operation there is no arcing between the electrodes e Every three months or no more than 1000 operating hours Check operation that there are no water leaks and if necessary replace the cylinder Check that there are no blackened parts of the cylinder If there are blackened parts of the cylinder check the condition of the electrodes and if necessary replace the cylinder e Annually or no more than 2500 operating hours Replace the cylinder Maintenance of Plumbing Components AWARNING When cleaning the plastic components do not use deter gents or solvents Cleaning the fill valve Disconnect the cables and the hoses Remove the valve and check the condition of the inlet filter Clean if necessary with a soft brush and warm water Cleaning the drain pump Remove the valve body Clean if necessary with a soft brush and warm water Cleaning the drain pan Clean the drain pan of any mineral deposits and check that the water flows freely from the pan to the drain at the drain pump Page 21 Cleaning the supply fill and overflow pipes Check that the piping is clear of obstructions clean or replace if necessary After replacing or checkin
4. see low voltage control diagrams figures 14 through 18 for control wiring options NC C NO IN GND AB AB N1 GND N2 NO C EXT FAN ALARM XKKXX gt RK XXXXA RRRS xX RRRS KK SSK S PSS ane oe S PSS PSS Dlls XX DC gt RS S AE gt lt N ON oF CAS Button 4 Water outlet Water inlet Connected to External disconnect to ground be installed not sup plied respect local codes For 110 VAC only Power supply switch the hot wire not 110 VAC 1 phase 50 60 Hz neutral for 230 VAC or switch both hot amp neut 230 VAC 1 phase 50 60 Hz Figure 20 Humidifier Internal Controller Wiring Diagram Page 15 HCSTEAM 16 35 SERIES Start Up HCSteam 16 35 Humidifier Controller The HCSteam 16 35 humidifier controller features a comprehensive information display that shows the operation of the system at a glance Display is of nominal capacity Maintenance or adjust ment Display is amperage default Steam is being pro duced Cylinder filling Foaming Water presence inside the cylinder Cylinder draining LED icons indicate left operation green middle power yellow right alarms red A operation power alarm Drain button for manual draining of cylinder and confirming parameter values ON OFF button I de pressed is the
5. Drain alarm unable to drain Press reset sel key for 1 Check drain pump operation ae aS aah or decease seconds to reset check drain connection The warning is automatically Cylinder exhausted reset if HCSteam 16 35 can l ai critical performance detected produce the demand Of nange cyinger urgent otherwise turn off and then on If it continues perform some Press reset sel key for 1 cleaning cycles read section a FOAM ARIEGE seconds to reset off Initial Start up with a new cylinder Page 16 Unit disabled Cylinder lifetime expired 3000 Reset the hour counter read Ee hours section Resetting the hour On Change the cylinder counter The warning is automatically eee E9 High controller temperature reset if the temperature Off controller replace the above 176 F 80 C decreases below 176 F 80 Page 19 controller if the temperature is OK HCSTEAM 16 35 SERIES Troubleshooting The humidifier does not turn on The humidifier does not start operation The humidifier fills with water without producing steam The humidifier wets the duct The humidifier wets the floor below Water in the cylinder turns black Heavy arcing occurs within hours of startup Humidifier continuously fills and drains without producing steam 506746 01 No electrical power On off switch of the humidifier in position O OFF Control connectors improperly connected
6. FAN contacts open de energizing the blower interlock coil and stopping the indoor blower if not running due to a heating demand or thermostat blower demand When the indoor blower stops the air proving switch contacts will open Figure 18 Humidifier with HC Digital Automatic Humidistat Connected for Modulating Operation Page 13 HCSTEAM 16 35 SERIES OFF ON wiring panel QC NO Humidifier Td ON HC DIGITAL AUTOMATIC HUMIDISTAT umiaitier ofr DIP SWITCH SETTINGS FOR HUMIDISTAT low voltage ONLY OPERATION Note 1 Blower interlock is required Note 2 48G96 relay field supplied Required Air Proving Note 3 Remove factory jumper between AB AB Switch provided Note 4 Connected for ON OFF configuration Alarm terminals if used Z l Typical Air Handler L Furnace Control AHC or IFC Thermostat HC Digital Automatic Humidistat FAN ALARM zZ Z ONN0N0 EXT Cat no Y3760 Qa GND H 24VAC H Outdoor Sensor 48G96 SPDT Interlock Relay OA Outdoor AC Unit When the humidity in the space falls below the humidistat s RH set point the circuit closes humidistat terminals 1 and 2 to complete humidifier controller circuit to IN and GND and then closes the humidifier controller EXT FAN contacts NO to C Terminal R on the furnace or air handler feeds 24V to the EXT FAN con
7. higher not applicable for these models If value is higher than 02 press reset sel until the display goes back to the normal operating mode and re start from step 1 4 Press and hold drain min drain EDN imum 1 second the display shows P1 then the present FP gt signal type and then set T i GE 5 Press reset sel for signal type of 0 or 1 reset 2 0 On Off humidistat se 1 external 0 10 Vdc modulating signal a humidistat 6 Press and hold drain minimum 1 rna second when done to confirm the new value of P1 and exit to the normal op m erating mode 7 Switch the humidifier off Figure 23 Selecting Signal Type HCSTEAM 16 35 SERIES Table 4 Humidification Load Required Gallon day Liter day Ref AHRI Guideline F 2008 24000 680 32000 906 40000 1133 Changing the Maximum Production Percentage The maximum production can be adjusted between 20 and 100 of the nominal production in steps of 5 in order to suit either the 110 VAC or 230 VAC unit Default settings are factory set at 100 110 VAC unit 70 230 VAC unit Adjust capacity per humidity calculation or system application air flow Table 4 shows the humidification load requirements This chart will be helpful in setting the correct production percentage 1 Switch the humidifier off 2 While pressing and HOLD ING both reset sel and drain butt
8. installed jumper from the R terminal on the control board through the closed HUM terminals and to the humidifier isolation relay coil The isolation relay contacts close to complete the circuit from GND and IN terminals on the humidifier controller When the indoor blower achieves sufficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidity demand is satisfied When the RH set point is reached the thermostat removes the demand to the furnace board which opens the HUM contacts opens the isolation relay circuit and in turn opens the circuit between GND and IN on the humidifier controller stopping steam production The indoor blower will be turned off if not running due to a heating demand or thermostat blower demand Figure 17 Humidifier with icomfort Wi Fi thermostat used as Humidistat with an icomfort enabled SL280 Gas Furnace Humidifier a ON HC DIGITAL AUTOMATIC HUMIDISTAT Blower interlock is required papers So oFF DIP SWITCH SETTINGS FOR HUMIDISTAT 48G96 relay field supplied low voltage ONLY OPERATION Set sianal type to 1 dulating Step 5 Fi wiring panel a OFF et signal type to or modulating Step 5 Figure ON 23 Page 17 Required Air Proving Remove factory jumper between AB AB O Switch provided Connected for Modulating Operation Al Typical Air Handler
9. report any discrepancies to the last carrier NOTICE The humidifier must be installed in accordance with all local and national standards Installation adjustments alterations service and main tenance must be performed by a qualified service techni cian 506746 01 Table 1 Clearances Unit Dimensions and Component Feature Specifications Clearances Unit Dimensions B in mm A 6 150 B 6 150 C 6 150 n F in mm Lbs kg 2 A TAN 13 1 2 343 16 8 8 1 8 206 22 10 F max 0 2 23 3 4 603 26 12 angle D Component Feature Nominal Specifications Range Tolerance Steam capacity HCSteam 35 12 Ib h 5 4 kg h 15 10 Steam capacity HCSteam 16 5 1 2 Ib h 2 5 kg h 15 10 Water supply pressure limits 15 psi to 116 psi 0 1 to 0 8 MPa Water supply temperature limits 34 F to 104 F 1 C to 40 C Water supply flow minimum 0 12 gpm 0 45 L min Power supply HCSteam 35 230 VAC 15 10 Power supply HCSteam 16 110 VAC 15 10 Total Drain Water Flow 7 gpm 26 2 L min 10 10 Ambient temperature operating 34 F to 104 F 1 C to 40 C Ambient Sena operating 10 to 60 rH AWARNING Before installing or handling the humidifier please care fully read and follow the instructions and safety stand ards described in this manual and on the labels attached to the HCSteam 1
10. strain relief see figure 13 and then up the side of the control module to the top right wiring terminal blocks Connect the control wiring to the control wiring terminal blocks found at the top right side of the control module Required Air Proving Note 1 Blower interlock is required Note 2 48G96 relay field supplied wiring panel Switch provided P Note 3 Remove factory jumper between AB AB QC NO Conventional 24 VAC Humidistat Cat no Alarm terminals if used X9553 or equivalent Typical Air Handler Furnace Control AHC or IFC Thermostat R GND not 24VAC used 48G96 SPDT Interlock Relay O c y Outdoor AC Unit When the humidity in the space falls below the conventional humidistat s RH set point the circuit closes from GND to IN on the humidifier controller and in turn closes the EXT FAN contacts NO to C in the humidifier controller Terminal R on the furnace or air handler feeds 24V to the EXT FAN contacts now closed and to the blower interlock relay coil The interlock relay normally open contacts close to energize G on the furnace or air handler and start the indoor blower if not already running by a heating demand The interlock relay also isolates G from the thermostat to prevent a back feed that would start the outdoor unit When the indoor blower achieves suf
11. the cabinet The hose end may be run through the knockout at the top of the humidifier and be inserted into the hole located on top of the fill cup See figures 6 and 11 NO SLOPE 1 3 height min 8 centered a Figure 9 Plastic Nozzle Installations Installing Steam Hoses NOTICE Ninety percent 90 of all operation problems are cre ated by improper steam piping from the humidifier unit to the duct steam nozzle Make the connection between the humidifier steam hose adapter and nozzle using only the provided hose unsuitable hoses may weaken and crack causing steam leaks e Avoid the formation of pockets or traps where condensate may form e Avoid choking the hose due to tight bends or twisting e Fasten the end of the hose to the steam hose adapter on the humidifier and the steam nozzle using metal hose clamps so that these do not detach due to the high temperature UN DRAINED ELBOW NO DISTRIBUTION PIPE DRAIN Figure 10 Unacceptable Examples of Installing Steam Hoses Page 9 HCSTEAM 16 35 SERIES 5 ft 1 5 M MAX IF NO SLOPE DRAINS TYPICAL INSTALLATION WHEN UNIT IS ABOVE THE STEAM NOZZLE p P trap NOTE Height of traps must be greater than the duct static pressure OBSTRUCTION NOTES Slope piping up in
12. up from the cylinder and remove flip up the cylinder holding bracket and lift up on the cylinder 6 Disconnect the electrical connections from the top of the cylinder 7 Carefully remove cylinder from the pump manifold Make sure the O ring remains in the manifold see figure 27 8 Verify cylinder model voltage first Then install the new cylinder in the humidifier by performing the previous operations in reverse 9 Perform initial start up with new cylinder as provided on page 17 OO HCSTEAM 16 35 SERIES A NOTICE Do not tighten the hose clamp so tight that it crushes the cylinder adapter outlet Electrical connections to the cylinder must be tight or possible fire hazard may result Threaded nuts on power wires must be torqued to 44 in lb 10 5 Nm 10 STEAM HOSE OD ore REMOVED STEAM HOSE gt 7 a Be gt CYLINDER ADAPTER f 12 DZ HOLDING M S r kV 7 olj BRACKET ALi a H DRAIN BUTTON STEAM CYLINDER Figure 26 Figure 27 Replacing the Cylinder 506746 01 Page 22 070222075 rel 1 3 dated June 2013 Table 5 Replacement Parts Description STEAM CYLINDER CYLINDER STD CONDUCTIVITY 110 120 1 5 5 LBS HR MODELS CYLINDER STD CONDUCTIVITY 220 240 1 12 LBS HR MODELS CYLINDER LOW COND
13. 6 35 Residential Steam Humidifier 4 NOTICE Water supply to humidifier cannot be from a hot water supply Using a hot water supply can damage some humidifier components and will void warranty The HCSteam 16 35 humidifier produces non pressurized steam which is then used to humidify the air The quality of the water used affects the operation of this unit so the humidifier may be supplied with untreated water as long as it is drinkable and not heated softened or de mineralized The water converted into steam is automatically replaced through an electric fill valve Periodically based on the water quality the unit will also drain some water to dilute the build up of minerals in the steam generator 506746 01 Page 2 This humidifier has been designed to directly humidify ducts using a distribution system The installation use and maintenance operations must be carried out according to the instructions contained in this manual and on the labels applied internally and externally Disconnect the humidifier from the main power supply before accessing any internal parts The conditions of the environment and the power supply voltage must comply with the specified values listed on the data label in the humidifier All other uses and modifications made to the humidifier that are not authorized by Lennox are considered unauthorized and Lennox assumes no liability for the consequences of any such unauthorized use Pleas
14. Fur Sait nace Control AHC or IFC Thermostat terminals if used HC Digital Automatic i Humidistat a gt a Cat no Y3760 AQ Outdoor 24VAC Al 48G96 SPDT Interlock Relay Outdoor AC Unit C Steam production is modulated between 20 and 100 of the maximum production proportionally to the signal provided by the humidistat When the humidity in the space falls below the humidistat s RH set point the humidistat sends a 0 to 10Vdc from 7AOUT terminal to the IN terminal on the humidifier controller and in turn closes the EXT FAN contacts NO to C in the humidifier controller Terminal R on the furnace or air handler feeds 24V to the EXT FAN contacts now closed and to the blower interlock relay coil The interlock relay normally open contacts close to energize G on the furnace or air handler and start the indoor blower if not already running by a heating demand The interlock relay also isolates G from the thermostat to prevent a back feed that would start the outdoor unit When the indoor blower achieves sufficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidity demand is satisfied When the humidistat has reached its RH set point its contacts open stopping steam production The humidifier controller EXT
15. HCSteam 16 35 humidifier must be connected to an air proving switch that is a device that senses the flow of air in the duct provided by the furnace or air handler This air proving switch should be connected to the remote enabling input terminals AB AB In some applications a field provided limit humidistat normally closed may be installed in series with the air proving switch connected to terminals AB AB Table 3 Wiring Connections Terminals Functions si Electrical specifications L1 L2 GROUND Power supply and Ground Power supply 110 VAC 1 phase 50 60Hz 1 86kW or 230 VAC 1 phase 50 60Hz 4 05kW connections Programming port Connecting to Programming port or supervisor factory use only AB AB Remote enabling input Imposes an external NO contact Rmax 300 Ohm Vmax 33 Vdc Imax 6mAdc humidifier enabled contact closed IN GND Control signal input Humidistat connection NC alarm contact 250V 8Amp max with resistive load 4 Amp max with inductive load Common alarm contact In the event of an active alarm the alarm LED will come on and the relay is energized NO alarm contact External fan relay 250V 8Amp max with resistive load 4 Amp max with inductive load 24 GND Power for external humidistat Power supply for external humidistat 24 VAC 2 Watt 506746 01 Page 14 070222075 rel 1 3 dated June 2013 Programming port for factory use KEY rl Fill valve Drain pump Drain tempering valve High level sensor
16. ON posi tion O depressed is OFF Reset button to reset alarms and access parameters Level of output 33 66 100 Fan relay is activated Figure 21 Humidifier Controller AWARNING Before starting check that the humidifier is in perfect condition that there are no water leaks and that the elec trical parts are dry Do not connect power if the humidifier is damaged or even partially wet 506746 01 Page 16 When installation is complete flush the supply pipe for 10 minutes by piping water directly into the drain without sending it into the humidifier this will eliminate any scale or residues that may cause foam when boiling Pre Start up Checklist Before starting the humidifier the following should be checked e Water is connected the line has been flushed and external valves are open e Drain is connected run to an open drain and has a trap under the unit e Electricity is connected in accordance with instructions local codes and data labels in the unit e Make sure all electrical connections to the cylinder are tight e The power fuses are installed and intact e All control wiring is complete and tested e Air proving switch is wired to close when air flow is proved e Hi limit humidistat if used is wired to open on humidity rise above setpoint e Unit wires have been checked to make sure they and all connectors are tight from shipping e The steam hose s are run correc
17. SOLUTIONS THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE Shipping and Packing List Items Shipped e Model HCSteam 16 catalog number Y3478 Duct steam injection 16 gallons per day 5 5 pounds per hour 110 VAC 15 10 94 121 VAC e Model HCSteam 35 catalog number Y3479 Duct steam injection 35 gallons per day 12 pounds per hour 230 VAC 15 10 196 253 VAC Humidifier installation parts 10 foot steam hose steam hose adapter steam nozzle water fill hose condensate hose mounting template installation instructions product warranty steam hose clamps 2 condensate hose clamp Air proving switch kit Cat no Y3786 includes 6 tubing switch installation sheet two ductwork pressure tube taps mounting screws and anchors Other Required Items e 1 2 water line e 25 Amp dedicated electrical circuit e 1 1 4 extension tube can be plumbed into a open drain or water drain receiver or a high capacity condensate pump that can hold 1 gallon of 140 F water then plumbed into a 3 4 drain line and pump at least 7 1 gallons per minute or 426 gallons per hour with installed lift Hartell A5 series condensate pumps are capable of meeting the pumping requirements up to 24 foot lift 6 2013 Page 1 INSTALLATION INSTRUCTIONS HCSteam 16 35 Residential Healthy Climate Steam Humidifier INDOOR AIR QUALITY 506746 01 6 2013 1e Technical Supersedes 5 2012 Publications Tab
18. UCTIVITY 220 240 1 12 LBS HR MODELS CONTROL MODULE 5 4 kg h 220 240 VAC CONTROL MODULE 2 5 kg h 110 120 VAC ON OFF SWITCH special order FILL 5a amp DRAIN TEMPERING VALVE 5b 110 120 VAC FILL 5a amp DRAIN TEMPERING VALVE 5b 220 240 VAC DRAIN PUMP 110 120 VAC DRAIN PUMP 220 240 VAC 90 DEGREE DRAIN ELBOW FILL CUP PLUG FILL CUP HOSE DRAIN HOSE 10 COVER HOLDING SCREWS 4 USED 11 DRAIN PAN 12 DRAIN TANK PLUG 13 Y3801 Steam Hose 10 Y3782 Steam Condensate hose 10 Y3783 e Fill Hose Y5880 Steam flows VAC kW STEAM CYLINDER HOSE ADAPTER Other replacement parts and accessories Air proving switch Y3786 s HC Digital Automatic Humidistat Y3760 ComfortSense 7000 thermostat Y2081 Table 6 Technical Specifications 5 5 Ibs hr 2 5 kg h 110 VAC 1 phase 50 60 Hz 1 86 kW 12 lbs hr 5 4 kg h 230 VAC 1 phase 50 60 Hz 4 05 kW icomfort Wi Fi thermostat Steam Nozzle Y3781 Steam pressure 3 81 in w c 950 Pa For duct only Dimensions mm 24 x 14 x 8 600 x 341 x 204 mm Height x Width x Depth Weight empty packaged installed with water 18 22 26 Ibs 8 10 12 kg Electrode power cables 12 AWG Power relays 2 x 30 Amp On board Ground connection Screw Input water type Potable water No demineralized or softened water Conductivity range 125 1250 uS cm Special cylinder for low cond
19. ain amp A 5 Reset the hour counter as per the instructions on page 18 During cleaning the electrodes are powered and water fills until it touches the high level sensor or the phase current equals 20A whichever occurs first After either of the events is detected the steam cylinder is fully discharged with the electrodes un powered the drain pump and the drain tempering valve are activated for 3 minutes Lennox recommends to perform two cleanings when starting a new humidifier After the cleaning ends the humidifier starts regular operation The HCSteam 16 35 humidifier is now ready for operation Page 17 Displaying Information By pressing the reset sel button for 2 seconds the display will loop from amperage to production in of the maximum production to the hour counter and back to amperage see figure 22 Selecting the Signal Type NOTE The HCSteam 16 35 humidifier is preset for a manual humidistat with only an ON OFF feature and normally does not require any change Should the need ever arise to reset it proceed as follows 1 Switch the humidifier off 2 While pressing and HOLD ING both reset sel and s drain buttons switch the gt humidifier back on DO NOT release reset sel and sel drain buttons until the wrench icon blinks then re lease both buttons 3 Press reset sel until the display shows 02 DO NOT confirm any value higher than 02 Values of 03 or
20. as this will lead to foam electrode corrosion and greatly shortened cylinder life e Water containing disinfectants or corrosion inhibitors as these are potential irritants e Industrial water boiler water or water from cooling circuits e Any potentially chemically or bacteriologically contaminated water e Heated water Testing Water A conductivity meter is z recommended for sses testing the water Cat Y3480 AP 2 ETETE Water Quality Tester Specifications EC Range 0 9999 uS Temperature Range 0 80 C 32 176 F Resolution 1 uS Temp resolution is 0 1 C F Accuracy 2 Calibration Digital calibration by push button Housing Water resistant Power source 1 x 3V button cell included model CR2032 Dimensions 15 x 2 8 x 1 3 cm 5 9 x 1 1 x 5 inches Weight 42 5 g 1 5 oz Water Supply Connection The recommended connection between the fill valve and the water supply line is by way of the provided fill hose 5 1 5 m hose with one straight 3 4 fitting and one 90 degree 3 4 fitting The provided hose absorbs water hammering in order to avoid fill valve damage The water line may be routed through the back or through the bottom of the unit The fitting then threads onto the valve assembly inlet located on the bottom of the humidifier see figure 6 using a 3 4 female hose connection Note that there is a strainer built into the fill valve fitting underneath the unit which will require periodi
21. c cleaning so be sure to allow clearance for access NOTICE Do not use any thread sealant Secure fill hose fittings by tightening 1 4 turn past hand tight with a wrench Do not use hard piping for direct connection to the humid ifier Only use supplied flexible fill hose or equivalent 070222075 rel 1 3 dated June 2013 FILL CUP DETAIL A Ts STEAM HOSE STEAM HOSE STEAM CONDENSATE INSTALL TRAP IN RETURN LINE CONDENSATE LINE lt gt iilii PER FIGURE 11 A i STEAM Cy E f L RETURN TO SUPPLY AIR TAP TO RETURN AIR TAP if used HOSE SHUTOFF VALVE AND FILTER Recommended Water inlet with filtering screen 3 4 hose con nection 1 1 4 Water drain SUPPLY WATER COLD WATER DRAIN LINE ONLY OPEN DRAIN SHUTOFF VALVE AND FILTER Recommended LINE Figure 6 Typical Installation Page 7 HCSTEAM 16 35 SERIES Table 2 Limit Values for Water Supplying the HCSteam 16 35 Humidifier Limit Values For Normal Water Limit Values For Low Salt Content Water Units i Units Specific conductivity OR 20 c uS cm Specific conductivity OR 20 C uS cm Hydrogen ions pH 8 5 Hydrogen ions pH Total dissolved solids Cp mg l Dry residue at 180 C R180 mg l mg l CaCO3 400 mg l CaCO3 300 Iron Manganese mg l Fe Mn 0 2 Chlorides ppm Cl 30 Chlorides ppm Cl Silica mg l SiO oe 20 Silica mg l SiO2 Chlorine r
22. d alarm LED 4 will flash the alarm relay will energize and the alarm code will flash in the display Multiple alarms will flash in sequence alternating with the main display Pressing the reset sel button for 2 seconds will reset the alarms although still active alarms will continue to display Alarms Display Description Action Red Alarm Symbol Remote on off open Unit disabled Off EE Internal memory error Unit disabled On i Replace control for EE amp E0 E0 oe board configuration not ini digabied On p Turn off check connections check cylinder no limescale bridges between electrodes no electrodes short circuited E1 High current alarm Unit disabled On Use a ohm meter to check whether they are short circuited Look through the steam outlet to see whether the electrodes are loose OW production OW Supply Unit disabled Check supply water E2 e AE R E A dein Press reset sel key for 1 On conductivity too low replace the cylinder seconds to reset the cylinder Cylinder almost exhausted Press reset sel key for 1 l ES already used for 2000 hrs seconds to reset Off Change cylinder not urgent Press reset sel key for 1 Fill alarm unable or slow fill oie Check water supply water inlet E4 current does not increase On strainer and fill valve check within timeout automatically AA 10 minutes drain pump for leakage until the supply water is available again
23. dimensions and details Page 5 HCSTEAM 16 35 SERIES Installing the Air Proving Switch included IMPORTANT Failure to install the air proving switch will void the humidifier warranty The air proving switch Cat no Y3786 provided with humidifier is a differential pressure switch that is required to make sure that the blower is running prior to steam production Six feet of 3 16 tubing is provided along with two pressure taps mounting screws are not included to connect both pressure taps to the switch however install the switch first and then install one pressure tap in only the supply duct positive pressure application step 2 below See figure 6 1 Install Switch and Pressure Tap Select a mounting location near the supply duct which will not be subject to vibration or where the switch could be damaged Mount the air proving switch in any vertical plane except with the tubing connections directed upward Connect the normally open terminals on the air proving switch to the low voltage terminal strip in the humidifier See wiring diagrams in figures 14 through 18 2 Positive Pressure Application Use the positive pressure application when large amounts of air flow or high static is present at the pressure tap in the supply duct Install the duct air sampling tap to the supply duct work as close to the switch as possible on the positive side of the blower see figure 6 From the 6 tubing provided cut just enoug
24. direction of steam flow at 20 or greater 2 1 2 per foot 63 mm per 305 mm Slope piping down in direction of steam flow at 5 or greater 3 4 per foot 19 mm per 305 mm Max length of rubber steam hose is 10 3 m SUPPORTED STEAM HOSE AND OR COPPER PIPE DRAINS Figure 11 Installing Steam Hoses NOTE Maximum length of rubber steam hose is 10 ft 3 m Insulated copper tubing may be up to 20 ft 6 m in length In all cases minimize sharp bends and elbows Use 2 45 elbows instead of 90 elbows Hose inner diameter 7 8 22 mm Hose outer diameter 1 1 4 30 mm Power Wiring All wiring must be in accordance with local state and national electric codes Power Steam External External supply Output Power Fuse single Ibs hr Wire A or Model phase kg h kW Amps Gauge Breaker 110 ae WAC BG 1 80 1640 AWG10 25 50 60Hz 230 ne NAC Le 3 89 1695 AWG10 25 50 60Hz AWARNING ELECTRIC SHOCK HAZARD The humidifier uses electrical power Always disconnect the main power before opening or servicing the humidifier NOTE To avoid unwanted interference the power cables should be kept separate from any control wiring NOTE Tolerance allowed on main voltage 15 to 10 506746 01 Page 10 Insert the power and ground connection cables into the electrical panel compartment using the strain reliefs supplied see figure 12 A and connect to the terminals An external fused disconnec
25. e note that the humidifier contains powered electrical devices and hot surfaces NOTICE The humidifier requires water to operate Do NOT mount it above materials or machinery that could be damaged if a leak occurs Lennox assumes no responsibility for consequential or inconsequential dam age as a result of any leaks If unit must be located where any leaking water could cause damage an auxiliary drain pan is recommended Disposal of Humidifier Parts The humidifier is made up of metallic and plastic parts All parts must be disposed of according to the local standards on waste disposal 070222075 rel 1 3 dated June 2013 Basic Humidifier Operation em Z raar DRAIN TANK USER INTERFACE DISPLAY FILL VALVE TEMPERING VALVE 4 CAUTION SCALDING HAZARD The humidifier has heated parts 100 C 212 F The HCSteam 16 35 is an electrode humidifier It produces steam for humidification by passing electric current through metal electrodes 7 figure 2 immersed in water inside a plastic steam cylinder 5 There are no heating elements Steam output is directly proportional to the conductivity of the water and the amount of electrode immersed in the water On a call for humidity the HCSteam 16 35 humidifier controller opens the water fill valve 1 and allows water to enter the cylinder A flow restrictor 4
26. esidue mg l Clo 0 2 Chlorine residue mg l Clo mg l CaSO 100 mg l CaSO Total dissolved solids Cpr mg l Dry residue at 180 C R480 mg l mg l CaCO3 mg l CaCO3 mg l Fe Mn Total hardness Total hardness Temporary hardness Temporary hardness Iron Manganese Calcium sulphate Calcium sulphate Values dependent on the specific conductivity in general CR 0 93 OR 20 c R180 0 65 OR 20 C Note There is no relationship between the hardness and conductivity of water Water Drain AWARNING lf a condensate pump is required it must be able to pump the volume and temperature listed below at the installed lift Hartell A5 series condensate pumps are capable of meeting the pumping requirements up to 24 foot lift The drain water characteristics are e Drain Rate 7 1 gal min 26 8 lit min e Connection 1 1 4 32mm e Temperature 140 F 60 C The drain pipe must be free without back pressure We recommend an external anti flooding device not sup plied to protect from faults of external hydraulic circuits The HCSteam 16 35 humidifier also requires a connection to a drain The drain line may be routed out the back or bottom of the unit using the included angle fitting The drain line can be 1 1 4 PVC CPVC or polypropylene tubing drain line must be able to withstand 140 F water The drain line is not glued or otherwise attached to the hu
27. ficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidistat demand is satisfied When the humidistat has reached its RH set point its contacts open stopping steam production The humidifier controller EXT FAN contacts open de energizing the blower interlock coil and stopping the indoor blower if not running due to a heating demand or thermostat blower de mand When the indoor blower stops the air proving switch contacts will open Figure 14 Humidifier with Conventional 24V Humidistat and Interlocked with HVAC Blower Page 11 HCSTEAM 16 35 SERIES Humidifier low voltage wiring panel Required Air Proving SLP98 Furnace CBX40 Air Handler ComfortSense 7000 Switch provided 2 Thermostat 2 Alarm terminals if used not used not used 06 d r 48G96 Relay Outdoor AC Unit O Note 1 Note 2 Note 3 Do not connect H on CS7000 to H on furnace or air handler control board Set up humidifier per CS7000 thermostat installa tion instructions GND 24VAC 48G96 relay field supplied Remove factory jumper between AB AB Note 4 Humidification is controlled by the humidity sensor in the thermostat When the humidity in the space falls below the thermostat s humidity RH set point 24 v
28. for connections to the humidifier and to the condensate drain Also see figure 6 for a typical installation diagram Drill a 2 1 4 57 mm hole in the ductwork at the selected location for inserting the nozzle into the duct work Position the nozzle in the hole Mark and drill 1 16 mounting holes and use self tapping sheet metal screws to attach the nozzle to the duct Removing the Humidifier Front Cover The front cover is secured by four screws located at the four corners of the unit Using a Phillips head screwdriver loosen the four cover screws and then pull the front cover away from the back part of the unit see figure 3 Installing the Humidifier 4 CAUTION Do not install the humidifier in an location that is within the reach of children If unit must be located where any leaking water could cause damage an auxiliary drain pan is recommended Do not install the humidifier in an unconditioned space or where ambient temperature would be outside humidifi er s specified operating temperature attic or crawl space 506746 01 Page 4 Positioning the Humidifier The HCSteam 16 35 humidifier has been designed for on wall installation The simplest and most efficient installation would have the humidifier installed just below the duct where the steam nozzle is to be installed This minimizes steam hose length and the amount of condensate Certain clearances must be maintained around the unit for safety and maintena
29. g the plumbing check that all components have been reconnected correctly using the proper seals Re start the humidifier and perform 2 or 3 cleaning cycles see section Starting with a new cylinder then check for any water leaks AWARNING Always disconnect the main power before touching the cylinder in the event of leaks as current may flow through the water Cylinder Maintenance The life of the cylinder depends on a number of factors including the amount and type of mineral in the water the correct use and sizing of the humidifier and the output as well as careful and regular maintenance Another factor affecting cylinder life is Maximum Production the higher the production rate the shorter the cylinder life for this reason the HCSteam 35 humidifiers is preset from the factory at 70 Further reductions in maximum production will extend cylinder life Replacing the Cylinder AWARNING Scalding hazard The cylinder may be hot Allow it to cool before touching it or wear protective gloves To replace the cylinder 1 Completely drain the cylinder by pressing and holding the drain button for 15 seconds until the cylinder is empty 2 Turn the humidifier off and disconnect the main power Remove the cover 4 Loosen the hose clamp and slip the steam hose from the steam hose adapter 5 Loosen two screws that hold the steam hose adapter onto the back wall of the humidifier then slide the adapter
30. h 3 16 tubing to reach from the pressure tap to the P1 switch port P2 remains open NOTE Check for closure of the blower switch using the lowest blower speed setting If the switch fails to close the open set of contacts you must use the differential application 3 Differential Pressure Application Use the differential pressure application when small amounts of air flow or low static is present across the pressure tap Install the 2nd pressure tap in the return duct work see figure 6 Use the remaining 3 16 tubing to connect P2 switch port to the negative pressure tap Check for closure of the switch when blower is turned on Water characteristic requirements The humidifier must be supplied with water with the following characteristics e Pressure between 20 psi and 110 psi 0 137 MPa and 0 758 MPa 1 4 and 7 6 bar e Cold water supply e Flow rate minimum of 0 21 gpm 0 45 L m e Hardness no greater than 400 ppm of CaCO 40 fH e Conductivity from 125 to 1250 uS cm 506746 01 Page 6 e Drinkable and absent of organic compounds e The characteristics of the water supply must fall within the supply water characteristics outlined in table 2 Unacceptable Water Types NOTICE Do not connect water supply near the water heater without using proper plumbing techniques use a heat trap Do not install between an expansion tank and water heater Connect only to cold water line e Softened Water
31. hat connectors are properly inserted in terminal block Check the power source check condition of fuses check for tripped breaker Check for proper voltage across 24VAC and GND on control If no voltage present replace controller Close ON OFF contacts Check the external connection Replace the humidistat Confirm for correct signal type for connected humidistat using Selecting the signal type procedure on Page 17 Using RH meter confirm accuracy of RH sensor s If 230 VAC humidifier consider installing the Low Conductivity cylinder Y3484 listed on Page 23 Check that the steam hose is not kinked or sagging trapping condensate Clean the fill valve strainer Clean the fill cup Check that the steam nozzle is installed correctly Increase air flow in duct or decrease maximum steam production setting see Page 17 Check the connection of the device flow switch or differential pressure switch controlling the humidifier to the ventilation in the duct Clean the drain assembly and pan Check the entire water circuit Check the correct position of the condensate drain hose in the drain pan Check the fastening of the hose clamps on the steam outlet Check for sags amp kinks that could trap condensate in the steam hoses that could cause a back pressure on the cylinder Check the duct static pressure Check the fill valve and inlet strainer Check t
32. he drain pump operation Correct installation problems and replace cylinder If you are using a softener discontinue use Check the electrodes in the cylinder to be sure they were not damaged in shipping Use a ohm meter to check whether they are short circuited Look through the steam outlet to see whether the electrodes are loose Perform cleaning cycles or replace the cylinder Check the steam hoses for kinks or gullies that might be trapping condensate Replace the fill valve stuck open Consider using a mix of demineralized water with raw water Check cylinder replace if exhausted 070222075 rel 1 3 dated June 2013 Maintenance AWARNING Electrical shock hazard Always disconnect the main power before performing maintenance on the humidifier The humidifier and its cylinder contain live electrical components and hot surfaces and therefore all service and or maintenance operations must be performed by expert and qualified personnel who are aware of the ne cessary precautions Remove the cylinder from the hu midifier only after having drained it completely using the manual drain button or procedure Check that the mod el and the power supply voltage of the new cylinder cor respond to the data on the rating label NOTICE It is recommended that during the off season or long in activity the unit is drained of water the water supply turned off and the unit is powered down
33. le of Contents Shipping and Packing List 1 Clearances Unit Dimensions and Component Feature Specifications 2 General 0 ccc eens 2 Basic humidifier operation 0000 3 WIStANAON 2 0 esas 50 c 2teee cre 24665088 bo ees ore ox 4 EMD UING eet bey eee se eect a te aw ese 8 wr ee Redd oe ee hie E 6 Steam Distribution 0 0 0 eee 8 NVI 5 oe ee weed te eee hd aed on se 10 Start up Start up checklist 16 Controller isr ses ieena sehen ee dake oe eee 16 Starting the humidifier 004 16 Initial Start up with New Cylinder 17 Operating the humidifier 17 Displaying humidifier information 17 Changing the maximum production percentage 18 Activating manual drain 000 00 ee 18 Resetting the hour counter 18 PAIS see hee ee tee wee week oan 19 Troubleshooting 000 cece eee eee 20 Maintenance 0 00 ees 21 Periodic CheckS 0 2 00 cece eee eens 21 Cylinder maintenance 0000 eee eee 21 Replacement partS 0 00 c eee ees 23 Technical specifications 0 ee eee 23 Before beginning installation Check for shipping damage to cartons Mark the shipping waybill accordingly Open cartons and check equipment for shipping damage or missing components if found immediately
34. midifier so it must be supported by itself The humidifier includes a drain tempering valve that runs whenever the drain pump runs and flushes cool water into the drain line to insure the drain water temperature never exceeds 140 F 60 C When only a 1 or 3 4 drain is available a temporary drain reservoir can be constructed as shown in figure 7 This is a field supplied device Devices such as the one shown have been tested and are approved to be used with the HCSteam in the described applications The drain water from the HCSteam is diverted into the top opening of the riser pipe The figure shown also acts as an air gap and allows the drain water from the HCSteam to Figure 7 Slow Restricted Drain Lines 3 4 Drain Connections empty via gravity into the available 3 4 drain The reservoir can be constructed from field supplied plumbing fittings PVC CPVC PEX etc rated for 140 F drain water applications The reservoir in the diagram is constructed with the following e 4in x 12 in PVC Sch 40 DWV plain end pipe e 4in x2in PVC reducing coupling bushing e 2in x 3 4 in bushing e 3 4 in elbows and valve If 3 in pipe is used it should be at least 21 in long The elbows and valve shown allow more flexibility when aligning humidifier drain with existing drain line A drain trap can also be incorporated into this fixture where needed 506746 01 Page 8 When using a rear outlet drain passing through drywall we
35. nce see table 1 on Page 2 If present remove packing as shown in figure 4 REMOVE PROTECTIVE FILM FROM COVER lt SS Z SS REMOVE PACK 7 r ING BEFORE IN STALLING REMOVE RESTRAINT BEFORE IN STALLING REMOVE PRO TECTIVE FILM FROM DISPLAY REMOVE PACKING BEFORE INSTALLING Figure 4 Removing Packing 070222075 rel 1 3 dated June 2013 Installing Humidifier on a Wall Fastening to the Wall Drill mounting holes in the wall using the installation template then secure the humidifier firmly to the wall using the supplied screws and anchors see figure 5 Dimensions in inches mm gt STEAM O A oki CONDENSATE g dg MI OQ B 13 7 16 218 8 8 341 54 9 10 1 8 257 i 7 g 2 1 2 1 7 8 2 3 4 lt _ gt lt _ gt lt 4__ gt 128 128 65 48 70 M 1 1 8 dia 30 CIL lt 1 5 8 dia 40 CONDENSATE MOUNTING a lA HOLES o JE S 8 MN st A N ELECTRICAL 2 dia 51 7 8 dia 23 lt 3 lt gt 5 8 16 gt 1 1 2 2 3 8 3 5 8 3 1 4 1 3 8 ee TARY 92 82 35 3 7 8 3 1 8 1 1 2 2 1 8 o a gt SIS 78 37 53 Ens gt 2 1 2 o 62 4 3 7 8 102 98 Figure 5 Installation
36. olts goes on the thermostat s H terminal to energize the humidifier isolation relay coil which closes the open set of contacts in the relay and completes the circuit between GND and IN on the humidifier controller The thermostat will also send power to the G terminal on the air handler or furnace control to start the indoor blower When the indoor blower achieves sufficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidity demand is satisfied When the RH set point is reached the thermostat removes 24 volts from H which opens the isolation relay circuit and in turn opens the circuit between GND and IN on the humidifier controller stopping steam production The G signal will also be removed to turn off the blower if not running due to a heating demand or thermostat blower demand When the indoor blower stops the air proving switch contacts will open Figure 15 Humidifier with ComfortSense 7000 thermostat used as Humidistat and Interlocked with HVAC Blower Humidification must be added in icomfort Wi Fi thermostat during commissioning Refer to icomfort Wi Fi Installer Guide for details 48G96 relay field supplied Remove factory jumper between AB AB Note 1 GREEN WHITE YELLOW RED icomfort Wi Fi thermostat QOYQ OSOON Note 2 Note 3
37. ons switch the humidifier back on DO NOT release reset sel and drain buttons until the wrench icon blinks then re lease both buttons ao Sa WO i mn se Qe ve Press reset sel until the display shows 01 DO NOT confirm any value higher than 01 Values of 02 or higher not applicable for these models If value is higher than 01 press reset sel until the display goes back to the normal operating mode and re start from step 1 E Press and hold drain min imum 1 second the display shows PO then the current maximum production percent age and then set Press reset sel to change the Maximum Production in steps of 5 between 20 and 100 Press and hold drain minimum 1 second to confirm the new maximum production percentage and exit to the normal operating mode PO drain E J v reo Ox Figure 24 Changing Maximum Production Percentage 506746 01 Type of Volume of Building ft m approximate Construction 8000 227 10000 282 12000 340 16000 453 20000 566 Tight 4 3 16 5 3 20 6 4 24 12 7 48 2 Average 8 6 32 10 6 40 2 12 8 48 4 17 0 64 4 3 80 2 25 4 96 5 Loose 12 7 48 3 15 9 60 3 19 1 72 6 25 5 96 6 3 31 8 121 Legend HCSteam 16 HCSteam 35 Page 18 17 0 64 4 21 2 80 4 34 0 148 42 6 160 38 1 145 51 0 193 63 6 241 Exceeds capacity of HCSteam units Resetting the Ho
38. ower will be turned off if not running due to a heating demand or thermostat blower demand Figure 16 Humidifier with icomfort Wi Fi Thermostat used as Humidistat with an icomfort enabled SLP98 Gas Furnace or icomfort enabled CBX40UHV or CBX32MV Air Handler 506746 01 Page 12 070222075 rel 1 3 dated June 2013 GREEN WHITE icomfort Wi Fi YELLOW i thermostat RED Note 1 Humidification must be added in icomfort Wi Fi thermostat during commissioning Refer to icomfort Wi Fi Installer Guide for details Note 2 48G96 relay field supplied Note 3 Remove factory jumper between AB AB Q a 9998 SOOO INDOOR UNIT Pu Humidifier low voltage GREEN WHITE YELLOW RED Required Air Proving wiring panel Switch provided D 2 A OUTDOOR UNIT mi icomfort enabled outdoor unit I Alarm r 1 terminals if used not used QYVOVOVOO A 24VAC used GND Al not SL280 ONLY Humidification is controlled by the humidity sensor in the thermostat When the humidity in the space falls below the thermostat s humidity RH set point a demand message for humidification is sent to the furnace control board The demand message starts the indoor blower and closes the HUM contacts on the furnace control 24 VAC passes through a field
39. prevents the unit from filling too quickly or with too much pressure The water flows up the fill tube 2 and into the fill cup 3 Water then flows over the dam in the fill cup 3 creating a 1 air gap that prevents contaminated water backflow into feed lines Water then flows through the fill tube 6 and into the bottom of the steam cylinder 5 Any backflow or overflow of water travels through the overflow hose 13 to the drain Page 3 STEAM HOSE ADAPTER FILL CUP INLET AND FILTER ON OFF amp SET BUTTONS CYLINDER FULL PROBE 9 3 FILL CUP ELECTRODE 13 OVERFLOW HOSE XK KX ISSE NZ XXO STEAM CYLINDER 2 5 FILL TUBE lt X KX es lt x Sx FILL TUBE Xx Xx i STRAINER 12 4 FLOW RESTRICTOR 10 1 TEMPERING FILL VALVE VALVE Figure 2 Basic Humidifier Operation As the water fills the cylinder it will reach the electrodes 7 and current will begin to flow As the water continues to fill the cylinder the current will increase and this is monitored by an amperage transformer connected to one of the power wires and located on the electronic controller When HCSTEAM 16 35 SERIES the desired current is reached the fill valve 1 will close and the water will then begin to warm and produce steam lf
40. splay shows 13 the real hour value will be between 130 and 139 hours Amperage the amount of current flowing through the water causing the water to heat boil and pro duce steam default display Figure 22 Displaying Information Initial Start up with New Cylinder Flush the cylinder to remove trace contaminants in the cylinder and water lines after new installations and after cylinder maintenance Flushing prevents contaminants from causing excessive foaming during initial cylinder start up The cylinder flushing cycle can produce drainage from the HCSteam beyond the high capacity condensate pump tank and pumping capacity when installed in applications with over a 24 foot lift When starting with a new cylinder you should activate the cylinder cleaning function as follows 1 Make sure the humidifier switch is off press O part of switch 2 While pressing and HOLD ING both reset sel and drain buttons switch the humidifier back on DO NOT release reset sel and drain buttons until the wrench icon blinks then re lease both buttons 3 Press and hold reset sel until the display reset Z9 shows 04 WARNING DO NOT confirm We any value higher than 04 If 05 orhigheris rary displayed press reset sel until the dis play goes back to the normal operating mode and restart from step 1 4 Press and hold drain minimum 1 second the cleaning starts EEA dr
41. suggest using a 1 1 4 extension tube When using a bottom outlet drain attach the included 90 fitting to the drain outlet The drain outlet may be rotated Then connect a 1 1 4 trap adaptor to connect to drain pipe Steam Distribution 4 CAUTION Do not touch steam hose when humidifier is operating The steam hose is a heated part Allow to cool before servicing Duct Steam Injection The maximum allowed duct static pressure is 2 w c 070222075 rel 1 3 dated June 2013 The HCSteam 16 35 humidifier include a plastic injection nozzle figure 8 O D 2 2 56mm drill 2 1 4 67mm hole in duct qs STEAM JIER INLET CONDENSATE CONNECTION Figure 8 Plastic Injection Nozzle A typical installation is shown in figure 6 NOTICE Nozzle location is very important to the proper absorp tion of the steam in the air stream Select a location ob serving the following nozzle must be installed in supply duct nozzle location must be easily accessible nozzle location must allow at least 3 1m of straight metal duct without elbows or obstructions duct must be un insulated interior and if in uncondi tioned spaces insulated exterior clearances shown in figure 9 must be maintained Installing Return Condensate Hose The return condensate hose from the nozzle must be trapped Coil the hose into a vertical loop and secure it below the nozzle This trap prevents steam from being released into
42. t must be installed Check that the power supply voltage to be connected matches the value indicated on the rating plate inside the electrical panel Connect power wires to the power terminal block located at the bottom left of the control module polarity does not matter see figure 12 B Connect the ground wire to the unit s chassis ground located just behind the power wiring terminal block see figure 12 C WIRE NUT STRAIN RELIEF Figure 12 Power Wiring Connections 070222075 rel 1 3 dated June 2013 Control Wiring The humidifier is controlled by humidistat and safety devices such as high limit humidistat air proving switch and remote on off The humidifier is operated by the closing of a mechanical humidistat or by the closing of a normally open dry contact The most common is a combination of a humidistat and air proving switch Diagrams A and B in figure 13 show the routing to the terminal block Connect control devices to humidifier using the diagrams shown in figures 14 through 18 Following each diagram is SO pes ZE OSE C Humidifier low voltage an explanation of the sequence of operation associated with each wiring configuration Air Proving Switch and Safety Switches Remove the jumper between terminals AB AB and connect air proving switch DO NOT apply any voltage to AB AB Thread the control wiring through the bottom of the unit and the
43. tacts now closed and to the blower interlock relay coil The interlock relay normally opencontacts close to energize G on the furnace or air handler and start the indoor blower if not already running by a heating demand The interlock relay also isolates G from the thermostat to prevent a back feed that would start the outdoor unit When the indoor blower achieves sufficient speed the air proving switch contacts close completing the circuit from AB to AB on the humidifier controller Steam production will now start and continue until the humidity demand is satisfied When the humidistat has reached its RH set point output to the humidifier controller IN and GND terminals falls to O Vdc stopping steam produc tion then opens the EXT FAN contacts which will stop the indoor blower if not running due to a heating demand When the indoor blower stops the air proving switch contacts will open Figure 19 Humidifier with HC Digital Automatic Humidistat Connected for ON OFF Operation Interlock between HCSteam 16 35 Humidifier and Furnace or Air Handler Fan The following sequence of events must occur for HCSteam 16 35 to produce steam e External humidistat contacts must close between terminals IN and GND providing a steam humidification demand e The air proving switch NO contacts wired between humidifier terminals AB and AB must close when significant air volume is provided to allow the humidifier to operate The
44. the water reaches the cylinder full probe 9 or if current rises too much the drain pump 11 will be activated to drain away some water and reduce the current flow to acceptable levels Note that any time the drain pump is activated the tempering valve 10 will be opened for tempering the hot drained water down to 140 F 60 C in accordance to local and national standards Periodically based on the incoming water conductivity the unit will run the drain pump 11 and drain some water to reduce the mineral concentration A strainer 12 in the cylinder helps to prevent mineral debris from jamming the drain pump 11 In case the HCSteam 16 35 humidifier remains powered but idle i e without producing steam for more than 48 hours 2 days the cylinder will be emptied to not have stagnant water inside If there is no water in the cylinder there will be no current flow and no steam production The electrodes do not burn out but they will eventually become completely coated with mineral and the cylinder will then need to be replaced Cleaning cylinders may cause electrode damage therefore voiding its warranty See maintenance section on Page 21 Installation Installing the Nozzle The HCSteam 16 35 humidifier s nozzle must be installed onto the ductwork near the humidifier Refer to the Steam Distribution section Page 8 for information on how to properly locate the nozzle for dimensions for the hole mounting pattern and
45. tly with no sags or kinks and sloped properly according to the manual e Condensate hoses are run correctly with no sags or kinks and sloped properly according to the manual e An auxiliary drain pan and float switch are installed under humidifier if humidifier is installed in area where a water leak could cause damage Humidifier Start up Checklist e Insure that the external power to the humidifier is on e Press the I part of the On Off button IN The yellow Power LED middle will light The HCSteam 16 35 humidifier is now ready to operate e With a call for humidity the humidifier will close its power relays and send power to the electrodes in the plastic steam generator The green Operation LED will light indicating that operation has begun Operation Checkout Check that the air proving switch closes on the lowest blower speed e After 10 minutes of operation check duct for signs of excessive condensation or wetness by inspecting inside of duct using an access door or by removing the nozzle e f wetness exists increase blower cfm or reduce humidifier output capacity see figure 23 on page 17 0 70222075 rel 1 3 dated June 2013 cre ee nan T A Production the amount of steam being produced ex pressed as a percentage of the humidifier s capacity p eae Leta Amperage is repeated I gt I f eee A reset 1 M reset a LI Se Hour counter expressed in tens for instance when the di
46. uctivity lt 350 for 230 volt model only Water fill connection 3 4 female water hose connection Adapter to 3 4 FPS Water fill instant flow 0 09 0 16 gpm 0 35 0 60 I min Drain connection 1 25 O D 32 mm Adjustable from horizontal to downward May be from back or bottom of unit Drain water temp lt 140 F lt 60 C Drain tempering device Drain flow Max 7 1 gpm max 26 8 l min Ambient indoor operating and storage temperatures and humidity outdoor installation not valid Operating temperature Operating relative humidity 10 to 60 RH 34 F to 104 F 1 C to 40 C 14 F to 158 F 10 C to 70 C 5 to 95 rH Storage temperature Storage relative humidity Page 23 Storage conditions only apply to HC Steam units prior to installation HCSTEAM 16 35 SERIES
47. ur Counter The hour counter must be reset every time the cylinder is changed in order to reset and restart the internal maintenance timer 1 Switch the humidifier off 2 While pressing and HOLD ING both reset sel and Z7 i X drain buttons switch the e A _ S humidifier back on DO NOT me release reset sel and drain buttons until the wrench icon blinks then re lease both buttons 3 Press reset sel until the display shows 03 DO NOT confirm any value higher than reset 03 Values of 04 or higher not applicable for these models If value are higher than 03 Lia press reset sel until the display goes back to the normal operating mode and re start from step 1 4 Press and hold drain minimum 1 second to confirm the hour counter will be reset at once and HCSteam 16 35 humidifier will go back to the normal operating mode Figure 25 Resetting Hour Counter Activating the Manual Drain Press and hold the drain button on the front of the unit until the cylinder is drained NOTE Water will continue to flow from the tempering valve after the cylinder is empty Draining should take around 20 seconds if the cylinder was full Sequence of Operation For a complete description of how the humidifier operates using the various control devices see the wiring section page 11 through page 13 0 70222075 rel 1 3 dated June 2013 Alarms In the event of an alarm the re
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