Climate Platform Climate Business Unit heatersteam titanium Following up the revision of the resistive steam humidifier heatersteam happened two years ago, Carel has started and completed a thorough research on two specific points: the electronic controller and the resistive elements. The new heatersteam range employs the features of the latest generation of Carel s electronic controllers and uses Titanium heaters, thus representing a continuity solution in the development of heater humidifiers. heatersteam is the ideal solution for applications needing superior performance for controlling air humidity very accurately (±1%RH), mission critical service continuity using all types of feed water and ensuring connectivity tools able to anticipate remote management requirements. 1
1. Strengths The main strengths of heatersteam titanium are: I. MISSION CRITICAL DNA The heating elements are made in titanium, designed to work with extreme aggressive water such as demineralized/deionized water with conductivity below 1 µs/cm and softened water of up to 0 fh. The reliability of the titanium in combination with the overheating protection (heatersteam is the only humidifier on the market with heaters featuring temperature sensors) makes Carel solution ideal for applications where service continuity is essential (clean rooms, hospitals and museums). II. PERFORMANCE HeaterSteam titanium is the solution to relative air humidity control accuracy requirements. By using demineralized water Carel s heater humidifier can meet humidity requirements with ±1% accuracy. The production capacity modulation range from 0 to 100% in combination with the possibility of pre-heating the water inside the boiler means that heatersteam is ready to respond to humidity requirements. III. CONNECTIVITY Another element that sets heatersteam apart from the competitors is undoubtedly the state-of-the-art electronic controller. The Modbus and Bacnet communication protocols are available as standard on both the BMS serial output and Ethernet. The Carel communication protocol is available only through the BMS output. No additional electronic boards are therefore required. The Ethernet connection can also be used to access the integrated web server on the local network. It is therefore possible to configure and monitor the units directly from a PC using a standard web browser. heatersteam is also tera ready. Enabling the service via Ethernet connection permits remote monitoring and interaction with the unit. 2
IV. MODULARITY Thanks to the Master/Slave Mirror function, the capacity of the humidifiers installed can be expanded without complicating the system. The Mirror function allows heatersteam to control up to 19 further units through a proportional signal. V. SIMPLIFIED MAINTENANCE The electronic controller exploits the mechanical characteristics of the heaters to perform thermal shock cycles in complete safety in order to remove any limescale deposits from the heating elements. This results in longer routine maintenance intervals and greater cleanliness of the unit. 3
2. Technical characteristics The new heatersteam range is segmented in two different types of units by chassis size and steam production capacity: heatersteam UR002 UR013: heatersteam UR020 UR080: heatersteam titanium ** Thanks to the Endurance functionality, heatersteam titanium can manage another 19 units via Ethernet. This feature includes the redundancy, rotation and maintenance functions. This represents a profound innovation: if we take an installation of 3 URs with a capacity of 176 lb/h (80 kg/h), during maintenance on one of the other units, the other two will compensate for its temporary absence by increasing their steam production! *** heatersteam titanium, thanks to the mechanical strength of its resistive elements, is the only one in the market able to get up to 50 evaporation cycles before a dilution drain! (The market benchmark among our competitors is 40 cycles). 4
3. Code structure It will be possible to identify the new version of heatersteam through the product code: The complete lists of the units available is reported in the charts below accordingly to the power supply options. 5
CERTIFICATIONS HeaterSteam UR*1U3, available from September 2016, will have the ETL certification according to the UL998 standards. Please note that only heatersteam titanium will be available with that certification. The codes relating to ETL certification and available at Carel USA are indicated in the table below: UL998 - ETL (Made in USA - Carel USA) U D W K L M N 208V ~1 230V ~1 208V ~3 230V ~3 400V ~3 460V ~3 575V ~3 UR002HU1U3 UR002HD1U3 UR004HU1U3 UR004HD1U3 UR006HU1U3 UR006HD1U3 UR006HW1U3 UR006HK1U3 UR006HL1U3 heatersteam titanium UR010HW1U3 UR010HK1U3 UR010HL1U3 UR010HM1U3 UR013HK1U3 UR013HL1U3 UR013HM1U3 UR013HN1U3 UR020HW1U3 UR020HK1U3 UR020HL1U3 UR020HM1U3 UR020HN1U3 UR027HK1U3 UR027HL1U3 UR027HM1U3 UR027HN1U3 UR040HL1U3 UR040HM1U3 UR040HN1U3 UR053HL1U3 UR053HM1U3 UR053HN1U3 UR060HL1U3 UR060HM1U3 UR060HN1U3 UR080HL1U3 UR080HM1U3 UR080HN1U3 AVAILABILITY The new heatersteam range will be available starting in week 11 of 2016 (14 18 March). The standard expected delivery time for heatersteam version 3 remains that of the previous version and is 3 working weeks. Certain heatersteam models will also be available for purchase through Carel Quick ship to deal with urgent delivery requests. PHASE-OUT & PHASE-IN MANAGEMENT Taking the week in which production of the new version of heatersteam UR*03 starts into account, we wish to completely transfer production from the old code UR*02 to the new code UR*03 in a maximum of 3 months (for mid August 2016). The old UR*02 codes will be set to phase-out status at the end of 2016 thus not available anymore. After the week number 25 the lead-time of the previous heatersteam range will need to be checked and confirmed order by order. We recommend that you bear the product availability date in mind for making offers in the future. 6
4. Commercial approach UNIQUE ELEMENTS THAT DISTINGUISH heatersteam FROM COMPETITORS The main distinguishing elements that make heatersteam titanium unique in its category are: I. Titanium heating elements with integrated thermal protection. II. The dilution drainage every 50 evaporation cycles compared to the typical figure of 40 cycles adopted by competitors, this leads to both: water and energy savings! III. Operation with modulating limit sensor. IV. Possibility of combination with wireless sensors. V. Integrated web server for access from local network. POSITIONING COMPETITOR ANALYSIS (Europe Market only) Devatec RTH Hygromatik HL NEPTRONIC SKE Armstrong HC dristeem Vaportstream Condair Nortec RS Carel UR titanium Heating elements Incoloy Incoloy Incoloy Incoloy Incoloy Incoloy Titanium Protection against overtemperature NO NO NO NO NO NO YES Modbus Modbus built Modbus Bacnet and built in Bacnet in built in Modbus Optional Bacnet optional Bacnet Bacnet supervision optiona optiona optiona Built-in Built-in Foam detection YES NO YES NO NO YES YES Limit sensor Ease of cylinder cleaning On/Off humidistat Limescale collection tank NO Limescale collector filter On/Off humidistat NO YES Ion bed at bottom of boiler On/Off humidistat Removable heaters On/Off humidistat Limescale collection tank YES Kevlar sheath Web server NO NO NO NO Optional NO Built-in Wireless sensors NO NO NO NO NO NO YES USB Port NO NO NO Software updates (PC required) NO Variable logs software updates Variable logs software updates 7
config import APPLICATIONS heatersteam titanium heatersteam titanium stands out not only thanks to its continuous humidity control modulation and precision performance, but also by achieving unprecedented levels of reliability. In particular, it can work with treated water of any quality, including ultra-pure demineralized water, since titanium heating elements are not at risk of corrosion. This type of water, purified to an extreme, is used frequently in the pharmaceutical field and, due to its organoleptic characteristics, can be aggressive towards the materials normally used inside humidifiers. The overtemperature protection (unique to the market) and patented Anti-Foaming System are a further guarantee of the application s reliability, whereas the modulating limit sensor prevents condensation from forming without compromising the accuracy of the system. Strengths: Reliability: rotation and redundancy ensure continuity of service also during maintenance. Performance: ±1%RH accuracy around the set point in a continuous 0 100% modulation range. Connectivity: the Modbus and BACnet protocols permit flawless integration of heatersteam in any system. The web server facilitates maintenance management and scheduling. The heatersteam titanium s characteristics make it the perfect solution for the most challenging applications: clean rooms and research laboratories hospitals museums and libraries Clean rooms and research laboratories (pharmaceutical and electronics industries) Accuracy, reliability and continuity of service are priorities in clean rooms, where an interruption in humidity control can jeopardize the whole process. Hygiene is guaranteed by the steam, which is completely aseptic. Hospitals (in patients facilities and surgery rooms) In addition to the hygiene of the solution, ensured by the steam, the possibility of reduced maintenance in terms of frequency, complexity and duration, which can be scheduled in advance, takes on greater importance. Museums and libraries Artworks in hygroscopic materials, such as wood and paper, require constant environmental conditions in terms of temperature and relative humidity. There may be great variations over the course of the day, caused by factors such as weather conditions and number of visitors. The humidification system must be operational 24 hours a day. 8
food processing and preservation production processes comfort Food processing and preservation (agricultural and food industry) Food weight and quality are affected by the relative air humidity level. The humidifiers are frequently installed on ovens to control the process of cooking, or they are used to preserve food for longer, maintaining their weight and properties. The steam protects against the emission of solid particles. Production processes (wood, paper and printing application) The processing of hygroscopic materials such as paper and wood requires the control of relative humidity throughout the process. heatersteam can be installed in all conditions and can easily be adapted in the event of demand for larger loads thanks to its mirror function. Comfort (naval and residential application) The characteristics of the feed water are usually not controlled in applications for personal comfort: they may vary significantly between towns and even change abruptly over time, as in the case of naval applications. This is no problem for heatersteam. 9
COMMERCIAL OBJECTIVES 2015 was a good year for the present heatersteam; however, performance analysis by country and product immediately highlights a profound difference between Carel and its main competitors: the comparison between sales of immersed electrodes humidifiers and heater humidifiers. About 240 UE were sold last year globally for every 100 UR (we excluded the KUE from the analysis). A partial explanation of this scenario probably lies in Carel s origins. Our company was founded in 1973 to serve OEMs operating in the field of precision air conditioning: the first humidifier developed was the KUE submerged-electrode kit. Our organization went on to become more and more confident and familiar with this technology. Today, heatersteam is part of Carel s range of high-efficiency solutions. The technological progress made with the new heatersteam range is remarkable: the introduction of the new titanium heating elements and the new c.phc electronic controller have changed the heart and the head of our heater humidifier. We have set ourselves the goal of achieving the following sales mix: for every 100 UR, 195 UE by 2017, with the intermediate target of 225 UE by 2016 for every 100 UR. UNITS PER YEAR 6,000 5,000 4,000 UE+UR UR 3,000 2,000 1,000 0 2015 2016 2017 The introduction to the market will be accelerated by the presentation of an operating unit in all institutional events and by participation in conventions and fairs in the main application sectors (activity already begun during 2015). 10
In-depth information STATE-OF-THE-ART ELECTRONIC CONTROLLER The new heatersteam electronic controller, named c.phc, has been designed and developed by Carel based on the c.pco. The new c.phc technology, specific to humidifiers, has made it extremely simple to install and commission, yet with considerable flexibility in terms of operation: the new heatersteam 3 adds many new technical characteristics and functions to those already present in the previous version: Start-up wizard: quick, simple step-by-step configuration of the main parameters for machine commissioning. Once the wizard is completed, the unit is fully operational (naturally, the electrical and hydraulic connections must be made first). Integrated Modbus and Bacnet communication protocols: the default communication protocols on the machine will be Modbus, Bacnet and Carel on the BMS serial port and Modbus and Bacnet on the Ethernet port as well. Thermal shock: the thermal shock function is implemented to help the limescale to detach from the heating elements. The function drains and refills water after the set point is reached. The thermal shock is managed by time. 9 types of regulation: proportional to external signal, proportional to external signal with limit sensor, On/Off signal, humidity (single sensor), temperature (single sensor), humidity with limit, temperature with limit, humidity (two sensors), temperature (two sensors) Wireless sensors: if it is not possible to use wired sensors, in the case of retrofitting for example, wireless sensors can be used. Up to 4 sensors that communicate with an access point directly connected to heatersteam titanium. Single control with Humidity or Temperature regulation: can be configured by the user with humidity or temperature regulation. Quick and simple maintenance: the new Kevlar limescale collection bag is even more robust and performs even better in terms of easy removal of limescale (only UR002-UR013). Web Server: the Ethernet connection can also be used to access the integrated web server on the local network. It is therefore possible to configure and monitor the units directly from a PC using a standard web browser. This feature is available only with heatersteam titanium. Mirror Master/Slave functionality: in order to extend the steam production capacity the Mirror functionality connects up to 20 units. 11
Endurance Master/Slave functionality: heatersteam titanium manages multiple units (max. 20). The Endurance functionality includes automatic management of backup for maintenance, rotation and advanced preheating. Backup: in the event of malfunction on one of the units in the Master/Slave system, the backup unit will be activated automatically or, if possible, the system will attempt to meet the demand for steam by increasing the output of the single machines in operation. Backup for maintenance: during maintenance (on unit 1), it is possible to activate the backup unit in advance, switching it to production; when the backup machine is ready (in production), a message will be generated in order to switch off the machine (unit 1) and perform maintenance. Multi-unit management: two types of management can be defined: Equal and Grouped. The first results in equal output on all machines in the system (in parallel). Grouped rotation, on the other hand, activates the machines one by one in accordance with the requested load (in series). In the case of grouped rotation, the machines can also be set for rotation by time so as to make usage uniform. Advanced pre-heating: in the case of grouped rotation, the subsequent machine can be pre-heated when the output of the previous machine reaches, for example, 90% capacity. This way, the machine which is activated next will be ready for output sooner. Hardware backup: in addition to the software backup of the Master/Slave system, there is a digital input and a digital output that can be used to activate a backup machine. Status (relay) contacts: the following contacts are provided for remote signalling of the presence of one or more events: alarm contact, machine status (production) or maintenance pre-alarm contact (can be configured by user), backup or ON/OFF unit contact (can be configured by user), ventilation head contact (UR002 UR013 unit), contact for external drain tempering valve. Field software updating: any software update can now be carried out directly in the field using a normal USB key to connect to the c.phc. After copying the update file to the key, it suffices to launch the update from the appropriate screen of the pgd. Machine log saving: The USB port can also be used to download the log file. It contains the states of the main machine variables. It is also possible to save the alarm history. Copy and paste parameter configurations between units: the configuration of the main parameters on a unit can saved to a USB key for copying to a second machine. In this way, installation and commissioning are even quicker. THE NEW GRAPHIC INTERFACE The graphic terminal includes display and keypad with six keys which permit all control programming and configuration operations. As shown in the above image, the new main screen is divided into six graphic areas: 1 Date and time 2 Sensor reading or output percentage requested by the external regulator 3 Notification centre 4 Humidifier status 5 Quick access menu 6 Humidifier status icon 12
Specifically, the notification centre (3), accessible from the main screen using the ESC key, rapidly brings up the main messages on activities carried out by the humidifier or information regarding maintenance, for example. The quick access menu (5), on the other hand, permits rapid access to unit information and settings. From the main screen, the UP/DOWN arrows are used to display three different icons in the graphic areas: Info: the main information on the humidifier which can be displayed is, for example, unit status, request, output, water conductivity and boiler operating time. On/Off: switching the unit on/off using the keypad. It is useful for quickly bypassing the Master control in the event of maintenance/testing. Set: useful for quickly configuring the unit s setpoint, both the main and the limit setpoint (if present). ALL CONNECTIVITY OPTIONS The new c.phc electronic controller offers many options for managing and monitoring heatersteam: Supervision via BMS port (M12 terminals) that can be selected by default from Modbus, Bacnet and Carel without adding any device or external board. Supervision via Ethernet port (M11 terminals) that can be selected by default from Modbus and Bacnet without adding any device or external board. Integrated Web Server present by default on Ethernet port (M11 terminals) for monitoring and managing units via local network. (only for heatersteam titanium) Master/Slave e unit backup function available by default on Ethernet port (M11 terminals). Wireless sensors available with connection via access point to the fieldbus port (M3 terminals). USB port for updating software, saving machine logs and saving the configuration. 13
THE INTEGRATED WEB SERVER The electronic controller s Ethernet port can also be used to access the integrated web server functionality. It is therefore possible to configure and monitor the units directly from a PC, using a web browser, simply by entering the IP address for the individual unit. The web server Home provides direct access to the display, with the possibility of configuration as if you were physically present in front of heatersteam. It is also possible to have an immediate overview of humidifier operation thanks to the dedicated graphics. All the main configurations and information are available in the integrated web server, such as sensors, regulation, configuration, maintenance notification, display of any Master/Slave system, variable logs for carrying out any debugging on the unit. By way of example, the Scheduler menu window is shown to one side. This makes it very quick and intuitive to define the humidifier activation/deactivation periods. The graph at the top displays the hourly progress of the set points that are being configured, in real time. 14
THE WIRELESS SENSORS For installations where it is not possible to use standard wired sensors, when modifying existing installations for example, wireless sensors can be used. The connection is made via Carel Access Point using a maximum of 4 wireless sensors. The installation type is indicated in the figure below (in the case of 4 wireless room sensors): 4 4 2 3 4 1 1 - heatersteam titanium; 2 - Carel access point W01AB2M20; 3 - fieldbus connection; 4 - Carel room sensor WS01G01M00 or Carel industrial environment sensor WS01F01M00 4 15