Summary of Contents for HydroMatik HeaterCompact
- Page 1 Manual Electric Heater Steam Humidifier HeaterCompact Installation yellow Plumbing blue Electrics red Maintenance green General Information white ÁHC.EN0È HC.EN...
- Page 2 © Copyright HYGROMATIK GmbH; HeaterCompact 08.09.2015 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.
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Page 3: Table Of Contents
1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation ........................5 1.3 Directions for Use ......................6 2. Safety Notes ........................7 2.1 Overview ........................... 7 2.2 Guidelines for Safe Operation ................... 7 2.3 Disposal after Dismantling ....................8 3. - Page 4 6.4 Water Treatment ....................... 38 6.5 Water Discharge ....................... 39 6.6 Checklist ..........................40 7. Electrical Installation ......................41 7.1 Electrical Installation ......................41 7.2 Safety Interlock ........................42 7.3 Control Connection ......................43 7.4 Control Connection - Steam Bath Application ..............43 7.4.1 Temperature Sensor Connection ...................
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Page 5: Introduction
1. Introduction Dear Customer, Thank you for choosing a HygroMatik steam humidifier. HygroMatik steam humidifiers represent the latest in humidifica- tion technology. They will impre ss you with their safety, ease of use and econo- mical operation. In order to operate your HygroMatik steam humidifier safely, pro- perly and efficiently, please read these operating instructions. -
Page 6: Directions For Use
(all hu midifier types) or fully demineralized wate r / conde nsate water (only for humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim). Warning: HygroMatik steam humidifiers emit steam with a tem- perature o f 10 0°C. -
Page 7: Safety Notes
2. Safety Notes 2.1 Overview These sa fety notes are required b y law . The y p romote work- place safety and accident prevention. Warnings and Safety Symbols The safety symbols be low identify sections containing warnings about hazards or pot ential da ngers. Please fa miliarize yourself with these symbols. -
Page 8: Disposal After Dismantling
Accident Prevention Regulations Attention: In t he e vent of leaky or faulty components un con- trolled hot steam may flow. HygroMatik steam humid ifiers a re 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. -
Page 9: Transport
3. Transport Overwiew Note:Proceed carefully when t r ansporting 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. -
Page 10: Included In The Delivery
Time limits for filing freight claims with shipping companies are*: Transport Company After Receipt of Goods Mail 24 hours at the latest Rail 7 days at the latest Truck and railway compa- 4 days at the latest nies Parcel Service immediatly * Subject to change without prior notice. -
Page 11: Operation And Device Construction
4. Operation and Device Construction 4.1 Mode of Action The Imersion Heater Principle One to three heater eleme nts (Pos. 8 in the explo ded view, please see co ver foldout) a re pla ced in a close d cylin der and connected to a lternating current. -
Page 12: Installation And Method Of Operation
4.2 Installation and Method of Operation By pressing the control switch („Pos. I”) the humidifier is turned on. Wh en th e hygrost at 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). - Page 13 General survey The heater elements are equipped with a mechanical high tem- perature sa fety. Th is mechanism provides a re dundant safety system in the event of excessively low water levels (“Dry Run”). The cylinder water is periodically flushed out with a hea vy-duty blow-down pump (10).
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Page 14: Internal Output Setting
95°C is being 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 th e hu midifier ca n be prop ortionally op erated across the entire output range of 5% - 100% nominal capacity. -
Page 15: Mechanical Installation
5. Mechanical Installation Warning: Installation of this unit should be performed by quali- fied personnel only . HygroMatik accept no liability for d amage due to faulty installation. Obey all safe ty instructions and wa rnings on the unit. Durin g installation the unit must be disconnected from its power supply. -
Page 16: Equipment Dimensions Hc
5.1.1 Equipment Dimensions HC View from below Water inlet Cable entries Rear view Waste water connection Condensate inlet Steam outlet View from top Page 16... - Page 17 HC02 HC03-09 HC06P-09P HC12-HC27 all dimensions in mm General Survey Page 17...
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Page 18: Fitting Measures
5.1.2 Fitting Measures Wall Distance (all dimensions in mm) Note: It 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 installed 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 th e equipment is inst alled on... -
Page 19: Absorption Distance Bn
5.2 Absorption Distance B The "ab sorption d istance" (B ) is defined as th e dist ance from the steam feed to where the steam is completely absorbed in the treated air. W ithin the ab sorption d istance, steam is visible as mist in the air stream. - Page 20 Length I of the usable steam manifold depends on the dimen- sions of the air duct. Th e length of the absorption distance can be reduced by using multiple st eam manifolds (also see section on the steam manifold). Method: Graphically determine absorption distance B using the absorp- tion distance nomogram (also see Section „...
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Page 21: Fan Unit (Option)
5.3 Fan Unit (option) Note: The fan unit shou ld be positioned to avoid drafts. A mini- mum height of 2 m is generally sufficient. Install the fan unit directly on a wall. • Type Fan Unit HC02,HC03 VG 08 HC06(P) HC09(P), VG 17... - Page 22 Fan unit, wall installation Side view, wall-mounted fan unit Technical Specifications Fan Unit VG Fan Unit VG08 VG17 VG30 Quantity of Steam [kg/h] Steam Inlet [mmφ] Condensate Outlet [mmφ] Airflow Capacity [cbm/h] Nominal Output Nominal voltage Dimensions W [mm] H [mm] D [mm] Weight [kg]...
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Page 23: Absorption Distance Nomogram
5.3.2 Absorption Distance Nomogram Source: Henne, Erich: Luftbefeuchtung (Air Humidification), 3 Edition 1984 (Page 101), Olden- bourg Industrieverlag, Munich Page 23... -
Page 24: Steam Manifold
5.4 Steam Manifold 5.4.1 Notes on Installation These notes are based on a homogeneous Horizontal installation of Standard steam manifold installation: steam manifold Duct Steam Manifold Air flow L1=L2=L3 An even distribution of steam manifolds ensures a uniform steam distribution. Please use the total hight of the duct! Steam Manifold Air flow... - Page 25 Air duct Positioning of steam manifolds Sample flat Staggered vertically and laterally Air flow very flat By tilting t he steam manifo ld 30 - 45° very flat duct towards the air flow directio n, the mini- mum upper clearan ce ca n be reduced to 70mm.
- Page 26 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, th e ma ximum allowable nega tive air pressure is 500 Pa. Placeme nt o f th e steam manifold on the supply side of the air duct is preferred.
- Page 27 C10-DS, C17DS 1xDN40 DN40 DN12 (for SPA) C22, C30 1xDN40 DN40 DN12 C45** 2xDN40 DN40 DN12 2xDN40 2xDN40 2xDN12 HeaterCompact/Kit: Type Steam Manifold Steam Hose Condensate Hose HC02/Kit 1 xDN25 DN25 DN12 HC03-12* 1xDN25 DN25 DN12 HC03-12/Kit 1xDN40 DN40 DN12...
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Page 28: Steam Line
5.5 Steam Line Note: Whe n inst alling the st eam hose, p lease p ay att ention to the following: • The steam hose diameter may n ot b e smaller than the steam ou tlet of th e HygroMatik steam humidifier (do not restrict the cross-section , otherwise back pressu re will increase). -
Page 29: Cover Plate
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 flan ge plate s are ava ilable for the DN2 5 and DN40 steam manifolds. flange plate DN25 E-2604260 flange plate DN40 E-2604410 Page 29... -
Page 30: Drill Pattern
5.7 Drill Pattern Drill Pattern not to scale DN25 ( Note: Due to variable print med ia the dimension s are not to scale. Page 30... - Page 31 Drill Pattern not to scale DN40 ( Note: Due to variable print med ia the dimension s are not to scale. Page 31...
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Page 32: Condensate Hose
5.8 Condensate Hose Note: When inst alling the conden sate hose , plea se p ay atten- tion to the following: Warning: To ke ep cond ensate from accumula ting in the duct, make sure condensate can drain freely. If the s team m anifold i s positio ned hig her than 5 00 mm above the steam humidifier: »... - Page 33 » If enough space is available, lay a loop as a vapor trap. The steam manifold must be at least 500 mm from the loop. If the ste am ma nifold is position ed lower than 5 00 mm above the steam humidifier: »...
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Page 34: Steam Solenoid Valves
5.10 Steam Solenoid Valves When humidifying a number of loads, which are to be controlled separately, using a sin gle steam hu midifier, steam solenoid valves can be included in the steam hoses. Valve control has to provided by the customer. •... -
Page 35: Water Installation
When employing demineralized water or purified conden- sate, do not use copp er or brass in the supp ly or drain lines of the HeaterCompact u nit. These materials ca n be corroded by demineralized wate r or pu rified conden sate. -
Page 36: Water Supply (For Operation With Demineralized Water Or Purified Condensate)
6.2 Water Supply (For Operation with Demineral- ized 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. -
Page 37: Water Supply (For Operation With Tap Water Or Partially/Fully Softened Water)
6.3 Water Supply (For Operation with Tap Water or Partially/Fully 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. -
Page 38: Feed From Holding Tank
6.4 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 100% output. HeaterCompact Max. Water Consump- tion in over24 h [l] HeaterSlim Max. Water Consump-... -
Page 39: Water Discharge
Water Discharge Warning: Please pay attention to free a nd non-pressure drain- age of the wate r! During blo w down up to 0,3 L/s is b eing drained. For wa ter discharg e, we recommend installation of a flexible water drain hose. Humidifier and waste water discharge must be on the same pressure level. -
Page 40: Checklist
6.6 Checklist Verify correct system installation using the checklist below: Can flushed-out water drain freely? Have all screws and clamps been properly tightened? Is the water supply line properly flushed out? Has the water installation been performed correctly? ... -
Page 41: Electrical Installation
7. Electrical Installation Warning, Haza rdous V oltage! All work re lated to ele ctrical installation may b e perfo rmed b y au thorized pe rsonnel o nly (electricians or professionals with equivalent training). The cus- tomer is resp onsible for checking qualifications.Warning, Haz- ardous V oltage! Do not connect the steam humidifier to the power grid un til after all inst allation work has bee n completed. -
Page 42: Safety Interlock
We recommend using a main f use with medium blow r ating (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- Fuses sumption HC02 230V/1Phases/N... -
Page 43: Control Connection
7.3 Control Connection Within the scope of this manual there is only a short descrip- tion of the „Adjustment of th e Control to th e Control Signal” at this point. More detailed information please find in the technical manual for the co ntrol that is also delive red with the Heater Compact. -
Page 44: 1-Step Control
7.5.1 1-step control With 1-S tep Controls, the external control hyg rostat or co ntrol switch is wired in series with the contacts of the safety interlock. 230V int. Warning: Cont acts laid between terminals 1 and 2 mu st be potentialfree and rated for 230V switches By the use of a Basic control: For 1 -step controls the jumpers must be set as indicated below:... - Page 45 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 e xternal control signal the jumpers must be set as indicated below: Setting fo r External Control Signal: 0(2) - 10 V DC Basic Control...
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Page 46: Proportional Control With Built-In Pi-Controller
7.5.3 Proportional Control with Built-In PI-Controller Upon reque st, Hygro Matik will provide an active sen sor with a control signal of 0 -10 V DC. Sensors with othe r control signals can also be used; the control (only available at Comfort or Com- fort-Plus Control) need only be set to them. -
Page 47: Cable Connections
7.6 Cable Connections The t able belo w shows t he ca ble connectio ns pro vided in HeaterLine steam humidifiers: Unit Connection Connection Connection HC02 - 09 HC06P-HC09P HC12 - HC27 Characteristics of metric cable connections: Thread for cable diameter across-flats [mm] dimensions [mm]... -
Page 48: Wiring Diagram
7.8 Wiring Diagram Please refer to th e wiring diagram in the technical manual sup- plied with th e con trol used wit h you r humidifier . Eve ry steam humidifier comes with a u nit-specific technical manual an d a manual fo r the control. -
Page 49: Maintenance
Maintenance The HygroMatik steam humidifier is easy to maintain. Neverthe- less, ina dequate or imp roper ma intenance can le ad to opera- tional ma lfunctions. Perfo rm reg ular main tenance to g ive your unit a long life span. Since steam and co ndensate hoses are also subject to wear they have to be checked regularly. -
Page 50: Maintenance For Operation With Demineralized Water / Condensate
Immediate cylinder maintenance is indicated by: a green, blinking LED on the display and operating panel. the display reads Service (on ly with co ntrols of T ype Comfort and Comfort Plus). Maintenance for Operation with Demineralized Water / Condensate Instructions f or maintena nce and clean ing intervals are b ased exclusively on typical, empirically determined values. -
Page 51: Maintenance For Operation With Tap Water Or Partially Softened Water
Maintenance for Operation with Tap Water or Par- tially Softened Water No precise ma intenance intervals can be specified because these always de pend on water q uality an d quan tity of steam generated. It is advisable to adjust the frequency of maintenance to the specific operational application. -
Page 52: Access To Control Unit
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 guides. -
Page 53: Removing And Cleaning The Steam Cylinder
8.4 Removing and Cleaning the Steam Cylinder Warning: Please follow the detailed instructions in these operat- ing in structions! The unit is only to be se rviced by qualified, authorized personnel. Note the warnings and safety notes in the operating instru ctions. F ailure to ob serve warnings a nd safety notes may result in injury, serious injury o r d eath, and/or dam- age to the unit. - Page 54 disconnect unit from water check for voltage disconnection supply remove steam hose from check cylinder temperature adapter push clip on adapter lift steam cylinder out of base outside cabinet Page 54...
- Page 55 detach connecting cable for heater element(s) remove flange clamps remove used O-ring open cylinder clean cylinder inside clean the two strainers Cleaning of Steam Cylinder and Cylinder base When using mineral deposit removers or cleaners to clea n the cylinder and h eater e lements, ma ke sure you th oroughly rinse the unit before return ing reasse mbling it.
- Page 56 » 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.
- Page 57 Note: When putting the cylinder back toge ther, the jo ints and reinforcements of both sections must fit together snugly. remove old O-ring install connecting cable for heater element(s) insert new O-ring push adapter onto place cylinder vertically steam outlet into cylinder base reconnect to power supply fix adapter with clip...
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Page 58: Maintenance Of The Control Cylinder
8.5 Maintenance of the Control Cylinder When clea ning the steam cylinder th e co ntrol cylinder sh ould also be cleaned. As the access to the control cylinder is only possible if the steam cylinder is remo ved o ne can fi nd the sub chapte r „Cleaning of the Control Cylinder”... -
Page 59: Replacing Thermo Sensor (For Heater Element)
8.7 Replacing Thermo Se nsor (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). » Disconnect capillary (T) tube from the heater elements (8). -
Page 60: Unlocking Of A Released Thermo Sensor (For Heater Element)
8.8 Unlocking of a Re leased Ther mo S ensor (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 it s holder. -
Page 61: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter
8.10 Removing Inlet Sole noid Valve and Clean- ing Fine Mesh Filter Removal » Remove and open the steam cylinder as described above in section “Removing and Cleaning the Steam Cylinder - Removal.” » Seal off water supply and remove screw joint from fresh water connection. -
Page 62: Cleaning Blow-Down Pump
8.11 Cleaning Blow-Down Pump Removal » Remove and open the steam cylinder as described above in section “Removing and Cleaning the Steam Cylinder - Removal.” » Detach electrical connector from the pump (10). » Detach union adapter (E) from the pump. »... -
Page 63: Cleaning Connection Hoses And Cylinder Base
8.12 Cleaning c onnection hose s a nd c ylinder base All connection hoses should be free of deposits and under good conditions. As well check all conne ctions of the cylinder base (11) and the steam hose adapter (2) for deposits and remove if neccessary. Page 63... -
Page 64: Checking Cable Screw Connections, Heater Element Wires
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: Lo ose cable connection s cause excessive cont act resistance and overheating of contact surfaces. 8.14 Operational Check »... -
Page 65: Commissioning
9. Commissioning Warning: This unit is only to be started by qualified personnel. Switching off steam humidifier Warning: Before starting up the unit, make su re you know h ow to switch it off. » Switch off unit by setting control switch to “0” »... -
Page 66: Ec-Declaration Of Conformity
10. EC-Declaration of Conformity Page 66... -
Page 67: Spare Parts
11. Spare Parts Article No. Description Cabi net HC Steam Generation B-2205493 Cylinder c ompl., with 1 h eater element 1,5k W, 1 thermal sensor and terminal, 230V B-2205483 Cylinder c ompl., with 1 h eater element 2,25kW, 1 t hermal sensor and t erminal, 230V B-2205455 Cylinder c ompl. - Page 68 Article No. Description Water feed B-2304059 double solenoid valve, 0. 2-10 bar, 200-240VAC, 1.2 l/min B-2304061 double solenoid valve, 0. 2-10 bar, 200-240VAC, 2.5 l/min B-2304069 double solenoid valve, 0. 2-10 bar, 200-240VAC, 3.5 l/min E-2304024 fine filter in solenoid valve inlet E-2304103 captive coupling ring f or solenoid valve 3 /4"...
- Page 69 Article No. Description Control E-2501005 main contactor 1 6A, (ABB), coil voltage. 230VAC B-2507041 main contactor 2 0A, DILM7, coil voltage.230VAC B-2507061 main contactor 3 5A, DILM17, coil voltage 2 30VAC E-2502412 control button 2 pole B asic, L3/ DS, middle 0 E-2205110 solid state relais 25 A , without cooler B-2602001 solid state relay 25 A , 1ph., cooling device 15 0 x 50 mm, thermal circuit breaker...
- Page 70 Article No. Description Accessori es E-2604034 Reducing piece DN40/DN25 for steam hose E-2604012 Steam hos e DN25, p er m E-2604013 Steam hos e DN40, p er m E-2604002 Condensat e hose DN12, per m E-2404004 Steam hos e clamp DN25 E-2604016 Steam hos e clamp DN40 E-2304015 Condensat e hose clamp DN12 E-2420423 Drain h ose 1 1/4"...
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Page 71: Fax Form - Order For Spare Parts
12. Fax Form - Order for spare parts Fax Form Please copy, fill in and fax to Badgermeter Swiss AG . +41 (0)31 931 08 67 Mittelholzerstrasse 8 Fax.No 3006 Bern Tel. +41 (0)31 932 01 11 Order of spare parts unit type *______________ serial no.* ___________________ commission: ______________ order no.: __________________ quantity article... -
Page 72: Index
Exploded View ................76 Fan Unit ..................21 Installation Equipment Dimensions HC ..........16 Fitting Measures ..............18 Installation of a HeaterCompact ..........15 Internal Output Setting ............. 14 Maintenance ................49 Blow Down Pump ............... 62 Control Cylinder ..............56 Heater Elements .............. - Page 73 Technical Specification ............74 Unlocking Thermo Sensor (for heater element) ...... 60 Unlocking Thermo Sensor (for Solid State Relais) ....60 View of Cabinet ................ 77 Water Installation ..............35 Water Supply ................36 Page 73...
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Page 74: Technical Specifications
14. Technical Specifications HeaterCompact HC Type HC02 HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Steam Output [kg/h] Electrical Supply* 230V/1/N 400V/3/N 50-60Hz Power Rating [kW] 2,25 13,5 20,3 Power Consumption 19,6 11,3 16,9 11,3 16,9 19,5 29,3 29,3... - Page 75 HeaterCompact HC for SPA HC03..-DS - HC27..-DS Type HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Steam Output [kg/h] Electrical Supply* 230V/1/N 400V/3/N 50-60Hz Power Rating [kW] 2,25 13,5 20,3 Power Consumption 19,6 11,3 16,9 11,3 16,9 19,5 29,3...
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Page 76: Exploded View
15. Exploded View Page 76... -
Page 77: View Of Cabinet
16. View of Cabinet Page 77... - Page 78 12/2004...
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