User manual - CGF Products
Contents
1. O J z Check that the power supply voltage to be connected matches the value indicated on the rating uou KK plate inside the electrical panel Le N NJ H du H i Insert the power and ground connection cables into the electrical panel compartment using the js strain reliefs supplied and connect to the terminals An external fused disconnect must be Tite installed See Fig 3 0 See O See ON All wiring must be in accordance with local state and national electric codes L1 looo 9 K dil B Ls NOTE to avoid unwanted interference the power cables should be kept separate from any MM KU control wiring j lt 5 JI NOTE Tolerance allowed on main voltage 15 to H1096 TO Connect power wires to the power terminal See Fig 3 p ORO N Fig 3 m Power supply Steam Output Steam Output POWER CURRENT EXTERNAL EXTERNAL FUSE A single phase Ibs hr gal day kg h kW A POWER WIRES OR BRAKER DS50 230Vac 50 60Hz 20 58 9 69 83 X AWG8 40 A fast blow DS50LC 230Vac 50 60Hz 20 58 9 69 830 AWG8 40 A fast blow 3 6 Control wiring The Elite Steam allows connection of any simple or automatic humidistat and safety devices such as high limit2. DESCRIPTION fill cup current sensor control module 230Vac on off switch power terminal block kit w cover cover screws kit 90deg drain adapter drain pump assembly fill tempering valve assembly 7637 50 17 internalwiringkit S 763899 5023 Jinternalhosekit O 7633 50 05 installation instructions gt SS 7500 2004 fillconnector 0 7636 50 16 jintemalfilerandgasketkitds5O 10 0 0 NEN p E 8 EEE po DS 50 DS 50 LC 4030222065 Rev 1 2 7655 50 21 7657 50 10 hardware kit ds50 2 Small cable clamp 4 Screws for small cable clamp 1 Large cable clamp 2 Screws for large cable clamp 1 90 Deg drain adapter 1 Kit of 4 Mounting screws and anchors 23 Steam flows VAC kW 20 Ibs hr 9 kg h 230 VAC 1 phase 50 60 Hz 6 9 kW Notes Outlet pressure limits 5 4 in WC 1350 Pa For duct only Dimensions mm 31 x 18 x 11 4 790 x 460 x 290 mm Height x Width x Depth Weight empty packaged installed 24 29 51 Ibs 11 13 23 kg with water IP class MM Electrode power cables 8 AWG ae AP Ground connection Terminal block Input water type Potable water no demin or softened water Conductivity range 125 1250 uS cm Special cylinders for cond lt 350 S cm Water fill connection 1 4 O D Compression Adapter to 34 FPS Water fill instant flow 0 22 0 3 gpm 0 825 1 1 l min Drain conne
3. OPERATING THE ELITE STEAM In 5 1 DISPLAYING INFORMATION 5 2 CHANGING THE MAXIMUM PRODUCTION 5 3 ACTIVATING MANUAL DRAIN 5 4 RESETTING THE HOUR COUNTER 5 5 HUMIDISTATS 5 6 ALARMS 6 TROUBLE SHOOTING IN MAINTENANCE 7 1 PERIODIC CHECKS 7 2 CYLINDER MAINTENANCE 7 3 REPLACEMENT PARTS 8 TECHNICAL SPECIFICATIONS 9 LIMITED WARRANTY DS 50 DS 50 LC 4030222065 Rev 1 2 NND 22 22 23 24 25 1 1 Basic Operation The Elite Steam is an electrode humidifier It produces steam for humidification T by passing electric current through the water between metal electrodes in the 8 plastic steam generator cylinder There are no heating elements Steam output T M is directly proportional to the conductivity of the water and the amount of electrode immersed in the water r Rey HL 3 On a call for humidity the Elite Steam controller will open the water fill valve 1 e d m f and allow water to enter the cvlinder A flow restrictor 4 prevents the unit from lt 25 i 2 filling too quickly or with too much pressure The water flows up the fill tube 2 x KR and into the fill cup 3 Water then flows over the dam in the fill cup 3 which z m creates a 1 air gap to prevent backflow of contaminated water into the feed us mund lines and through the fill tube 6 and into the bottom of the steam cylinder b 42 a i E Any backflow or overflow of water travels t
4. During the cleaning the electrodes are powered and water is filled in until it touches the high level sensor or the phase current equals 20A whichever occurs first After either of the events is detected the boiler is fully discharged with the electrodes un powered the drain pump and the drain tempering valve are activated for 3 minutes Warming the filling water helps washing out any mould release or dirt General Filters Inc recommends to do two cleanings when starting a new boiler After the cleaning ends the humidifier starts the regular duty When starting the unit with a new or empty cylinder it may take a significant amount of time hours for the unit to build up enough mineral concentration to reach rated capacity This time can be shortened by the addition of Alka Seltzer through the steam outlet on top of the cylinder 5 1 Displaying Information By pressing the reset button for 2 seconds the display will loop from amperage to production in 90 of the maximum production to the hour counter and back to amperage I I J _ 70 reset I l I reset lt I I m IL lA e LI I ey LI l e IL lA Fig 5 a 1 Amperage it is the value of the current that flows through the water making it boiling off default display 2 Production 96 it is the current production expressed as a percentage of the humidifier s capacity 3 Hour counter expressed in tens for instance when the display shows 13 the real hour value will be betw
5. AB O AB D D The E2 is capable of Outdoor Temperature Compensation see E2 manual Fig 3 u AIR CONDITIONER RELAY TOAIR CONDITIONING CONTACTOR Se sess Arz 1109 l DPDT RELAV l FIELD SUPPLIED I lt Thread control wiring through the bottom of the unit and the strain relief Fig 3 m and 3 n then up the side of the control module to the wiring terminal blocks DS 50 DS 50 LC 030222065 Rev 1 2 16 3 7 Wiring Connections Terminals Functions Electrical specifications L1 L2 GROUND Power supply and Ground connections Power supply 230 VAC 1 phase 50 60Hz 6 9kW KEY Programming port Connecting to Programming port or supervisor N1 GND N2 Connection to NTC 2K and 10K to 20 C 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 If programmed O 10V Input impedance 10 kOhm If programmed ON OFF Vmax 33Vdc Imax 5mA Rmax 300 Ohm NC C NO NC alarm contact 250V 8Amp max with resisti
6. Replace the humidistat 1 Check that the steam hose is not kinked or sagging trapping condensate 2 Clean the fill valve strainer 3 Clean the fill cup 4 Check for voltage at the drain solenoid valve and or drain solenoid replacement 1 Check that the steam distributor is installed correctly 2 Increase air flow in duct or decrease PO maximum steam production setting 3 Check the connection of the device flow switch or differential pressure switch controlling the humidifier to the ventilation in the duct 1 Clean the drain assembly and pan 2 Check the entire water circuit 3 Check the correct position of the condensate drain hose in the drain pan 4 Check the fastening of the hose clamps on the steam outlet Tab 6 a Water in the cylinder turns 1 Minerals in the cylinder have overconcentrated 1 Check for sags amp kinks that could trap condensate in the Heavy arcing occurs within 1 The feed water contains large amounts of Iron hours of startup Copper or other conductive contaminants Humidifier and are deteriorating the electrodes continuously fills 1 Mineral has bridged between the electrodes steam hoses that could cause a back pressure on the cylinder 2 Check the duct static pressure 3 Check the fill valve and inlet strainer 4 Check the drain pump operation 5 Correct installation problems and replace cylinder 1 If you are using a softener Discontinue use 2 Check the electrod
7. The E2 may be wall or duct mounted 3 6 3 A Air pressure Safety and High Limit Switches Remove the jumper between terminals AB AB and connect 12500 pressure switch High Limit Humidistat safety switch or remote contact in series If none are to be installed the jumper must remain in place DO NOT apply any voltage to AB AB 3 6 4 Air Conditioner Relay Interlock Auxiliary DPDT safety relay Use this method in the following situations 1 To prevent the air conditioner from running when there is a call from humidity The DPDT relay will open the Y circuit and close the G circuit for operation while a call for humidity is present Demand for humidity will override call for cooling 2 In systems using a thermostat where G and Y are a single circuit The DPDT relay will allow blower operation to occur without back feeding the compressor Do not use this method when simultaneous humidification and cooling will be desired Use a high limit humidistat in to avoid condensation in ductwork The humidistat should be set to OFF during the air conditioning season if humidification is not desired For variable speed or DC systems consult furnace manufacturer ALARM EXT FAN 24V FOR EXTERNAL HUMIDISTATS GFX50 HUMIDISTAT 66 OUTDOOR TEMP SENSOR D ne not used in manual mode I pe QD N1 D
8. 1 4 Press drain minimum 1 second to confirm the hour counter will be reset at once and the humidifier will go back to the normal operating mode DS 50 DS 50 LC 4030222065 Rev 1 2 19 5 5 Humidistats Several GeneralAire humidistats mav be used with the Elite Steam Humidifier GFX50 included Allows Modulating or On Off operation Is capable of Outdoor Temperature Compensation and has other programmable functions Backlit LCD display E2 optional On Off operation only Is capable of Outdoor Temperature Compensation LCD display M3 and SCX3 optional Manual On Off operation only For detailed installation programming and operating instructions please see the Humidistat s Operating Manual WARNING Do not allow excess humidification Excess humidity can cause condensation and enable mold and mildew growth 5 6 Alarms In the event of an alarm the red alarm LED will flash the alarm relay will close and the alarm code will flash in the display Multiple alarms will flash in sequence alternating with the main display Pressing the sel button for 2 seconds will reset the alarms although still active alarms will continue to display Led reny Remote oma onen umasa or Of heck Pressure Sw crout ABAB High current alarm Unit disabled Turn off check connections check cylinder no limescale bridges between electrodes no electrodes short circuited Low production low supply water Unit disabled Check
9. as these are potential irritants 3 Industrial water boiler water or water from cooling circuits 4 Any potentially chemically or bacteriologically contaminated water 5 Heated water Water drain outlet Fig 3 9 Extension tube 3 3 2 Water Supply Connection We recommend the connection between the fill valve and the water supply line by a soft poly hose capable of absorbing the water hammering in order to avoid damage to the fill valve itself The water line may be routed through the back or through the bottom of the unit With poly tubing a tubing support must be used to prevent tubing collapse and leaks The fitting then threads onto the fill valve inlet located on the bottom of the humidifier using a 3 4 G connection Note that there is a strainer built into the fill valve fitting underneath the unit which will require periodic cleaning so be sure to allow clearance for access Length of 1 4 tube should be kept to less than 1M or 3 ft TAL Fill valve and filter Water drain Fig 3 h DS 50 DS 50 LC 4030222065 Rev 1 2 11 3 3 8 Water Drain The DS50 and DS50 LC 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 The drain line is not glued or otherwise attached to the
10. code There are several factors that influence cvlinder life 1 2 2 Water Characteristics of water influence cvlinder life and can varv greativ from place to place Total mineral content of the water is important Equally important is what minerals are present in the water Most water conditions result in flakv scale that eventually fills the bottom of the cylinder until it can no longer function Water with high silica content can result in a thin glass like coating on the electrodes that is highly insulating resulting in shorter cylinder life Only cold non softened tap water is to be used Water conductivity that is not matched to the correct cylinder will shorten cylinder life 1 2 3 Water Filtration Typically additional filtration of the incoming water supply is not necessary If however mineral content is known to reduce cylinder life excessively or if cylinder life proves insufficient then water filtration can be added In most cases the addition of a two element water filter can improve cylinder life The filter should contain an activated carbon element and a particulate filter element rated for 5 microns or less Micron is a size measurement The filter system should have a flow rate of at least 2 gpm The activated carbon will absorb much of the mineral content while the particulate filter will catch any granular material or sediment It is important to remember that the increase in cylinder life will be accompanied by the need to replace fi
11. cylinder 1 Completely drain the cylinder by pressing and holding the drain button until the cylinder is empty 2 Turn the humidifier off and disconnect the main power 3 Remove the cover 4 DS Models o Remove the steam hose from the cylinder I o Flip up the cylinder holding belt and lift the cylinder out of the unit i 5 Disconnect the distributor from the cylinder and lift the cylinder out of the unit HT IB 6 Disconnect the electrical connections from the top of the cylinder i 7 Install the new cylinder in the humidifier by performing the previous operations in reverse ss jie CAUTION Do not tighten the 1 1 4 hose clamp so tight that it crushes the cylinder outlet NW WARNING connect the gray wire with the electrical connections A on the top of the cylinder and connect the black wire with the electrical connections D on the top of the cylinder lt j oJ KO 7 2 2 Maintenance of the other plumbing components G IMPORTANT WARNINGS e External power must always be disconnected when performing any maintenance on the humidifier e Whencleaning the plastic components do not use detergents
12. humidifier fills with water without producing steam The humidifier wets the duct The humidifier wets the floor below Problem Causes Causes 1 No electrical power 2 On off switch of the humidifier in position O open 3 Control connectors improperlv connected 4 Blown fuses 5 Transformer failure 1 Remote ON OFF contact open 2 The humidistat has not been connected correctiv 3 Humidistat failure 4 Control signal not compatible with the tvpe set 5 Value measured by the sensor s higher than the corresponding set point 1 High steam back pressure 2 Fill valve strainer clogged 3 Mineral in the fill cup 4 Drain solenoid valve leaking 1 The distributor is not installed correctly too near the top of the duct or the condensate return is blocked 2 Air flow rate is too low 3 Humidifier active when the fan in the duct is off 1 The humidifier drain is blocked 2 The supply water or overflow circuit has leaks 3 The condensate drain pipe does not bring the water back to the drain pan 4 The steam hose is not properly fastened to the cylinder Solutions 1 Check the safety devices upstream from the humidifier and the presence of power 2 Close the switch on the panel position 3 Check that connectors are properly inserted in terminal block 4 Check the condition of fuses 5 Check that the proper voltage is connected and turned on 1 Close ON OFF contacts 2 Check the external connection 3
13. humidifier is damaged or even partially wet When installation is completed flush the supply pipe for around 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 4 1 Startup Checklist Before starting the humidifier the following should be checked Water is connected cold non softened the line has been flushed and external valves are open Drain is connected run to an open drain and has a trap under the unit Electricity is connected in accordance with instructions local codes and data labels in the unit The power fuses are installed and intact All control wiring is done and tested Airflow switch is wired to open on air flow loss Optional hi limit humidistat is wired to open on humidity rise above set point Unit wires have been checked to make sure they and all connectors are tight from shipping The steam hose s are run correctly with no sags or kinks and sloped properly according to the manual Condensate hoses are run correctly with no sags or kinks and sloped properly according to the manual 4 2 The Elite Steam Controller The Elite Steam controller features a comprehensive information display that shows the operation of the system at a glance d Display is of nominal capacity 2 Maintenance 3i Display is amperage default 4 Steam is being produced 5 Cylinder filling 6 Foaming 7 Water pre
14. ou 01 35 x IF NO SLOPE p 22000 0 9 m 3 FT max TYPICAL INSTALLATION WHEN UNIT IS ABOVE GENTLE BEND THE DISTRIBUTOR PIPE 22000 0 gt 5 gt 20 Y OBSTRUCTION TP TRAP NOTE HEIGHT OF TRAPS MUST BE GREATER THAN THE DUCT STATIC PRESSURE SUPPORTED STEAM HOSE AND OR COPPER PIPE NOTES SLOPE PIPING UP IN DIRECTION OF STEAM FLOW AT 20 OR GREATER WHICH MEANS 65 5mm x 305mm 2 1 2 PER FOOT e SLOPE PIPING DOWN IN THE DIRECTION OF STEAM FLOW AT 5 OR GREATER WHICH MEANS 20mm x 305mm 3 4 PER FOOT e MAX LENGTH OF RUBBER STEAM HOSE IS 3 m 10 FT HEIGHT OF P TRAPS MUST BE GREATER THAN THE DUCT STATIC PRESSURE NO SLOPE UNDRAINED BOW N O ELBOW LI NO DISTRIBUTION PIPE DRAIN NO SLOPE NO TRAP Fig 3 m IMPORTANT Maximum length of rubber steam hose is 4m 12 feet Insulated copper tubing may be up to 6m 20feet in length In all cases minimize sharp bends and elbows Use 2 45 elbows instead o f 90 s Hose inner diameter 1 18 30 mm Hose outer diameter 1 1 2 40 mm Installation Items Included Steam hose 8 feet Condansate hose 9 feet Hose Clamps 4 Steam manifold 12 inch Sheet Metal Screws 4 Water supply tube kit Fill Connector Code Valve Ball valve Pressure Switch GFX50 Humidistat Mounting Template DS 50 DS 50 LC 4030222065 Rev 1 2 14 3 5 Power wiring
15. should be placed close to the point where the steam will be used to minimize the steam hose length and the amount of condensate Do not mount on furnace air handler or ductwork Certain clearances must be maintained around the unit for safetv and maintenance 3 2 Mounting 3 2 1 Removing the front cover The front cover is secured by two screws located in the bottom side of the unit Use a phillips screwdriver to remove the screws The front is clasped with 2 clips on the top of the back part To remove the front cover hold by the sides pivot the bottom out and lift cover When installing the cover be careful not to over tighten the screws SCREWS M5x16 Fig 3 c u Millimeters Inch 445 mm 17 5 290 mm 12 32 Pounds Weight empty 24 Ibs Weight packaged 29 Ibs Weight installed with water 23kg 51 Ibs Tab 3 c Fig 3 d DS 50 DS 50 LC 030222065 Rev 1 2 9 3 2 2 Fastening to the wall Drill the wall according to the drilling template supplied then secure DS 50 DS 50 LC firmly to the wall by the screws and anchors supplied Do not mount on furnace air handler or ductwork Dimensions are in millimeters and inches In mm inch DS 50 DS 50 LC 4030222065 Rev 1 2 10 3 3 Plumbing 3 3 1 Water Char
16. DED THE MANUFACTURER ASSUMES NO LIABILITY IN CONNECTION WITH THE INSTALLATION OR USE OF THIS PRODUCT EXCEPT AS STATED IN THE LIMITED WARRANTY THE MANUFACTURER WILL IN NO EVENT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES This limited warranty gives you specific legal rights and you may also have other rights which vary from state to state Some states do not allow either limitations on implied warranties or exclusions from incidental or consequential damages so the above exclusion and limitation may not apply to you Any questions pertaining to this limited warranty should be addressed to General Filters Inc General Filters Inc has elected not to make available the informal dispute settlement mechanism which is specified in the Magnuson Moss Warranty Act General Filters Inc Canadian General Filters Inc 43800 Grand River 400 Midwst Road Novi MI 48375 1115 Scarborough ON M1P 3A9 www generalfilters com www cgfproducts com 150 I o o U O o O E gt m 4 m 2 lire fd 2 BE 2 R gt azM Fresh Indoor Air Quality o m H u 4 ju U a m E gt 6 gt ocm FILL OUT AND MAIL THIS Z 5 z 9 GD AJ A j WARRANTY CARD AND a m AN lt 53 A LITERATURE REQUEST FORM d m OMe Z O gt O z o gz9 Por Z Erz 29 2o rom 2 x 2 x gt AIR CLEANERS AND AIR PURIFIERS SH SH O O lt HUMIDIFIERS y p DIGITAL HUMIDITV GAGE Z gt O 282 AIR FILTER GAGE S O FUE
17. DS 50 DS 50LC Fresh Indoor Air Quality User manual gt READ AND SAVE lt Revision 1 2 THESE INSTRUCTIONS Warning If present remove the following items REMOVE BEFORE INSTALLING X SER 1 ch ZUR A can ADR y I WEN D J n WV FF i Z Y IMPO RTANT WARNINGS We wish to save you time and money We can assure you that the thorough reading of this manual will guarantee correct installation and safe use of the product described BEFORE INSTALLING OR HANDLING THE HUMIDIFIER PLEASE CAREFULLY READ AND FOLLOW THE INSTRUCTIONS AND SAFETY STANDARDS DESCRIBED IN THIS MANUAL AND ON THE LABELS ATTACHED TO THE DS 50 DS 50 LC THIS HUMIDIFIER MUST BE INSTALLED BY A QUALIFIED HVAC PLUMBING OR ELECTRICAL CONTRACTOR ALL WARRANTIES ARE VOID IF INSTALLED BY A NON TECHNICIAN CAUTION ALWAYS DISCONNECT THE MAIN POWER BEFORE OPENING OR SERVICING THE HUMIDIFIER The Elite Steam produces non pressurized steam by means of electrodes immersed in the water contained in the plastic steam generator cylinder Electric current passes through the water between the electrodes heating the water into steam which is then used to humidity the air The quality of the water used affects the operation of this unit so the Elite Steam may be supplied with untreated water as long as this is drinkable and not softened or demineralized The water converted into steam is automatically replaced through an electric fill
18. HE MAIN POWER BEFORE DOING MAINTENANCE CAUTION always disconnect the main power before touching the cylinder in the event of leaks as current may flow through the water 7 2 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 DS 50 are preset from the factory at 7096 Further reductions in maximum production will extend cylinder life See figure 7 a IMPORTANT WARNINGS 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 necessary precautions Before performing any operations on the cylinder check that the Cylinder humidifier is disconnected from the power supply Remove the cylinder from the humidifier only after life having drained it completely using the manual drain button or procedure Check that the model and the power supply voltage of the new cylinder correspond to the data on the rating label 1 2 1 Replacing the cylinder m E IMPORTANT WARNING the cylinder may be hot Allow it to cool before touching it or use protective gloves Fig 7 a To replace the
19. L OIL FILTERS AND bs S m O O ta ACCESSORIES o o a5 m c 220 O Q ats O O O g g B m m ex m DS 50 DS 50 LC 4030222065 Rev 1 2 75 NOTES GENERAL FILTERS INC 43800 GRAND RIVER AVE NOVI MICHIGAN 43875 1115 248 476 5100 WWW GENERALAIRE COM CANADIAN GENERAL FILTERS INC 400 MIDWEST POAD SCARBOROUGH ONTARIO M1P3A9 416 757 3691 WWW CGFPRODUCTS COM Fresh Indoor Air Quality Agency DS 50 DS 50 LC 4030222065 REV 1 2 Form 50 05 Rev 1 2
20. Press both and hold both buttons Reset and Drain and switch Elite Steam back on When the wrench blinks DN release the 2 buttons 3 Press reset until the display shows 01 WARNING DO NOT confirm any value higher than 04 If 05 or higher is displayed press Reset until the display goes back to the normal operating mode and restart from step 1 4 Press drain minimum 1 second the display shows PO then the current Maximum Production Percent and set 5 Press reset to change the Maximum Production in steps of 5 between 20 and 100 6 Press and hold drain minimum 1 second when done to confirm the new Maximum Production and exit to the normal operating mode 5 3 Activating Manual Drain Press and hold the drain button on the front of the unit until the cylinder is drained Note Water will continuate to flow from the tempering valve after the cylinder is empty 5 4 Resetting the hour counter The hour counter should be reset every time the cylinder is changed in order to reset and restart the internal maintenance timer 1 Switch Elite Steam off 2 Press and hold both buttons Reset and Drain and switch Elite Steam back on When the branch ws blinks release buttons 3 Press and hold reset until the display shows 03 WARNING DO NOT confirm any value higher than 04 If 05 or higher is displayed press reset until the display goes back to the normal operating mode and restart from step
21. acterisitc Requirements The humidifier must be supplied with water with the following characteristics pressure between 20psi and 110psi or 0 1 and 0 8 MPa 1 and 8 bar e temperature between 33 F and 104 F or 1 C and 40 C flow rate minimum of 0 83 L min or 0 22gpm e hardness no greater than 40 fH equal to 400 ppm of CaCO conductivity from 125 to 1250 uS cm absence of organic compounds e the characteristics of the water of supply must fall within the following limits LIMIT VALUES FOR LOW SALT CONTENT WATER LIMIT VALUES FOR LOW NORMAL WATER pu Max F s 85 Specific conductivity R 20 C 50 C LTotalhardmss mglCaGO o Temporary hardness mglCaCO Miron Manganese mglte Mn Chords pemG J uM CNN Values dependent on the specific conductivity in general cR 0 65 oR 20 C R180 0 9 oR 20 C Note There is no relationship between the hardness and conductivity of water Tab 3 e 0 00 2 0 Water Conductivity must be matched by specifications of the steam cylinder Check or know the water conductivity of the proposed site before installation Replace the steam cvlinder before startup if not correct See Table 3 f right Tab 3 f The following water types are not acceptable 1 Softened water as this will lead to foam electrode corrosion and greatly shortened cvlinder life 2 Water containing disinfectants or corrosion inhibiters
22. coil is off Contact IN GND If on off operation is enabled see section 5 1 1 closed steam production starts if contact AB AB is closed open steam production is stopped after 5 sec Pressure switch rir Fig 3 r Pressure Switch mium MODULATING HUMIDISTAT DS 50 DS 50 LC 4030222065 Rev 1 2 15 Fig 3 s 3 6 1 Connect the GFX50 Humidistat for Modulating operation Connect Elite Steam terminals 24V and GND to GFX50 terminals GO5 and G6 respectively Do not reverse these connections Connect GFX50 terminal A OUT 6 to Elite Steam terminal IN See fig 3 t NOTE 1 MODULATING OPERATION requires Elite Steam signal type be changed SEC 5 1 1 page 19 2 The GFX50 is capable of ON OFF operation See the GFX50 manual 3 The GFX50 is capable of Outdoor Temperature Compensation see the GFX50 manual 4 The GFX50 is designed to wall mount It is not intended for duct installation 5 Reversing the 24V and GND leads will result in humidifier malfunction 3 6 2 Connect the E2 Humidistat ON OFF Operation Connect Elite Steam terminals 24V and GND to E2 terminals ACL ACN Connect E2 terminals HUM to Elite Steam terminals GND and IN NOTE 1 Toremove humidistat from the base squeeze the louvered base at the top and bottom To remove from wall lift up on the humidistat and pivot top away Terminal block may be pulled off humidistat for easy connecting A ad bd
23. ction 1 25 O D 32 mm Adjustable from horizontal to vertical May be from back or bottom of unit Drain water temp lt 140 drain tempering device lt 60 C Drain flow Max 5 1 gpm max 21 l min Serial communication RS485 DS 50 DS 50 LC 4030222065 Rev 1 2 24 DS Humidifiers if properlv registered bv the return of the page 25 warrantv registration to General Filters Inc are warranted to the consumer against defects in materials and workmanship for a period of two vears from the date of installation so long as the product has been installed bv a qualified HVAC Plumbing or Electrical Contractor and operated in accordance with all appropriate manuals and wiring diagrams in a residential structure Installation in commercial industrial or office building will void all warranties Installation to a water source that does not meet unit specification will void all warranties Replacement of routinely replaceable parts such as steam cylinders and gaskets are not covered by this limited warranty or any other warranties Any other defective parts will be repaired without charge except for removal reinstallation and transportation costs To obtain repair service under this limited warranty the consumer must send the defective part to General Filters Inc THERE ARE NO EXPRESS WARRANTIES COVERING THIS HUMIDIFIER OTHER THAN AS SET FORTH ABOVE THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLU
24. een 130 and 139 hours 5 1 1 Select Signal Type The DS50 is preset for the included E Series humidistat signal type 0 If the ON Off operation is used this section may be omitted If another humidistat is used review this section to see if changes are needed 1 Switch Elite Steam off 2 Press and hold both buttons reset and drain and switch Elite Steam back on When the wrench blinks ws release the 2 buttons 3 Press Reset until the display shows 02 WARNING DO NOT confirm any value higher than 04 If 05 or higher is displayed press Reset until the display goes back to the normal operating mode and restart from step 1 4 Press drain minimum 1 second to confirm the display shows P1 then the current signal type and set 5 Press Reset to change signal type between 0 and 1 0 On Off humidistat such as the GeneralAire M or E series humidistat 1 external 0 10 Vdc modulating signal such as the GeneralAire ADCD series humidistat 6 Press drain minimum 1 second when done to confirm the new value of P1 and exit to the normal operating mode 7 Switch Elite Steam off you can now proceed with connecting the control wiring 5 2 Changing The Maximum Production The maximum production can be adjusted between 20 to 100 of the nominal production in steps of 5 in order to suit the environment characteristics DS50 and DS5OL Maximum production is factory set at 70 1 Switch Elite Steam off 2
25. es in the cylinder to be sure they were not damaged in shipping 1 Clean or replace the cylinder and drains without producing 2 There is back pressure from the steam hoses 2 Check the steam hoses for kinks or gullies that might be steam or duct trapping condensate 3 The flow regulator in the fill valve is broken or 3 Replace the fill valve out of place 4 Water conductivity is very high 5 Water is foaming excessively DS 50 DS 50 LC 4030222065 Rev 1 2 21 4 Consider using a mix of demineralized water with raw water 5 Check cylinder replace if exhausted If feed water contains silica or nitrates install a 1 micron water filter Tab 6 b 7 1 Periodic checks e After one hour of operation Check that there are no significant water leaks e Every fifteen days or no more than 300 operating hours Check operation that there are no significant 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 significant 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 1990 operating hours Replace the cylinder CAUTION ALWAYS DISCONNECT T
26. hrough the overflow hose 13 to the pp iee MAE D drain r nU ka As the water fills the cylinder it will reach the electrodes 7 and current will Fig 1 a T 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 the desired current is reached the fill valve will close 1 and the water will then begin to warm and produce steam If the water reaches the cylinder full probes 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 degrees F 60 degrees C in accordance to local and national standards Periodically based on the incoming water conductivity the unit will run drain pump 11 and drain some water to reduce the mineral concentration Every 120 hours the unit automatically drains to remove mineral sediment on the bottom of the cylinder A strainer 12 in the cylinder helps to prevent mineral debris from jamming the drain pump 11 In case DS 50 DS 50 LC remains powered but idle i e without producing steam for more than 72 hours 3 days the cylinder will be emptied to not have stagnant water inside If there is no water in the cylinder the
27. humidifier so it must be supported by itself A coupling should be used The DS 50 DS 50 LC 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 60 C or 140 F The drain water characteristics are Drain Rate 26 8 liter per minute or 7 1 gallons per minute Connection 32mm or 1 1 4 Temperature 60 C or 140 F NOTE Drain line must be trapped under the unit to prevent flash steam from condensing in the unit cabinet min 59 3 3 4 Drain Connections When using a rear outlet drain passing through drywall we suggest using a 1 1 4 extension tube type SJ see Fig 3 1 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 IMPORTANT WARNING The drain pipe must be free without back pressure We recommend an external anti flooding device not supplied to protect from faults of external hydraulic circuits 3 4 Steam distribution 3 4 1 Duct steam injection The maximum allowed duct static pressure is 2 in WC The DS 50 DS 50 LC duct injection models include a 12 Steam Distribution Manifold Mounting screws Steam Inlet Condensate drain Flange gasket Fig 3 j Select an accessible location on the duct allowing at least 36 of straight duct no elbows or obstructions after the po
28. humidistat air flow proving switch and remote on off Included with the humidifier is the GFX50 Modulating Humidistat The control will increase a steam output if the humidity and setpoint are far apart It will reduce output as the humidity nears the setpoint This allows for the most precise humidity control For on off operation the humidifier is operated by the closing of a mechanical humidistat H or by the closing of a voltage free remote contact or alternatively by a combination of both A pressure switch is always used to confirm blower operation The diagrams in the figures show the connections to be made on the terminal block in case of Fig 3 r Operation performed by an external mechanical humidistat or control contact and pressure switch Fig 3 s Operation controlled by the included GFX50 Humidistat and pressure switch es SE Goo Contact AB AB Closed humidifier enabled to produce when humidistat closes closes or increases voltage Open steam production is immediately stopped The remote on off contact is usually the pressure switch included with the humidifier The pressure switch NO and C terminals are connected to the AB AB terminals e The remote on off may include safety switches wired in series with the pressure switch These may include a high limit humidistat a relay that closes when fan is running or a downstream cooling coil contact that closes when
29. imes higher than when finished Elite Steam humidifiers may be operated while construction is underway but reduced cylinder life is to be expected and budgeted for Good practice dictates that the steam cylinders also be replaced once the project is complete 1 3 Calculating Humidity Load 1 3 1 Steps to Determine Humidity Load Table 1 2 Pounds of Moisture Hour Cubic Foot Total Square Footage x Average Ceiling Height Indoor Air 35 RH ye Po LE SUN 0 00015 0 00018 0 00021 0 00024 x 1 05 for each Fireplace _ Humidity Load in Ibs hour 0 00017 0 00020 0 00023 0 00026 0 00019 0 00022 0 00025 0 00028 Based on 5 air charges per hour x 2 88 convert to gallons day Gallons per Day Humidity Load Based on 5 air changes per hour DS 50 DS 50 LC 4030222065 Rev 1 2 7 2 MODELS There are two basic models available for different water conditions Duct Steam Injection Fig 2 a MODEL LIST PART NUMBER DESGRIPTION PARTS INCLUDED DS 50 Duct steam injections 58 gallons per day Humidifier with Duct Mount Kit and Humidity GFX50 control 20 Lbs per hour 220 240V DS 50LC Duct steam injections 58 gallons per day Humidifier for Low Conductivity water Includes Duct Mount 20 Lbs per hour 220 240V Kit and GFX50 control DS 50 DS 50 LC 4030222065 Rev 1 2 8 3 1 Positioning The Elite Steam has been designed for wall mounting and since it is an atmospheric steam Clearance Dimensions humidifier
30. int where the manifold will be installed and the clearances can be maintained as per the following drawings See Fig 3 j To mount the steam manifold cut a 2 1 2 hole in the duct Install the supplied o ring or apply caulk to the mounting plate of the nozzle Attach the manifold to the duct using four sheet metal screws Manifold must level or vertical to condensate outlet to the bottom Connect the steam and condensate hoses using the clamps supplied Note End support bracket supplied only with 36 and longer manifold IMPORTANT 1 Allow 3 feet 1m of straight duct downstream of the manifold for absorption of the steam 2 Always allow 2 feet 0 6m of straight duct upstream of the manifold Turbulent air flow may require more 3 Duct must be kept warm Ducts in unconditioned spaces or over faulted ceilings must be well insulated to prevent condensation DS 50 Steam outlet dia mm in 30 1 2 DS 50LC Max capacity kg h Ib h 9 20 Steam inlet dia mm in Max capacity kg h Ib h Length mm in 7599 50 09 steam distributor 30 1 2 15 33 300 11 8 DS 50 DS 50 LC 4030222065 Rev 1 2 12 Mc Min 8 Airflow Bac W Airflow DO cfm min 1 3 Height A es sl Airflow 1000 cfm min Fig 3 k ie Downstream IMPORTANT Allow 1 M 3 feet of straight duct downstream of the distributor pipes and nozzles for absorption of the steam Always allow 0 6M 2 feet of straight duct ups
31. lter elements with each cylinder change 1 2 4 Humidity Load and Cylinder Life Humidity load demands have an effect on cylinder life Normal installations where humidity capacity is properly sized require only intermittent periods where full humidifier capacity is required This allows the water level in the cylinder to be increased only as electrode segments become insulated This tends to maximize cylinder life Extraordinary installations that require constant operation at full capacity reduce cylinder life The water level in the cylinder is on average much higher and the electrodes become completely insulated more quickly Installations like this may result in cylinder life of less than 1000 hours The importance of providing adequate humidifier capacity should not be underestimated Cylinder Life 1 2 5 Maximum Production Another factor affecting cylinder life is the maximum production setting A higher production rate will result in a shorter cylinder life For this reason DS50 or DS50LC units are preset from the factory at 70 Further reductions in Maximum Production will extend cylinder life Fig 1 c See Figure 1 c 10096 20 1 2 6 Structures Under Construction In high end construction projects humidification is often required while the structure is being finished Humidification is necessary to protect and stabilize wood floors trim and decoration Humidification load however in an unfinished structure may be five to eight t
32. onnect 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 the manufacturer are considered incorrect and the manufacturer assumes no liability for the consequences of any such unauthorized use Please note that the humidifier contains powered electrical devices and hot surfaces WARNING Your humidifier requires water to operate Do NOT mount it above materials or machinery that could be damaged if a leak occurs General Filters Inc assumes no responsibility for consequential or inconsequential damage as a result of any leaks Disposal of the parts of the humidifier the humidifier is made up of metallic and plastic parts All parts must be disposed of according to the local standards on waste disposal DS 50 DS 50 LC 4030222065 Rev 1 2 3 DS 50 DS 50 LC 4030222065 Rev 1 2 CONTENTS 1 HOW THE ELITE STEAM WORKS 1 1 BASIC OPERATION 1 2 CYLINDER LIFE 1 3 CALCULATING HUMIDITY LOAD 2 MODELS 3 INSTALLATION 3 1 POSITIONING 3 2 MOUNTING 3 3 PLUMBING 3 4 STEAM DISTRIBUTION 3 5 POWER WIRING 3 6 CONTROL WIRING 3 7 WIRING CONNECTIONS ka START UP 4 1 STARTUP CHECKLIST 4 2 THE ELITE STEAM CONTROLLER 4 3 STARTING THE ELITE STEAM 4 4 STARTING WITH A NEW CYLINDER
33. or solvents e Scale can be removed using a solution by using vinegar or a weak solution of acetic acid and a soft brush then rinse the cylinder thoroughly with fresh water Cleaning the fill valve After having disconnected the cables and the hoses remove the valve and check the condition of the inlet filter clean if necessary using the same cleaning solution as for the steam cylinder and a soft brush Cleaning the drain pump Remove the valve body clean if necessary using the same cleaning solution as for the steam cylinder and a soft brush Cleaning the drain pan Clean the pan of any mineral deposits and check that the water flows freely from the pan to the drain at the drain pump Cleaning the supply fill overflow pipes Check that these are clear and clean or replace if necessary IMPORTANT WARNING after having replaced or checked the plumbing check that components have been reconnected correctly with the proper seals Re start the humidifier and perform a number of cleaning cycles from 2 to 4 read chap Starting with a new cylinder then check for any water leaks DS 50 DS 50 LC 4030222065 Rev 1 2 22 7 3 9 7620 50 25 Replacement Parts i i U s N SPANO je uam fi Jd B N
34. re 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 7 2 2 maintenance section on page 21 SNAM s No Description Steam generator cylinder N B User interface display On Off SET buttons C ID Fill amp tempering valves Tab 1 a FR 4 S DS 50 DS 50 LC 4030222065 Rev 1 2 1 2 Cvlinder Life 1 2 1 Basics of the Steam Cvlinder The Steam Cylinder is the engine of the humidifier As the humidifier operates water is evaporated and minerals are left behind Much of these minerals are removed through the cvlinder drain Some are deposited on the walls of the cvlinder and the cvlinder electrodes When a lower section of the electrodes develop a thick coating the water level is raised to expose clean electrode surface Eventuallv minerals cover the electrodes entire length with a thick coating and little electrical current can pass between them resulting in poor steam output The humidifier can sense the low amperage and will displav the E6 Cvlinder Exhausted error
35. sence inside the cylinder 8 Cylinder draining 9 LEDs indicate power yellow operation green and alarms red 10 Drain button for manual draining of cylinder and confirming parameter values 11 ON OFF button 12 Reset button to reset alarms and access parameters 13 Level of output 3396 6696 10096 14 Fan relav is activated The DS 50 DS 50 LC is now ready to operate 4 3 otarting the Elite Steam e Insure that the external power is turned on e Push the top part of the On Off button so that the l part is in The yellow Power LED will be lit The Elite Steam is now ready to operate e When there is a call for humidity DS 50 DS 50 LC 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 4 4 Starting with a new cylinder When starting with a new cylinder you should activate the cylinder cleaning function as follows 1 Switch Elite Steam off 2 Press and hold both buttons reset and drain and switch DS 50 DS 50 LC back on When the wrench blinks then release the two buttons 3 Press and hold reset until the display shows 04 WARNING DO NOT confirm any value higher than 04 If 05 or higher is displayed press reset until the display goes back to the normal operating mode and restart from step 4 Press drain minimum 1 second the cleaning starts DS 50 DS 50 LC 4030222065 Rev 1 2 18
36. supply water conductivity too conductivity or excessive Press reset sel key for 1 seconds to reset low replace the cylinder foam limescale in the cylinder oO m N Fill alarm unable or slow fill Press reset sel key for 1 seconds to reset otherwise Check water supply and fill valve check current does not increase within the warning will be reset automatically every 10 drain pump for leakage timeout minutes until the supply water is available again m O1 Drain alarm unable to drain Press reset sel kev for 1 seconds to reset Check drain pump and drain connection current does not decrease within timeout m O gt Cylinder exhausted The warning is automatically reset if DS 50 DS 50 LC Change cylinder urgent critical performance detected can produce the demand otherwise turn off and then on Foam detected Press reset sel key for 1 seconds to reset If it continues do some cleaning cycles read chap Starting with a new cylinder Cylinder lifetime expired 2000 hours Reset the hour counter read chap Resetting the hour Off Off Change the cylinder counter High controller temperature above The warning is automatically reset if the temperature Off Off Check the ambient temperature replace 176 F 80 C decreases below 176 F 80 C the controller fe DS 50 DS 50 LC 4030222065 Rev 1 2 20 Problem The humidifier does not turn on The humidifier does not start operation The
37. tream of the distributor pipes for evaporation of the steam Turbulent air flow may require longer lengths 3 4 2 Return Condensate Connection The return condensate hose from the manifold must be trapped Coil the hose into a vertical loop and secure it below the manifold This water trap prevents steam from being released into the hose Insert the barbed fitting into the end of the hose Route the manifold drain hose through the top of the humidifier into the top of the fill cup This is just above and to the right of the steam cylinder See Fig 3 Fig 3 1 DS 50 DS 50 LC 4030222065 Rev 1 2 13 3 43 Steam Hoses IMPORTANT WARNING NINETY PERCENT 90 OF ALL OPERATION PROBLEMS ARE CREATED BY IMPROPER STEAM PIPING FROM THE HUMIDIFIER UNIT TO THE DUCT DISTRIBUTOR PIPES To avoid these problems remember one simple fact when running the steam hose steam naturally flows up hill and condensate naturally flows downhill Run the steam hose or piping to avoid any kinks sharp elbows or low spots that could collect or restrict the flow of steam to the distributor pipe or the flow of condensate back to the humidifier Support the hose adequately to avoid sags The following diagrams are to provide you with some guidelines If you have a situation you are unsure of please contact Technical Support for instructions Contact information is printed on the back cover 1 5 m 5 FT max 22000 IF NO TRAP WITH TRAP 1 5 m 5 FT max
38. 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 In cases of high water mineral content an activated carbon filter is series with a particulate filter no more than 5 microns is suggested This humidifier has been designed exclusively to directly humidify rooms or 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 IMPORTANT BEFORE beginning installation e Check for shipping damage to cartons Mark the shipping waybill accordingly e Open cartons and check for any hidden damage Mark the shipping waybill accordingly e Check packing slip to ensure all items have been received Notify GENERAL FILTERS INC of any shortages or damaged parts You must notify General Filters Inc within 5 working days of any shortages CAUTION ELECTRIC SHOCK HAZARD The humidifier has components under power inside CAUTION SCALDING HAZARD The humidifier has hot parts 100 C 212 F WARNING Install the humidifier out of the reach of children The humidifier must be installed in accordance with all local and national standards All service and or maintenance operations must be performed by qualified personnel who are aware of the necessary precautions and are capable of performing the operations correctly Disc
39. ve load 4 Common alarm contact Amp max with inductive load NO alarm contact NO C External fan relay 250V 8Amp max with resistive load 4 Amp max with inductive load 24GND Power for external humidistat Power supply for external humidistat 24 Vac 2 Watt K Contactor TAM Amperometric transformer Setting TAM 500 with pin strip 3 1 Wiring diagram of controller eee INTERNAL BOX f en u s Q NTC AIR PROVING n 6 i 2 el SENSOR m e em x Pi I AIR PRESSURE SWITCH D lt 6 je HUMIDISTAT 2 z Erant el P N x ALARM EVF Ed 9 o amp 9 x Q 9 EXTERNAL DUCT FAN DP r ER EX N up KO Rd EJ Be A 2 n RO PAN OI m ee x Bl peer A 24VAC FOR a 2 TAM Fe een m a STEAM BOILER UNIT 1q 2 2 6 BOTTON LE H E ee ee E CONNECTED TO GROUND KEY FOR PROGRAMMING PORT EVF FILL VALVE DP DRAIN PUMP DT DRAIN TEMPERING VALVE EXTERNAL FUSED l 2 DISCONNECT TOBE HL HIGH LEVEL SENSOR INSTALLED NOT I SUPPLIED RESPECT LOCAL CODES p E F 1 is sa la POWER SUPPLV 230 VAC 1 PHASE 50 60HZ Fig 3 w DS 50 DS 50 LC 4030222065 Rev 1 2 17 IMPORTANT WARNINGS 1 Before starting check that the humidifier is in perfect condition that there are no water leaks and that the electrical parts are dry 2 Do not connect power if the
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