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Related Manuals for HygroMatik HeaterLine Series
Summary of Contents for HygroMatik HeaterLine Series
- Page 1 Manual Electric Heater Steam Humidifier IMPORTANT: READ AND SAVE THESE INSTRUCTIONS ÁHL.CSAKÈ HL.CSA...
- Page 2 CSA HeaterLine 02.09.2016 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 Typographic Distinctions ....................5 1.2 Documentation .......................5 2. Safety Instructions ......................7 2.1 Overview ........................7 2.2 Guidelines for Safe Operation ..................7 2.3 Disposal after Dismantling ....................8 3. Transport .........................9 3.1 Overview ........................9 3.2 Transport Size and Weigth .....................9 3.3 Packing ...........................10 3.4 Interim Storage .......................10 3.5 Check for Complete and Correct Delivery of Goods ............10... - Page 4 6.3.1 Feed from Holding Tank ....................41 6.4 Water Treatment ......................41 6.5 Water Discharge ......................42 6.6 Checklist .........................43 7. Electrical Installation .....................44 7.1 Electrical Installation .......................44 7.2 Cable Connections ......................46 7.3 Safety Interlock .......................46 7.4 Wiring Diagram .......................47 7.5 Electrical Installation Checklist ..................47 8.
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Page 5: Introduction
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. Employ yo ur ste am hu midifier only in sound condition a nd as directed. - Page 6 HygroMatik steam humidifiers se rve for st eam production using different tap water qualities or partial softened water (all humidi- fier types) or fully demine ralized wate r / cond ensate water (for humidifier typ e He aterLine, HeaterCompact/Kit and HeaterSlim only).
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Page 7: Safety Instructions
2. Safety Instructions 2.1 Overview These sa fety instructions are required by law . They pro mote workplace safety an d accident p revention. According to ANSI Z535.6 the follwowing signal words are used in this document: DANGER indicates a hazardo us situation which, if not avoided, will result in death or serious injury. -
Page 8: Disposal After Dismantling
(such a s grounding resis- tance). Unit operating environment HygroMatik ste am humidif iers are IP20-pro tected. 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 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 10: Packing
The h eating elemen t humidifiers type HeaterLine 60-9 0 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) -
Page 11: 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 12: 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 co nnected to alternating cu rrent. The cylinder (9 ) is filled with t ap wate r, fully d emineralized water or partially sof tened water. - Page 13 At the standard setting, the inlet solenoid valve (14) opens when the water level remains below “humidif ication” level for 10 sec- onds. The water level then rises again to “humidification” level. Position Discription Steam hose adapter Connection control capsule O-ring, steam hose adapter Cover, cylinder Control cap sule / W ater level...
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Page 14: Internal Output Setting
Direct room humidification (without ducts) is performed using fan units (with blower and n ozzle). T he st eam g enerator is con- nected to the fan unit with steam and condensate hoses. Steam lines in stea m bath cabins employ spe cial steam hoses and piping (if required). -
Page 15: Installation
Risk of electrical shock by hazardous voltage! During installation the unit must be disconnected from the power grid. HygroMatik accepts no liability for damage due to faulty installa- Please note tion. Please note Attaching or inst alling add itional compo nents is permitted only with the written conse nt of the manu facturer, or else the wa r- ranty is void. - Page 16 Hoses must be laid at a consistent 5 -10% incline to • prevent sagging and kinking The rear panel of the steam humidifier heats up during • operation (to a maximum of 60°C/140°F). Take c are that the construction on which the unit is mounted is not made of temperature-sensitive material.
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Page 17: Fitting Measures
5.1.1 Fitting Measures Wall Distance > 50mm/ > 200mm/ > 500mm/ > 300mm/ When selecting the stea m humidifier set-up location, make use Please note of existing connections (supply water and drain), if possible. Wall Mounting Please note For proper functioning of the steam generator the plumb-vertical installation is mandatory Measures for drills for wall mounting please see table (measures d and e) in chapter „Equipment Dimensions”.If there is no suit-... -
Page 18: 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 19: 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 HL 6... -
Page 20: Absorption Distance Bn
5.3 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 21 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 22: 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 22... -
Page 23: Steam Manifold
5.4 Steam Manifold 5.4.1 Notes on Installation Horizontal installation of These notes refer to a homogeneous standard steam manifold steam manifold installation: 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! Air flow direction Minimum distances in order to avoid condensation:... - Page 24 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/2.8inch.
- Page 25 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 26 “ “ * 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 26...
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Page 27: Steam Line
When installing the steam hose, please pay attention to the fol- lowing: • 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 28: Cover Plate
5.6 Cover Plate HygroMatik flange plates may be used to neatly complete instal- lation of th e ste am h umidifier in t he air duct . Two-piece flange plates are available for the DN25/1“ and DN40/1 “ steam man- ifolds. -
Page 29: Drill Pattern
5.7 Drill Pattern Drill Pattern not to scale DN25/1“ ( Please note Due to variable print media the dimensions are not to scale. Page 29... - Page 30 Drill Pattern not to scale DN40/ 1 “ ( Please note Due to variable print media the dimensions are not to scale. Page 30...
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Page 31: Types Of Installation
Types of Installation 5.7.1 Installation type 1 If the stea m m anifold is positioned h igher th an 5 00mm/ 19.7inch above the steam humidifier: » Lay the steam hose at a height of at least 400mm/ 15.7inch above unit and then connect to the steam manifold with a constant rise or fall. - Page 32 Installation type 2 If the steam mani fold is posit ioned lower than 5 00mm/ 19.7inch above the steam humidifier: » Lay steam hose at a height of at least 400mm/15.7inch above unit and then connect to the steam manifold with a constant fall.
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Page 33: Condensate Hose
5.8 Condensate Hose Warning: To ke ep cond ensate from accumula ting in the duct, make sure condensate can drain freely. Installation type 1 If the stea m m anifold is positioned h igher th an 5 00mm/ 19.7inch above the steam humidifier: »... - Page 34 HL30 - HL45 HL6 -HL27 Connection condensate hose / hoses Lay the condensate hose at an approximate incline of 5-10% to the steam cylinder connection fitting, to allow the condensate to drain freely. Please note It is recommended to form a loop of 200mm/7.9inch diameter as a vapour trap provided there is enough space.
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Page 35: Steam Solenoid Valves
Installation type 2 If the steam mani fold is posit ioned lower than 5 00mm/ 19.7inch above the steam humidifier: » The condensate must be drained separately. » To prevent steam loss, lay a loop at least 200mm/ 7.9inch in di-ameter. »... -
Page 36: Unit Installation Check
components. For proper function make sure that the three holes in the top side of the ho using are not covered - othe rwise the heat removal is too low and a thermal cutout could be triggered. 5.11 Unit Installation Check Please check the installation using the following list: Does unit hang vertically? ... -
Page 37: Water Installation
6. Water Installation Very hot water on the humidifier drain side! Have a ll work p erformed by pro fessional st aff t o avoid risk of scalding by inadequate water flow. Risk of electrical shock by hazardous high voltage! Before starting installation work ensu re yourself that the unit is not connected to the power grid. -
Page 38: Water Quality
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. Foreign material in water supply pipe may cause premature damage to the solenoid valve! Flush th e wate r su pply p ipe before makin g conne ction to the solenoid valve. -
Page 39: Water Supply (For Operation With Demineralized Water Or Purified Condensate)
Make sure that a backflow preventer is installed in the water supply line. Shut-off valve (AV), water filter (WF) and backflow preventer are Please note not provided by HygroMatik. Install as follows: » Check whether the valve strainer has been inserted in the solenoid valve. -
Page 40: Water Supply (For Operation With Tap Water Or Partially/Fully Softened Water)
Water supply: 1bar min., 10bar max./ 14.5psi min., 145psi max. » 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 pro- trudes from the base. -
Page 41: Feed From Holding Tank
6.3.1 Feed from Holding Tank If a holding tank will be used to supply water, the „option sole- noid valve 0-1 0bar” must be ord ered. Make sure that th e feed height is at least 0.5 m/19.7inch. If the height is less th an 0.5m/ 19.7inch, insert a feed pump or install the humidifier lower if pos- sible. -
Page 42: Water Discharge
6.5 Water Discharge During blow down hot water with a temperature of about 95 °C/203 °F is being drained! Wastewater must drain freely and pressureless! During blow down up to 0.3 l/sec are being drained 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 43: 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 44: Electrical Installation
7. Electrical Installation Risk of electrical shock by hazardous high voltage! All work rela ted to electrical inst allation to be pe rformed 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 grid before all installation work has been completed. - Page 45 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: HL06...
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Page 46: Cable Connections
7.2 Cable Connections The t able belo w shows t he ca ble connectio ns pro vided in HeaterLine steam humidifiers: Unit Connection Connection Connection HL6 - 45 Characteristics of metric cable connections: Thread for cable diameter across-flats [mm] dimensions [mm] M16x1,5 4,5 - 10 M25x1,5... -
Page 47: Wiring Diagram
Please note Detailed information concerning initial operation, control, service and malfunctions as well as circuit diagrams can be found in the operation manua ls for Hyg roMatik control u nits a s well as on www.hygromatik.co.uk . Page 47... -
Page 48: Commissioning
8. Commissioning Start-up of the unit is restricted to qualified personnel only! Only trained and qualified people that h ave read and fully un derstood this operating manual and the safety instructions included may put the steam humidifier into operation. Steam generator switch-off procedure must be well known! Before st arting-up the uni t the position and ha ndling o f a ll co ntrols involved in switching-of f the unit must be identified and familiarized... - Page 49 Step 5: Normal operation starts • the water solenoid valve opens and feeds water into the steam cylinder • Initiation of steam production may take up to 20 min- utes. » 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.
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Page 50: Maintenance
Maintenance The HygroMatik steam humidifier is easy to maint ain. However, inadequate or improper main tenance can le ad to o perational malfunctions. Perform regular mainte nance to give your u nit a long life span. The unit is only to be serviced by qualified, authorized per- sonnel! All safety instructions must be observed. -
Page 51: Maintenance For Operation With Demineralized Water / Condensate
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. Cycle Maintenance Task 4 W eeks af ter Visual check o f electrical and me chanical Initial Operation connections. -
Page 52: Maintenance For Operation With Tap Water Or Partially Softened Water
Part of this solid build-up is removed through periodic blow-downs and fresh tap water refills with the aid o f the HygroMatik SUPER FLUSH flushing system. The SUPER-FLUSH system genera tes a whirlpool effect in the strainer basket, intensifying removal of calcium p articles during blow-down. -
Page 53: Access To Control Unit
9.3 Access to Control Unit Risk of electrical shock by hazardous voltage! Make sure the unit is switched of f before installing or removing the display panel. » Remove cover (or electric compartment cover) from humidifier (B) and lift display panel (A) off guiding. »... - Page 54 » Lift steam cylinder (9) out of the base (11). Take care in order not to damage the heating element cable when lifting the cylinder out. » Remove cylinder base o-ring (13). » Lift strainer insert (12) out of the base using the two access holes on the side.
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Page 55: Cleaning Steam Cylinder
When inserting the cylinder take care in order not to damage the heating element cable. The “Hot surface” sticker must show towards the humidifier front. Please note » With a gentle rotational movement, slide adapter (2) over the o-ring on the steam outlet and fix it with the star screws (1). - Page 56 Cleaning Excessive mechanical cleaning may damage the cylinder and/or the heater elements. Deposit removers only to be applied to the cylin der and the heater elements! When using mineral deposit removers or cleaners to clea n the cylinder and heater elements, make sure the unit is t horoughly rinsed before reassembly.
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Page 57: Cleaning Connection Hoses, Cylinder Base And Nozzle
9.6 Cleaning connection hoses, cylinder base and nozzle When operating with partially softened water or tap water scale can be discharged with the steam flow and can settle in the noz- zle (3) sitting in the steam hose adapter. Therefore, this nozzle should be inspe cted regu larly as p art of t he ge neral ma inte- nance review and cleaned if necessary. -
Page 58: Replacing Thermo Sensor (For Heater Element)
9.7 Replacing Thermo Se nsor (for Heater Ele- ment) Removal » Close off water supply. » Drain steam cylinder (9) by setting main switch to Pos » Disconnect power supply and secure against restart (switch off control switch, remove main fuse and control fuse F1). - Page 59 » Remove thermo sensor. » » » » » » » » » » » O: Thermo Sensor P: Unlocking Button for Thermo Sensor Q: Sealing R: Cylinder Do not bend the capillary tube of the thermo sensor! Installation » Install heater element and thermo sensor.
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Page 60: Unlocking Of A Released Thermo Sensor (For A Heater Element)
9.8 Unlocking of a Re leased Ther mo S ensor (for a heater element) If a th ermo sensor (fo r a hea ter elemen t) has trig gered due to overtemperature, the blue button (P) is leve l with th e top of the sensor cap. -
Page 61: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter
» Open pump (bayonet lock). » Remove all residue from the drain hoses and pump (if required, replace o-ring (A)). » Assemble pump. » Moisten o-ring (C) and place in the side connection of the base. » Push pump into the base and secure tightly with screws (G). - Page 62 » Verify absence of electric current. » Remove cylinder as described above in section “Clean- ing Steam Cylinder.” » Seal off water supply and remove screw joint from fresh water connection (L). » Detach connector hoses (G) from base (11) and mark a position.
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Page 63: Checking Cable Screw Connections, Heater Element Wires
» Install cylinder as described above in section “Cleaning Steam Cylinder”. » Open water supply. » Switch on unit and check for leakage after 15-30 min- utes of operation. If leakage occurs, switch off power supply and repair the leaks, following safety instructions for work on live components! 9.13 Checking Cable Screw Connections,... -
Page 64: 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 65 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.
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Page 66: Spare Parts
11. Spare Parts Description HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 Article No. Cabinet B-2129001 Cabinet L 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 67 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 68 Description HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 with control with control Article No. 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 SuperFlush HY05/0 8,...
- Page 69 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 70 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...
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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: Exploded View
13. Exploded View Page 72... -
Page 73: View Of Cabinet
14. View of Cabinet Page 73... -
Page 74: Technical Specifications
15. 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 ating [kW] 11.0 14.7 Input Current [A]*** 17.7 30.6 30.6 48.0 Circuit rotection Number of Heater Elements Data at 480V/3 Phase, Steam Output [kg/h]... - Page 75 This page intentionally left blank Page 75...
- Page 76 12/2004...
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