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

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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 08.09.2015 Information in this manual is subject to change or alteration without prior notice. Current version of this manual can be found at: www.hygromatik.de Warning, Hazardous Voltage: All work to be performed by trained personnel only. All electrical installation and servicing of the electrical components of this unit to be performed by qualified electricians only.

  • Page 3: Table Of Contents

    1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation .......................5 1.3 Directions for Use ......................6 2. Safety Notes ........................7 2.1 Overview ........................7 2.2 Guidelines for Safe Operation ..................7 2.3 Disposal after Dismantling ....................8 3. Transport .........................9 3.1 Overwiew ........................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 6.4 Water Treatment ......................38 6.5 Water Discharge ......................39 6.6 Checklist .........................40 7. Electrical Installation .....................41 7.1 Electrical Installation .......................41 7.2 Cable Connections ......................43 7.3 Control Connection ......................43 7.4 Safety Interlock .......................43 7.5 Wiring Diagram .......................44 7.6 Electrical Installation Checklist ..................44 8.

  • 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: Directions For Use

    / condensate water (only for humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim). Warning: HygroMatik steam humidifiers emit steam with a tem- perature of 100°C/212°F. The steam may not be inhaled directly. Proper usage also entails following HygroMatik's instructions for installation, dismantling, reassembly, initial operation and opera- tion and maintenance, as well as disposal procedures.

  • Page 7: Safety Notes

    2. Safety Notes 2.1 Overview These safety notes are required by law. They promote work- place safety and accident prevention. Warnings and Safety Symbols The safety symbols below identify sections containing warnings about hazards or potential dangers. Please familiarize yourself with these symbols.

  • Page 8: Disposal After Dismantling

    After proper electrical installation or repair, test all safety mechanisms (such as grounding resis- tance). HygroMatik steam humidifiers are IP20-protected. 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 Overwiew Note:Proceed carefully when transporting the steam humidifier in order to prevent damage from rough or careless loading and un- loading. Transport Size and Weigth Type* Heigth depth width weigth [cm]/ [cm]/ [cm]/ [kg]/[lb] [inch] [inch] [inch] HL 6 36.6 16.5 29.1...

  • Page 10: 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 11: Included In The Delivery

    Time limits for filing freight claims with shipping companies are*: Transport Company After Receipt of Goods Mail 24 hours at the latest Rail 7 days at the latest Truck and railway compa- 4 days at the latest nies Parcel Service immediatly * Subject to change without prior notice.

  • Page 12: Operation And Installation

    4. Operation and Installation 4.1 Mode of Action The Imersion 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 13 (“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. The SUPER FLUSH mecha- nism generates a strong whirlpool effect in the strainer basket which aids removal of scale deposits during the blow-down pro- cess.

  • Page 14: Internal Output Setting

    Direct room humidification (without ducts) is performed using fan units (with blower and nozzle). The steam generator is con- nected to the fan unit with steam and condensate hoses. Steam lines in steam bath cabins employ special steam hoses and piping (if required). Accumulated condensate is normally routed into the steam cabin.

  • Page 15: Installation

    The minimum clearances indicated in the diagram below must be observed; these are necessary to ensure adequate ventilation for the housing. • HygroMatik humidifiers are not suitable for direct out- door installation. • The steam humidifier should be installed as close as possible to the steam manifold.

  • Page 16: Fitting Measures

    5.1.1 Fitting Measures Wall Distance > 50mm/ > 200mm/ > 500mm/ > 300mm/ Note: It is often advantageous to use existing water connections (feed and drain) when selecting the steam humidifier. Wall Mounting Note: To function properly the steam humidifier must be installed vertically.

  • Page 17: 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 18: 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 19 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 20: 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 20...

  • Page 21: Steam Manifold

    5.3 Steam Manifold 5.3.1 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 22 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 23 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 24 “ “ * 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 24...

  • Page 25: Steam Line

    Note: When installing the steam hose, please pay attention to the following: • 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 26: Cover Plate

    5.5 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 DN25/1“ and DN40/1 “ steam man- ifolds. flange plate DN25/1“ E-2604260 flange plate DN40/ 1 “...

  • Page 27: Drill Pattern

    5.6 Drill Pattern Drill Pattern not to scale DN25/1“ ( Note: Due to variable print media the dimensions are not to scale. Page 27...
  • Page 28 Drill Pattern not to scale DN40/ 1 “ ( Note: Due to variable print media the dimensions are not to scale. Page 28...

  • Page 29: Types Of Installation

    Types of Installation 5.6.1 Installation type 1 If the steam manifold is positioned higher than 500mm/ 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 30 Installation type 2 If the steam manifold is positioned lower than 500mm/ 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. »...

  • Page 31: Condensate Hose

    5.7 Condensate Hose Note: When installing the condensate hose, please pay atten- tion to the following: Warning: To keep condensate from accumulating in the duct, make sure condensate can drain freely. Installation type 1 If the steam manifold is positioned higher than 500mm/ 19.7inch above the steam humidifier: »...
  • Page 32 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. Note: It is recommended to form a loop of 200mm/7.9inch diame- ter as a vapour trap provided there is enough space.

  • Page 33: Steam Solenoid Valves

    Installation type 2 If the steam manifold is positioned lower than 500mm/ 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. » To ensure condensate drainage, place the loop (vapor trap) as far away as possible below the steam manifold connection.

  • Page 34: 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 35: Water Installation

    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 (For Operation With Demineralized Water Or Purified Condensate)

    Make sure that a backflow preventer is installed in the water supply line. Note: Shut-off valve (AV), water filter (WF) and backflow pre- venter are not provided by HygroMatik. Install as follows: » Check whether the valve strainer has been inserted in the solenoid valve.

  • Page 37: 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 38: 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 0-10bar” must be ordered. Make sure that the feed height is at least 0.5m/19.7inch. If the height is less than 0.5m/ 19.7inch, insert a feed pump or install the humidifier lower if pos- sible.

  • Page 39: Water Discharge

    6.5 Water Discharge Warning: During blow down hot water with a temperature of about 95 °C/203 °F is being drained. If touched this can cause burns to the skin. With the optional wastewater cooling system HyCool, HygroMa- tik offers an option for limiting the wastewater temperature of the steam humidifier.

  • Page 40: 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? Is the drainage system correctly installed? Are the water supply and drain lines free of leaks? Warning: Flush out the water supply line before connecting to...

  • Page 41: Electrical Installation

    7. Electrical Installation Warning, Hazardous Voltage! All work related to electrical installation may be performed by authorized personnel only (electricians or professionals with equivalent training). The cus- tomer is responsible for checking qualifications. Warning, Hazardous Voltage! Do not connect the steam humidifier to the power grid until after all installation work has been completed.
  • Page 42 Type Main Power Supply HL6 - HL45 1 x (208V or 480V or 600V) /3Phase HL60 - HY90 2 x (208V or 480V or 600V) /3Phase We recommend using a main fuse with medium blow rating (applies only to the mains voltages above.) See table below indi- cating maximum power consumption corresponding to each type of circuit protection: The steam generator should be operated with a residual current...

  • Page 43: 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 for cable diameter across-flats [mm] dimensions [mm] M16x1,5 4,5 - 10 M25x1,5 9 - 17 M32x1,5 11 - 21...

  • Page 44: Wiring Diagram

    Every steam humidifier comes with a unit-specific technical manual and a manual for the control. In addition, you will find downloadable wiring diagrams and technical manuals at www.hygromatik.de. 7.6 Electrical Installation Checklist Perform electrical installation checks in compliance with cus- tomer site requirements and public power utility regulations: ...

  • Page 45: Commissioning

    8. Commissioning Warning: This unit is only to be started by qualified personnel. Switching off steam humidifier Warning: Before starting up the unit, make sure you know how to switch it off. » Switch off unit by setting control switch to “0” »...

  • Page 46: Maintenance

    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. Since steam and condensate hoses are also subject to wear they have to be checked regularly.

  • Page 47: Maintenance For Operation With Demineralized Water / Condensate

    Maintenance for Operation with Demineralized Water / Condensate Instructions for maintenance and cleaning intervals are based exclusively on typical, empirically determined values. Cycle Maintenance Task 4 Weeks after Visual check of electrical and mechanical Initial Operation connections. Visual check of water level control. Visual check of steam cylinder interior.

  • Page 48: 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 of the HygroMatik SUPER FLUSH flushing system. The SUPER-FLUSH system generates a whirlpool 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 » Remove cover (or electric compartment cover) and lift display panel (A) out of its guide. » Turn display panel (see drawing) and hang display panel on the humidifier cabinet (B) by placing the two guide pins in the two front guides.
  • Page 50 » Remove cylinder base o-ring (13). » Lift strainer insert (12) out of the base using the two access holes on the side. » Remove all deposits from the coarse strainer. » Keep coarse strainer clean with mechanical utilities. » Check base for deposits and remove if necessary.

  • Page 51: Cleaning Steam Cylinder

    » Attach steam cylinder connector plug. » 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 52: 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) that is in the steam hose adapter. Therefore, this nozzle should be tested regularly as part of the general maintenance review and cleaned if necessary.

  • Page 53: Replacing Thermo Sensor (For Heater Element)

    9.7 Replacing Thermo Sensor (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 54 » Remove thermo sensor. » » » » » » » » » » » O: Thermo Sensor P: Unlocking Button for Thermo Sensor Q: Sealing R: Cylinder Warning: Do not bend the capillary tube of the thermo sensor! Installation »...

  • Page 55: Unlocking Of A Released Thermo Sensor (For Heater Element)

    9.8 Unlocking of a Released Thermo Sensor (for heater element) If a thermo sensor (for heater element) has released due to a too high temperature the blue button (P) is on the same level as the top of its holder. Additional the control reports a failure „thermo sensor activated“.

  • Page 56: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter

    » Open pump (bayonet lock). » Remove all residue from the drain hoses and pump (possibly 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 57 » 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. » Remove electrical connectors from double solenoid valve (H) and mark position.

  • Page 58: Checking Cable Screw Connections, Heater Element Wires

    » 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, Heater Element Wires...

  • Page 59: 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 60 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 61: Spare Parts

    11. 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 62 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 63 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 64 with control with control HL6 HL9 HL12 HL18 HL24 HL27 HL30 HL36 HL45 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 65 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 66: Fax Form - Order For Spare Parts

    12. 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 67: Exploded View

    13. Exploded View Page 67...

  • Page 68: View Of Cabinet

    14. View of Cabinet Page 68...

  • Page 69: 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 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 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 A member of the Group...

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