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Summary of Contents for HygroMatik HPS250
- Page 1 Operating manual Adiabatic humidification and cooling system ÁHPS.ENvÈ HPS.EN E-8881140...
- Page 2 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
4.1 Functioning ........................11 4.2 Design and process ......................11 4.2.1 High-pressure pump group ..................... 12 4.2.2 Dimension drawing of HygroMatik high-pressure nozzle system ........12 4.2.3 Vortex modules ......................13 4.2.4 Atomising nozzles ......................14 4.2.5 Aerosol separators ......................15 4.2.6 Humidification section .................... - Page 4 8. Water connection ......................27 8.1 Connection ........................27 8.2 Water quality ........................27 8.3 Water inlet ......................... 28 8.4 Water drain ........................28 8.4.1 Design of the water drain ....................28 8.4.2 Water drain for the humidification chamber ..............29 9.
- Page 5 14.1.3 Flushing the mains water system ................. 55 14.1.4 Cleaning the high-pressure nozzle ................56 14.1.5 Cleaning the aerosol separators .................. 57 14.1.6 Cleaning the vortex module wall .................. 57 14.1.7 Cleaning the mounting profiles ..................57 14.1.8 Cleaning the humidification chamber ................58 14.2 Extended HPS Service Manual ..................
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Page 6: Introduction
HygroMatik high-pressure nozzle system HPS, please read this operating manual. Only use the HygroMatik high-pressure nozzle system HPS if it is in perfect condition and only for its intended purpose, consid- ering all safety and risk aspects as well as all instructions in this manual. -
Page 7: Intended Use
1.3 Intended use The HygroMatik high-pressure nozzle system HPS is used for air humidification and cooling with desalinated water having a conductivity of 5-20 µS/cm. The feed water should have a tem- perature of 5-15°C. Caution: Proper use includes fulfilment of the assembly, disas- sembly, reassembly, start-up, operating and maintenance condi- tions specified by us as well as disposal measures. -
Page 8: Safety Instructions
During operation of the HygroMatik high-pressure nozzle system it is not allowed to stay in the humidification chamber. The desalinated water used for feeding the HygroMatik high- pressure nozzle system is unsuitable for drinking. Page 8... -
Page 9: Disposal Upon Disassembly
IP22. Ensure that the devices are protected from dripping water at the installation location. If a HygroMatik high-pressure nozzle system is to be set up in an area without water drainage, safety measures which eliminate the possibility of water entering the system due to leaks must be taken. -
Page 10: Transport
3. Transport 3.1 General information Note: Take care when transporting the HygroMatik high-pres- sure nozzle system to prevent the device and packaging from be- ing damaged by impact or accidental loading or unloading. 3.2 Packaging Note: The HygroMatik high-pressure nozzle system is delivered on a pallet. -
Page 11: Function And Design
4. Function and design 4.1 Functioning The HygroMatik high-pressure nozzle system is based on atom- isation of water. Desalinated water is fed into a high-pressure piston pump. With an operating pressure of up to 75 bar, the water is atomized by means of high-pressure nozzles. -
Page 12: High-Pressure Pump Group
[kg/h] [rpm] HPS250 46-250 1400 (14-180 with Bypass) HPS500 90-500 1400 (65-390 with Bypass) *: with an efficiency rate of 98% 4.2.2 Dimension drawing of HygroMatik high-pres- sure nozzle system HPS250 approx 60 Kg HPS500 approx 80 Kg Page 12... -
Page 13: Vortex Modules
4.2.3 Vortex modules The vortex modules provide for effective mixing of the air and water mist. Due to their special design, they generate turbulence and shear zones which lead to a homogeneous distribution of moisture along the humidification section (0.9 m). The vortex modules (dimensions: 150 x 150 mm) are delivered individually and can be assembled to form a wall. -
Page 14: Atomising Nozzles
4.2.4 Atomising nozzles Desalinated water at a pressure of 25-75 bar reaches the high- pressure nozzles where the water is atomised to form ultra-fine mist-like aerosols. The aerosols enter the area of the vortexed air stream downstream of the vortex modules. The air and aero- sols are mixed intensively here. -
Page 15: Aerosol Separators
4.2.5 Aerosol separators There are no more atomised water droplets in the air stream behind the HygroMatik high-pressure nozzle system (if the envi- ronmental parameter specifications are complied with). The two wire-mesh aerosol separators arranged in series ensure this. -
Page 16: Connnections
Temperature: max. 15°C pH value: 7 +/- 1 Note: The supply water for the HygroMatik high-pressure nozzle system must comply with VDI 6022; i.e. from a microbiological point of view it must be of drinking water quality. 5.2 Waste water... -
Page 17: Electrical
5.4 Electrical Power supply: LNE 230 V AC, 50 Hz External control signal: 0-10 V DC System enabling: via ext. potential-free contact Collective fault signal: potential-free contact (change over contact) Operating status signal: potential-free contact (NO) Page 17... -
Page 18: Interfaces To The Hygromatik High-Pressure Nozzle System
6. Interfaces to the HygroMatik high-pressure nozzle system 6.1 Air Air purity: A Class F7 pre-filter is to be placed upstream of the HygroMatik high-pressure nozzle sys- tem. Air velocity: 0.9-2.8* m/s If the air velocity is outside this range please contact HygroMa- tik. -
Page 19: Mechanical Assembly
7. Mechanical assembly Caution: The device may only be assembled by qualified staff. HygroMatik accept no liability for damages resulting from incor- rect assembly. Observe all safety instructions and warnings found on the device. The device must be de-energised during assembly. -
Page 20: Housing Of The High Pressure Nozzle System
Note: Between vortex module wall or droplet separator and a fan, a minimum distance of 1 m has to be observed. The air flow must be laminar. 7.2 Housing of the high pressure nozzle sys- Screwing the housing of the high pressure nozzle system to the floor ensures a stable stand. -
Page 21: Examplary Design Of Guide Rails For A Vortex Module Wall)
7.3.2 Examplary design of guide rails for a vortex module wall) Drawing: Rail, vortex module wall foot profile Material: 1.4301, 1mm sheet metal Drawing: Rail, vortex module wall head profile Material: 1.4301, 1mm sheet metal Note: A project specific drawing is offered in the context of the bid phase already. -
Page 22: Side Rails For The Vortex Module Wall
7.3.3 Side rails for the vortex module wall If the wall consists of 11 or more vortex module rows side rails are required in order to avoid bending of the vortex module wall. In the case of more than 16 vortex modules in the horizontal dimension the the vortex module wall has to be vertically sepa- rated into two halfs each of which is fixed fixed by its own side rails. -
Page 23: Assembling The Aerosol Separators
7.4 Assembling the aerosol separators The guide rails must be installed in a way that allows for lifting- up the vortex module wall. 7.4.1 Examplary design of guide rails for the aerosol separators Note: One piece required per system riveted connection riveted base plates 4 x M6 threaded bolts... -
Page 24: Assembling Two Aerosol Separators In A Stack
7.4.2 Assembling two aerosol separators in a stack For installation heights of more than 1.5 m, two aerosol separa- tors must be mounted in a stack. The waste water from the upper aerosol separator is drained via an additional collector. For this the waste water from the upper trap is drained via a flexible hose either directly or into the collec- tion tray. -
Page 25: Assembling Of The Distribution Pipe
7.5 Assembling of the distribution pipe The distribution pipe has to be attached to the vortex module wall in accordance to the assembling sketch that HygoMatik delivers for each project. Each nozzle on the vortex module wall has to be connected to the distribution pipe by using a high pressure hose. - Page 26 On the back side of the vortex module a washer (8) and another nut (4) are added to the screw (2). The nut has to be tightened. Next step is to put a second nut (5), the distribution pipe (7) and a third nut (6) onto the screw.
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Page 27: Water Connection
Note: We recommend designing the last segment of the water pipe to be flexible to prevent translation of vibration from the high-pressure pump group to the pipework. Note: A stopcock in the direct vicinity of the HygroMatik high- pressure nozzle system is to be provided on-site. 8.2 Water quality Conductivity: 5-20 µS/cm... -
Page 28: Water Inlet
8.4.1 Design of the water drain The plastic hose (connected to the HygroMatik high pressure nozzle system) has to be fed to the external drain. Ensure that the laying shows a constant fall and incorporates a siphon. -
Page 29: Water Drain For The Humidification Chamber
8.4.2 Water drain for the humidification chamber Note: In the humidification chamber the water drain of a collec- tion tray must be at the lowest point and be equipped with a siphon. Page 29... -
Page 30: Water Connection
9. Water connection 9.1 Overview on water connection 1: Water supply 2: Water drainage 3: 12mm plastic tube (1.5 meter ): included 4: plastic hose DN12: on site 5: Water filter (input side: 3/4 external thread output side: 12mm snap-connector) 6: Mounting bracket 7: Pump station 8: External drain, siphoned (free entry must be assured) -
Page 31: Water Supply
Note: There must be a stopcock and a sampling valve in the immediate vicinity of the HygroMatik LPS nozzle system pro- vided. 9.2 Water supply Attention: Please observe during installation: • All work must only be performed by qualified personnel •... -
Page 32: Drainage
9.3 Drainage At the bottom of the housing, a DN12 spout is sticking out. This is a drain and is used to: • empty and relieve the pressure lines to the vortex wall after removal of the module enable signal •... -
Page 33: Water Quality
9.5 Water Quality Conductivity: 5 - 50 µS/cm Pressure: 0.15 - 0.4 MPa (1.5 - 4 bar) Flow rate greater than max output of the nozzle system Temperature: 5-15°C PH value: 7 +/-1 9.6 Inspection of water supply Water supply ... -
Page 34: Hygiene
Addition of a biocide is not required. 10.2 Automatic flushing If the HygroMatik high-pressure nozzle system is in stand-by mode and there is no demand for operation for a period of 24 hours, the system will periodically run a flush cycle to obviate the growth of bacteria in standing water. -
Page 35: Electrical Connection
It is the customer's responsibility to monitor qualifications. Caution: Voltage! All installation work must be completed before the HygroMatik high-pressure nozzle system is con- nected to the mains supply. Please observe all local regulations for electrical installation work. -
Page 36: Connection Data
Caution: The contacts across terminals X2.1 and X2.2 must be potential-free and suitable for switching 24 V DC / 100 mA. After the HygroMatik high-pressure nozzle system has been started, a voltage of 24 V DC is generally available at terminal X2.1. -
Page 37: Circuit Diagram
11.3 Circuit diagram Page 37... -
Page 38: Inspecting The Electrical Installation
11.4 Inspecting the electrical installation The electrical installation must be checked by an electrician in accordance with customer requirements and the regulations set out by the public electricity supply company: Does the mains voltage match the voltage specified on the nameplate / delivery note? ... -
Page 39: Commissioning
12. Commissioning Caution: The commissioning of a HygroMatik high-pressure nozzle system HPS may only be performed by HygroMatik or an approved installer. The notification of readiness for the commissioning can be found below. Please send the filled-ready message to said email address or to the fax number given. -
Page 40: Device Control
The higher the water pressure, the better the spray pattern and thus humidification. The main switch (4) on the right hand side serves to switch the HygroMatik nozzle system HPS on and off. HygroMatik nozzle system HPS 1 Display and... -
Page 41: Control Options (Modes Of Operation)
13.2 Control options (modes of operation) The usability of the modes of operation described below depends on the actually available physical system implemantation, i.e. the number of available nozzle sections. Basic prerequisite for operating the system is the enabling via terminals 1 and 2 by a max.-humidity switch or an on-site disengaged locking mechanism. - Page 42 This mode requires an on-site control signal of 0-10V (4-20mA) on terminals 4 and 5. In the range from 0 to 30 percent of the control signal, only one nozzle section is driven with an atomisation pressure of 25-75 bar. The range is called „the first stage“.
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Page 43: Description Of The Control Functions
13.3 Description of the control functions 13.3.1 Display and control unit The display and control unit for monitoring and activating the system functions is built in the cover of the HygroMatik nozzle system HPS. The display and control unit comprise a display field and 5 function keys for navigation and parameter input. -
Page 44: Switch On System
13.3.2 Switch on system » Switch on the system using the main switch on the side of the housing When the switching the system on the device control initialises itself. After approx. 15 seconds, the display shows: 6.0.1 After additional 30 seconds, the display shows: The current operating state is displayed. -
Page 45: Reading Values
Menu structure overview 1. READING VALUES 2. SETTINGS • DATE & TIME • LANGUAGE • PASSWORD • PARAMETER (only available on Code 010 level) • FAULT HISTORY (only available on Code 010 level) 13.3.4 Reading values The operating parameters of the system can be read out in the READING VALUES menu. -
Page 46: Set Time And Date
Menu SETTINGS on Code 010 level: 13.3.6 Set time and date Select DATE AND TIME » Position the cursor to the DATE AND TIME icon using the menu navigation keys » Confirm the selection with the .key Set time The time is displayed in the hr:min:sec format. »... -
Page 47: Set Language
Save settings » Position the cursor to the UPDATE field using the keys » Save the settings with the The display therafter shows the SETTINGS menu again. The changes were saved. Note: If the unit is without power for 48 hours, the set values will be lost. - Page 48 menu navigation keys. » Confirm the selection with the key Parameter 1 is displayed. Select the parameter to be changed with the keys » Confirm the selection with the » Browse through the available pre-defined parameter settings using the keys »...
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Page 49: Fault History (Code 010)
13.3.10 Fault history (Code 010) The FAULT HISTORY menu allows for the reading of the last 8 error messages. » Position the cursor to the FAULT HISTORY icon using the menu navigation keys » Confirm the selection with the The last error message is displayed. »... - Page 50 Clean or replace pressure pressurised water nozzles exceeds 75 bar for Pressure relief valve not Please contact 30 seconds properly set HygroMatik Sensor error The pressure sensor Pressure sensor Replace pressure pressure value is outside the defective sensor normal range...
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Page 51: Menu Set-Up And Parametrisation
13.5 Menu set-up and parametrisation Page 51... -
Page 52: Maintenance
14. Maintenance The HygroMatik high-pressure nozzle system HPS is mainte- nance-friendly. However, operational faults which can be traced back to inadequate or improper maintenance may occur. Regular maintenance of the HygroMatik high-pressure nozzle system HPS is indispensable for ensuring long service life. -
Page 53: Changing The Oil In The High-Pressure Pump
Changing the oil: 1. Switch off the HygroMatik high-pressure nozzle system by setting the main switch on the control cabinet to position '0'. 2. Unscrew the oil dipstick (see no. 12). -
Page 54: Checking/Replacing The Mains Water Filter
14.1.2 Checking/replacing the mains water filter The mains water filter must be checked monthly for contamina- tion and replaced if necessary. Colouring of the originally white water filter cartridge indicates contamination. Contamination results in an increased resistance to flow. This lowers the supply pressure to the pump. -
Page 55: Flushing The Mains Water System
1. Set the main switch on the control panel of the HygroMatik high-pressure nozzle system HPS to '0'. 2. Close the (external) stopcock. 3. Relieve the line pressure. 4. Open the filter housing by hand. The threads may be dam- aged if pliers are used. -
Page 56: Cleaning The High-Pressure Nozzle
14.1.4 Cleaning the high-pressure nozzle 1. Set the main switch on the control panel of the HygroMatik high-pressure nozzle system to '0'. 2. Unscrew the nozzle from the holder. 3. Unscrew the nozzle by screwing the inside parts out. 4. Clean the nozzle components in an ultrasonic bath for about 10 minutes, if necessary use a lime remover in low concentra- tion (less than 10%). -
Page 57: Cleaning The Aerosol Separators
14.1.5 Cleaning the aerosol separators The aerosol separators should be checked every 4 weeks for possible contamination and cleaned if necessary. The aerosol separators should be thoroughly cleaned at least once a year. Cleaning the aerosol separators: 1. Pull or lift the aerosol separators out of the guide rails. 2. -
Page 58: Cleaning The Humidification Chamber
14.1.8 Cleaning the humidification chamber Clean the humidification chamber and the base tray as required with a cleaning agent, then rinse and dry them. For cleaning and disinfection we recommend INCIDUR pro- duced by Ecolab. When using other cleaning and disinfection agents please check material compatibility with all plastic materials used in the humid- ification chamber. -
Page 59: Extended Hps Service Manual
14.2 Extended HPS Service Manual 14.2.1 Replacing the shaft sealing ring of the high- pressure pump EH2009 To remedy any oil leakages on the shaft output side of the pump, the shaft sealing ring must be replaced. The following preparatory measures are required: the water supply must be turned off, the system must be switched off at the main switch, the oil of the high-pressure pump must be drained off and cor- rectly disposed off. - Page 60 Loosen the 4 bolts (pos.5) that hold the coupling bell housing (pos.6) and remove the bell-shaped top. Now remove the key (pos.7) and lever the shaft sealing ring (pos.8) out of its seating with a suitable tool. Note: When removing the shaft sealing ring, take care not to damage the seat and the shaft! After removing the shaft sealing ring, carefully remove any resi- dues of material left by the sealing ring from the shaft.
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Page 61: Replacing The Valves
14.2.2 Replacing the valves HygroMatik uses two high-pressure pumps that differ only in size for the high-pressure jet systems. The construction is generally the same. They each have 3 identical valves on the low-pres- sure and high-pressure side. If the pump can no longer build up the required pressure, worn valves may be the cause. -
Page 62: Replacing The Seals On The Water Side
14.2.3 Replacing the seals on the water side If water leaks occur on the pumps, the seals must be replaced. In order to do this, the water supply must be turned off, the sys- tem must be switched off at the main switch and the water con- nection hoses must be dismantled from the pump. -
Page 63: Ec Declaration Of Conformity
15. EC declaration of conformity Page 63... -
Page 64: Fax Form - Order For Spare Parts
16. Fax Form - Order for spare parts Fax Form Please copy, fill in and fax to Lise-Meitner-Str. 3 . +49(0)4193/895-33 Fax.No 24558 Henstedt-Ulzburg Tel. +4904193/895-0 Order of spare parts unit type *______________ serial no.* ___________________ commission: ______________ order no.: __________________ quantity article article no. -
Page 65: Spare Parts
17. Spare parts HPS250 HPS500 Article-No. Pump Station E-7703020 Motor, 1.1 KW 230/400V-50 Hz ; 1400 rpm E-7703040 Motor, 2.2 KW 230/400V-50 Hz ; 1400 rpm B-7773151 Pump, highpressure EH 2009 incl. automatic press.contr., clutch, covering B-7773155 Pump, highpressure EH 1416 incl. automatic press.contr., clutch, covering... - Page 66 HPS250 HPS500 Article-No. Pump Station E-0605001 Main switch 25 A E-0605002 Main switch 32 A E-7702200 Protection grill, cabinet fan, incl. filter inlay 120 x 120 mm Thermal circuit breaker ; NC with automatic reset, switching point at 50°C ±...
- Page 67 HPS250 HPS500 Article-No. Pump Station Hose, high pressure, DN 8 mm B-7776402 Hose inlet fitting for humidification chamber Hose, high pressure, DN 8 mm, length 2 m to connect pump station and E-7706062 nozzle collector pipe Hose, high pressure, DN 8 mm, length 2,5 m to connect pump station and...
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Page 68: Plant Scheme
18. Plant scheme Page 68... -
Page 69: Technical Data
Humidifica- Rated Rated current Max. Fuse [A] tion output* at 75 bar power speed [kg/h]] [kVA] [rpm] HPS250 46 - 250 0.94 1400 HPS500 90 - 500 1400 *: with an efficiency rate of 98% Weight HPS250 60 Kg HPS500... - Page 70 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 CAREL Group member of...
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