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Summary of Contents for HygroMatik HeaterCompact HC02
- Page 1 Manual Electric Heater Steam Humidifier HeaterCompact Installation yellow Plumbing blue Electrics red Maintenance green General Information white ÁHC.EN0È HC.EN E-8881110...
- Page 2 Current version of this manual can be found at: www.hygromatik.co.uk All rights reserved. HygroMatik GmbH grants the legal user of this product [or device] the right to use the Work(s) solely within the scope of the legitimate operation of the product [or device]. No other right is granted under this licence.
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Page 3: Table Of Contents
1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation ........................5 1.3 Intended Use ........................6 2. Safety Instructions ......................7 2.1 Guidelines for Safe Operation ................... 7 2.1.1 General ........................... 7 2.1.2 Unit control ........................7 2.1.3 Unit operation ......................... 7 2.1.4 Mounting, dismantling, maintenance and repair of the unit .......... - Page 4 6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ..... 37 6.4 Feed from Holding Tank ....................38 6.5 Water Treatment ....................... 39 6.6 Water Discharge ........................ 39 6.7 Water Connection Installation Checklist ................40 7. Electrical Installation ......................41 7.1 Electrical Installation ......................
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Page 5: Introduction
They will impress 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. Employ your steam humidifier only in sound condition and as directed. -
Page 6: Intended Use
The HygroMatik steam generator serves for steam production based on various water qualities or partially softened water (valid for all of the HygroMatik humidifier models). With the Heat- erLine, HeaterCompact/Kit and HeaterSlim familiy of products, also fully desalinated water/cleaned condensate may be used. -
Page 7: Safety Instructions
2. Safety Instructions These safety instructions are required by law. They promote workplace safety ans accident prevention. 2.1 Guidelines for Safe Operation 2.1.1 General Comply with the accident prevention regulation „DGUV Regula- tion 3“ to prevent injury to yourself and others. Beyond that, national regulations apply without restrictions. -
Page 8: Mounting, Dismantling, Maintenance And Repair Of The Unit
Do not remove or disable safety devices. 2.1.4 Mounting, dismantling, maintenance and repair of the unit The HygroMatik steam humidifier is IP20 protected. Make sure that the unit is not object to dripping water in the mounting loca- tion. -
Page 9: Electrical
Promptly repair any damage such as loose connections or burned wiring.Responsibility for intrinsically safe installation of the HygroMatik steam humififiers (steam generators) is incumbent on the installing specialist company. 2.2.1 Disposal after dismantling The operator is responsible for the disposal of unit components as required by law. -
Page 10: Transport
3. Transport Overwiew Please note Proceed carefully when transporting the steam humidifier in order to prevent damage from rough or careless loading and unloading. 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 11: Included In The Delivery
Time limits for filing freight claims with shipping companies are*: Transport Company After Receipt of Goods Carriers 4 days at the latest Parcel Service immediatly * Subject to change without prior notice. 3.6 Included in the Delivery The delivery includes: •... -
Page 12: Operation And Device Construction
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. -
Page 13: Installation And Method Of Operation
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). - Page 14 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).
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Page 15: Internal Output Setting
For maintenance purposes, the cylinder water may be drained by pressing and holding the control switch in the „II“ position. Risk of electrical shock! Hazardous electrical high voltage. In case of leakage from the humidifier, switch off the unit and eliminate leakage. -
Page 16: Installation
Hazardous electrical voltage. During installation the unit must be disconnected from power supply. HygroMatik accepts no liability for damage due to faulty installa- tion. Attaching or installing additional components is permitted only with the written consent of the manufacturer, or else the war- ranty is void. - Page 17 • Install the steam humidifier as close as possible to the steam manifold. Use only short lengths of steam and con- densate hose to ensure optimal performance • The back surface of the steam humidifier heats up during operation (to max. 70°C). Take care that the construction on which the unit is mounted is not made of temperature- sensitive material •...
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Page 18: 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 18... - Page 19 HC02 HC03-09 HC06P-09P HC12-HC27 all dimensions in mm General Survey Page 19...
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Page 20: Fitting Measures
Fitting Measures 5.1.2 Wall clearance (all dimensions in mm) Please note When determining the steam humidifier positioning, make use of existing water connections (feed and drain). Wall Mounting To function properly, the steam humidifier must be installed verti- cally. Measures for drills for wall mounting please see table (measures Please note d and e) in chapter „Equipment Dimensions”.If there is no suit- able wall, it is recommended that the equipment is installed on... -
Page 21: Absorption Distance Bn
5.2 Absorption Distance B The "absorption distance" (B ) is defined as the distance from the steam feed to where the steam is completely absorbed in the treated air. Within the absorption distance, steam is visible as mist in the air stream. Condensation may occur on anything installed within the absorption distance. - Page 22 Length I 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 B using the absorp- tion distance nomogram (also see Section „Absorption Distance Nomogramm“).
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Page 23: Absorption Distance Nomogram
5.2.2 Absorption Distance Nomogram Source: Henne, Erich: Luftbefeuchtung (Air Humidification), 3 Edition 1984 (Page 101), Olden- bourg Industrieverlag, Munich Page 23... -
Page 24: Fan Unit (Optional)
5.3 Fan Unit (optional) Please note The fan unit should be positioned to avoid drafts. A minimum height of 2 m is generally sufficient. Model Fan unit HC02, HC03 VG 08 HC06(P) HC09(P), VG 17 HC12 HC18 - 27 VG 30 •... - Page 25 Technical Specifications Fan Unit VG Fan Unit VG08 VG17 VG30 Quantity of Steam [kg/h] Steam Inlet [mmφ] Condensate Outlet [mmφ] Nominal Output Nominal voltage Dimensions W [mm] H [mm] D [mm] Weight [kg] Sound Level (1m dis- [dB(A)] tance to the source of noise) Risk of skin burning or scalding! During operation and for at least 10 mins afterwards the steam...
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Page 26: 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 27 Air duct Positioning of steam manifolds Sample flat Staggered vertically and laterally Air flow very flat By tilting the steam manifold 30 - 45° very flat duct towards the air flow direction, the mini- mum upper clearance can be reduced to 70mm.
- Page 28 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.
- Page 29 DN40 DN12 * 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 sepa- rating the steam on two steam manifolds.
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Page 30: Steam Line
HygroMatik hoses only • 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) •... -
Page 31: 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 flange plates are available for the DN25 and DN40 steam manifolds. flange plate DN25 E-2604260 flange plate DN40 E-2604410... -
Page 32: Condensate Hose
5.7 Condensate Hose To keep condensate from accumulating in the duct, ensure that the condensate drains freely. If the steam manifold is positioned higher than 500 mm above the steam humidifier: » Bore up the connection stub on the upper steam cylin- der part (Diameter: 8mm;... - 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 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.
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Page 34: Steam Solenoid Valves
5.9 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 •... -
Page 35: Water Installation
6. Water installation Risk of scalding! Very hot water on the humidifier drain side! Have all work performed by professional staff (plumber or per- sonnel with equivalent traning) to avoid risk of scalding by inade- quate water flow. Risk of electrical shock! Hazardous electrical high voltage! Before starting installation work ensure yourself that the unit is not connected to the power supply. -
Page 36: Water Quality
We recommend to use a water treatment device in order to prevent scaling. In case of any questions regarding water treatment devices please contact HygroMatik. 6.2 Water Supply (For Operation with Deminer- alized Water or Purified Condensate) Water supply... -
Page 37: Water Supply (For Operation With Tap Water Or Partially/Fully Softened Water)
Please note Shut-off valve (AV), water filter (WF) and backflow preventer 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. -
Page 38: Feed From Holding Tank
HygroMatik provides a water hose (56) with a cap nut at both ends which can be used for water installation. Install as follows: Screw and tighten the cap nut with its inner seal ring around the water supply screw connection that protrudes from the base. -
Page 39: Water Treatment
6.5 Water Treatment For water treatment system specifications, use the following table. The figures below assume that the humidifier runs for 24 hours at 100% output. Heater- Max. Water Consump- Compact tion in 24 hrs [l] 6.6 Water Discharge Risk of scalding! Wastewater must drain freely and pressureless! During blow down up to 0.3 l/s are being drained with a tempera- ture of about 95 °C. -
Page 40: Water Connection Installation Checklist
» 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. There is a 3 mm-wide gap between the pump drain hose jacket and the inner surface of the cabinet drain connection. -
Page 41: Electrical Installation
7. Electrical Installation Risk of electrical shock! Hazardous electrical high voltage! All work related to electrical installation may be performed by authorized personnel only (electricians or professionals with equivalent training). Do not connect the steam humidifier to the power grid until after all installation work has been completed. -
Page 42: Electrical Installation
7.1 Electrical 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) We recommend using a main fuse with medium blow rating... -
Page 43: Control Connection
7.4.1 Temperature Sensor Connection Connect the temperature sensor cable to the designated termi- nals 6 and 7 on the HygroMatik steam generator. The factory setting for the value for the set point of steam bath temperature is 45°C. After switching the main switch to I (=ON) -
Page 44: Control Connection - Air Conditioning Application
7.5 Control Connection - Air Conditioning Application Valid for Controls: Basic (B), Comfort (C) und ComfortPlus (CP). The factory setting for the controls is to an „External control sig- Please note nal, 0-10 VDC“, if no other setting is described in the humidifier delivery note. -
Page 45: Proportional Control With An External Control Signal
7.5.2 Proportional Control with an external control signal The control may be adjusted to the following external control sig- nals: 0(2) - 5 V DC 0(2) - 10 V DC 0(4) - 20 V DC 0(4) - 10 mA DC 0(4) - 20 mA DC 0 - 140 Ohm Factory setting is a 0 - 10 V control signal. -
Page 46: Proportional Control With Built-In Pi-Controller
0 - 140 Ohm 7.5.3 Proportional Control with Built-In PI-Controller Upon request, HygroMatik will provide an active sensor with a control signal of 0-10 V DC. Sensors with other outpt signals may also be used; the control (only available at Comfort or Com- fort-Plus Control) need only be set to them. -
Page 47: Cable Connections
Connection: active sensor; current output, single-cylin- der and double cylinder units, two-wire system Humidifier Terminals The desired relative humidity value is set at Parameter P8 (fac- Please note tory setting: P8=50%). 7.6 Cable Connections The table below shows the cable connections provided in HeaterLine steam humidifiers: Model Connection Connection Connection... -
Page 48: Wiring Diagram
Are all electrical plug connections secure? Is the unit grounded? After this check the unit can be switched on. For initial operation, control, service, malfunctions, and circuit Please note diagrams, consult the operation instructions for the HygroMatik- controls or at www.hygromatik.de Page 48... -
Page 49: Maintenance
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. The unit is only to be serviced by qualified personnel! All safety instructions must be observed. -
Page 50: Maintenance For Operation With Demineralized Water / Condensate
As part of the maintenance works, the screw terminals must be checked and retightened, if necessary. 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. -
Page 51: Maintenance For Operation With Tap Water Or Partially Softened Water
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. -
Page 52: Access To Control Unit
8.3 Access to Control Unit Risk of electrical shock Hazardous electrical high voltage! Make sure the unit is switched off before installing or removing the display panel. » Remove cover (or electric compartment cover) and lift display panel (A) off its guide. »... -
Page 53: Removing And Cleaning The Steam Cylinder
8.4 Removing and Cleaning the Steam Cylinder Risk of skin burning! Hot steam cylinder during operation and for some time after- wards. Drain steam cylinder before any maintenance work is com- menced. Switch off unit and protect against restart. After that, wait approx. 10 mins before starting maintenance work. - Page 54 disconnect unit from water check for zero voltage supply remove steam hose adapter clip check cylinder temperature push clip on adapter lift steam cylinder off base outside cabinet Page 54...
- Page 55 detach connecting cable for remove flange clamps heater element(s) remove flange clamps open cylinder remove used O-ring remove used O-ring clean cylinder interior clean the two strainers Page 55...
- Page 56 Cleaning of Steam Cylinder and Cylinder base Please note When using mineral deposit removers or cleaners to clean the cylinder and heater elements, make sure to thoroughly rinse the unit before returning reassembling it. Use mineral deposit removers only for cylinder and heater elements. Risk of material damage! Excessive mechanical cleaning may damage the cylinder and/or the heater elements.
- Page 57 Assembly connect upper and lower insert new O-ring part with clamps When reassembling the cylinder halfs, the joints and reinforce- Please note ments of both sections must fit together snugly. insert new O-ring remove used O-ring remove old O-ring install connecting cable for hea- insert new O-ring ter element(s) Page 57...
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Page 58: Maintenance Of The Control Cylinder
push adapter onto place cylinder vertically steam outlet into cylinder base fix adapter with clip engage main circuit breaker » Switch on unit and check for leakages during 15 to 30 mins. trial run. » Redeem leakages, if applicable. » Check again. -
Page 59: Replacing Heater Elements
Cleaning the steam hose adapter nozzle From the top of the control cylinder a hose runs to the steam hose adapter connecting piece. The nozzle integrated in the connecting piece must be cleaned regularly otherwise blocking by hardeners might occur. 8.6 Replacing Heater Elements Removal »... -
Page 60: Replacing The Heater Element Sealing
8.7 Replacing the Heater Element Sealing » Remove heater element as described above in „Repla- cing Heater Elements/Removal“ section. » If necessary, slit shrink sleeving (X) and remove. » Lift retaining plate (Y) and slide over connecting wires away from heater element. »... -
Page 61: Replacing Thermo Sensor (For Heater Element)
8.8 Replacing Thermo Sensor (for Heater Ele- ment) Removal » Remove and open the steam cylinder as described above in “Removing and Cleaning the Steam Cylinder” section. » Detach capillary tube (T) clips. » Disconnect capillary (T) tube from heater elements (8). »... -
Page 62: Unlocking Of A Released Thermo Sensor (For Heater Element)
8.9 Unlocking of a Released Thermo Sensor (for heater element) If a thermo sensor (for heater element) has released due to a temperature too high, the red unlock button (P) protrudes a few millimetres from its holder top. After the system has cooled down, the thermo sensor may be unlocked by forcefully pressing the unlock button (P) back down in its holder for a few millime- tres. -
Page 63: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter
8.11 Removing Inlet Solenoid 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.” » Shut off water supply and remove cap nut of the fresh water connection. -
Page 64: Cleaning Blow-Down Pump
8.12 Cleaning Blow-Down Pump » Remove and open the steam cylinder as described above in the “Removing and Cleaning the Steam Cylin- der - Removal” section. » Detach electrical connector from the pump (10). » Detach union adapter (E) from the pump. »... -
Page 65: Cleaning Connecting Hoses And Cylinder Base
8.13 Cleaning connecting hoses and cylinder base Regular maintenance also comprises the check of the connec- ting hoses for good order and free passage. Also, all of the cylinder base (11) and steam hose adapter (2) connections must be checked for free passage and cleaned, if neccessary. -
Page 66: Dismantling
8.16 Dismantling Once the steam humidifier will no longer be used, dismantle (demolish or scrap) it by following the installation procedures in reverse order. Risk of electrical shock! Hazardous electrical high voltage. Dismantling must only be accomplished by expert staff (electri- cians or personnel with equivalant training). -
Page 67: Commissioning
9. Commissioning Risk of operating error! Start-up of the unit is restricted to expert staff only (electricians or expert personnel with equivalent training). Switching off steam humidifier Before starting up the unit, make sure you know how to switch it Please note off. - Page 68 Further checks: 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. »...
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Page 69: Ec-Declaration Of Conformity
10. EC-Declaration of Conformity Page 69... -
Page 70: Spare Parts
11. Spare Parts Article No. Description Cabinet HC Steam Generation B-2205493 Cylinder compl., with 1 heater element 1,5kW, 1 thermal sensor and terminal, 230V B-2205481 Cylinder compl., with 1 heater element 2,25kW, 1 thermal sensor and terminal, 230V B-2205455 Cylinder compl. Incl 1 heater element 4.5kW, 1 thermal sensor and terminal B-2205459 Cylinder compl. - Page 71 Article No. Description Cabinet HC Steam Generation B-2205493 Cylinder compl., with 1 heater element 1,5kW, 1 thermal sensor and terminal, 230V B-2205481 Cylinder compl., with 1 heater element 2,25kW, 1 thermal sensor and terminal, 230V B-2205455 Cylinder compl. Incl 1 heater element 4.5kW, 1 thermal sensor and terminal B-2205459 Cylinder compl.
- Page 72 Article No. Description Control E-2501005 main contactor 16A, (ABB), coil voltage.230VAC B-2507041 main contactor 20A, DILM7, coil voltage.230VAC B-2507061 main contactor 35A, DILM17, coil voltage 230VAC E-2502412 control button 2 pole Basic, L3/DS, middle 0 E-2205110 solid state relais 25 A, without cooler B-2602001 solid state relay 25 A, 1ph., cooling device 150 x 50 mm, thermal circuit breaker B-2602103 solid state relay 50 A, 2ph., cooling device 150 x 50 mm, thermal...
- Page 73 For ordering spare parts, a template can be found on the www.hygromatik.com website under the „Contact“ tab. Your spare parts order may as well be directed per e-mail to the HygroMatik main office using the address hy@hygromatik.de. Please make sure to specify your unit model and serial number. Page 73...
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Page 74: Technical Specifications
12. 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 [A]** Circuit Protection [A] 1 x 10 1x10... - 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 29,3 [A]** Circuit Protection [A]...
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Page 76: Exploded View
13. Exploded View Page 76... -
Page 77: View Of Cabinet
14. View of Cabinet Page 77... - Page 78 Lise-Meitner-Str.3 • D-24558 Henstedt-Ulzburg Phone +49(0)4193/ 895-0 • Fax -33 eMail hy@hygromatik.de • www.hygromatik.com 12/2004 A member of the Group...
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