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Related Manuals for HygroMatik DDS Series
Summary of Contents for HygroMatik DDS Series
- Page 1 Manual Steam Injection Humidifiers DDS for existing steam nets ÁDDS.CSAßÈ DDS.CSA...
- Page 2 CSA DDS 01.08.2016 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 Risk of electrical shock by 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 Directions for Use ......................5 1.2 Typographic Distinctions ....................5 2. Safety Instructions ......................7 2.1 Overview ........................... 7 2.2 Guideline for Safe operation ....................7 2.3 Disposal after dismantling ....................8 3. Transport ..........................9 3.1 Packing .......................... - Page 4 15. Installation ........................31 15.1 Attaching steam pipes ..................... 31 15.2 Water hammer prevention ....................32 15.3 Electrical Installation ......................33 15.4 Separator ......................... 34 15.5 Control Valve and Actuator ..................... 34 15.6 Pneumatic start-up protection ..................35 15.7 Steam Lances ........................ 36 15.8 Installation Examples ......................
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Page 5: Introduction
It is extremely economical, safe in operation and easy to use. In order to operate the HygroMatik steam injection humidifier in a safe, orderly and economical fashion please take the time to read this operating manual. - Page 6 Installation step which must be checked off. Page 6...
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Page 7: Safety Instructions
2. Safety Instructions 2.1 Overview These safety instructions are required by law. They promote workplace safety and accident prevention. According to ANSI Z535.6 the follwowing signal words are used in this document: DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. -
Page 8: Disposal After Dismantling
Installation, dismantling, servicing and repair Steam injection humidifier parts on which maintenance or repair work is to be done must be disconnected from voltage and the steam supply shut off. Installation of any additional parts is allowed only after written permission from the manufacturer. After repair, operational safety must be checked out by autho- rised personnel. -
Page 9: Transport
3. Transport Overview Please note Proceed carefully when transporting the steam injection humidi- fier in order to prevent damage due to stress or careless loadig and unloading. 3.1 Packing Please note Notice the symbols afixed to the box(es). The kind of packing used is dependent upon the type of unit sup- plied. -
Page 10: Function And Assembly
4. Function and Assembly The HygroMatik Steam Injection Humidifier comprises 4 basic elements: • Separator • Control valve with or without control operation • Steam Lances • Additional materials There is a stainless steel version Type A and a mixed material version Type C 4.1 Function... -
Page 11: Strainer
5. Strainer There should be a strainer installed in the steam supply line directly in front of every separator. Only if this is done there is guarantee that no foreign particles enter the humidifier unit. Valve cone and valve face in both the control valve and steam trap are sensitive to fouling. -
Page 12: Separator
Separator The stainless steel separator is the essential component for moisture separation. The separator is available as models „20“ and „40“. The separator size is dependent upon the desired steam output and available steam pressure. 6.1 Function Steam flows through the pipe union (1) into the separator. Steam and condensate are separated by the joint action of the inlet pipe (2) and the spiral-shaped flow system. -
Page 13: Control Valve And Actuator
If equipment made by other manufacturers is used, the customer must check the compatibility with the HygroMatik steam injection humidifier. 7.1 Control Valve The control valve regulates the steam quantity by means of the valve lift. -
Page 14: Actuator
In order to comply with DIN 32 730*, electrical actuators must feature a fail-safe function so that in the case of power failure the Type Hygromatik E-4111680 control valve is driven to a safe position (fully closed). Pneumatic Actuator Pneumatic Actuators are controlled using compressed air (e.g. -
Page 15: Start-Up Safety Switch
8. Start-up safety switch The function of the start-up safety switch is to ensure that no condensate from the steam network invades the air conditioning duct through the steam lances. Electrical Start-up safety switch With an electrical actuator the supply voltage is looped through the start-up safety switch. -
Page 16: Steam Lances
9. Steam Lances In the steam lances (1) dry steam is blown out of specially formed nozzles (2). They are designed for low noise steam emission. The nozzles take steam from the driest area in the steam lance centre. In order to prevent accumulated condensate or aerosol droplets from being transported with the steam, the steam lances are provided with a steam lance heating system (3). -
Page 17: Technical Data
Technical Data Model 20 Lance- Weight code [in/mm] [in/mm] 86/218 133/338 1 lb 15 oz/0.88 kg 154/392 202/512 2 lb 8 oz/1.14 kg 224/568 271/688 3 lb 1.4 oz/1.4 kg 330/838 377/958 3 lb 15.5 oz/1.8 kg 452/1148 499/1268 4 lb 15.7 oz/2.26 kg 554/1408 602/1528 5 lb 13.5 oz/2.65 kg 676/1718 724/1838... -
Page 18: Number Of Steam Lances
Steam lance piping for multiple steam lances HygroMatik standard supply is for lengths of 118 in (300 mm) und 177 in (450 mm). Distances are approximate and can vary from installation to installation. Piping should be installed for even lance distribution along the duct height. -
Page 19: Pressure Gauge Station
Installation of a pressure gauge on the steam injection unit ensures immediate detection of pressure drops or fluctuations. The HygroMatik Pressure gauge station consists of a tubular spring pressure gauge (0-6 bar), a T-junction and a dual nipple. The pressure gauge is temperature resistant up to 392° F (200°... -
Page 20: Ball Float Steam Trap
11. Ball Float Steam Trap After separation from the steam inside the separator condensate is drained out through a ball float steam trap. 11.1 Function The discharge valve is controlled by the ball float dependent upon the density of the incoming medium. Starting Position / Air When the unit starts, air present in the system is discharged through the thermostatic air extractor fan. -
Page 21: Technical Data
11.2 Technical Data 11.2.1 KS-Condensate Drain for DDS Type A Screwfitting : 1/2“ external thread Materials: Clip Stainless steel 1.4404 Float Stainless Steel 1.4404 Flange seal Soft seal Adjust. screw Stainless Steel 1.4404 Housing Stainless Steel 1.4404 The KS-Condensate drain for type A is integrated into the sepa- rator. -
Page 22: Thermostatic Capsule Steam Trap
12. Thermostatic Capsule Steam Trap Condensate that has collected in the steam lance heating sys- tem is discharged through a thermostatic capsule steam trap. 12.1 Function The discharge valve is controlled dependent upon the capsule volume and the temperature and pressure of the incoming medium. -
Page 23: Technical Data
12.2 Technical Data Type Spirax Sarco MST 21 max. operating pressure 18 bar max. operating temperature 410° F/210° C Dimensions: 19.7/50 in/mm 17.7/45 in/mm Materials: Housing Stainless Steel 1.4305 Cover Stainless Steel1.4057 Capsule Stainless Steel 1.4541 Spring Stainless Steel 1.4300 Spacer Stainless Steel 1.4301 Strainer... -
Page 24: Humidification Output
13. Humidification Output The maximum humidification output [lb/h] of a steam injection unit depends upon the available steam pressure in bar. Maximum humidification output can be more than 1697 lb/h (770 kg/h) (Type A) or 1609 lb/h (730 kg/h) (Type C). Maximum oper- ating pressure is pmax = 4 bar. - Page 25 Example: Desired humidification output: 242 lb/h (110 kg/h) Operating pressure, p = 2 bar The length and number of steam lances is determined by the duct dimensions. See Section 9 "Steam Lances". Please note 1 lb = 0.453592 kg 1 kg = 2 lb 3.273962 oz Result: Follow the operating pressure line until the desired humidifica- tion output in kg/h is reached.
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Page 26: Separator Model 20 With One Steam Lance
13.3 Separator Model 20 with one steam lance KVS-Value [m³/h] Pressure [bar] Page 26... -
Page 27: Separator Model 20 With Multiple Steam Lances
13.4 Separator Model 20 with multiple steam lances KVS-Value [m³/h] Pressure [bar] Page 27... -
Page 28: Separator Model 40 With One Steam Lance
13.5 Separator Model 40 with one steam lance KVS-Value[m³/h] Pressure [bar] Page 28... -
Page 29: Separator Model 40 With Multiple Steam Lances
13.6 Separator Model 40 with multiple steam lances KVS-Value [m³/h] Pressure [bar] Page 29... -
Page 30: Graph For Determing Absorption Distance
14. Graph for Determing Absorption Distance Page 30... -
Page 31: Installation
Risk of injuries due to improper installation! Installation of this steam injection humidifier may only be accom- plished by qualified personnel. HygroMatik can accept no responsibility for any damage caused by incorrect installation. Please observe all safety and hazard instructions supplied with the steam injection humidifier. -
Page 32: Water Hammer Prevention
Steam extraction points must lie on the upper side of the pipe surface to prevent condensate being dragged from the pipe. The HYGROMATIK steam injection system must have a filter installed in front of the system. This is delivered with the system or is already installed on-site. -
Page 33: Electrical Installation
Install a pressure sensor in the ducting and integrate this into the safety chain. The pressure sensor prevents over-humidification of the ducting in the case of a malfunctioning fan. HygroMatik Actuator wiring diagram Circuitry for alternative actuators may be found in the relevant installations documents. -
Page 34: Separator
15.4 Separator Separator efficiency may be severely decreased by conden- sate in steam piping! Supply steam fed into the steam humidifier should feature maxi- mum possible dryness. Before making installation ensure that steam piping by design allows for as little condensate as possi- ble (e.g. -
Page 35: Pneumatic Start-Up Protection
Actuator and valve installation positioning When pneumatic actuators are implemented Risk of malfunction! Control air for pneumatic actuators must be free from oil and humidity. 15.6 Pneumatic start-up protection Please note Pneumatic start-up protection is set to 205° F/96° C. This value may only be altered by the manufacturer. -
Page 36: Steam Lances
Angle pieces for installation of humidifier/valve unit parallel to ducting walls are available from HygroMatik. In order to reduce the absorbtion distance the steam from the lance should be directed opposed to the air direction in the duct- ing. - Page 37 In order to prevent steam condensing on the duct inner walls, the steam lances should be installed observing the following dimensional prerequisites: Dimension [in./mm] Model DDS 20 1.5/ 1.2/30 0.8/20-3.1/80 Model DDS 40 2.1/ 1.2/30 0.8/20-3.1/80 *„k“ is the necessary drill diameter in the duct wall A duct wall thickness of 1.2 in/30 mm is assumed.
- Page 38 Number Description Duct wall Screw M6x35 Nut M10 Steam Lance Threaded bar M10 & M8 x 250 Angle anti-vibration collar * In installation set B-4600100. Lance guide is installed in the following manner: - feed bar through hole in angle profile - Screw M10 bar end in the steam lance - use nut to lock to lance Alternatively, the lance can be installed from the duct ceiling with...
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Page 39: Installation Examples
15.8 Installation Examples Please note If lances are positioned vertically, the steam supply piping should have an additional float controlled condensate drain. Page 39... - Page 40 Position lances in the duct centre if possible. If the humidifier blows into a compact multi-zone unit, it should be installed directly in the air flow and as close as possible to the fan. The bifurcated pipe should never be installed less than one meter in front of the fan suction side.
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Page 41: Steam Lance Heating System
15.9 Steam Lance Heating System Risk of material damage due to excess pressure The heating system feed pipe must allow for pressures of up to 8 bar. Please note Bending the pipe is easily accomplished with a suitable tool. The customer must adjust the pipe in accordance with the conditions on site. -
Page 42: Allowable Environmental Parameters
15.10 Allowable environmental parameters Please note When selecting the HygroMatik steam pressure humidifier instal- lation location pls. consider the following: • Environment temperature must lie between +41° F (5° C) and +104° F (40° C) • Air humidity must no exceed 80% r.h. -
Page 43: Initial Operation
16. Initial Operation Risk of injury! Commissioning of the steam injection humidifier may only be done by qualified personnel. Risk of functional disorder! Follow the instructions below to ensure correct operation of your steam injection humidifier. Please note For actuator initial operation please refer to the instructions of the regulator and/or installations company. - Page 44 Check specified system pressure using the pressure gauge. Wait 10 - 15 minutes so that the steam injection humidifier can warm up. The pipes between the separator and the steam trap should be about the same temperature. Set the Max. Hygrostat to the desired value.
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Page 45: Maintenance
17. Maintenance The HygroMatik steam injection humidifier is easy to maintain. However, inadequate or improper maintenance can lead to oper- ational malfunctions. Regular maintenance is essential so that your steam injection humidifier achieves a long, trouble free life span. Risk of injury! -
Page 46: Ball Float Condensate Drain
Screw down both Allen screws simultaneously. » Check for leakages by re-start. Please note Use only original HygroMatik parts. Maintenance set for DDS 20 Type A: B-4111917 Maintenance set for DDS 40 Type A: B-4111919 The maintenance sets include 1x sieve filter, flange seal, steam supply entry seal, and seals for the ball float and drain. - Page 47 Screw down new complete float unit (E-C) with valve screws (D) . » Screw down cover with new seal (T). Please note Use HygroMatik spare parts number E-4111834 Exchanging air vent » Loosen C spring clamp (L). » Remove capsule element (H) and spacer (M).
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Page 48: Thermostatic Capsule Steam Trap Type Mst21
Check steam injection unit for correct functioning. » Start up unit and operate for 15 minutes ideally at maxi- mum output. » Check safety features. » Check pipe connections for possible leakage. Please note Use HygroMatik spare part number E-4111828. Page 48... -
Page 49: Malfunctions
18. Malfunctions Risk of injuries! Switch off unit immediately in case of a malfunction being detected. Malfunctions may only be repaired by qualified per- sonnel under observation of all safety instructions. Problem Possible Cause Resolution No steam from • Defective Hygrostat or humidity •... - Page 50 Problem Possible Cause Resolution • Improper steam pipe installation • Check installation towards humidifier • Clean or replace steam • Defective or dirty steam trap on trap separator or steam lance heating system • Reduce pressure in the • Counter-pressure from condensate condensate return line;...
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Page 51: Dismantling
19. Dismantling After the steam injection humidifier is no longer in use it must be dismantled (scrapped and disposed of) following the installation procedures in reverse order. Risk of injuries! Dismantling the unit may only be done by trained and qualified personnel, the electrical dismantling by trained electro-person- nel. -
Page 52: Steam Injection System Dimensions And Installation Schematic
20. Steam Injection System dimensions and Installation Schematic Steam injection system type A (stainless steel) Steam Injection system type C (Mixed materials) Type A*) Type C*) Model 20 Model 40 Model 20 Model 40 Kvs 0.2- 25 0.2 - 12 16.5 16.5 16.5 16.5 10.6 10.6 13.4 13.4 13.4 13.4 1.57 1.57 2.76 2.76 2.76 2.76 15 16.1 16.1 16.1 16.1... -
Page 53: Spare Parts
21. Spare Parts Type A Type C Model Model Article Number Description Separators E-4111090 Separator, without additions E-4111092 Separator, without additions B-4500001 Separator DDS20 incl. ball float steam trap and dirt trap B-4500003 Separator DDS40 incl. ball float steam trap and dirt trap B-4111917 maintenance set DDS20 Version A (encloses: seals, dirt trap) B-4111919... - Page 54 Type A Type C Model Model Article Number Description Steam lance E-4111000 steam lance 20, Code 1, 218 mm fitting lenght E4111002 steam lance 20, Code 1.5, 393 mm fitting lenght E-4111004 steam lance 20, Code 2, 568 mm fitting lenght E-4111006 steam lance 20, Code 3, 838 mm fitting lenght E-4111008...
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Page 55: Fax Form - Order For Spare Parts
22. Fax Form - Order for spare parts Fax Form Please copy, fill out and fax to: Lise-Meitner-Str. 3 04193/895-33 Fax.Nr. 24558 Henstedt-Ulzburg Tel. 04193/895-0 Spare Parts Fax Order Form for Unit -Type *______________ Serial Nr.* ___________________ From Department: ______________ Order Number: __________________ Number of pieces Article Description Article Number... - Page 56 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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