HygroMatik HeaterLine Series Manual
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HygroMatik HeaterLine Series Manual

Electric heater steam humidifier
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Electric Heater Steam Humidifier
IMPORTANT: READ AND SAVE
THESE INSTRUCTIONS
Manual
ÁHL.CSAKÈ
HL.CSA
E-8881708

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  • Page 1 Manual Electric Heater Steam Humidifier IMPORTANT: READ AND SAVE THESE INSTRUCTIONS ÁHL.CSAKÈ HL.CSA E-8881708...
  • Page 2 Current version of this manual can be found at: www.hygromatik.de/us 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.

  • Page 3: Table Of Contents

    1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation .......................5 1.3 Symbols in Use ......................6 1.3.1 Specific Symbols related to Safety Instructions ............6 1.4 Intended Use ........................6 2. Safety Instructions ......................8 2.1 Guidelines for Safe Operation ..................8 2.1.1 General ........................8 2.1.2 Unit control ........................8 2.1.3 Unit operation ......................8 2.1.4 Mounting, maintenance, repair and dismantling of the unit .........9...
  • Page 4 5.7 Unit Installation Check ....................33 6. Water Installation ......................34 6.1 Water Quality ........................35 6.2 Water Supply (when unit is operated with demineralized water or purified condensate) 36 6.3 Water Supply (when unit is operated with tap water or partially/fully softened water) ...37 6.3.1 Steam Humidifier Feed from Holding Tank ..............39 6.4 Water Treatment ......................39 6.5 Water Discharge ......................40...

  • Page 5: Introduction

    Thank you for choosing a HygroMatik steam humidifier. HygroMatik steam humidifiers represent the latest in humidifica- tion technology. 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: Symbols In Use

    NOTICE is used to address practices not related to physical injury. 1.4 Intended Use HygroMatik steam humidifiers serve for steam production using different tap water qualities or partial softened water (all humidi- fier types) or fully demineralized water/cleaned condensate (heater element humidifiers only).
  • Page 7 You should place a copy of the Operation and Maintenance Instructions at the unit‘s operational location (or near the unit). By construction, HygroMatik steam humidifiers are not qua- lified for exterior application. Risk of scalding! Steam with a temperature of up to 212 °F is produced.

  • Page 8: Safety Instructions

    2. Safety Instructions These safety instructions are required by law. They promote workplace safety and 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 9: Mounting, Maintenance, Repair And Dismantling Of The Unit

    Do not remove or disable safety devices 2.1.4 Mounting, maintenance, repair and dismantling 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. When installation is made in a room without a drain, safety pre- cautions must be taken in order for to shut off the humidifier‘s...

  • Page 10: Transport

    3. Transport Overview Please note Proceed carefully when transporting the steam humidifier in order to prevent damage due to stress or careless loading and unload- ing. Transport Size and Weigth Type* Heigth depth width weigth [cm]/ [cm]/ [cm]/ [kg]/[lb] [inch] [inch] [inch] HL 6...

  • Page 11: Packing

    The heating element humidifiers type HeaterLine 60-90 are double units - they consist of two separate units. HL 60 HL 30 HL 30 (Slave) HL 70 HL 36 HL 36 (Slave) HL 80 HL 45 HL 36 (Slave) HL 90 HL 45 HL 45 (Slave) 3.3 Packing...

  • Page 12: Included In The Delivery

    3.6 Included in the Delivery The delivery includes: • 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.).

  • Page 13: Functional Description And Device Composition

    4. Functional description and device compo- sition 4.1 Mode of operation The Immersion Heater Principle One to five heater elements (8) are placed in a closed cylinder and connected to alternating current. The cylinder (9) is filled with tap water, fully demineralized water or partially softened water.
  • Page 14 (“Dry Run”). The cylinder water is periodically flushed out with a heavy-duty blow-down pump (10). Hygromatik’s SUPER FLUSH system effectively assists this operation. During this procedure, steam production is interrupted for a few minutes.

  • Page 15: Internal Output Setting

    4.3 Internal Output Setting Continuous control of the HeaterLine Type steam humidifier is achieved by proportional control (pulse-width modulation) of the heater elements. In this way the humidifier can be proportionally operated across the entire output range of 5% - 100% nominal capacity.

  • Page 16: Installation

    Unit may drop during mounting involving a single person. Helping hand of a second person is required. Please note HygroMatik accepts no liability for damage due to faulty installa- tion. Please note Attaching or installing additional components is permitted only with the written consent of the manufacturer, or else the war- ranty is void.
  • Page 17 • Ambient temperature must lie between +41 and +104 °F in order to protect the unit electronics against damage; frost may damage the steam cylinder • Relative humidity must not exceed 80 % r.h., since values beyond may lead to electronic malfunction or damage •...

  • Page 18: Fitting Measures

    5.1.1 Fitting Measures Wall Distance > 50mm/ > 200mm/ > 500mm/ > 300mm/ When determining the steam humidifier positioning, make use of Please note existing connections (supply water and drain), if possible. Wall Mounting For proper functioning of the steam generator the plumb-vertical Please note installation is mandatory Measures for drills for wall mounting please see table (measures...

  • Page 19: Equipment Dimensions Hl 06-45

    5.1.2 Equipment Dimensions HL 06-45 View from below HL 06-27 HL 30-45 [mm]/ [mm]/ [inch] [inch] 830/ 855/ 32.7 35.0 645/ 688/ 25.4 27.1 325/ 395/ 12.8 15.6 591/ 634/ 23.3 25.0 771/ 795/ Rear view 30.4 31.3 268/ 310/ 18.6 12.2 167/...

  • Page 20: Fan Units (Options)

    5.2 Fan Units (options) Please note The fan units should be positioned in a way that avoids drafts. In general, a minimum height of 6 ft 7 in (2 m) above floor is suffi- cient. Install the fan units directly on a wall. Unit Type Fan Units Risk of skin burning or scalding!

  • Page 21: Absorption Distance Bn

    5.3 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“).

  • 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 Guidelines for Installation Positioning within duct • Install the steam manifold as close as possible to the steam humidifier in order to minimize steam loss through condensation • Steam manifold placement on the supply side of the air duct is preferable •...

  • Page 25: Recommendations For Dimensioning

    5.4.2 Recommendations for dimensioning Horizontal installation of The recommendations given below are based on homogenous steam manifold air flow in the duct. Standard steam manifold arrangement Duct Steam Manifold Air flow L1=L2=L3 An even distribution of steam manifolds ensures a uniform steam distribution.
  • Page 26 Steam manifold arrangement for special air duct shapings 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/2.8inch.
  • Page 27 Length of steam manifold [mm]/[inch]*: 220/ 400/ 600/ 900/ 1200/ 1450/ 15.7 23.6 35.4 47.2 57.1 DN25/1“ DN40/1 1/2“ * special lenght on request 70mm/ 120mm/ 90mm/ 2.8 inch 4.7 inch 3.5 inch 1,5mm/ 0.06 inch 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.
  • Page 28 “ “ * For units HL 6 - 12 delivers one adapter DN40 / 25. ** For units HL 36 - 45 HygroMatik delivers one t-connector for separating the steam on two steam manifold. *** Special lenght on request. Page 28...

  • Page 29: Steam Line And Condensate Hose Layout

    HygroMatik hoses only. 5.5.1 Guidelines for steam line design • Steam hose nominal diameter must not be smaller than the steam outlet of the HygroMatik steam humidifier (do not restrict the cross-section, otherwise back pressure will increase) • Steam hoses must be laid without sags and kinks and with a continuous slope of 5-10% (otherwise sags may result).

  • Page 30: Condensate Hose Layout

    5.5.2 Condensate hose layout The condensate hose may be run from the steam manifold back to the steam cylinder, as depicted in the schematic drawing below with concern to installation type 1. The condensate hose is connected to the manual drain hose (38) via a stainless steel tube (1 condensate hose) or a T-piece (2 condensate hoses).
  • Page 31 How to connect the condensate hose(s) to the steam cylinder manual drain hose For connecting one or two condensate hoses to the manual drain hose, HeaterLine steam humidifier delivery comprises an adapter set consisting of a stainless steel tube or a Nylon T- piece (the manual drain hose is provided to drain the steam cyl- inder even when the blow-down pump is not functioning).
  • Page 32 Installation type 2 Steam manifold is positioned less than 500 mm/20 inch above or below device upper edge: Please note In this arrangement the condensate hose cannot be fed back to the steam humidifier. » Run steam hose to a height of 400 mm/16 inch mini- mum above the steam humidfier and then to the steam manifold with a continous decline of 5 to 10 %.

  • Page 33: Chimney Compartment

    Chimney compartment Between electrical compartment (right side) and steam produc- tion compartment (left side) the chimney compartment is located. The chimney compartment is used to cool electronic components. For proper function make sure that the three holes in the top side of the housing are not covered - otherwise the heat removal is too low and a thermal cutout could be triggered.

  • Page 34: Water Installation

    If this is not the case, implementing of a system separator of at least the CA type (when free discharge into drainage is supported) or of the HygroMatik HyFlow system separator (retrofit option for installation by the customer) is required. For DIN EN 61770 compliance,...

  • Page 35: Water Quality

    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...

  • Page 36: Water Supply (When Unit Is Operated With Demineralized Water Or Purified Condensate)

    6.2 Water Supply (when unit is operated with demineralized water or purified condensate) » Install a shut-off valve (AV) in the supply line. » Install a water filter (WF) if necessary. » Make sure that a system separator is installed in the water supply line.

  • Page 37: Water Supply (When Unit Is Operated With Tap Water Or Partially/Fully Softened Water)

    Make sure that a system separator is installed in the water supply line. Shut-off valve (SV), water filter (WF) are not included in the stan- Please note dard delivery, but may be ordered seperately from HygroMatik. Water supply: 1bar min., 10bar max./ 14.5psi min., 145psi max.
  • Page 38 Make installation as follows: » Check presence of solenoid valve fine mesh filter („K“ in solenoid valve fig. , see maintennace section, chapter 9.12). Insert filter, if not yet in place. » Screw one of the cap nuts with its inner seal ring onto the solenoid valve connection stub protruding from the humidifier housing and tighten.

  • Page 39: Steam Humidifier Feed From Holding Tank

    6.3.1 Steam Humidifier Feed from Holding Tank If a holding tank is used for water supply, the „Solenoid valve 0- 10 bar” option must be ordered to cope with the reduced inlet pressure. Make sure that the feed height is at least 0.5 m/20 inch.

  • Page 40: Water Discharge

    6.5 Water Discharge Risk of scalding! During blow down up to .3 l/sec (.08 gallon/sec) are being drained with a temperature of about 95 °C/203 °F. Wastewater must drain freely and pressureless! Avoid contact in order not to burn skin. With the optional wastewater cooling system HyCool, HygroMa- Please note tik offers an option for limiting the wastewater temperature of the...

  • Page 41: Water Installation Checklist

    For grounding purposes, a metallic clip is attached to the cabinet drain connection stub from below (s. fig. below) making contact to the pump drain hose end (23). When water flows through the pump drain hose during blow-down, any stray current that might have built up in the drain water is grounded.

  • Page 42: Electrical Installation

    7. Electrical Installation Risk of electrical shock! Hazardous electrical high voltage! All work related to electrical installation to be performed by authorized personnel only (electricians or professionals with equivalent training). Please note The customer is responsible for checking qualifications. Do not connect the steam humidifier to the live power sup- ply before all installation work has been completed! General installation rules •...
  • Page 43 Fusing We recommend employing medium blow main fuses. The tables below show input currents and the circuit protection required for the various HygroMatik humidifier models. The steam generator should be operated with a residual current circuit breaker (RCCB). HeaterLine: Model...

  • Page 44: Cable Connections

    7.2 Cable Connections The table below shows the cable connections provided in HeaterLine steam humidifiers: Unit Connection Connection Connection HL6 - 45 Characteristics of metric cable connections Thread across-flats for cable diameter dimensions [mm] [mm] ([inch]) ([inch]) M16x1,5 19 (~ 0.75) 4,5 - 10 (~ 0.18 - 0.39) M25x1,5...

  • Page 45: Wiring Diagram

    On the succesful completion of all of the checks the unit is ready for switching on. Please note Detailed information concerning initial operation, control, service and malfunctions as well as circuit diagrams can be found in the operation manuals for HygroMatik control units as well as on www.hygromatik.co.uk . Page 45...

  • Page 46: Commissioning

    8. Commissioning Risk of electrical shock! Hazardous high electrical voltage! Start-up of the unit is restricted to expert staff only (electricians or expert personnel with equivalent training). Step 1: Check of mechanical integrity » Check cylinder seating. » Check steam and condensate hose clamps. Step 2: Check of electrical wire connections »...

  • Page 47: Maintenance

    Maintenance Perform regular maintenance to give your unit a long life span. Inadequate or improper maintenance may cause operational malfunctions. Risk of electrical shock! Unit must be switched off and protected against restart by expert staff (electricians or expert personnel with equivalent training) before any maintenance work is commenced.

  • Page 48: Maintenance For Operation With Demineralized Water / Condensate

    Part of this solid build-up is removed through periodic blow-downs and fresh tap water refills with the aid of the HygroMatik SUPER FLUSH flushing system. The SUPER-FLUSH system generates a whirl- pool effect in the strainer basket, intensifying removal of calcium particles during blow-down.

  • Page 49: Access To Control Unit

    9.3 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) from humidifier (B) and lift display panel (A) off guiding. »...
  • Page 50 Removal » Shut off water supply. » Drain steam cylinder by setting main switch to Pos II. » Disconnect power supply (set main switch to Pos 0) and secure against restart (remove main fuse and con- trol fuse F1). » Make sure the device is voltage-free.
  • Page 51 Assembly » Thoroughly clean o-ring seating in cylinder base. No calcium residue is allowed on the seating. » Moisten new cylinder base o-ring and insert in base. » Remove o-ring (4) from the steam hose adapter (2). » Moisten new o-ring and place on the upper part of the cylinder collar on the cylinder cover (5).

  • Page 52: Cleaning Steam Cylinder

    » Switch breaker back on. » 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! 9.5 Cleaning Steam Cylinder Removal »...

  • Page 53: Cleaning Connection Hoses, Cylinder Base And Nozzle

    9.6 Cleaning connection hoses, cylinder base and nozzle As part of periodical maintenance work, all connection hoses should be checked for good overall condition and for freedom of deposits. Also, all cylinder base (11) connections must show unobstructed passage. Clean and remove deposits, if required. When operating the unit with partially softened water or tap water, scale can be discharged with the steam flow and may set- tle in the nozzle (3) sitting in the steam hose adapter.

  • Page 54: Replacing Thermo Sensor (For Heater Element)

    Installation » Install new heater element, replacing the parts in the correct sequence according to the diagram, and screw nut with a torque of 5Nm onto the pressure plate. » Insert the heater element’s connecting cable into the two marked terminals and tighten. Polarity of heater element connecting cable is not important.
  • Page 55 Risk of material damage! Heater element wiring may come in contact with cabinet cover support angle edges. Take care in order not to damage the heater element cable insu- lation when re-inserting the cylinder. » Remove thermo sensor cable from steam cylinder plug. »...

  • Page 56: Replacing The Heater Element Sealing

    9.9 Replacing the Heater Element Sealing » Remove heater element as described above in section „Replacing Heater Elements/Removal“. » If necessary, slit shrink sleeving (X) and remove. » Lift retaining plate (Y) and slide over connecting wires away from heater element. »...

  • Page 57: Unlocking Of A Released Thermo Sensor (For A Heater Element)

    9.11 Unlocking of a Released Thermo Sensor (for a heater element) If a thermo sensor (for a heater element) has triggered due to overtemperature, the red button is level with the top of the sen- sor cap. Additionaly the control electronics reports the fault „Thermo sensor activated“.

  • Page 58: Cleaning Blow-Down Pump

    9.14 Cleaning Blow-Down Pump » Close off water supply. » Drain steam cylinder by setting the main switch to Pos. » Disconnect power supply and secure against restart (switch off control switch, remove main fuse and control fuse F1). » Make sure the device is voltage-free.

  • Page 59: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter

    Risk of electrical shock! Hazardous electrical high voltage! Follow safety instructions for work on live equipment. » Switch on unit and monitor for leakage during 15-30 minutes of operation. » In case of leakage switch off unit and redeem lea- kage(s).
  • Page 60 Installation » Insert solenoid valve with seal in hole in unit cabinet. » Secure solenoid valve with screws (I). » Make fresh water connection (L). » Connect elecrical cable to double solenoid valve. Take care to position correctly. » Attach connector hose (G) to cylinder base using clamps (M).

  • Page 61: Checking Cable Screw Connections, Heater Element Wires

    9.16 Checking Cable Screw Connections, Heater Element Wires Risk of material damage! Loose cable connections may cause excessive contact resis- tance and overheating of contact surfaces. Check that all cable screw connections are securely tightened. » Check all wiring and screw terminals. »...

  • Page 62: Dismantling

    10. 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.

  • Page 63: Csa Certificate Of Compliance

    Certificate: 2125886 Master Contract: 238708 Project: 70027120 Date Issued: March 23, 2015 Issued to: Hygromatik GmbH Lise-Meitner Strasse 3 Henstedt-Ulzburg, D-24558 GERMANY Attention: Michael Lutkemann The products listed below are eligible to bear the CSA Mark shown with adjacent indicators 'C' and 'US' for Canada and US or with adjacent indicator 'US' for US only or without either indicator for Canada only.
  • Page 64 Supplement to Certificate of Compliance Certificate: 2125886 Master Contract: 238708 The products listed, including the latest revision described below, are eligible to be marked in accordance with the referenced Certificate. Product Certification History Project Date Description 70027120 Mar 23 2015 Update report 2125886 to add 230 VAC Control options.

  • Page 65: Spare Parts

    12. Spare Parts Description HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 Article No. Cabinet B-2129001 Cabinet HL 6-27 B-2129003 Cabinet HL 30-45 Steam Generation 208V Cylinder compl. incl. 1 heater element 3,7 5 kW, B-2205365 1 thermal sensor and termin al Cylinder compl.
  • Page 66 Description HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 Article No. Cover for cylinder, sma ll, for 1 hea ter elemen t E-2205070 and 1 thermal sensor Cover for cylinder, sma ll, for 2 hea ter elemen t and 1 thermal sensor E-2205072 Cover for cylinder, sma ll for 3 heater element and 1 thermal sensor...
  • Page 67 HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 with control with control Article No. Description voltage 24V voltage 208- 240V Water Feed HL Double solenoid valve, 0.2-10 bar, 24VAC, 2.5 B-2304045 l/min Double solenoid valve, 0.2-10 bar, 24VAC, 3.5 l/min B-2304047 Double solenoid valve Su perFlush HY05/0 8,...
  • Page 68 HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 with control with control Article No. Description voltage 24V voltage 208- 240V Control 208V B-2507043 main contactor 20A, DILM7, Spulenspg.24VAC B-2507063 main contactor 35A, DILM17, Spulenspg. 24VAC B-2507073 main contactor 50A, DILM40, Spulenspg. 24VAC Ma in contacto r 20A, DILM17, Coil vo ltage 230VAC B-2507041...
  • Page 69 HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 with control with control Article No. Description voltage 24V voltage 208- 240V Comfort B-2526209 Electronic pcb Basis for HL B-2526203 Electronic pcb Basis for HL B-2526209 Elektronik pcb Basis for slave un its B-2526203 Elektronik pcb Basis for slave un its (1 ) B-2526219 Electronic pcb Basis for HL steambath...

  • Page 70: Fax Form - Order For Spare Parts

    13. Fax Form - Order for spare parts Fax Form Please copy, fill in and fax to HygroMatik GmbH Lise-Meitner-Str. 3 . +49(0)4193/895-31 Fax.No 24558 Henstedt-Ulzburg Tel. +4904193/895-0 Order of spare parts unit type *______________ serial no.* ___________________ commission: ______________ order no.: __________________...

  • Page 71: Exploded View

    14. Exploded View Page 71...

  • Page 72: View Of Cabinet

    15. View of Cabinet Page 72...

  • Page 73: Technical Specifications

    16. Technical Specifications HeaterLine HL Type HL12 HL18 HL24 HL27 HL30 HL36 HL45 Data at 208V/3 Phase, Steam Output [kg/h] 14.7 19.6 60Hz* [lbs/h] Power Rating [kW] 11.0 14.7 Input Current [A]*** 17.7 30.6 30.6 48.0 Circuit Protection [A] 3 x 20 3 x 35 3 x 35 3 x 50...
  • Page 74 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...

This manual is also suitable for:

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