gasteam 45/90/180 HD002 microprocessor electronic controller User manual NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT!

Transcription

1 gasteam 45/90/180 HD00 microprocessor electronic controller User manual NO POWER & SIGNAL CABLES TOGETHER READ CAREFULLY IN THE TEXT!

2

3 IMPORTANT WARNINGS The CAREL humidifiers are advanced products, whose operation is specified in the technical documentation supplied with the product or can be downloaded, even prior to purchase, from the website Each CAREL product, in relation to its advanced level of technology, requires setup/ configuration/programming/commissioning to be able to operate in the best possible way for the specific application. The failure to complete such operations, which are required/indicated in the user manual, may cause the final product to malfunction; CAREL accepts no liability in such cases. The customer (manufacturer, developer or installer of the final equipment) accepts all liability and risk relating to the configuration of the product in order to reach the expected results in relation to the specific final installation and/or equipment. CAREL may, based on specific agreements, acts as a consultant for the installation/commissioning/use of the unit, however in no case does it accept liability for the correct operation of the humidifier and the final installation if the warnings or suggestions provided in this manual or in other product technical documents are not heeded. In addition to observing the above warnings and suggestions, the following warnings must be heeded for the correct use of the product: DANGER OF ELECTRIC SHOCK The humidifier contains live electrical components. Disconnect the mains power supply before accessing inside parts or during maintenance and installation; DANGER OF WATER LEAKS The humidifier automatically and constantly fills/drains certain quantities of water. Malfunctions in the connections or in the humidifier may cause leaks; DANGER OF BURNS The humidifier contains high temperature components and delivers steam at 100 C/1 F. The conditions of the environment, the fuel and the power supply voltage must comply with the specified values. All other uses and modifications made to the appliance that are not authorised by the manufacturer are considered incorrect. Liability for injury or damage caused by the incorrect use of the appliance lies exclusively with the user. Please note that the appliance is connected to the gas mains, contains live electrical devices and hot surfaces. All service and/or maintenance operations must be performed by specialist and qualified personnel who are aware of the necessary precautions and are capable of performing the operations correctly and in accordance with the safety standards and legislation in force, with specific reference to: 1. Italian law 1083/71: Safety standards relating to the use of gaseous fuel ;. Italian Law no. 46/90: Safety standards relating to systems in buildings ; 3. Italian Presidential Decree no. 447, December 6, 1991: Regulations for the enforcement of law no. 46, dated March 5, 1990, on safety relating to systems in buildings ; 4. Italian Law 10/91: Regulations for the enforcement of the national plan for energy savings and the development of renewable sources of energy. Disconnect the appliance from the mains power supply before accessing any internal parts. The local safety standards in force must be applied in all cases. Warning: The installation of the product must include an earth connection, using the special yellow-green terminal available in the humidifier. Observe the standards in force in the place where the humidifier is installed. Keep the humidifier out of the reach of children and animals. Do not install and use the product near objects that may be damaged when in contact with water (or condensate). CAREL declines all liability for direct or indirect damage following water leaks from the humidifier. Do not use corrosive chemicals, solvents or aggressive detergents to clean the inside and outside parts of the humidifier, unless specifically indicated in the user manual. Do not drop, hit or shake the humidifier, as the inside parts and the linings may be irreparably damaged. CAREL adopts a policy of continual development. Consequently, CAREL reserves the right to make changes and improvements to any product described in this document without prior warning. The technical specifications shown in the manual may be changed without prior warning. The liability of CAREL in relation to its products is specified in the CAREL general contract conditions, available on the website and/or by specific agreements with customers; specifically to the extent where allowed by applicable legislation, in no case will CAREL, its employees or subsidiaries be liable for any lost earnings or sales, losses of data and information, costs of replacement goods or services, damage to things or people, downtime or any direct, indirect, incidental, actual, punitive, exemplary, special or consequential damage of any kind whatsoever, whether contractual, extra-contractual or due to negligence, or any other liabilities deriving from the installation, use or impossibility to use the product, even if CAREL or its subsidiaries are warned of the possibility of such damage. DISPOSAL The humidifier is made up of metal parts and plastic parts. In reference to European Union directive 00/96/EC issued on 7 January 003 and the related national legislation, please note that: 1. WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of separately;. the public or private waste collection systems defined by local legislation must be used. In addition, the equipment can be returned to the distributor at the end of its working life when buying new equipment; 3. the equipment may contain hazardous substances: the improper use or incorrect disposal of such may have negative effects on human health and on the environment; 4. the symbol (crossed-out wheeled bin) shown on the product or on the packaging and on the instruction sheet indicates that the equipment has been introduced onto the market after 13 August 005 and that it must be disposed of separately; 5. in the event of illegal disposal of electrical and electronic waste, the penalties are specified by local waste disposal legislation. Warranty on the materials: years (from the date of production, excluding consumables). Approval: the quality and safety of CAREL products are guaranteed by the ISO 9001 certified design and production system, as well as by the. mark. The environmental and power supply conditions must conform to the values specified on the product rating labels. The product is designed exclusively to humidify rooms either directly or through distribution systems (ducts). Only qualified personnel who are aware of the necessary precautions and able to perform the required operations correctly may install, operate or carry out technical service on the product. Only water with the characteristics indicated in this manual must be used for steam production. All operations on the product must be carried out according to the instructions provided in this manual and on the labels applied to the product. Any uses or modifications that are not authorised by the manufacturer are considered improper. CAREL declines all liability for any such unauthorised use. Do not attempt to open the humidifier in ways other than those specified in the manual. 3

4

5 CONTENT 1. GENERAL CHARACTERISTICS OF THE MAIN CONTROL BOARD 7. CONTROL SIGNALS FROM THE FIELD 8.1 Humidity or temperature control Pin strip position on the board for probe confi guration Using other brand probes AUXILIARY CONTACTS Alarm contact Dehumidifi cation contact Remote terminal GSM network connection (send SMS) Supervisory network Checks USER INTERFACE pgd0 graphic display (CAREL code: PGD0PH0F00) Main menu Reading and setting the confi guration parameters - USER submenu Service submenu Clock submenu STARTING, SHUTTING DOWN AND ADVANCED FUNCTIONS Starting Shutting down the unit Manually draining the boiler Cascading control of other units ALARMS, TROUBLESHOOTING Alarms Alarm management and signals OPERATING AND CONTROL PRINCIPLES, OTHER FUNCTIONS Operating principle Control principles Other functions Controlling the board via the network

6

7 1. GENERAL CHARACTERISTICS OF THE MAIN CONTROL BOARD Fig. 1.a This is a microprocessor electronic controller developed by CAREL for the management of all models of humidifier. It is made up of two electronic boards, positioned one on top of the other and connected together by pin strip: bottom board - main control board : connected to the board with the microprocessor and the clock card, as well as the serial card; top board, or expansion board. The controller is designed to run the control program, and is fitted with the set of terminals required for connection to the controlled devices (for example: valves, power contactors) and to the field (probes, external controller). The program and the parameters are saved in FLASH MEMORY, meaning the data is safe even in the event of a power failure (without the need for a backup battery). The controller can be connected to plan (pco Local Area Network) and tlan networks. Connection to the supervisor/telemaintenance serial line on the RS485 standard is ensured by fitting the controller with optional cards, using the CAREL, Modbus or ECHELON, RS3 and GSM communication protocols. Terminal block L1 L GN D AL 1U U 3U 4U 5U 6U 7U 8U 9U 10U 11U 1U 13U 14U 1T T 3T 4T 5T 6T 7T 8T 9T 10T 11T 1T 13T 14T U T 1Z Z 3Z 4Z 5Z 6Z 7Z 8Z 9Z 10Z 11Z 1Z Z 1S S 3S 4S 5S 6S 7S 8S 9S 10S 11S 1S 13S 14S S 1O O 3O 4O 5O 6O 7O 8O 9O O 1Y Y 3Y 4Y 5Y 6Y 7Y 8Y 9Y Y Fig. 1.b 7

8 . CONTROL SIGNALS FROM THE FIELD.1 Humidity or temperature control The humidifier can be configured to ensure the desired humidity or temperature value. It can be controlled in the following four different ways: a) Type C control: ON/OFF The humidifier is operated by a mechanical humidistat H, by a voltagefree remote contact CR, or by a combination of the two, which must be connected to terminals 7U, 8U, 9U and 10U on terminal block U in the electrical panel. The diagrams in Fig..b show the connections to be made in the case of: a) operation controlled by a simple remote contact (CR); b) operation by external mechanical humidistat (H); c) a combination of the two. CR H External regulator OUT REF 1U U 3U Fig..d c) Type H control: humidity control with room probe (and outlet limit probe, if required). With this configuration (see Fig..e) the main control board, connected to a humidity probe HT, performs a complete control action according to the humidity measured. An outlet humidity limit probe (see Fig..f ) can also be connected: with this configuration, the main control board, connected to a humidity probe HT, performs a complete control action, while also limiting the steam production according to the relative humidity value in the outlet duct, measured by the probe CH. The diagrams shown in Fig..g indicate the connection to be made using CAREL probes, with: just one relative humidity probe (a); an outlet humidity limit probe (b). CR 7U 8U a Remote ON/OFF 7U 8U Action ON/OFF 9U 10U b Remote ON/OFF 7U 8U Fig..a Action ON/OFF 9U 10U c Remote ON/OFF 7U 8U Action ON/OFF 9U 10U CAREL PROBES AVAILABLE rooms air ducts industrial applications DPWC DPDC DPPC10000 DPDC10000 DPPC Tab..a CR H CR H Fig..b HT b) Type P control: proportional control, with signal sent by an external controller. Steam production is managed by an external controller R, which sends the controller a humidity request signal (Fig..c); the controller can be programmed to receive one of the following proportional signals (see par. 7.): voltage: 0 to 1 Vdc; 0 to 10 Vdc; to 10 Vdc; current: 0 to 0 ma, 4 to 0 ma. Fig..e CR The reference (zero) of the external controller must be connected to the GND terminal (U) and the control signal to terminal B1 on terminal block U. To avoid unstable control, the earth of the external controller must be connected to the earth of the controller. This type of control can also be used with an enabling contact (CR) connected to the Remote ON/OFF terminal. HT CR CH R Fig..f CR Fig..c 8

9 The controller can also be connected to non-carel probes (see par..3.). HT: CAREL relative humidity probe; CH: CAREL outlet relative humidity probe. configuration HT out H M + (G) CR 1U U 3U 4U 5U 6U 7U 8U HT CH out H M + (G) out H M + (G) CR 1U U 3U 4U 5U 6U 7U 8U JS6 JS5 M a b Fig..g d) Control for steam baths: Temperature control with room temperature probe Temperature control with room temperature probe The humidifier is connected to a temperature probe TT (see Fig..h), and performs a complete control action according to the temperature measured inside the controlled environment. Fig..i shows the connection of the CAREL probe model ASET03001, with a range of measurement -30T90 C. The recommended CAREL probes have a 0 to 1 Volt output, and therefore the range of reading must be set (see par ). The control signal must be connected to 1U, and the earth reference is GND (U). The controller can also be connected to non-carel active probes (see par..3). TT: CAREL temperature probe. TT Fig..m pin strip configuration position 0 to 10 Vdc to 10Vdc 0 to 1 Vdc, 4 to 0/0 to 0 ma, NTC probes JS5 main probe JS6 limit probe basic configuration basic configuration.3 Using other brand probes Different brand probes can also be used, with the output signals, selectable from the following standards: voltage: 0 to 1 Vdc, 0 to 10 Vdc, to 10 Vdc; current: 4 to 0/0 to 0 ma. In addition, the minimum and maximum values of the signal must be set (see par ). Fig..h CR A 15 Vdc power supply is available for the probes, terminal 3U. The control signals must be connected: for the control probe HT (or TT) to terminal 1U, the earth reference for which is GND (U); for the limit probe CH to terminal 5U, the earth reference for which is GND (6U); for the current probe to terminal 4U, the earth reference for which is GND (6U). TT out T M + (G) CR Fig..i 1U U 3U 4U 5U 7U 8U Important warnings: To avoid unstable control, the earth of the probes or the external controllers must be connected to the earth on the appliance s controller. For the operation of the humidifier, the terminals corresponding to the remote ON-OFF signal must be connected to an enabling contact or jumpered (default solution). If these terminals are not connected, all the internal and external devices managed by the controller are disabled, with the exception of the drain pump, limited to the drain cycle due to extended inactivity (see par. 7.3). Connection to NTC CAREL probe: NTC NTC 1U U 3U 4U 5U CR 7U 8U Fig..l. Pin strip position on the board for probe 9

10 3. AUXILIARY CONTACTS 3.1 Alarm contact The humidifier controller is fitted with a voltage free contact for the remote alarm signal (one or more events). The alarm contact is connected via terminals 70, 80 and 90, as shown in Fig. 3.a. electrical specifications 50 Vac; Imax: 8 A resistive A inductive C NO NC Tab. 3.a Remote connection of the terminal up to 00 m 4 A J14 J SC C B 1 J18 humisteam Fig. 3.a 3. Dehumidification contact When the humidifier is used as in case c) in paragraph.1 (relative humidity control), a contact (NO, voltage-free) can be used to activate an external dehumidification device; in this case, the humidifier can provide complete control over the ambient relative humidity. The dehumidification contact is connected via terminals 13U, 14U on terminal block U, as shown in Fig. 3.b. For further details, see par Remote terminal electrical specifications 50 Vac; Imax: 8 A resistive A inductive 13U 14U Fig. 3.b NC C Tab. 3.b The display terminal can be detached from the humidifier and moved to another place. Depending on the distance required, the following are necessary: up to 50 metres: 6-wire telephone cable and two EMC filters (code AXX) (see Fig. 5.a); up to 00 metres: two CAREL TCONN6J000 boards, 6-wire telephone cables and an AWG0- shielded cable with 3 twisted pairs (for the connection of the two boards, Fig. 5.b). Remote connection of the terminal up to max 50 m A J14 J SC C B Fig. 5.b Key: 1 telephone cable (up to 0.8 m distance); CAREL TCONN6J000 board; 3 pin strip J14 and J15 in position 1- (power supply available on the telephone connectors A, B and C and screw SC); 4 WG0- shielded cable with 3 twisted pairs to move the display terminal up to 00 m away. Connection to the TCONN6J00 board: terminal SC function 0 EARTH (shield) 1 +VRL GND 3 RX/TX- 4 RX/TX+ 5 GND 6 +VRL 5 remote display terminal 3.4 GSM network connection (send SMS) The humidifier can be configured to send SMS message for alarms and malfunctions (see menu installer > supervisor > GSM protocol). humisteam J19 c 1 a MODEM 3 b 5 humisteam 3 1 Fig. 5.a Key: 1 telephone cable (up to 50 m distance); EMC filters (code AXX) to be applied to the ends of the telephone cable; 3 remote display terminal. J18 Fig. 5.c Key: 1 electronic board PCOI00MDM0 (to be connected to connector J19 on the humidifier board) CAREL GSM kit PLW0P65M00, made up of:.a modem.b antenna (with magnetic base).c serial cable.d power supply 3 SIM card to be inserted in the modem. Make sure that the access password (PIN number) is not enabled d 10

11 3.4 Supervisory network The controller can also be connected to a supervisory system via RS485, RS3 serial lines or FTT10 LON using the optional cards shown in the following table. optional cards characteristics supported protocols PCO1000WB0 provides BACnet Ethernet, BACnet BACnet/IP and MS/TP connectivity PCO1000BA0 Provides BACnet MS/TP over RS485 BACnet PCO100MDM0 used for the direct interface of the CAREL for controller to an RS3 network with remote an external modem connections PCO10000F0 used to interface of the controller to an FTT10 LON network, when suitably programmed LON-Echelon Tab. 3.c Connection is also possible to TREND systems using a card sold directly by TREND. 3.6 Checks The following conditions represent correct electrical connection: the rated voltage of the appliance corresponds to the mains voltage; the fuses installed are suitable for the line and the power supply voltage; mains disconnecting switch has been installed so as to be able to disconnect power to the humidifier; the electrical connections have been performed as shown in the diagrams; the power cable is secured to the tear-proof cable clamp; terminals 7U-8U are jumpered or connected to an enabling contact; the earth of any non-carel probes is connected to the earth on the controller; if the appliance is controlled by an external controller, the earth of the signal is connected to the earth of the controller. 11

12 4. USER INTERFACE 4.1 pgd0 graphic display (CAREL code: PGD0PH0F00) The pgd0 graphic display is an electronic device used for the complete management of the humidifier, by displaying graphic icons and alphanumeric characters. It allows a wide range of operating temperatures (-0T60 C) and guarantees a high index of protection (IP65). The terminal is plug&play, that is, it is automatically detected and managed by the control board. The pgd0 graphic display (0 columns x 4 rows) is backlit Keypad 3 1 Fig. 4.a button function (1) alarm lists the active alarms and resets any alarms () PRG from the main screen accesses the main menu (3) ESC returns to the main screen (4) UP scrolls the menus, the screens, the parameters and the values of the parameters (5) ENTER accesses the individual configuration parameters from the main screen accesses quick set (6) DOWN scrolls the menus, the screens, the parameters and the values of the parameters Tab. 4.a 4.1. Main screen 1 rh 100.0% Setp. 50.0%rH Off by Keyboard Fig. 4.b symbol function (1) indicates the selected control mode () value read according to the type of signal connected (3) set point value (4) general operating status (*) (5) alarm icon Tab. 4.b (*) Types of descriptions: PR,000.0 kg/h: steam production in progress (the current steam flow-rate is displayed), ALARM: steam production disabled by alarm, OFF FROM SUPERVISOR: steam production disabled by supervisor, OFF FROM TIME BAND: steam production disabled during pre-set time band, OFF FROM REMOTE: steam production stopped by opening the Remote ON/OFF contact, OFF FROM KEYPAD: steam production disabled from the keypad NO REQUEST: unit on without steam request. DISABLED: humidifier disabled from the keypad INFO screen (read only) Readings of the measurements and the main parameters The main measurements and parameters can be displayed very simply by scrolling the screens that, staring from the main screen (par. 4.1.), are accessed by pressing the UP and DOWN buttons. These screens contain the values listed in Tab. 4.c. display UOM access description steam: kg/h or lb/hr total steam flow-rate Set P. %rh in H control humidity measured in the room Amb.Hum: %rh mode ambient humidity set point Set T.: C ( F) in T control room temperature RoomT: C ( F) mode room temperature set point Set P. Lim.: %rh in H control outlet set point Humid.Limit: %rh mode+limit outlet relative humidity Prod.B1: kg/h or lb/hr current production of burner 1 Fan 1: RPM speed of fan 1 Prod.B: kg/h or lb/hr current production of burner (UG180) Fan : RPM speed of fan (UG180) Flue gas C ( F) flue gas temperature temperature Burner 1: Burner : Preheat set: C ( F) set preheating point (if preheating is not enabled, N.A. is displayed) Antifreeze set: C ( F) antifreeze set point (if not enabled, N.A. is displayed) Conductivity μs/cm mains supply water conductivity Tab. 4.c text option description gasteam Status see par similar to the status shown on the main screen Burner 1 () status On combustion active Off combustion not active Alarm alarm activation: Off burner not active Production steam production in progress Preheat preheating in progress Purge purge in progress Antifreeze antifreeze in progress Speed: fan speed (rpm) Tab. 4.d Quick set screen Press ENTER from the main screen to quickly access the for setting the set point parameters: in control mode ON-OFF (type C): see Fig. 4.c; in control mode with external controller (type P): see Fig. 4.c; in control mode with humidity probe (type H): see Fig.4.d; in control mode with temperature probe (type T): Fig. 4.e. To change the value of a parameter, highlight it by pressing Enter and use the arrows to change the value. Quick set Humidifier On Max Prod. 70.0% Fig. 4.c Quick set Humidifier On %rh Set P. 50.0% Max Prod. 70.0% Fig. 4.d Quick set Humidifier On Temp Set P. 40 C Max Prod. 70.0% Fig. 4.e 1

13 4. Main menu To access this menu, press PRG button from the main screen. Buttons: UP and DOWN: scroll inside the submenus, change the range of values and settings; ENTER: scroll inside the screens and confirm the changes made; ESC to go back (pressed more than once returns to the main screen). MENU PRINCIPALE Set Humid. Enabled Y/N Burners sequence (only UG180) Sequence Hyster (only UG180) Control parameters %rh set point Max prod. %rh differential Limit set Limit Diff. Temp set point Temp Diff. Dehum. set point Dehum. diff. Room hum. Alarm thresholds Low High Limit probe Alarm thresholds High Ambient temp. Alarm thresholds Low High User Password Control type On-off External control Built-in %rh Built-in %rh+limit Built-in temp Probe type Unit measure Cfg Room probe Min calib. Max calib. Offset Cfg Limit probe Probe type Min calib. Max calib. Offset Autotest Y/N Fan speed for production Pre purge Manual Fill fill/drain Preheating On-off Set preheat No Frost On-off Set point Options Alarm relay Inactivity drain Inactivity days Service warning De-humidif. Min prod Fan Speed Min Nominal Burner min product. Maintenance Language Italiano English System Info Hour counters Password Service Conductivity Forced Y/N Warning Alarm Language choice at start up Y/N On-off from superv. Y/N BMS network ID number Speed Protocol Hour counters reset Burner 1 Y/N Burner Y/N gasteam Y/N Manual Fill Y/N Drain Y/N Dehum. Y/N Alarm Y/N Regul. limit Softened water Forced drains Fig. 4.f Clock Alarm history On-off unit Clock Clock update Time Date Password clock Scheduler Humid On - off Y/N Set point Y/N Scheduler S1-1 S1- S S3 S4 Week Scheduler Mon Two Wen Thu Fri Sat Sun Sched. Set point S1 S S3 S4 13

14 4.3 Set submenu This submenu is used to access the screens for enabling the steam production unit and setting the control parameters Enable operation - start/stop steam production Once the unit has been switched on from the keypad (see Par. 4.8), the enable function effectively starts the humidifier. Subsequently, steam production is related solely to the humidity request or the presence of an alarm or a remote OFF signal. If the humidifier is not enabled for operation, the main screen appears as shown in Fig. 4.g. rh 100.0% Setp. 50.0%rH Disabled Fig. 4.g - Enabling operation: 1. Select the MENU Press PRG. The Menu screen is displayed, select Set and press ENTER;. Start the Unit Press Enter to move the curso to Humidif. Enabled ; Press UP or DOWN to change the value. Press ENTER to confirm. The screen shown in Fig. 4.h is displayed. Note that in the main screen the term Disabled no longer appears, Fig. 4.v.g. *: the Burners Sequence row is only shown on the UG180. rh 100.0% Setp. 50.0%rH Fig. 4.h At this stage, the humidifier has been enabled and started from the keypad and is ready to produce steam. Note: lthe production of steam now depends only on the control parameters selected (see par ) and the signal applied (humidity or temperature probe or signal from external controller). - Disabling operation Similarly to the previous paragraph, the operation of the humidifier can be stopped, disabling the unit. The sequence is the same, but rather set the Humidif. enabled variable to NO Reading and setting the set point The main screen shows the value of the set point, in the field to the right of Set P. control mode Type H Type T display in the field to the right of Setp. ambient humidity set point temperature set point Tab. 4.e Warning: the outlet humidity set point, relating to the limit probe, is saved with the parameter Limit Set (see par ). Setting the temperature set point This operation is only possible if T control mode has been activated. Sequence: go to the main screen and press PRG : press ENTER to move the cursor to the field to the right of Temp Set. ; press UP & DOWN to change the value; press ENTER to confirm. Setting the outlet humidity set point This operation is only possible if H control mode with outlet limit has been activated (see the paragraph Setting the control mode, par ). Sequence: go to the main screen and press PRG ; access the SET submenu; scroll the screens until reaching the one indicated here; press ENTER to move the cursor to the right of Limit set ; press UP & DOWN to change the value; press ENTER to confirm Modifying the maximum production allowed The maximum production allowed can be modified in all control modes. 1. Select MENU: press PRG. The Menu screen is displayed; select Set and press ENTER ;. Access and modify the control parameters: use UP or DOWN to go to the Control Params. screen (Fig. 4.l); Control Params %rh Set P. 50.0% Max.Prod. 70.0% %rh Different. 5.0% Fig. 4.l - using the ENTER button, move to the field to be modified, Fig. 4.m. Control Params. %rh Set P. 50.0% Max. Prod. 70.0% %rh Different. 5.0% Fig. 4.m - use UP & DOWN to change the value and press ENTER to confirm, Fig. 4.n. Control params. %rh Set P. 60.0% Max.Prod. 70.0% %rh Different. 5.0% Fig. 4.n Setting the ambient humidity set point Sequence: go to the main screen and press PRG ; access the SET submenu; scroll the screens until reaching the one indicated (Fig. 4.i); Control Params %rh Set P. 50.0% Max.Prod. 70.0% %rh Different. 5.0% Fig. 4.i press ENTER to move the cursor to the field to the right of rh Set P. ; press UP or DOWN to change the value; press ENTER to confirm. Characteristics and limits of the set point: unit of default min. limit max. limit humidity control (H control) measure value (1) % rh Tab. 4.f 14

15 4.3.4 Setting the control parameters The control parameters are the values corresponding to the ambient humidity control (or temperature) control process. To access these parameters, scroll the screens under the SET submenu. The procedure for setting these parameters is similar to the one described for setting the maximum production (Par ). Control parameters Sc.. display range default UOM access description Burner sequence Parallel, Parallel always Operating mode (see Chap. 9 Operating principles) UG180 only Series Seq. hyster.: UG180 only 0 to % always Hysteresis for stopping/igniting the burners only in series or parallel burner sequence with rotation (see Setting the operating sequence of the two burners ) UG180 Control parameters Alarm threshold Max.prod. 5.0 to if UG045/90 & UG180 if sequence = parallel & rotation not active 1.5 to UG180 only if boiler sequence = series 70.0 % always Maximum production of the humidifier as a percentagefor the concept of rotation see par. 6.3 Options Note: for the minimum limit for this parameter - see par Setting production %rh Set P. 0 to % In H control mode and H control Humidity set point %rh Differential.0 to % mode with outlet limit Limit Set (%rh set point) to % only in H control mode with Outlet humidity set point L. Diff..0 to % outlet limit Outlet humidity differential Temp Set 0 to C Only in T control mode Temperature set point 3.0 to F Temp Diff..0 to C Temperature differential 35.6 to F Low (Room hum.) 0 to % In H control mode and H control Low humidity alarm threshold High (Room hum.) 0 to % mode with outlet limit High humidity alarm threshold High (Limit) 0 to %rh only H control mode with outlet High outlet humidity alarm threshold limit Low (Temp.) 0 to (high threshold) 0 C only in T control mode Low temperature alarm threshold 3.0 to (high threshold) 3.0 F High (Temp.) (low threshold) to C High ambient temperature alarm threshold (low threshold) to F Tab. 4.g 15

16 4.3.5 Setting the operating sequence of the two burners (UG180 only) The gasteam 180 manages the operation of the two burners so that in steady operation these produce 180 kg/h of steam. Ideally, the gasteam 180 can be considered as two separate humidifiers, each with its own burner, and able to produce up to 90 kg/h. The two systems are managed based on the setting of the Burner Sequence parameter, seen in the previous table. PARALLEL mode: the steam request is divided equally between the burners. In this case, therefore, the steam production provided by the two burners is the same. Series mode (also called sequential ): if the steam request is less than 50% of the rated production, only one burner is operated. Only if the request exceeds the 50 % does the other burner start. As each burner must operate so that the corresponding ideal humidifier produces a minimum of 5% (for natural gas; 33% for butane-propane) of the ideal flow-rate of 90 kg/h, Series mode naturally offers a wider overall range of modulation of steam production. PARALLEL mode: the minimum possible production is 45 kg/h; Series mode: the minimum production is.5 kg/h Example of PARALLEL mode Key 1 production burner 1; total total request 3 production burner ; total 4 % in P control; 0.1xP0 in H/T control 5 total production %; 50% 100%; 50% 100% bd; bd/ bd; bd/ bd 4 100% Min. Prod (bd) 100% bd 100% Fig. 4.o Example of Series mode 100%; 50% 1 hyst bd/ 50% - hyst 100%; 50% 3 100% 4 7 P**; P**/ P*; p*/ % bd; bd/ bd/ H 50% 100% bd; bd/ bd 50% 100% bd bd/ bd/ bd 50% 100% 100%; 50% bd; bd/ 1 hyst bd/ 50% - hyst P*=P** 100%; 50% bd; bd/ 3 Key 1 production burner 1; totale richiesta globale 3 production burner ; totale 4 production totale 5 H= % in P control; 0,1xP0 in H control/t 6 hyst= parametro Seq.Hyster (def: 5.0%, range: 0-0.0%) 7 P*= 100% - *hyst - bd P**= 100% - bd 50% 100% 50% 100% Fig. 4.p 16

17 It can be seen that an hysteresis is required in the intermediate burner On/Off zone, which is managed by the Seq. Hyster. parameter seen in the previous table. To offer a wider range of modulation in parallel mode, the concept of ROTATION has been introduced (see OPTIONS - Rotation of the request between the burners). If ROTATION is active, in PARALLEL mode too one burner is started first, while the other remains off until the steam request is between 1.5% and 5%. Above 5%, both burners start operating in parallel mode.. 100%; 50% 1 hyst 100%; 50% 1 100% 3 hyst Key 1 production burner 1; total total request 3 production burner ; total *bd; bd 50% bd; bd/ bd/ bd 100% bd; bd/ bd 50% 100% bd bd/ bd/ bd 50% 100% Fig. 4.q burners (UG180 only) parameter name options default Burner rotation NO ROTAZIONE No Rotation AT START IN PRODUCTION Tab. 4.h Description In normal operation, depending on the humidity request and the control mode selected (series or parallel), the control logic automatically calculates how much energy must be generated by each burner/fan system. The rotation of the request consists in periodically reversing these production references. The rotation of the request ensures, in the long term, similar operating hours for the two burners in the gasteam, with the consequence of not only having more uniform wear on the combustion systems, but also a more uniform accumulation of lime-scale deposits on the two exchangers. Two types of rotation are available: IN PRODUCTION: this is rotation by time, that is, whenever the difference in operating hours between the two burners reaches 10 hours, the production references are reversed. AT START: whenever that the steam production ends, when following request is received, the burner with the less operating hours always starts first, along as the difference in operating hours has exceeded 10 h. Note: the difference of 10 h can be modified. The parameter is called Time Diff. and is displayed on the same screen as the Burner rotation only if one of the two rotation modes is enabled. 4.4 Reading and setting the configuration parameters - USER submenu The configuration parameters are used to set the operating modes of the controller, that is, assign the essential functions of the humidifier. These parameters are normally managed by the installer or the service personnel, and therefore a password is required to access the screens that contain these parameters. To access these screens, the sequence is: press PRG ; access the USER submenu; when the User Password is requested, enter the number 77. To change the parameters in the same screen, proceed as follows: press ENTER to to position the cursor on the desired parameter; press UP or DOWN to change the value; press ENTER to confirm and access the next parameter. The type and meaning of these parameters are listed in the following paragraphs Configuring the control mode This parameter can be used to choose between 5 different control modes, listed in the table below. parameter name Type of control display description (for a detailed description see par. 7.) H: %rh probe H control Humidity control with room (default) probe H: %rh probe + Limit H control Humidity control with room probe and limit probe P: Ext. control P control Proportional control with signal set by external controller T: Temp. control T control Temperature control with room probe C:ON/OFF C control Humidity control with humidistat 4.4. Selecting the type of probe This is used to set the type of probe or the type of signal sent. parameter name Probe type (not accessible in C control mode: ON/OFF) display 0 to 1 V 0 to 10 V (default) to 10 V 0 to 0 ma 4 to 0 ma NTC 0 to 135 ohm Unit of measure Select the unit of measure, between metric and imperial. parameter name Unit of measure display C-kg/h (default) F - lb/hr Tab. 4.i Tab. 4.l Tab. 4.m 17

18 4.4.4 Configuring the room humidity (or temperature) probe This is used to set the minimum value, maximum value and the offset for the probe used in the room. screen name parameter name range default access UOM H control T control Config. Room Probe Min. 0 to (Max. ) 0.0 %rh C (not accessible in C control mode: ON/OFF) Max. (Min) to %rh C Offset to %rh C (o F) Tab. 4.n NOTE for T control: the setting of the minimum and the maximum values for the probe is only in degrees centigrade. The offset, on the other hand, being linked to the difference between the reading made by the probe and by a reference thermometer, depends on which unit of measure has been selected. For example, if having selected imperial measurements: if based on the measurements made it is clear that the value read by the probe is normally F higher than the reading made by a reference thermometer, to correct the error set the offset to -.0 F) Configuring the limit humidity probe This is used to set the minimum value, maximum value and the offset for the limit probe. screen name parameter name range default UOM Config. Limit Probe Type 0 to 1 V 0 to 10 V (accessible only in H control mode with outlet limit) 0 to 10 V, to 10 V, 0 to 0 ma, 4 to 0 ma, NTC Min. 0 to (Max.) 0.0 %rh Max. (Min) to %rh Offset to %rh Tab. 4.o Initial autotest This is an automatic procedure used to check the correct status of the fill valve and the drain pump and the level sensor system. The procedure is as follows: the boiler is filled until reaching the highest point of the level sensor a drain cycle is performed until reaching the lowest point of the level sensor. All this takes place without igniting the burners. To enable/disable the auto-test procedure, go to the USER submenu, enter the password 77 and go to the screen shown in Fig. 4.r. Move the cursor to Autotest and use the UP/DOWN arrows to set YES or NO. The default value is YES. Burners rotation: NO ROTATION Autotest: NO Fig. 4.r Burners rotation: NO ROTATION Autotest: YES NOTE: The autotest is only performed if the humidifier is enabled for production, Humid. Enabled=Yes and if the controller is enabled from the keypad This function is useful for service or when first starting the appliance. IMPORTANT: In these conditions, the autotest occurs whenever the controller is switched off an on again Setting the pre-purge speed and manual procedure for flue gas calibration NOTE: These operations must be carried out by qualified personnel. The pre-purge speed is indicated in RPM and is normally set by the manufacturer based on the characteristics of the combustion system and the gas. To modify this parameter, go to the screen (Fig. 4.s) and change the Pre-purge parameter. During service, it may also be useful to check if the fan speed measured with a stroboscope coincides with the speed set via SW. The Manual parameter can be used to force a desired speed for performing the test Setting the maximum ratio between the water filled and the water drained for dilution During normal operation, the gasteam periodically performs drain cycles, called drain for dilution, followed by refilling with supply water. These drain cycles have the fundamental task of reducing the high conductivity of the water inside the boiler due to the continuous concentration of salts during the repeated fill/evaporation cycles. The control logic calculates how many fill/evaporation cycles must be completed before performing the dilution, based on the conductivity of the supply water. Normally, if the supply water is not very conductive, the drain cycles for dilution are performed less frequently. With this type of water, therefore, the number of fills between two successive drain cycles for dilution can be very high Preheating The preheating function is used to keep the water above a temperature set by the user when no steam is requested. Preheating thus speeds up the return to steam production when next requested. There are three options: 1. preheating disabled;. preheating enabled: operation by temperature + restriction on %rh. In classic mode, preheating is controlled depending on the water temperature and is activated according to the value read by the humidity (in H control) or temperature probes (in T control) or the signal applied (in P control). Blower speed Pre-purge 3450RPM Manual 3000RPM Fig. 4.s 18

19 This is enabled by setting TEMP. + %rh for the preheating options present in the screen shown in Fig. 4.t. Pre-heating: TEMP. +%rh Set PreHeat: 80.0 C Fig. 4.t Preheating is activated depending on the humidity value measured by the probe and by the operating mode set. In C mode (ON/OFF), preheating is never activated. In P mode (proportional), preheating is activated and deactivated depending on the signal applied to the room probe input. By default, preheating is activated when the signal applied exceeds 3%, while it is deactivated when it falls below 1% (see Fig. 4.u). In humidity control mode preheating is activated when the relative humidity falls below the humidity set point + preheating offset - hysteresis and is deactivated when it rises above the humidity set point + preheating offset (see Fig. 4.u). The values of the preheating offset and hysteresis parameters can be changed from the default values. These must be as follows: Preheating offset: Range= [ C] ; Default= 3.0 [ C] Hysteresis: Range= [ C] ; Default=.0 [ C] 3) Preheating enabled: operation with temperature control only In this case, preheating is always enabled, that is, it is not activated depending on the humidity value or the temperature measured by the external probe. The reference for the combustion systems only depends on the water temperature measured by the NTC probe and by the preheating set point, as illustrated in the previous graph. This option is enabled by choosing the TEMPERATURE ONLY option in the previous screen (Fig. 4.u) Antifreeze The antifreeze option can be very useful in applications that feature the installation of the gasteam outdoors, especially in colder countries where there is the real risk that, if no steam is requested, the water inside the boiler might freeze. For this reason, an option has been added that starts heating the water if the temperature measured by the NTC probe is too low. The humidifier must be activated and continuously connected to the power and gas supplies, excluding any interruptions. The antifreeze function acts as displayed in the following graph (Fig. 4.z). Max Prod 1 diff. 3 C hyst= 5 C Max Prod 1 1 Max Prod diff hyst Min Prod hyst hyst 4 100% 100% Key 1 reference % for the burner NTC temperature Fig. 4.z Set Nofrost 7 C OFF ON 1 3 Key 1 production % signal applied to probe 1 input 3 preheating 4 probe rh1 Fig. 4.u OFF ON hy Set Prerisc Once preheating is activated, the heating is modulated by the systems (burners + fans) depending on the water temperature measured by the NTC probe and the preheating set point (see Fig. 4.v). The preheating set point temperature must be a parameter with a range 70T-90 C and a default equal to 80 C. 100 bd 1 Fig. 4.v Key 1 reference % for the burner temperature 3 fixed differential of 0 C 4 preheating temperature (def.: 80 C) 3 hyst 4 Hyst=,5 C Options Reversing the logic of the alarm relay Normally, the alarms that stop the humidifier close the alarm relay contact. This logic can be reversed, so that the coil remains energised when no alarm is present, and the contact is open when an alarm is activated. To do this, set the following parameter: screen name parameter name range default Options Al. relay ENERGISED ENERGISED NOT ENERGISED Tab. 4.p Drain due to inactivity The drain due to inactivity option is used to completely empty the water from the cylinder if the cylinder does not produce steam for a period set by parameter, which by default is 3 days. By default, drain due to inactivity is enabled. It can be disabled by setting the parameter in the following table: screen name parameter name range default Options Drain for inactivity. Y,N Y In addition, the value of the parameter relating to the period of inactivity can be changed, available by scrolling the screens. The parameter is: screen name parameter name range default UOM Options Days of inactivity 1 to d (days) 19

20 Warn when exceeding maintenance hour limit The gasteam features a limit to the number of operating hours of the humidifier, beyond which it is recommended to perform maintenance (see the par. on MAINTENANCE). In this case, a maintenance request alarm is sent. Nonetheless, this alarm can be disabled, by setting the Maint. warning parameter to N. screen name range default UOM Maint. warning Y, N Y h (hours) Dehumidification The dehumidification function is only possible if terminals 13U - 14U on terminal block U are connected electrically to a dehumidifier (see par. 3.). By default, dehumidification is not enabled. During normal operation, dehumidification may occur only if the following conditions are satisfied: 1. the dehumidification option is enabled;. the ambient humidity probe is connected; 3. the humidifier has not been disabled by Remote ON/OFF ; If these conditions are satisfied, the dehumidification process is activated depending on the humidity measured, based on the dehumidification set point and dehumidification differential parameters, as shown in the graph (Fig. 4.a.a) Dehumid ON OFF Dehum Set Dehumid Diff. %rh Fig. 4.a.a To activate the dehumidification function, the following parameter needs to be enabled: screen name parameter name range default Options Dehumidify Y, N N Once dehumidification has been enabled, the set point and differential parameters can be modified. To do this, go to the following screen (Fig. 4.a.b), under the SET submenu. Control Params DeHum. set 100.0% DeHum.diff. 5.0% The characteristics of these parameters are listed below: Fig. 4.a.b screen name parameter name range default UOM Control Param. Dehumid.set (humdity set % point) to Dehumid.diff..0 to % Setting the production ramp During operation, the steam request may change depending on the readings of the probes or the signal from the external controller. The speed at which the humidifier shifts to the new request can be slowed down by setting the parameter (formerly parameter b9 in the old gasteam models 40, 45, 90) that is found in the screen shown (Fig. 4.a.c). parameter set to zero: the control logic uses an internal ramp (30 s) to shift from one request to the next; parameter set to a value other than 0: the logic recalculates the fan speed variation step, based on the assumption that to change from 0 to 100% of production must take the time set for this parameter. Setting the fan speed for minimum and rated production These values are set by default to ensure the correct air/gas mix with natural gas. They are found on the screen shown below (Fig. 4.a.d). Blower speed for produuction: Min.: 1800RPM Nominal: 5150RPM Fig. 4.a.d Setting the minimum production The minimum production as a % guaranteed by each burner depends on the type of gas used. Normally, its value is 5% for natural gas, and 33% for butane and propane. The reference screen is the following (Fig. a.e). Burner minimum production: 5% Fig. 4.a.e Manually setting the conductivity of the supply water and setting the conductivity alarm thresholds The conductivity of the supply water, as well as normally being monitored to prevent excessively conductive water from entering ( High conductivity alarms - see Alarms ), is also useful for determining the limit of fill/evaporation cycles between two drain cycles for dilution. A water conductivity value different from the reading of the conductivity meter can be set, by changing parameter B4 on the conductivity screen. The default value 0 indicates that the value used is the reading made by the conductivity meter. Any value 0 indirectly affects the maximum number of evaporation cycles between two drain to dilute cycles: the lower the conductivity setting, the higher the maximum number of cycles. The limit values for the high conductivity warning and alarm can also be set on the same screen. The screen has the following characteristics: screen name parameter name range default UOM Conductivity Forced (B4) 0 to 000 (*) 0 us/cm Pre-Al (B5) 0 - (B6) 1000 us/cm Alarm (B6) (B5) us/cm (*): supply water conductivity: b4= 0: the controller uses the conductivity measured automatically by the conductivity meter; b4= 1 to 4: the value set corresponds to the number of evaporation cycles between two drain for dilution cycles: each b4 evaporation cycles one drain to dilute cycle is performed; b4> 4: the controller uses the value of b4 as the conductivity and IGNORES the value measured by the conductivity meter. Note: to the side of the above parameters there may be the codes B4, B5 and B6, which indicate the name of the parameter that was normally used with the gasteam 40, 45 and 90. Important: it is possible, when the treated water mode is disableb - see par Options Time (b9) Min.Pr min Fig. 4.a.c 0

21 Disabling the change language screen During the start-up sequence (see par. 5.1), the screen that is used to change the language normally appears for 30 seconds. To deactivate this screen: go to the screen shown below (Fig. 4.a.f ); set the value to the right of Language choice at start-up to N ; press ENTER to confirm. Language choice at start-up? Y Accept on-off from superv.? N Fig. 4.a.f Enabling remote off via supervisor In the same screen seen in the previous paragraph, humidifier on/off via supervisor can also be enabled. To do this, simply set Y to the right of the question Accept on-off from superv.? ) - (Fig. 4.a.f ). Configuring the communication protocols By accessing the screen containing the parameters shown in the table, the controller can be configured so as to be able to communicate correctly using different communication protocols. The parameters in question are listed in the following table: parameter name range default UOM ID number for BMS 0 to 00 1 Network Comm. speed 100, 400, 4800, 9600, Bps Protocol CAREL, Modbus, LON, RS3, CAREL GSM 4.5 Service submenu By entering the service submenu, the installer or service personnel can access information and perform any required operations Setting the language The language can be set to English or Italian. The sequence is listed below: a. Press PRG. The Menu screen is displayed; b. Using the DOWN button, move to the service field; c. Press ENTER, Fig. 4.v.r; d. Press ENTER to move the cursor to the language field and change the setting using UP or DOWN ; e. Press ENTER to confirm. The language can also be set during the start-up sequence : in fact, when the following screen appears, the language can be set by simply pressing one of the two UP or DOWN arrows, and then pressing the ENTER button to save the change. NOTE: the default language is English Information on the firmware The second screen in the service submenu indicates the code and the version of the application installed. The third screen corresponds to System info, that is, the BIOS and BOOT versions installed (Fig. 4.a.g). System info Bios /07/04 Boot /04/0 Fig. 4.a.g SERVICE - display the operating hours This screen indicates the total operating hours, and the operating hours of each individual burner (Fig. 4.a.h). Hour counters Humidifier 0h Burner 1 0h Burner 0h Fig. 4.a.h NOTE: The operating hours displayed are proportional to production. For example, if burner 1 has operated for 100 hours at 100%, the value displayed will be 100 h, On the other hand, if burner 1 has operated for 100 hours at 70 %, 70 h will be displayed. Operations with password access The following operations must only be carried out by installation or service personnel. Access is only possible on entering the password 77 in the screen shown below (Fig. 4.a.i). Service Password To enter the password, simply: press ENTER to move the cursor to the field with the 0 ; press UP or DOWN to enter the number 77 ; press ENTER to confirm. 0 Fig. 4.a.i - Reset the operating hours Password access only. The operating hours of the burner should be reset whenever the boiler is cleaned or the exchanger replaced. On the other hand, it is not recommended to reset the total operating hours of the humidifier, as it may be useful to know how many hours the humidifier has been working for. Resetting the total hour counter may be useful if completely replacing the combustion system (exchangers, burners). The operating hours can be reset from inside the following screen (Fig. 4.a.l). Hours counters reset Burner 1: NO Burner : NO GaSteam: NO To reset the hours: press ENTER to move the cursor to the field in question; change the value using UP or DOWN ; press ENTER to confirm and move to the next field. Fig. 4.a.l Procedure for testing the electrical parts Password access only. This procedure allows the manufacturer, the installer or the service personnel to check the correct connections between the electrical components, that is, to check: the activation of the fans/burners; the opening of the water fill valve; the activation of the drain pump; the activation of the dehumidification contact; the activation of the alarm relays. To access the test screens, the humidifier must be disabled (Humid. enabled: NO) and then activated from the keypad (ON). The sequence is as follows: 1. press PRG;. access the service submenu; 3. scroll the screens until reaching Service Password ; 4. enter la password 77 to accedere alle screens successive; 5. scroll the screens until reaching the enable manual procedure screen; 6. enable the manual procedures, setting the Manual field to Y. Once the screen has been enabled, the fields relating to the outputs will be active, Fig. 4.a.m; 7. to activate the outputs simply move to the desired output and change the value with the UP and DOWN buttons, Fig. 4.a.n; 8. note that by enabling the manual procedures, the following screen can be accessed to activate the burners/fans, Fig. 4.a.o; 1