Electric Heater Steam Humidifier
Contents
1. 41 7 1 Electrical Installation 2 0 0 cccccccccessseeceeeeeeeeeeceeeeeeeeeeseeeeseeeesseeseaeeessueessaeeesseeeeseeessueeesaees 41 A nn a 42 2 3 SOMO eet een T Um 43 7 4 Control Connection Steam Bath Application ooocccccccccncnnccconcnnoconononnononncnnononnnoncnnnos 43 7 4 1 Temperature Sensor Connection ccccccssseceecceeseceeccessececseaueeeceeueeeecsaaseeeessageeeeessages 43 7 5 Control Connection Air Conditioning Application ccccocccnncccconcnncccnononnnnnnnnnnononnnnnnnnnos 43 CAN A O ee 44 7 5 2 Proportional Control with an external control signal coonccccccnncoconcnconononnonanonononcnnos 44 7 5 3 Proportional Control with Built In Pl Controller cccccccccseecceceesseeeeseeeeeeeseeeeeeeeeeeees 46 AA e A 47 Tl CNN E 47 58 WI ale HR e AM een een 48 7 9 Electrical Installation Checklist A 48 8 MAINIENAMCEe NEST 49 8 1 Maintenance for Operation with Demineralized Water Condensate 50 8 2 Maintenance for Operation with Tap Water or Partially Softened Water 51 8 3 Access to Control Unit cocooonncccccccccnnccconcnncononnnnncnnncnnnononnnnnonnnnnnnnonnnnrnnnnnnnnnnnnnnnnnnnnnnnnns 52 8 4 Removing and Cleaning the Steam Cylinder nenne nnnnnnnnnennnnnnnnnnn 53 8 5 Maintenance of the Control Cylinder cccccccoccnnccccccnncccconcnncnnnonononnnnnnnnononnonnnonnnnenononaness 58 8 5 1 Cleaning the nozzl2. disconnect unit from check for voltage disconnection water supply remove steam hose from adapter A D j j l B i push clip on adapter der outside cabinet _ liftsteam cylinder out of base Page 54 HyGROMATIK WE HUNIDIFY THE AIR detach connecting cable for heater element s clean cylinder inside a T a A d J W iss clean the two strainers Cleaning of Steam Cylinder and Cylinder base When using mineral deposit removers or cleaners to clean the cylinder and heater elements make sure you thoroughly rinse the unit before returning reassembling it Use mineral deposit removers only for cylinder and heater elements Note Overly strong mechanical cleaning can damage the cylin der heater elements Page 55 HyGROMATIK WE HUNIDIFY THE AIR Remove all deposits However small amounts of scale deposits on the heater elements 8 are harmless Cylinder base 11 and the connections have also to be checked for deposits and cleaned if necessary Cleaning of the Control Cylinder The control cylinder 27 28 29 monitors the water level When cleaning the steam cylinder the control cylinder should also be cleaned Therefore Loosen the four top screws that interconnect floating switch 27 and control cylinder housing 29 Pull out floating switch and clean it carefully Take off sealing 28 and clean it Note The rod assembly may not b
3. The steam cylinder consists of a top 16 and lower 9 part joined with a cylinder flange The seal between the cylinder and cylinder base 11 as well as between the top and lower part of the cylinder is maintained using an o ring Page 12 y WE HUMIDIFY THE AIR General survey The heater elements are equipped with a mechanical high tem perature safety This mechanism provides a redundant safety system in the event of excessively low water levels Dry Run The cylinder water is periodically flushed out with a heavy duty blow down pump 10 Steam is fed into air conditioning ducts through special steam hoses and steam manifolds Under normal conditions this steam has virtually no heating effect on the air to be humidified Accumulated condensate can be returned to the steam cylinder via a condensate hose Direct room humidification without ducts is performed using fan units with blower and nozzle The steam generator is con nected to the fan unit with steam and condensate hoses Page 13 HycroMarile Steam lines in steam bath cabins employ special steam hoses and piping if required Accumulated condensate is normally routed into the steam cabin At a relative humidity of 100 the supplied steam is used to heat the steam bath Warning Leakage of the steam cylinder can cause a serious hazard such as giving an electric shock Warning During blow down hot water with a temperature of about 95 C is being
4. Page 5 HycroMarile 1 3 Directions for Use The proven principle of heating water by the use of electric immersion heaters is exploited to generate steam Using differ ent tap water qualities or partial softened water all humidifier types or fully demineralized water condensate water only for humidifier type HeaterLine HeaterCompact and HeaterSlim Warning HygroMatik steam humidifiers emit steam with a tem perature of 100 C The steam may not be inhaled directly Only qualified and authorised personnel may operate the unit Persons transporting or working on the unit must have read and understood the corresponding parts of the Operation and Maintenance Instruction and especially the chapter 2 Safety Notes Additionally operating personnel must be informed of any possible dangers You should place a copy of the Operation and Maintenance Instruction at the unit s operational location or near the unit The steam humidifier is not qualified for exterior application Page 6 HycnoMaArIK 2 Safety Notes 2 1 Overview These safety notes are required by law They promote work place safety and accident prevention Warnings and Safety Symbols The safety symbols below identify sections containing warnings about hazards or potential dangers Please familiarize yourself with these symbols Warning Failure to observe this warning may result in serious injury or death and or damage to the unit Danger Haza
5. otart up the unit and operate for a few minutes ideally at maximum output Check safety devices Check hose connections for possible leaks 8 15 Dismantling Once the steam humidifier will no longer be used dismantle demolish or scrap it by following the installation procedures in reverse order Warning Dismantling of the unit may only be performed by qualified personnel Electrical dismantling may only be per formed by trained electricians Obey the safety guidelines in section Safety Instructions espe cially the guidelines for disposal Page 64 HycroMarile 9 Commissioning Warning This unit is only to be started by qualified personnel Switching off steam humidifier Warning Before starting up the unit make sure you know how to switch it off Switch off unit by setting control switch to 0 Close water supply stopcock valve Check of electrical wire connections Check that all electrical wire connections including heater element wire connections are tight and secure Check cylinder seating and if necessary steam and condensate hose clamps Switching on Steam Humidifier Switch on main breaker Open water supply stopcock valve Operating pressure 100 x 10 to 100 x 10 Pa 1 to 10 bar overpressure Switch on unit by setting control switch to I Set control of initial operation check to humidity demand The following functions are operating The uni
6. HyGROMATIK Manual Electric Heater Steam Humidifier HeaterCompact r C c i a E IP Installation yellow Plumbing gt blue Electrics red Maintenance gt green General Information white HycRoMaATIK WE HUMIDIFY IHE AIR O Copyright HYGROMATIK GmbH HeaterCompact January 2012 Information in this manual is subject to change or alteration without prior notice Current version of this manual can be found at www hygromatik co uk Warning Hazardous Voltage All work to be performed by trained personnel only All electrical installation and servicing of the electrical components of this unit to be performed by qualified electricians only Disconnect power supply before installation and servicing Page 2 A d Le E 5 1 1 ypogra PNC DISUNCUONS RET UU UU Em 5 1 2 DOCUMENTACION mm 5 1 3 Directions for Use occoocccccccncoccnnocccncnonnnconcncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnanininos 6 A AEN Le 7 A e O O 7 2 2 Guidelines for Safe Operation ccccoooncnccoocnccncoconnnnncononnnnonnnnnnnnnnnnnrnnnnnnnnnnnononnnnnnnnnnenncnnnnness 7 2 9 Disposal alter DISMANI NG sas 8 SA A 9 A e e E o Aa 9 32 Transports ze and VV GION area as 9 SC cle dae E 9 34 IE Storage ee UOTE 9 3 5 Check for Complete and Correct Delivery of Goods ccccooccccccccccococnncconnnnoconcncnnnnonononennnnos 9 3 6 Meluded in Ue Delivery M Et 10 4 Operation and Device Construction
7. ae 2 2 2 2 gt gt 2 2 E 8501064 nose damp DNI amp 2 SES IS OI O SI SI Water Drain ST f LL E2206086 eyinderbasetorC Hy HO DNO 3 P 1 1J 1 1 1 1 1 E220022 ORingforcyliderbase DN40_ A BEN B 2404027 2 pump 230V 50 60Hz without mounting 1 1 1 B 2424014 Bes set for drain oump Eton ea ie vg 1 BB ee O ring cylinder base drain pump 1 E 2425002 adapter pump drain house straight DN2 5 13 D fao CIL LU LU LU TE E ES220995 oringfordrain pump re eieiei E fon wit ent pipe ose drain pump elbow IONES ES CES ALE 08 06 66 Easoicot Joan hose sbon oe MER EE LE oa B 3401 035 hose system for HCO3 09 consisting of pos 7 17 21 22 23 B 3401037 drain hose en for HCO6 P 27 consisting of pos 7 17 22 23 adaper Se Page 68 HycroMarile HCO3 HCO6 HCO9HCO6P HCO9P HCI2 HC18 HC27 Article No Description o Eo L Control Ctt t t t opos B 2507041 main contactor 20A DILM7 coil voltage 230VAC LL LL ud B 2507061 main contactor 35A DILM17 coil voltage 230VAC 1 1 1 1 1 B 2502412 control button 2 pole Basic L3 DS middle 0 CPPPLDTILL B 2602001 solid state relais 25 A 1ph cooling device 150 x 50 mm thermal circuit breaker B 2602103 solid state relais 50 A 2ph cooling device 150 x 50 mm thermal circuit breaker not at Slave units B 2602009 solid state relai
8. u zuuuu0n2an000nnnnnnnnnnnunnnnnnunnnnnnunnnnnnnnnnnnnnnnnnnnnnnn 11 del MOE O ACION oca To ES 11 4 2 Installation and Method of Operation 12 4 3 Internal Output Setting cececcceseecenccseneeecceeeeeesceseeeeececseecesccsesececceseesencosereestecesss 14 5 Mechanical Installation e EEN RREEE RRE RR EEN eere eren eene nnne nnn nnn nnn 15 5 1 Steam Humidifier environmental conditions 15 5 1 1 Egupment Dimensions tee eege 16 5 1 2 Fitting Measures EE 18 e AD SCMOUOM DISTANCE BNI c rea 19 5 2 1 Determining the Absorption Distance occccconnnncccnnncconcnconoconcnnncnnononcnnonannnnnnnnnnonanennonos 19 A PP A 21 A WE 21 5 3 2 Absorption Distance Nomogram cccccccceececeeeeeceeceeeeeeeseeeeseeeesseeeeseeeeseeeesseeseseeesseeeens 23 5A Steam Manifold E 24 5 4 1 Notes on Installation sessi 24 A Tm 28 BiG GOVE EES 29 A a a A E E a 30 9 3 Condernsdle EOS O rm eat 32 s Types REENEN iesen 32 5 10 Steam Solenoid Valves oooonccccccocnccnccnonnoncconnnnoncononnnnnononnnnnonnnnrnnnonnnnrnnnnnnnnnnnononrrnnnnnnness 34 Sol Bi ug eeler 34 6 Water E ETC de Vu NEE 35 Ae 35 6 2 Water Supply For Operation with Tap Water or Partially Softened Water 37 Ao ie ME E 38 6 3 Water TES HEIL errantes 38 6 Water Be e e racial 39 A PPP A o Musee ES I ie MM ee eee SUI 40 7 Electrical Installation
9. 1xDN12 For units HL 6 12 and HC3 12 HygroMatik delivers one adapter DN40 25 but not for SPA applications For units HL 36 45 HygroMatik delivers one t connector for separating the steam on two steam manifolds HI 60 90 are double units and consist of HI 30 45 units Page 27 HycroMarile 5 5 Steam Line Note When installing the steam hose please pay attention to the following The steam hose diameter may not be smaller than the steam outlet of the HygroMatik steam humidifier do not restrict the cross section otherwise back pressure will increase The steam hose must be without sags and kinks and be laid with a continuous slope of 5 10 otherwise sags will be formed The steam hose should be as short as possible In case of lengths of over 5 m the hose should be insulated to avoid excess condensation In the case that steam output is distributed on two steam manifolds the Y pieces for the steam and condensate hose should be installed near the manifolds If the installation is carried out in this way only one steam hose is necessary for the main part loss of condensate will be decreased If the installation is carried out in this way only one steam hose is necessary for the main part loss of condensate will be decreased In deviation of this the y piece that is delivered ex works with a humidifier type C45 HL36 HL45 should be installed near the humidifier Depending on how the hose is laid ho
10. drained This can cause burns to the skin at direct contact 4 3 Internal Output Setting Continuous control of the HeaterCompact Type steam humidifier is achieved by proportional control of the heater elements In this way the humidifier can be proportionally operated across the entire output range of 596 10096 nominal capacity Page 14 HycroMarile 5 Mechanical Installation Warning Installation of this unit should be performed by quali fied personnel only Hygromatik accept no liability for damage due to faulty installation Obey all safety instructions and warnings on the unit During installation the unit must be disconnected from its power supply Accessory equipment may not be installed on or in the unit with out prior written consent from HYGROMATIK Otherwise the warranty is void Warning If the installation of this unit is attempted by only one person there is a risk that the unit will drop down We propose to carry out the installation by two persons 5 1 Steam Humidifier environmental conditi ons Note When selecting the location for steam humidifier installa tion be aware of the following e Ambient temperature must be between 5 and 40 C e Relative humidity may not exceed 80 RH Observe clearances specified in the diagrams below to ensure adequate ventilation An Installation in a closed room requires aeration and if neccessary temperature conditioning in order to reach the above ment
11. generally sufficient Install the fan unit directly on a wall Fan Unit Warning 9 3 1 During operation and some time afterwards the steam nozzle is hot This can cause burns to the skin at direct contact During operation the cross flow fan rotates Do not touch the fan during operation During operation hot steam discharges from the nozzle In the field of the visible steam cloud contact can cause burns to the skin During operation the cross flow fan rotates Do not touch the fan during operation Fan Unit Type VG The fan unit is installed above the steam humidifier When using multiple fan units do not exceed a maxi mum distance of 5 m from the steam humidifier Observe the clearances specified in the diagrams below min 1000 1000 all dimensions in mm Page 21 HycroMarile Fan unit wall installation ca u min 3000 la steam Side view wall mounted fan unit LLL BERN QuamiyofSteam a je 7 90 Steam Inlet mmo 40 Condensate Outlet mmo a 12 Airflow Capacity com h 185 Nominal Output W Bo 67 Nominal voltage NM ee RN Dimensions W mm 441 507 C NM EM EM AAA Wem SSO Page 22 HyGROMATIK WE HUNIDIFY THE AIR 5 3 2 Absorption Distance Nomogram Air temperatur after 8 7 D 6 4 O y D E gt 1 c Example E z Given circulating air mode ie x 5g kg Ax 3g kg S ty t2 20 C
12. 0905 mounting plate with foil for Comfort Plus unit without display 1 1 1 1 1 1 1 1 B 2526447 Comfort plus display incl mounting plate with foil steam bath Page 69 HycroMarile po Accessories ZP pp TI 82604034 Reducing piece DN40 DN25 for steam hose _ Zap t LEE Steam hose DN25 perm ZP pp Tp LEE Steam hose DN40 perm App 82604002 CondensatehoseDN12 perm ZP pp Tp Sean hosedampDN25 TI E 2604042 Steam manifold piece DN25 stainless steel E E 2604023 Steam manifold piece DN40 stainless steel E 2604021 Condensate connector T piece DN12 E 260094 Double check valves TN E a ua B 2604025 steam solenoid valve 0 0 4 bar compl for steam hose DN 25 pp NE steam hose DN 40 If you order any spare parts specify type and serial number of the unit please see exploded view Page 70 HycnoMATIE 12 Fax Form Order for spare parts Fax Form Please copy fill in and fax to HygroMatik Lise Meitner Str 3 Fax No 49 0 4193 895 31 24558 Henstedt Ulzburg Tel 4904193 895 0 Order of spare parts unit type serial no commission order no em mem mx date of delivery forwarder shipment by delivery address if different from invoice address company stamp delivery adress date signature Order can only be processed if unit type and unit serial no are filled in Page 71 HycRoMaATIK WE HUMIDIFY THE AI
13. DN40 not to scale 75 140 5 150 Note CS scale 9 5 70 d 40 ge a fo Se 80 40 HycRoMaATIK WE HUMIDIFY THE AIR 130 Due to variable print media the dimensions are not to Page 31 HycroMarile 5 8 Condensate Hose Note When installing the condensate hose please pay atten tion to the following Warning To keep condensate from accumulating in the duct make sure condensate can drain freely If the steam manifold is positioned higher than 500 mm above the steam humidifier Remove the condensate plug 12 from the connection fitting on the cylinde Lay the condensate hose at an approximate incline of 5 1096 to the steam cylinder connection fitting to allow the condensate to drain freely Note It is recommended to form a loop of 200 mm diameter as a vapour trap provided there is enough space Possible operat ing noises can be reduced in this manner If the steam manifold is positioned lower than 500 mm above the steam humidifier The condensate must be drained separately To prevent steam loss lay a loop at least 200 mm in di ameter To ensure condensate drainage place the loop vapor trap as far away as possible below the steam manifold connection The condensate connection on the steam cylinder must be closed with a sealing cap Place hose clamps at intervals of at least 500 mm de pending on how the hose is laid 5 9 Types of Installation If the s
14. R 13 Index A Absorption Distance cc ecccccceeseccccceeecccecesecceeeaeeeceeeaneeceesaees 19 Determining the Absorption Distance 0seeeeeeseeeeeeessee 19 C ORIS SI PIITIC americana rro orinar 65 Condensate Hose Installation seeeeeessssses 32 E BREET e E 66 Electrical Installation eseeeeseeeeereeeenree 4 Environmental Conditions ccccccccccsssecccceesecceeeeecceeaeaeeees 15 Exploded View 76 F A UU 21 Installation Equipment Dimensions H 16 Fitting Meaeures nennen 18 Installation of a Heatert ompact 15 Internal Output Setting ccc eeessscccecceeeseceeeseeeseeeeeeseeeees 14 M USUS Le 49 BIOW Down le Discusion 62 COMO UI ANNE 56 PIC ANCE E 58 A e ne et 53 INS NO SENSOL T T 50 Method of Operation ooooccncccocccnnnconccnnnnnnccnnnnanocnnnonanicnnnnanoss 12 Mode O ACHON E 11 S odlety Interlock esce eerte ee ARO N NE 42 Selling ior Control SIONAl E 43 Spare JP OS ee ee 67 o PP A 28 Steam MARRON 24 Notes on Instala sica een 24 Page 72 HycRoMaATIK WE HUMIDIFY IHE ATR T Technical Specification occoooooocccnnncnnonocnnnncnnnoccnnnnnnnnos 74 U Unlocking Thermo Sensor for heater element 60 Unlocking Thermo Sensor for Solid State Relais 60 V VOW OF CADNO m Ur W Water Installation e
15. ach electrical connector from the pump 10 Detach union adapter E from the pump Remove screws G and take the pump out of the base 11 Open pump bayonet lock Remove all residue from the drain hoses and pump possibly replace o ring A Assemble pump Moisten o ring C and place in the side connection of the base Push pump into the base and secure tightly with screws G Moisten o ring D and place on the side connection of the pump Slide union adapter E over the side connection of the pump Connect electrical connector to the pump polarity not specified Open water supply Switch on unit and check for leaks after 15 30 minutes of operation If leakage occurs switch off power supply and repair the leaks following safety instructions for work on live components Page 62 HycRoMaATIK WE HUMIDIF Y THE AIR 8 12 Cleaning connection hoses and cylinder base All connection hoses should be free of deposits and under good conditions As well check all connections of the cylinder base 11 and the steam hose adapter 2 for deposits and remove if neccessary Page 63 HycroMarile 8 13 Checking Cable Screw Connections Heater Element Wires Check that all cable screw connections are securely tightened Ensure that heating element cable is not dammaged Warning Loose cable connections cause excessive contact resistance and overheating of contact surfaces 8 14 Operational Check
16. anderung des Ger tes f hrt zum Verlust der Konformitat The requirements of the German Appliance and Product Safety Law GPSG paragraph 4 clause 1 fo 3 are met Product modifications after delivery may result in a loss of conformity Henstedt Ulzburg den the 16 11 2009 HygroMatik GmbH Maike Nielsen Dirc Menssing General Manager Technical Manager Quality Manager Diese Erkl rung bescheinigt die Ubereinstimmung mit den genannten Richtlinien ist jedoch keine Zusicherung von Eigenschaften Die Sicherheitshinweise der mitgelieferten Produktdokumentation sind zu beachten This declaration certifies the conformity to the specified directives but contains no assurance of properties The safety documentation accompanying the product shall be considered in detail Page 66 MATIK WE HUNIDIFY THE AIR 11 Spare Parts HcrHc Hcz Antice No Description CabneHC 1 B212907 Cabinet nm 1 LL LL Ll Siem Generation 1 B 2205483 Cylinder compl with 1 heater element ee 1 B 2205455 Cylinder compl Incl 1 heater element 4 5kW 1 LE E Lo EL O Wies 1 B 2205459 Cylinder compl Incl 1 heater element 6 7 5kW LI LE EL DL LL DI Wie aema o 1 B 2205463 Cylinder compl Incl 1 heater element 4 5kW 1 LI LL LL DI Vie aaen oo 1 B 2205467 Cylinder compl Incl 1 heater element 6 75kW LL LL E LLL E LL ieee tina o 1 B 2205471 Cylinder compl Incl 2 heater elements 4 5kW ICT LLL D ma senso aa emra
17. atest at the latest Truck and compa 4 MELO at the latest nies Parcel Parcel Service immediatly eee ree NN to change without prior c E 3 6 Included in the Delivery The delivery includes e Unit of the selected humidifier type including selected con trol Water installation hose Manuals for the steam humidifier and the control Ordered accessories steam manifold steam hose con densate hose etc Maintenance o ring set for steam cylinder Page 10 HycroMarile 4 Operation and Device Construction 4 1 Mode of Action The Imersion Heater Principle One to three heater elements Pos 8 in the exploded view please see cover foldout are placed in a closed cylinder and connected to alternating current The cylinder is filled with tap water fully demineralized water or partially softened water Heat generated by the heater element increases water temperature to approx 100 C When fully demineralized water is used the feed water is practi cally free of minerals This ensures long life for the cylinder and heater elements since virtually no mineral deposits can settle or build up Fully demineralized water minimizes the number of ser vice maintenance checks When tap water is used some of the minerals dissolved in the water will settle in the cylinder as solids of various compositions Most of these scale deposits are removed by periodic flushing or use of a heavy duty blow do
18. cce eene 35 Water UD en a ee ee na 36 Page 73 HycroMarile 14 Technical Specifications HeaterCompact HC Steam Outpt 3 6 6 9 6 9 i2 18 27 400V 3 N 60 60H2 C O ELE PowerRating KW 225 45 45 68 45 68 90 185 203 PowerConsumplon A 98 196 71 3 169 143 169 195 293 293 Number of Steam Cylinder d NumberofHeaterElemenis 1 1 1 1 1 2 2 8 Condensate Hose 1x12mm Connection NetWeghkg 16 16 16 16 25 25 26 26 27 Operating Weight kg 18 18 18 18 48 43 44 44 45 Height mm TO 490 306 Water Supply Fully Demineralized Water Cleaned Condensate 1 to 10 bar 13mm Hose Partially Softened Water Tap Water different qualities 1 to 10 bar for 3 4 external thread Airflow Capacity of Fan Unit 160 160 160 185 160 185 185 350 350 m h Other voltages upon request Current load of phases is not uniform See table below incl reducing piece DN40 DN25 Max current load A according to phase 400V 3 N 50 60Hz Page 74 HycroMarile HeaterCompact HC for SPA HCO03 DS HC27 DS Seam oupi 3 6 6 9 6 9 i2 i8 27 PowerRating KW 225 48 48 68 45 68 90 135 203 Power Consumption A 98 19 6 13 169 113 169 195 293 293 Number of Steam Dinde o o O Number of eaterElements T T T I T I T 2 7 2 79 Conde
19. connect capillary T tube from the heater elements 8 Remove the etwo screws S of thermo sensor O Remove thermo sensor O Thermo Sensor P Unlocking Button for Thermo Sensor Q Seal R Steam Cylinder o Screw T Capillary tube Warning Do not bend the capillary tube of the thermo sensor Installation Install thermo sensor with new sealing Do not fix the screws too tightly Neatly connect the capillary tube to the heater element Having humidifiers with two or more heating elements the capillary tube is connected to two heating elements To proceed further follow the steps described above in section Cleaning Coarse Strainer in Cylinder Base Assembly Page 59 HyGROMATIK WE HUNIDIFY THE AIR 8 8 Unlocking of a Released Thermo Sensor for heater element If a thermo sensor for heater element has released due to a too high temperature the red release button P is some millimetres above the level of the top of its holder Additional the control reports a failure thermo sensor activated After the system has cooled down the release button P can be unlocked by pressing it down a few millimetres 8 9 Unlocking of a Released Thermo Sensor for Solid State Relay If a thermo sensor for solid state relay has released due to a too high temperature gt 100 C 5 K the control reports a fail ure thermo sensor activated After the system has cooled down the re
20. e 37 HycroMarile 6 2 1 Feed from Holding Tank If a holding tank will be used to supply water the option sole noid valve 0 10bar must be ordered Make sure that the feed height is at least 0 5 meter If the height is less than 0 5 m insert a feed pump or install the humidifier lower if possible Min 0 5 m without feed pump Manual valve Filter Feed pump only when the hight is less than 0 5 m option solenoid valve 0 10 bar 6 3 Water Treatment For water treatment system specifications use the following table The figures below assume that the humidifier has been running for 24 hours at 10096 output tion in over24 h I BL JI 248 L3 Max Water Consump tion in over24 h I Page 38 HycroMarile 6 4 Water Discharge Warning Please pay attention to free and non pressure drain age of the water During blow down up to 0 3L s is being drained For water discharge we recommend installation of a flexible water drain hose Humidifier and waste water discharge must be on the same pressure level Please note e Do not bend shorten or lengthen the drain hose e For the discharge line and drain pipe select materials temperature resistant up to 95 C Cabinet Pump drain hose ERA AA TARA EEE ARIE EER EP ERROR DE Connecting piece min 250mm max 1000mm HT pipe min DN40 Install the water drain system as follows e Run 250 1000 mm l
21. e in the steam hose adapter ooococcccccncccccccnnccnccnnnncnncnnnnccncononncnncnnnas 58 8 6 Replacing Heater Elements snm 58 8 7 Replacing Thermo Sensor for Heater Element occcccoccnccccnnnnoccnnncnnnnnnnnnnnncnnanonononennonos 59 8 8 Unlocking of a Released Thermo Sensor for heater element 60 8 9 Unlocking of a Released Thermo Sensor for Solid State Relay 60 8 10 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter 61 8 11 Cleaning Blow Down Pump seeeseseeeeeeeennnnenen nennen nennen nnn nnns nnns na nnn nnns 62 8 12 Cleaning connection hoses and cylinder base occcoonccnncccoccnncccnnccnncnnnnconcnnnnncnnnnnnncnnnnnnos 63 8 13 Checking Cable Screw Connections Heater Element Wires nennen 64 8 14 Operational Check 64 o mm 64 9 COMMISSIONING E 65 10 EC Declaration Of Conformity 2 2 2220000 aa00000nnnnnunnnnnnnnnnnnnnnnunnnnnnnnunnnnnnnnnnnn 66 11 Spare e CES 67 12 Fax Form Order for spare parts ccccccesseccsssseeceesseeeenseeeeeeseeeenseeseenseesenneeeeenseseenseeses 71 IS MOS aaa 72 14 Technical EE d TE 74 19 ele e Ee ATTEN 76 16 VIEW OF CANO eege 77 Page 4 HycroMarile 1 Introduction Dear Customer Thank you for choosing a HygroMatik steam humidifier HygroMatik steam humidifiers represent the latest in humidifica tion techno
22. e lubricated Clean the sealing surface it the control cylinder housing 28 For installation mount the a m components in reverse order Assembly EN mu a E d e WH o E ui Y 2 A F T dt C Lumen F 1 connect upper and insert new O ring lower part with clamps i n UM wis XN 4 remove used O ring insert new O ring Page 56 WE HUMIDIFY THE AIR Note When putting the cylinder back together the joints and Cg reinforcements of both sections must fit together snugly remove old O ring insert new O ring HL d Boe place cylinder vertically into cylinder base odia je fix adapter with clip bur Ms Ze install connecting cable for heater element s A x d 4 fi push adapter onto steam outlet it mem reconnect to power supply Switch on the unit and check for leaks after 15 30 minutes of operation Page 57 HycroMarile 8 5 Maintenance of the Control Cylinder When cleaning the steam cylinder the control cylinder should also be cleaned As the access to the control cylinder is only possible if the steam cylinder is removed one can find the sub chapter Cleaning of the Control Cylinder in chapter Cleaning the Steam Cylinder 8 5 1 Cleaning the nozzle in the steam hose adapter From the top of the control cylinder a hose is laid to the connec tor at the steam hose adapter Within this connector there is an in
23. e safety interlock Warning Contacts laid between terminals 1 and 2 must be potentialfree and rated for 230V switches Bv the use of a Basic control must be set as indicated below For 1 step controls the jumpers By the use of a Comfort Comfort Plus control For 1 step con trols Parameter U6 must be set to 1 step also see Section Parameter Setting with Codes PO 10 Advanced Customer Level in the technical manual for the Control 7 5 2 Proportional Control with an external control signal The control can be adjusted to the following external control sig nals 0 2 5V DC 0 2 10 V DC 0 4 20 V DC 0 4 10 mA DC 0 4 20 mA DC 0 140 Ohm Page 44 Basic Control Comfort Control HycRoMaATIK E HUNMIDIFSY HE AIR The factory setting is a control signal of 0 10V Controller Humidifier Terminals By the use of a Basic control For a Proportional Control with an external control signal the jumpers must be set as indicated below Setting for External Control E Signal 0 2 10 VDC d Setting for External Control Signal 0 4 20 mA d Setting for External Control d Signal IH 0 140 Ohm 7 By the use of a Comfort Comfort Plus control For a propor tional control connected to an external control signal Software Parameters U6 and E3 must be set as indicated below Setting for External D n 10V DC EM O V ler 20 mA external control 0 20 mA le
24. ength of 1 1 4 drain hose loosely into a drainpipe with a minimum inner diameter of 40 mm HC 3 27 1x1 1 4 HS 3 10 e Slide the drain hose over the pump discharge hose and secure to the cabinet drain connection A grounding clip is fixed on the inner surface of the cabinet drain connection Slide the end of the pump drain hose onto this clip During blow down the grounding clip will be in direct contact with the water and will conduct any residual currents which may appear away from the cabinet There is a 3mm wide gap between the pump drain hose jacket Page 39 HyGROMATIK WE HUNIDIFY THE AIR and the inner surface of the cabinet drain connection If water collects on the base plate it will flow through this gap into the drainage system Pump drain hose Case drain hose grounding 1 1 4 6 5 Checklist Verify correct system installation using the checklist below v Can flushed out water drain freely v Have all screws and clamps been properly tightened v Is the water supply line properly flushed out M Has the water installation been performed correctly Is the drainage system correctly installed Are the water supply and drain lines free of leaks Warning Flush out the water supply line before connecting to the solenoid valve especially when installing a new line This prevents dirt particles from damaging the solenoid valve Page 40 AN A HycroMarile 7 Electrical Installat
25. er air interlock etc in series between Terminals 1 and 2 Warning lt is standard practice for air conditioning to install a max hygrostat in the safety interlock not valid for steam bath applications The max hygrostat acts as a safety device in the event of a humidity sensor malfunction and protects against overhumidification Warning Contacts laid between Terminals 1 and 2 must be potential free and rated for 230V switches Terminal 1 is supplied with 230V AC after switching on the humidifier Page 42 HycroMarile 7 3 Control Connection Within the scope of this manual there is only a short descrip tion of the Adjustment of the Control to the Control Signal at this point More detailed information please find in the technical manual for the control that is also delivered with the Heater Compact The Heater Compact is used in both applications for steam bath and air conditioning As the Heater Compact is controlled via the temperature in steam bath applications and via the air humiditiy in air conditioning applications different types of controls are used Therefore the descriptions of the Control Connections are also different 7 4 Control Connection Steam Bath Applica tion Valid for Controls Basic DS B DS Comfort DS C DS und ComfortPlus DS CP DS 7 4 4 Temperature Sensor Connection Connect the temperature sensor cable to the designated termi nals 6 and 7 on the HygroMatik steam generator The fac
26. ff valve AV water filter WF and backflow pre venter are not provided by HygroMatik Install as follows Check whether the valve strainer has been inserted in the solenoid valve Screw cap nut Q onto the supply connection Tighten by hand The supply connection protrudes from the intermediate tray Note Excessive tightening will damage the threads Slide 13mm inner diameter hose SCH over the pres sure clip R and secure with a hose clamp Page 36 L HyGROMATIK WE HUNIDIFY THE AIR 6 2 Water Supply For Operation with Tap Water or Partially Softened Water Install a shut off valve SV in the supply line Install a water filter WF if water quality requires it Make sure that a backflow preventer is installed in the water supply line Note Shut off valve SV and water filter WF are not supplied with the unit Water supply 100 x 10 to 100 x 10 pascal 1 to 10 bar E 17 Connection HygroMatik provides a water hose 56 with a cap nut at both ends which can be used for water installation Install as follows ocrew and tighten the cap nut with its inner seal ring around the water supply screw connection that pro trudes from the base Note Tightening too much will destroy the fitting The valve strainer must be placed inside the solenoid valve Use a cap nut internal thread 3 4 with inner seal for a customer provided water installation Pag
27. folgender Europ ischer Richtlinien berein The products described above in the form as delivered are in conformity with the provisions of the following European Directives 2004 108 EG Richtlinie des Rates zur Angleichung der Rechtsvorschriften der Mitgliedstaaten ber die elektromagnetische Council Directive on the approximation of the laws of the Member States relating to electromagnetic compatibility 2006 95 EG Richtlinie des Rates zur Anleitung der Rechtsvorschriften der Mitgliedstaaten betreffend elektrische Betriebsmittel zur Verwendung innerhalb bestimmter Spannungsgrenzen Council Directive on the approximation of the laws of the Member States related to electrical equipment designed for use within certain voltage limits Die Konformit t mit den Richtlinien wird nachgewiesen durch die Einhaltung folgender Normen Conformity to the Directives is assured through the application of the following standards Referenznummer Ausgabedatum Referenznummer Ausgabedatum Reference number Edition Reference number Edition DIN EN 55022 2008 05 DIN EN 60335 1 2007 02 DIN EN 61000 4 2 2001 12 DIN EN 60335 1 A13 2009 05 DIN EN 61000 4 3 2008 06 DIN EN 60335 2 98 2009 04 DIN EN 61000 4 4 2005 07 DIN EN 62233 2008 11 DIN EN 61000 4 5 2007 06 DIN EN 62233 Ber 1 2009 04 DIN EN 61000 4 6 2008 04 Die Anforderungen des Ger te und Produktsicherheitsgesetzes GPSG 84 Abs 1 bis 3 werden eingehalten Eine vom Lieferzustand abweichende Ver
28. hat fix the steam cylinder halves have par tially sharp edges and could spring out uncontrolled during removement Prevent springing out clamps by covering the clamps with one hand during removement The steam humidifier s performance and maintenance intervals depend primarily on the existing water quality and the quantity of steam generated Variable water quality can lengthen or shorten the maintenance interval Ongoing maintenance intervals can be estimated based on the amount and type of residue found in the steam cylinder Immediate cylinder maintenance is indicated by a green blinking LED on the display and operating panel the display reads Service only with controls of Type Comfort and Comfort Plus Page 49 HycroMarile 8 1 Maintenance for Operation with Demineralized Water Condensate Instructions for maintenance and cleaning intervals are based exclusively on typical empirically determined values Maintenance Task 4 Weeks after Visual check of electrical and mechanical Initial Operation connections Visual check of water level control Visual check of steam cylinder interior Visual check of electrical and mechanical connections Visual check of water level control Visual check of heater elements thermo sen sor Visual inspection of interior of steam cylinder If needed cleaning of steam cylinder heater elements and thermo sensor Page 50 HycroMarile 8 2 Maintenance for Operation
29. ides The PCB C is now accessible Danger Hazardous Voltage Switch off unit before installing or removing the display plate Page 52 HyGROMATIK EHUMIDIFY THE AIR 8 4 Removing and Cleaning the Steam Cylinder Warning Please follow the detailed instructions in these operat ing instructions The unit is only to be serviced by qualified authorized personnel Note the warnings and safety notes in the operating instructions Failure to observe warnings and safety notes may result in injury serious injury or death and or dam age to the unit The steam cylinder may still be hot when you begin maintenance work Handle carefully Note After a longer period of operation the steam cylinder could shrink a little This doesn t matter but could lead to tightness dis crepancies when only one half of the cylinder is being exchanged Therefore we recommend not to change only one half of the cylinder but a complete cylinder Removal on off switch in position Il d RE Ze B e zi A igitnr m Ka i2 Pa Lu I e EZ i i 3 ae L3 E i Te ur 1 W W 1 lie 1 B L d Im 1 i t F z NW s 4 i L L a i pe EET ari kN i d ue 1 Xx after cylinder draining endlich off unit EA de ALS disconnect unit from voltage supply open unit Page 53 ATIK WE HUMIDIFY THE AIR GL KE i
30. ion Warning Hazardous Voltage All work related to electrical installation may be performed by authorized personnel only electricians or professionals with equivalent training The cus tomer is responsible for checking qualifications Warning Haz ardous Voltage Do not connect the steam humidifier to the power grid until after all installation work has been completed Please obey all local regulations concerning electrical installa tion Warning The electronic components of the humidifier contro are very sensitive to electrostatic discharges In order to safe guard these components during installation and servicing steps must be taken to protect against ESD Warning For installation note the following Disconnect power supply prior to installation and secure against restart Verify the absence of electric current Installation or removal of the display and control unit may only be performed when the unit is switched off See also section Access to Control Electrical connector cables must be wired by qualified per sonnel Install electrical connections as specified in the wiring diagrams For units with power ratings over 33 kW only a permanent connection to a permanent installation is permitted observe European Directives shown in chapter EC Dec laration of Conformity Ensure that all terminals have been tightened e We recommend to install a fault current circuit breaker 7 1 E
31. ioned environmental conditions e HygroMatik humidifiers are not suitable for direct out door installation e Install the steam humidifier as close as possible to the steam manifold Use only short lengths of steam and condensate hose to ensure optimal performance e Hoses must be laid at a constant 5 1096 grade to uni formly prevent sags and kinks e The back surface of the steam humidifier heats up dur ing operation to max 70 C Take care that the con struction on which the unit is mounted is not made of temperature sensitive material o Place the steam humidifier so that the unit is easily accessible with sufficient space to perform mainte nance o The unit s protection class is IP20 Page 15 HycRoMATIK 5 1 1 Equipment Dimensions HC View from below Water inlet Cable entries Rear view Steam outlet View from top Page 16 ATIK WE HUMIDIFY THE AIR HC12 HC27 707 427 490 306 all dimensions in mm General Survey Page 17 HyGROMATIK WE HUNIDIFY THE AIR 5 1 2 Fitting Measures Wall Distance gt 50 gt 200 gt 500 2300 D D D all dimensions in mm CE Note lt is often advantageous to use existing water connections feed and drain when selecting the steam humidifier Wall Mounting Note To function properly the steam humidifier must be i
32. ions Install the steam manifold safe from contact with people in order to prevent injuries or burns Do not install the steam manifold near a tempera ture sensor or inaccurate readings may result Air flow rates over 3m s can possibly lead to condensate drainage problems at the steam manifolds which may require adaptation measures Length of steam manifold mm special lenght on request Note 120 4 70 y 80 At lengths of 600mm or more steam manifolds are shipped with an extra alternative mounting fixture Nut M8 on the closed end Page 26 HycnoMaArIK The number and size of appropriate steam manifolds as well the nominal width of their respective steam and condensate hoses are found in the tables below HyLine Ea tefl lios HY05 HY17 1xDN25 DN25 DN HYO5DS HY17DS for 1xDN40 Co MS eg SPA HY23 HY30 1xDN40 DN40 DN12 HY45 HY60 2xDN40 2xDN40 2xDN12 HY90 HY116 4xDN40 4xDN40 4xDN12 CompactLine Steam Manifold Condensate Hose 1xDN25 DN25 DN12 C10 DS C17DS 1xDN40 DN40 DN12 for SPA C22 030 1xDN40 DN40 DN12 2xDN40 2xDN40 2xDN12 HeaterCompact Steam Manifold Condensate Hose HC3 12 1xDN25 DN25 DN12 HC16 27 1xDN40 o DN40 DNI2 HC3 27 for EE CB ec 2 SPA DBE HeaterLine Steam Manifold Condensate Hose 1xDN25 DN25 DN12 1xDN40 DN40 DN12 for SPA HL 18 30 1xDN40 DN40 DN12 HL 36 45 2xDN40 1xDN40 1xDN12 HL 60 90 2x 2xDN40 2x 1xDN40 2x
33. lease pin that lays between the both plain connectors can be released by pressing it carefully down until there is a klick sound Helease button Page 60 HycnoMaArIK 8 10 Removing Inlet Solenoid Valve and Clean ing Fine Mesh Filter Removal gt Remove and open the steam cylinder as described above in section Removing and Cleaning the Steam Cylinder Removal oeal off water supply and remove screw joint from fresh water connection Detach connector hose from base Remove electrical connectors from solenoid Remove solenoid valve mounting screws Take the solenoid valve out of hole Cleaning Remove fine mesh filter from the solenoid valve and clean Installation Place solenoid valve with seal in the hole in the unit cabinet Secure solenoid valve tightly with screws Attach fresh water connection Connect elecrical cable to the solenoid valve Attach connector hose to the base by using clamps Install cylinder as described above in section Cleaning oteam Cylinder Assembly Open water supply Switch on unit and check for leakage after 15 30 min utes of operation If leakage occurs switch off power supply and repair the leaks following safety instructions for work on live components Page 61 8 11 HycroMarile Cleaning Blow Down Pump Removal Remove and open the steam cylinder as described above in section Removing and Cleaning the Steam Cylinder Removal Det
34. lectrical Installation Breakers must have a contact gap of at least 3 mm per pole Each steam cylinder requires a separate main power supply including main fuses main breaker etc Connect potential equalization inside the unit to the external ground bolt located on the underside of the cabinet beside the cable connections Observe European Directives shown in chapter EC Declaration of Conformity Page 41 HycroMarile 230V int Terminals Humidifier E We recommend using a main fuse with medium blow rating applies only to the mains voltages above See table below indi cating maximum power consumption corresponding to each type of circuit protection Type Power Supply Power Con sumption HCO3 230V 1Phases N 98A 8A 1x1 1x10A HCO6 230V 1Phases N 19 a m HCO6 P 400V 3Phases N 11 3A 3x20 A 7 2 Safety Interlock Between terminal 1 and 2 of the humidifier the so called safety interlock is located If the safety interlock is not closed the humidifier is not allowed to work Any additional safety devices see below have to be installed between those terminals The safety interlock is also used for an On Off control mode remote switch There is no jumper between terminal 1 and 2 ex works If neither a Remote Switch nor any safety devices are wired to terminal 1 and 2 an electrical bridge has to be set Note Install contact interlocks i e max hygrostat vane relay pressure controll
35. logy They will impress you with their safety ease of use and econom ical operation In order to operate your HygroMatik steam humidifier safely properly and efficiently please read these operating instructions Employ your steam humidifier only in sound condition and as directed Consider potential hazards and safety issues and fol low all the recommendations in these instructions If you have additional questions please contact us Tel 49 0 4193 895 0 Main Number Tel 49 0 4193 895 293 Technical Support Hotline Fax 49 0 4193 895 33 e mail hot1 HygroMatik de For all technical questions or spare parts orders please be pre pared to provide unit type and serial number see name plate on the unit 1 1 Typographic Distinctions e preceded by a bullet general specifications preceded by an arrow Procedures for servicing or maintenance which should or must be performed in the indicated order v1 Installation step which must be checked off italics Terms used with graphics or drawings 1 2 Documentation Retention Please retain these operating instructions in a secure always accessible location If the product is resold turn the documenta tion over to the new operator If the documentation is lost please contact HygroMatik Versions in Other Languages These operating instructions are available in several languages If interested please contact HygroMatik or your HygroMatik dealer
36. mp 100 kg h Ip 1 25 m X WL 5 m s 1 Result absorption distance Bn 9 kg 1 gt E 9 z 2 c E D uU A D UN O E D G a D a Y C D E U E D x a 2 m K o lt o c o 40 50 60 Steam humidity Source Henne Erich Luftbefeuchtung Air Humidification 3 Edition 1984 Page 101 Olden bourg Industrieverlag Munich Page 23 Horizontal installation of steam manifold Steam Manifold HyGROMATIK WE HUNIDIFY THE AIR 5 4 Steam Manifold 5 4 1 Notes on Installation These notes are based on a homogeneous Standard steam manifold installation Duct Steam Manifold An even distribution of steam manifolds ensures a uniform steam distribution Please use the total hight of the duct Air flow direction i Minimum distances in order to avoid condensation Lmin 210mm distance steam manifold next steam mani fold L4min 120mm distance lowest steam manifold duct bot tom L5min 120mm distance highest steam manifold duct ceiling Installations depending on special designs of air ducts Page 24 HyGROMATIK E HUNIDIFY THE AIR Air duei Tree manifolds otaggered vertically and laterally By tilting the steam manifold 30 45 very flat duct towards the air flow direction the mini mum upper clearance can be reduced to 0mm Narrow channel min distances H1 mm narrow high Identical lenghts one on
37. n After proper elec trical installation or repair test all safety mechanisms such as grounding resistance 2 3 Disposal after Dismantling Note The operator is responsible for the disposal of unit compo nents as required by law Page 8 L L HycroMarile 3 Transport 3 1 Overwiew Note Proceed carefully when transporting the steam humidifier in order to prevent damage from rough or careless loading and un loading If the transport of this unit is attempted by only one person there is a risk that the unit will drop down We propose to transport the unit by two persons 3 2 Transport Size and Weigth SE 16 me 380 Test 507 16 Hoos 360 651 507 16 25 db dE Dimensions and weigths can vary insignificantly 3 3 Packing Note Observe the symbols affixed to the box 3 4 Interim Storage Keep the unit dry and protect from frost 3 5 Check for Complete and Correct Delivery of Goods Upon receipt of the unit make sure that type and serial number on the name plate match what is in the purchasing and delivery documents equipment is complete and in perfect condition Note In case of damage during shipment and or missing parts immediately file a written claim with your carrier or supplier Page 9 HycnoMaArIK Time limits for filing freight claims with shipping companies are Transport Company After Receipt of Goods 24 hours at the latest 7 7daysatthe l
38. nected steam hose that Page 7 HycroMarile safely leads the steam HygroMatik steam humidifiers are IP20 protected Make sure that the unit is protected from drips in its installed location Installing a humidifier in a room without water discharge requires safety devices to protect against water leakages Accident Prevention Regulations Comply with the Accident Prevention Regulation Electrical Sys tems and Equipment to prevent injury to yourself and others Operation of the Unit Do not perform any work which compromises the safety of the unit Regularly check that all safety and monitoring devices are functioning normally Do not remove or disable safety devices Installation Dismantling Maintenance and Repair of the Unit Disconnect unit components from power supply prior to mainte nance or repair work Attaching or installing additional components is permitted only with the written consent of the manufacturer Electrical Work on the electrical system must be performed by qualified personnel Disconnect unit components from power supply prior to work It is not allowed to connect the unit to DC voltage supply In case of a malfunction in the electrical power supply switch off the unit immediately Use only original fuses with the appropriate amperage rating Regularly check the unit s electrical equip ment Promptly repair any damage such as loose connections burned wiring or defective electrical insulatio
39. nsate Hose mE Connection NetWeightIkg 16 Te i6 i6 25 25 26 26 27 Operating Weight i8 18 18 18 48 43 44 44 45 8p A Height mm Width mm 490 Depth mm 306 Water Supply Fully Demineralized Water Cleaned Condensate 1 to 10 bar 13mm Hose Partially Softened Water Tap Water different qualities 1 to 10 bar for 3 4 external thread Other voltages upon request Current load of phases is not uniform See table below Max current load A according to phase Phase Hoer HCO9 P HC12 HC18 HC27 Electrical Supply 400V 3 N 50 60Hz Page 75 HycRoMaATIK WE HUMIDIF Y THE AIR 15 Exploded View Page 76 96 57 16 View of Cabinet TIK WE HUMIDIFY THE AIR Page 77 HyGROMATIK Lise Meitner Str 3 e D 24558 Henstedt Ulzburg Phone 49 0 4193 895 0 e Fax 33 eMail hy hygromatik de e www hygromatik com A member of the SPiraX reo Group
40. nstalled CE vertically Measures for drills for wall mounting please see table measures d and e in chapter Equipment Dimensions If there is no suit able wall it is recommended that the equipment is installed on brackets which can be embedded in the floor Page 18 HycroMarile 5 2 Absorption Distance By The absorption distance By is defined as the distance from the steam feed to where the steam is completely absorbed in the treated air Inside the absorption distance steam is visible as mist in the air stream Condensation may collect on anything installed inside the absorption distance Although steam outside the absorption distance By is com pletely absorbed it is not yet evenly diffused in the duct If you plan to install any parts or devices inside the absorption dis tance such as sensors or elbows we recommend increasing the absorption distance using the formulae below The absorp tion distances required for certain installed fittings are distin guished by separate symbols and calculated as a multiplier of the absorption distance By sors ventilators outlets Bs 2 5 3 x By for particle filters By 2 5 3 x By for humidity sensors duct humidistats The absorption distance has no fixed value but depends on many factors These are depicted in the absorption distance nomogram below 5 2 1 Determining the Absorption Distance To determine the absorption distance the following parame
41. o 1 B 2205475 Cylinder compl Incl 2 heater elements 1L LL TI TU VE ee and emna 1 B 2205479 Cylinder compl Incl 3 heater elements EE LLL TL VE dese aema 16 1 1 1 B 3216050 op part of cylinder empty for 1 heater element DA NI I a a 16 1 1 B 2206051 Hop part of cylinder empty for 1 heater TI er perm 16 1 1 B 2206059 top part of cylinder empty for 2 heater LLLLL EL e emu 16 1 B 2206061 top part of cylinder empty for 3 heater LLL es Bee AP ee ee Pt tT fy 1 B 2209029 heater element 230V 2 25kW with sealing and I dL Lo Lo EL LL emie LL LLL LL ELLE e bigdamcin s o co mounting set big diameter p O pee heater element 400V 4 5kW with sealing and mounting set big diameter 1 B 2209023 heater element 400V 6 75kW with sealing and ll o ages og damier 1 2 B 2209001 heater element 400V 4 5kW with sealing and ICT LL LLL e Les 1 1 2 3 B 2209003 heater element 400V 6 75kW with sealing and CIL LL yy Pe ee fanga o wn sanaa 2 2 4 4 6 E22040 jGasktfoheaterelemnt 25 1 1 2 2 3 E220407 Mountingnutforheater 35 LIT E3216010 O ring seal for cylinder flange s 1 1 1 f E2206050 O ring seal for cylinder jonge ta B321609 O igsetforHCOo 09 SSS pop 1 1 1 1 1 B321607 JOrngsetfoHCOP 27 5 16 6 68 6 8 8 10 E 2205012 Clamp tor thermal sensor pe L6 pt 1 Jod p
42. od 1 1 1 1 E2205010 gasketforthermal sensor ipole__________ Fe p a p Cp 22 05025 begiers steam hose DIE Pag ch 1 2 2 2 2 2 2 2 2 E 2205088 star knob screw fixation for steam hose Pp pepe r Page 67 HycroMarile _eO q _ e o Desonpton Waterfeed feed M um 2304061 o Water food solenoid valve 0 2 10 bar 200 240VAC 2 5 l min 14 B 2304069 double solenoid valve 0 2 10 bar 200 240VAC 3 5 l min ttt E 2304024 fine filter in solenoid valve inlet 41 1 1 E 2304107 gasket for inlet screwed fitting solenoid E 8501034 hose collar for inlet scre wed fitting 3 4 Perel it a eee hose for water connection 0 6m 3 4 cap nuts on both sides seal included i1 1 15 1 1 1 1 1 B 2304040 mountingsetforsolenoid valve ess 135 7 95 135 1 35 E 2604002 hose solenoid valve cylinder oz 07 07 0 7 0 7 07 97 0 7 E 2604002 hose solenoid valve super flush Pp pp me umm n B 2504129 water level control compl with flow switch E 2504174 water level control without flow switch L z oz7 wz7 04 04 04 04 04 E 2604002 hose cylinder base control cylinder LT ML E 2604002 hose water level control steam hose adapter m 2 E2604029 hose nozzie DN25 RS ala EI Be patio cheek aes jejejeje 6 Te 6 6 E2304015 hosedampDNi2
43. ot be ruled out Use of additives is not advised unless specifi cally recommended by the unit manufacturer When employing demineralized water or purified conden sate do not use copper or brass in the supply or drain lines of the HeaterCompact unit These materials can be corroded by demineralized water or purified condensate Instead use stainless steel or temperature resistant pla stic pipes Water installation pressure 1 to 10 bar 100x10 to 100x104 Pa For water installation please use the water connecting hose that is delivered with the unit 6 1 Water Quality The HeaterCompact Type steam humidifier is designed for use with tap water of different qualities e demineralized water min conductivity 3uS cm fully cleaned condensate min conductivity 3uS cm e partially softened water Boiling normal tap water always produces lime Lime deposits on the surface of the heater elements may reduce their lifetime We recommend to use a water treatment device in order to pre vent scaling In case of any questions regarding water treatment devices please contact HygroMatik Page 35 HyGROMATIK WE HUNIDIFY THE AIR Water Supply For Operation with Demineralized Water or Purified Condensate Install a shut off valve AV in the supply hose Install a water filter WF if the water quality requires it Make sure that a backflow preventer is installed in the water supply line Note Shut o
44. pecified in the wiring diagram Fan motor 230 V IN The fan unit is activated deactivated in parallel with humidifica tion Note Terminals 37 und 38 are supplied with the unit only when the fan unit and humidifier are purchased simultaneously In other cases i e retrofitting the fan unit motor phase can be connected to Terminal 2 guided via the auxiliary contact of the main contactor Only cables with same diameter are alllowed to be connected to one common clamp Page 47 HycroMarile 7 8 Wiring Diagram Please refer to the wiring diagram in the technical manual sup plied with the control used with your humidifier Every steam humidifier comes with a unit specific technical manual and a manual for the control In addition you will find downloadable wiring diagrams and technical manuals at www hygromatik de T 9 Electrical Installation Checklist Perform electrical installation checks in compliance with cus tomer site requirements and public power utility regulations v Does the mains voltage match the voltage on the name plate Have all electrical connections been made according to the terminal diagram Have all electrical cable and plug connections been properly tightened Are all electrical plug connections secure NA WN RA Is the unit grounded After this check the unit can be switched on Warning The unit must be closed and locked only for humidifer type HeaterLine This guarantees tha
45. r 0 140 Ohm external control 0 140 Ohm ler Page 45 HycRoMaATIK WE HUMIDIFY IHE AIR 7 5 3 Proportional Control with Built In Pl Controller Upon request HygroMatik will provide an active sensor with a control signal of 0 10 V DC Sensors with other control signals can also be used the control only available at Comfort or Com fort Plus Control need only be set to them Connection Active Sensor active sensor one cylinder and double cyl inder humidifier voltage out put terminal block 24V e al bloc Si Humidifier Terminals If other types of active sensors are used Paramter E3 has to be adjusted Setting Tor Sensor Signal U6 E3 0 2 10V DC Pl Control 0 10V 0 4 20 mA Pl Control 0 20 mA 0 140 Ohm Pl Control 0 140 Ohm Connection active sensor current output single cylin 0 20mA der and double cylinder units two wire system 4 Humidifier Terminals Note The desired relative humidity value is set at Parameter P8 Le factory setting P8 50 Page 46 HycroMarile 7 6 Cable Connections The table below shows the cable connections provided in HeaterLine steam humidifiers Connection Connection Connection M1 HCO3 09 09 icc ds MNA HCO9P HC12 HC27 Characteristics of metric cable connections Thread across flats for cable diameter dimensions mm mm EJE 45 10 MS am 9 17 LEE m 7 7 Fan Unit Connect fan unit as s
46. rdous Voltage Hazardous electrical current Failure to observe this warning may result in injury or even seri ous injury or death Warning Failure to follow these instructions may result in dam age to the unit due to electrostatic discharge The electronic components of the humidifier control are very sensitive to elec trostatic discharges In order to safeguard these components during installation and servicing steps must be taken to protect against ESD Reminder Materials and consumables must be handled and or disposed of as required by law Note Appears before explanations or cross references which refer to other sections of the operating instructions 2 2 Guidelines for Safe Operation Overview Obey all safety notes and warnings present on the unit In case of a malfunction switch off the unit immediately and prevent a restart Repair malfunctions promptly After any repair work have qualified personnel check the safe operation of the unit Use original spare parts only Additional national safety regula tions also fully apply to the operation of this unit This unit is not designed for the use by persons also children with limited physical sensory and mental abilities or without knowledge and experience Unless they are supervised or trai ned by a person who is responsible for their safety Supervise children in order to ensure that they will not play with the unit The unit is only allowed to work with con
47. s 75 A 1ph cooling device 150 x 80 mm thermal circuit breaker not at Slave units TETON GI O SS CI US E 2205116 cooling device 150 x50 mm A ip ji 1 E2205118 cooling device 150 x80 mm LL LLL NNN E 2205108 Thermal circuit breaker with manual reset 100 C 5K a p t 1 f 1 f 1 1 E3720010 Fan 280VAC Basie a D 1 1 f 1 1 1 B 2526203 Elektronicpcbtype Basic PS EE Ee B 2526203 Elektronic pcb type Basic for Slave units B 2526213 Elektronic pcb type Basic for HC ste am bath t t t ttt t B 2120901 Mounting plate with foil for Basic without display Mid EAE without display 1 1 a 1 B 2526301 Relais pcb for Basis pcb PO Comfort BEE EEE EEE EEE B 2526203 Elektronic pcb type Basic for Slave units a 0 Ta La I 1 B 2526213 Elektronic pcb type Basic for HC steam bath MA aad ka B 2526401 Comfort display incl mounting plate with foil CHA B 2526445 Comfort display incl mounting plate with foil steam bath Dio I a 1 B 2120903 mounting plate with foil for Comfort unit without display 0 0 1 1 B 2120911 mounting plate with foil for Comfort unit for steam bath DS without display JL LLL LL LL LLLA Comfort Plus B 2526203 Elektronic pcb type Basic Lb Lb d B 2526203 Elektronic pcb type Basic for Slave units 0 1 B 2526213 Elektronic pcb type Basic for HC steam bath 0 1 a 1 B 2526403 Comfort Plus Display incl Mounting plate 1 la 1 B 212
48. se clips should be set at intervals of approx 500 mm Allow access to the steam hose so that it can be inspec ted later In case of straight lengths of several meters it is recom mended to place the steam hose in temperature resistant plastic pipe 40 mm dia for hose DN25 60 mm dia for hose DN40 or to use copper pipe Device output steam line installation and the duct influ ence pressure condition in the duct In an exeptional case this could mean to optimize ths steam line installation Only genuine HygroMatik hoses are capable of withstan ding the operating conditions Allowfor minimum bending radit oteam hose DN 25 Rmin 2 200 mm Steam hose DN 40 Rmin 400 mm Page 28 HyGROMATIK WE HUNIDIFY THE AIR 5 6 Cover Plate HygroMatik flange plates may be used to neatly complete instal lation of the steam humidifier in the air duct Two piece flange plates are available for the DN25 and DN40 steam manifolds 7n 40 La Ve 1U Ka tu n i d an in Kl e Bei i un gd pa z i 1 at k fj q7 ke e Lu g as E 7 Les We A 1 u KP Ki Gl meJ mi A gos Ki er le i AG 4 flange plate DN40 E 2604410 Page 29 HYGROMATIK WE HUMIDIF Y THE AIR 5 7 Drill Pattern Drill Pattern DN25 not to scale 51 8 30 8 25 e N Q EL C4 C Ps Lal 1 A ij 60 Note Due to variable print media the dimensions are not to scale Page 30 Drill Pattern
49. t performs a self test If the control includes a display the message self test is displayed If the safety interlock see also chapter Safety inter lock is closed the water inlet solenoid valve opens and feeds water into the steam cylinder If there is a demand for humidity the main contactor is switched and a few minutes later steam production starts Initiation of steam production can take up to 20 minutes Further checks v Let all electrically driven operations run to completion As soon as the solenoid valve begins replenishing the water periodically the steam humidifier operates at steady nominal output and the cold start sequence is complete Monitor the unit and let it operate for 15 to 30 minutes If leaks appear switch off the unit Repair leaks and in doing so Attention Hazardous Voltage Follow safety instructions for work on live components Page 65 10 EC Declaration of Conformity EG Konformit tserkl rung EC Declaration of Conformity Hersteller HygroMatik GmbH Manufacturer HygroMatik GmbH Anschrift Lise Meitner Stra e 3 Address D 24558 Henstedt Ulzburg Germany Produktbezeichnung Product description Heater Compact HC HC03 HC06 HC06P HC09 HCO9P HC12 HC18 HC27 In den Ausf hrungen Type Basic Comfort Comfort Plus Dampfbad Steam bath DS Die bezeichneten Produkte stimmen in der von uns in Verkehr gebrachten Ausf hrung mit den Vorschriften
50. t the cover is grounded Note For initial operation control service malfunctions and circuit diagrams consult the operation instructions for the Hygro Matik controls or at www hygromatik de Page 48 HycroMarile 8 Maintenance The HygroMatik steam humidifier is easy to maintain Neverthe less inadequate or improper maintenance can lead to opera tional malfunctions Perform regular maintenance to give your unit a long life span Warning When performing maintenance work please follow these instructions e During operation and also for a while after switching off the unit the steam cylinder is hot Before touching the cylinder check its temperature e Drained cylinder water could have a temperature up to 95 C e Before removing the steam cylinder make sure that it is completely drained and that it does not contain any hot water e During disassembling a steam hose hot steam could leave the steam hose if several humidifiers are working on the same air duct although the currently maintained unit is switched off e Have the unit serviced only by qualified authorized per sonnel Obey safety regulations e Switch off the unit prior to maintenance and secure against restart e After maintenance work have qualified personnel check that the unit is operating safely e If a defective cable is detected through a visual check switch off the unit secure it against restart and replace the cable e The clamps t
51. tallation Check Attention This unit may only be operated by qualified and prop erly trained personnel Please check the installation using the following list Does unit hang vertically Are wall distances to the unit within the range Does steam hose have a slope of 5 10 Is condensate hose installed with a loop of min 200 mm E KK KR Is steam manifold positioned correctly Are all bolts and clamps tightened Page 34 HycroMarile 6 Water Installation Warning For installation note the following Have all work performed by a professional Disconnect power supply prior to installation Obey regulations of local public utilities Verify that neces sary safety measures have been taken in compliance with either German Technical and Scientific Association for Gas and Water DVGW guidelines DIN EN1717 or local regulations to eliminate backflow of polluted water into drinking water treatment facilities This can mean installing a backflow preventer Within the humidifier two double check valves 58 are located in the water supply lines They prevent in accordance with DIN EN 61770 the backflow of water The water supply temperature may not exceed 40 C Flushed out water must be able to drain freely The water supply line must have a minimum diameter of DN 12 3 8 If chemical additives are present in the humidification water health risks and or impaired unit operation cann
52. team manifold is positioned higher than 500 mm above the steam humidifier Lay the steam hose at a height of at least 400 mm above unit and then connect to the steam manifold with a constant rise or fall Lay condensate hose with a slope to the steam cylin der Page 32 HyGROMATIK WE HUNIDIF Y THE AIR If enough space is available lay a loop as a vapor trap The steam manifold must be at least 500 mm from the loop DN25 200 mm DN40 400 mm If the steam manifold is positioned lower than 500 mm above the steam humidifier Lay steam hose at a height of at least 400 mm above unit and then connect to the steam manifold with a con stant fall Lay condensate hose with a loop of 200 mm diameter vapour trap to the drain The distance between vapour trap and steam manifold should have at least 500mm Detail x Detail x False Rmin DN25 200 mm DN40 400 mm Lay the loop of condensate hose 200 mm directly above the drain Detail x Page 33 HycnoMaATIK WE HUMIDIFY IHE AIR 5 10 Steam Solenoid Valves When humidifying a number of loads which are to be controlled separately using a single steam humidifier steam solenoid valves can be included in the steam hoses Valve control has to provided by the customer Install the vertical risers with flow from bottom to top The best position is just above the steam humidifier Installation of Steam Solenoid Valve 5 11 Unit Ins
53. tegrated nozzle that has to be cleaned regularly as it could be blocked by lime 8 6 Replacing Heater Elements Removal Remove and open the steam cylinder as described above in section Removing and Cleaning the Steam Cylinder Detach connecting cable for the heater element in question Mark these two terminals If necessary remove the capillary tube from the thermo sensor by detaching the retainer clips Detach the heater element from the cover by removing the nut and adjusting washer If present detach cable lug for grounding Pull heater element downward out of the steam cylin der Clean the sealing surface on the underside of the cover around the area where the new heater element will be installed Installation Install new heater element with sealing replacing the parts in the correct sequence and screw nut Insert the heater element s connecting cable into the two marked terminals and tighten Polarity of heater element connecting cable is not important If necessary Install capillary tube on the thermo sensor using retainer clips To proceed further follow the steps described above in section Removing and Cleaning the Steam Cylinder Page 58 8 7 Replacing Thermo Sensor for Heater Ele ment Removal Remove and open the steam cylinder as described above in section Removing and Cleaning the Steam Cylinder Loosen clips of capillary tube T Dis
54. ters are required e Air humidity before humidification x4 in g kg e Air temperature after humidification to in C with steam humidifiers the change in air temperature due to humid ification may be disregarded t or t e Specific increase in humidityA x in g kg can be deter mined in the h x diagram quantity of steam introduced Mo in kg h o air speed w in m s in air duct e Total length p of the steam manifold installed in the air duct Page 19 HycnoMaATIK WE HUMIDIFY IHE AIR Length Ip of the usable steam manifold depends on the dimen sions of the air duct The length of the absorption distance can be reduced by using multiple steam manifolds also see section on the steam manifold Method Graphically determine absorption distance By using the absorp tion distance nomogram also see Section Absorption Distance Nomogramm Enter the value of the parameters enumerated above into the respective quadrants The resulting point of inter section indicates the value of the desired absorption distance By Notes Air humidity before humidification vu g kg Air temperature after humidification t2 JL Specific increase in humidity AX gg quantity of steam introduced m kg h air speed t wi m s Total length of the steam manifold Ip mm Page 20 HyGROMATIK WE HUNIDIFY THE AIR 5 3 Fan Unit option Note The fan unit should be positioned to avoid drafts A mini mum height of 2 m is
55. top of the other Staggered laterally if possible square Identical lenghts staggered vertically and laterally low very facing each other wide Vertical installation of Steam manifold tow N steam manifold FREE placement a Al N il Steamsupply 8 N FEN N y iania Sn BW Horizontal installation of the steam manifolds is preferred Howe ver installation from below into the air duct is possible Page 25 L Note Install the steam manifold horizontal with it ensure a clean steam out Maximum allowable pressure in the air duct is 1200 Pa On the return side the maximum allowable negative air pressure is 500 Pa Placement of the steam manifold on the supply side of the air duct is preferred With high pressure air conditioning systems the unit s drain hose system must be modified depending on the over pressure When this is the case please consult HygroMatik Install the steam manifold as close as possible to the steam humidifier in order to minimize steam loss through condensation Depending on the design of the air duct additional moun ting of the steam manifold may be required Shown instal lation and position dimensions are based on experimental values Special environmental conditions could require adjustments We note that the German Association of Engineers VDI Guideline 6022 specifies a water drain within the absorp tion distance inside the air duct For steam bath applicat
56. tory setting for the value for the set point of steam bath temperature is 45 C After switching the main switch to I GON the humidifier starts to produce steam if the cabin temperature is a below setpoint of temperature and b if the safety interlock is closed please see also chapter Safety Interlock Connection for other steam bad components is described in the technical manual for the DS Control 7 5 Control Connection Air Conditioning Application Valid for Controls Basic B Comfort C und ComfortPlus CP Note The factory setting for the controls is to an External con trol signal 0 10 VDC if no other setting is described in the deliv ery note of the humidifier Within the scope of this technical manual there is only a short description of Adjustment of Con trol to the Control Signal For more detailed information please see the also delivered technical manual Controls Warning Set the control to prevent overly frequent activation and deactivation of the steam humidifier Main contactors are wearing parts and are guaranteed by the manufacturer for 150 000 cycles Operation which minimizes activation cycles will extend the life of the main contactors Page 43 230V int Basic Control E 1 rs i o 0000 Comfort Control HyGROMATIK WE HUNIDIFY THE AIR 7 5 1 1 step control With 1 Step Controls the external control hygrostat or control switch is wired in series with the contacts of th
57. with Tap Water or Par tially Softened Water No precise maintenance intervals can be specified because these always depend on water quality and quantity of steam generated It is advisable to adjust the frequency of maintenance to the specific operational application HYGROMATIK recommends to open and check the steam cyl inder two weeks after commissioning Ongoing maintenance intervals can be estimated based on the amount and type of res idue found in the steam cylinder Blow Down Cycles The vaporization process causes mineral calcium deposits of different compositions to settle in the steam cylinder Part of this solid build up is removed through periodic blow downs and fresh tap water refills Water quality When using tap water note that cleaning intervals shorten as the carbonate hardness level in the water increases As a gen eral rule it is preferable to operate the unit with fully demineral ized water Operation will not be affected by mineral deposits and flushing losses will be minimized Note If desired maintenance intervals can be lengthened by moderately increasing blow down rates Please consult Hygro Matik Page 51 ATIK WE HUMIDIFY THE AIR 8 3 Access to Control Unit Remove cover or electric compartment cover and lift display panel A out of its guide Turn display panel see drawing and hang display panel on the humidifier cabinet B by placing the two guide pins in the two front gu
58. wn pump See section Servicing During Operation with Tap Water The generated steam has a temperature of about 100 C and minimal positive pressure pressureless steam lt is virtually demineralized and germ free Page 11 HycroMarile 4 2 Installation and Method of Operation By pressing the control switch Pos I the humidifier is turned on When the hygrostat or controller signals a demand for humidification the inlet solenoid valve 14 opens The solenoid valve is designed for pressures from 100 x 10 to 100 x 10 Pas cals 1 to 10 bar Water is fed into the cylinder The water level in the cylinder must be maintained within a spec ified range If the water level is too high the ellbow acts as a safety overflow for water drainage If the water level is too low it could cause the heater element 8 to overheat Therefore power supply to the heater element is shut off when water levels are too low The cylinder water level is controlled by a level control 27 The level control consists of a stainless steel cylinder with two float switches and three reed contacts The float switches indicate the water level in the steam cylinder Dry Run Humidification and Max Level The control capsule is pressure equalized At the standard setting the inlet solenoid valve 14 opens when the water level remains below humidification level for 10 sec onds The water level then rises again to humidification level
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