The ultimateSAM is a direct steam humidification system manufactured by CAREL Industries. It is designed to humidify rooms directly or through distribution systems (ducts). The system is composed of a humidifier steam distributor and various optional components for pressurized or atmospheric steam supplies, such as actuators, valves, strainers, and steam traps. A controlling humidistat and/or sensor is also required for operation.
Function Description:
The ultimateSAM Humidification System discharges steam into a duct or air handler. The method of controlling steam discharge depends on whether the steam comes from a pressurized source or an atmospheric source. For pressurized steam supplies, the steam flow rate is controlled by a valve/actuator assembly, which opens or closes in response to a control signal. Both electronic and pneumatic actuators are configured to provide a linear relationship between the steam flow rate and the control signal. For atmospheric steam supplies, the flow rate is controlled by the rate at which the humidifier produces steam, with all generated steam discharged into the duct or AHU without further staging. The control signal for the actuator or atmospheric humidifier is generated by a humidistat or a humidity sensor and controller, which can be a standalone device or part of a Building Automation System (BMS).
Important Technical Specifications:
The ultimateSAM system is identified by a specific code (SA*) that defines its configuration, including width, height, upright type, insulation, frame, and drain type.
- Distributor Dimensions and Weights:
- Width ("X"): Ranges from 447 mm (17.75 in) to 3031 mm (119.50 in), accommodating 2 to 19 uprights for 152mm (6") spacing or 3 to 37 uprights for 76mm (3") spacing.
- Height ("Y"): Ranges from 598 mm (23.75 in) to 3030 mm (119.50 in) for bottom feed, and 749 mm (29.50 in) to 3181 mm (125.25 in) for top feed.
- Depth: All distributors have a consistent front-to-back depth of 133 mm (5.25").
- Weights: Vary significantly based on width and height, from 7.5 kg (17 lb) for the smallest SABSI30 to 213.5 kg (470 lb) for the largest SATRH30.
- Upright Steam Flow-rate:
- Upright Diameters: Uprights come in two diameters: "S" configuration (35 mm / 1.37") and "L" configuration (45 mm / 1.77").
- SAB/SAT Versions (Multi-upright):
- Type "S" (35 mm): Max 10 kg/h (22 lbs/hr) for SAB*, 30 kg/h (66 lbs/hr) for SAT*.
- Type "L" (45 mm): Max 16.7 kg/h (37 lbs/hr) for SAB*, 50 kg/h (110 lbs/hr) for SAT*.
- SAO Versions (Single-pipe):
- At atmospheric pressure (supplied by a steam humidifier): Max 50 kg/h (110 lbs/hr) (max 20 kg/h for SAOAA***** and SAOBA***** codes).
- With pressurized steam (0.1-4 bar / 1.45-58 psi): Max flow-rate increases with upright length, ranging from 20 kg/h (44 lbs/hr) for 358 mm (14.1 in) uprights to 140 kg/h (308 lbs/hr) for 2030 mm (79.9 in) uprights.
- Inlet Adapters (SAKI****):** Available for atmospheric and pressurized steam delivery systems. Options include 8-to-1, 4-to-1, and 2-to-1 adapters for 40 mm (1.6") pipes, single connections for 80 mm (3 1/8") ID steam hose, and straight or elbow threaded pipe connections (1", 1/2", 2", and 2½" size). A 150 mm (6") inlet extension is also available.
- Drain Connections: P-traps are generally suitable for header drains, with a recommended seal height of at least 500 Pa (50 mm or 2" H2O) greater than the static pressure in the header. Trap, strainer, and separator kits are available for pressurized steam supplies. SAO (single-pipe) versions feature two condensate drains: one on the steam inlet manifold and one at the end of the uprights.
Usage Features:
- Installation: The ultimateSAM distributor can be installed in the duct or Air Handling Unit (AHU). Proper positioning is crucial to avoid turbulence and ensure adequate evaporation distance. Minimum clearances must be maintained from downstream components like fans, heating coils, and filters.
- Mounting: The distributor should be centered within the duct. Structural integrity of the duct or AHU must be sufficient to support the distributor's weight. Shimming the inlet side of the distributor to create a 1% grade (~1 cm per meter, ~1/8" per foot) is suggested for condensate flow towards the drain pipe.
- Frame Assembly: Unassembled frames are shipped with SAB/SAT distributors and consist of bottom supports, side channels, corner brackets, a top channel, and fasteners. SAO (single-pipe) versions also come with an assembleable frame including a manifold with support flange, upright, flange gasket, upright o-ring, and fastening elements.
- Upright Insertion: Uprights are tilted and inserted into retaining rings/gaskets, then secured to the headers with fasteners, ensuring o-rings are properly positioned.
- Steam Supply Connections: Control valves (SAKV******) and fitting kits (SAKR******) are used for pressurized steam supplies. Actuator kits (SAKA******) are available for controlling valve motion. For atmospheric steam, the distributor should be positioned above the humidifier to allow condensate to drain back. Flexible steam hoses require a minimum 20° angle, while rigid pipes need a minimum 1% grade for proper drainage.
Maintenance Features:
- Distributor: The ultimateSAM distributor itself requires no regular maintenance due to its design lacking moving parts. However, external surfaces should be inspected once a year. Any evidence of a steam leak at static seals requires contacting CAREL.
- Optional Equipment: Valves, actuators, traps, and strainers require inspection at least once a year. For systems with inlet pressure to the control valve greater than 0.7 bar (10 psig), more frequent inspections may be necessary. Steam hoses should be inspected yearly for signs of cracking or hardening.
Troubleshooting:
The manual provides a comprehensive troubleshooting guide for common issues:
- Water spitting from nozzles: Check P-trap drainage, steam trap function, steam line slope, steam main overload, and valve sizing.
- No steam discharge: Verify valve opening, steam availability, steam pressure, and Y-strainer clogging.
- Steam valve not opening: Check power/air pressure to actuator, control signal, valve jamming, steam pressure, and valve orientation.
- Steam valve not closing: Check control signal, valve jamming, and steam pressure.
- Steam valve leaking: Check control signal, valve jamming, and steam pressure.
- Humidity exceeds set point: Check control signal compatibility, sensor calibration, sensor installation, valve jamming, steam pressure stability, and BAS system control type.
- Humidity remains below set point: Check control signal compatibility, sensor calibration, sensor installation, valve jamming, steam pressure, boiler pressure stability, BAS system control type, air flow switch, hi-limit controller proximity, and humidifier sizing.
- Condensate in duct: Verify humidifier capacity, hi-limit controller function, evaporation distance, steam valve leaks, and duct insulation.
- Steam leaks from P-traps: Check trap height, valve sizing, and inlet steam pressure.
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