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HPS High-pressure nozzle system Adiabatic humidification and cooling system FlexLine Operating Manual ÁHPS.ENvÈ HPS.EN E-8881140...
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HPS.EN 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. In particular and without prejudice to the generality of the foregoing,...
3.4 Check for Complete and Correct Delivery of Goods ............11 3.5 Scope of delivery ....................... 11 4. Composition and function of the HygroMatik high-pressure nozzle system HPS ..12 4.1 Fields of application ......................12 4.2 Functioning ........................12 4.3 Schematic diagram of the system components ..............
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5.2 Mechanical assembly Vortex wall ..................21 6. Mechanical installation ..................... 22 6.1 Environment Parameters to be met and Mounting Recommendations ......22 6.2 Unit installation ........................23 6.3 Unit connections ........................ 23 6.3.1 Dimensions and mounting instructions ................24 7.
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13.2 Screen 1 - Commissioning ....................47 13.2.1 Setting the language ....................47 13.2.2 Input of date and time ....................47 13.2.3 Control settings ......................48 13.2.4 Line-up of the commissioning parameters ..............49 13.3 Screen 2 - Main screen ....................50 13.3.1 Changing the set point humi-dity ..................
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15.2.1 Replacing the shaft sealing ring of the high-pressure pump EH2009 ......80 15.2.2 Replacing the valves ....................82 15.2.3 Replacing the seals on the water side ................82 15.2.4 Calibration work after repair or replacement of the high-pressure pumpstation ... 83 15.2.4.1 Setting of the overpressure protection ..............
1. Introduction 1.2 Documentation Retention Dear Customer, Thank you for choosing a HygroMatik high- Please retain these operating instructions in pressure nozzle system HPS. „HPS“ stands a secure, always accessible location. If the for „High Pressure System“, i.e. , in question...
When attempting to operate the system in a position higher than 1000 m above Only qualified and personnel may work on or sea level, pls. talk to HygroMatik prior with the system (a supplementary qualifica- to installation tion according to VDI 6022 Part B or an equivalent qualification is recommended).
WARNING prevention. Health hazard due to the inhalation of aerosols. 2.1 Guidelines for Safe Opera- During operation of the HygroMatik high- tion pressure nozzle system HPS, it is not permit- ted to stay in the humidifier chamber. 2.1.1 Scope Comply with the accident prevention regula- tion „DGUV Regulation 3“...
Use only original fuses with the appropriate amperage rating. Regularly check the unit‘s electrical equip- ment. Promptly repair any damage such as loose connections or burned wiring. Responsibility for intrinsically safe installation of the high-pressure nozzle system is incum- bent on the installing specialist company. Disposal after dismantling The humidifier is made up of metal parts and plastic parts.
3. Transport Time limits for filing freight claims with ship- ping companies are*: 3.1 General information After receipt of Shipping company Please note goods Take care when transporting the high-pres- Carriers no later than 4 days sure nozzle system to prevent the device and packaging from being damaged by impact or Parcel service immediately...
4. Composition and function of 4.2 Functioning the HygroMatik high-pres- The high-pressure nozzle system is based on sure nozzle system HPS atomisation of water. Desalinated water is fed into a high-pressure piston pump. With an operating pressure of Fields of application...
4.4 Control options (modes of 100 percent, the output pressure on the nozzles rises proportionally up to 75 bar and operation) the system reaches the maximum possible The usability of the modes of operation de- humidification output. Beyond the switching scribed below depends on the actually availa- point the system works in the „...
4.4.4 Supply air humidification 4 4.4.5 Exhaust air cooling load mode The high-pressure nozzle system was either The 4-load-configuration allows for exact ordered as an exhaust cooling system or can humidification controllability even in the be put to exhaust air cooling operation mode range of minimum output demand.
4.5 Main components 4.5.2 Overview on the electrical and electronic components of the 4.5.1 The unit cabinet and its internal system assemblies In the unit cabinet, the electrical and electro- nical components as well as the wiring termi- nals are installed below a hinged lid. The electronical control unit is responsable for control of the system.
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Construction of the High Pressure System 1 Touchscreen of the electronic control 8 High-pressure pump 2 Main switch 10 Wastewate connection 12 mm 3 Electronic control 11 Flushing solenoid 4 Frequency converter 12 Outlets to the nozzles 5 Main contactor 13 Water inlet solenoid, covered 6 Pump motor 14 Water connection ¾“...
Pump group max. feed humidification output [kg/h] max. speed output [l/h] @ 95 % efficiency rate [rpm] HPS250 46 - 250 1400 HPS500 90 - 600 1400 Pump station characteristics for the various unit models 4.5.2.2 By-Pass Task of the by-pass is to ensure the minimum speed of the high-pressure pump even in case of very low humidification demand.
4.5.3 Vortex modules 4.5.3.1 Atomising nozzles for vortex modules The vortex modules provide for effective mix- ing of the air and water mist. Desalinated water at a pressure of 25 to75 bar reaches the high-pressure nozzles where Due to their special design, they generate the water is atomised to form ultra-fine mist- turbulence and shear zones which lead to a like aerosols.
4.6 Flushing functions There are no more atomised water droplets The nozzle system offers a number of flush- in the air stream behind the HygroMatik high- ing variants in order to cope with the hygienic pressure nozzle system(if the environmental and maintenance oriented requirements.
5. Humidification chamber 5.1 Structural composition of a humidification chamber The fig. hereafter schematically shows the composition of a vortex module wall and two aerosol separators in a humidifcation chamber with the hygienic and safety prere- quisites required (drains, darkenable inspection window).
• Protection class IP20 >200/7,8 >200/7.8 >500/19.7 • By design, HygroMatik steam humidifi- ers are not qualified for outdoor instal- lation (electronical components and water-bearing parts may be damaged) • Ambient temperature must lie between +5 and +40 °C (+41 and +104 °F) in order to protect the unit electronics against damage;...
» Insert the pump station into the wall console and screw it tight HygroMatik HPS units are designed for wall mounting. The unit should be mounted on a stable wall. Due to the high weight of the unit, Tighten the screw connection only so firmly the wall bracket included in the scope of that the system can no longer slip.
7. Supply and waste water General rules connections • Obey local water utility regulations • Have all installation work done by expert staff (plumber or personnel with comparable expertise) WARNING • If desalinated water is used we recom- mend that stainless steel or plastic Risk of electrical shock! pipes be used Hazardous electrical high voltage!
» Transfer mounting bracket hole pat- vided on-site in the direct vicinity of the tern to a suitable location on wall. HygroMatik high-pressure nozzle system. » drill holes, dowel and attach moun- ting bracket with the mounting mate- rial included with the water filter.
7.3.1 Water drain of the humidifica- 7.4 Water connection final check tion chamber Water supply Was the water filter insert supplied as part of the delivery installed in the water filter housing of the pumpsta- tion? Is the feed water quality within the prescribed range? Water drain ...
0.9...2.8 m/s (ideal conditions) If the air velocity is outside this range please According to VDI 6022, flushing of the sys- contact HygroMatik. tem is required regularly within a 48 h time frame if no demand calls for the system ope- Pressure drop ration.
Please note If the ventilation system fails or the supply air When sizing the connection lines, observe face velocity is too low (less than 0.9 m/s) the that the supply impendance must be low! If a site monitoring must switch off the high-pres- short circuit occurs the circuit-breaker must sure nozzle system via the safety chain.
(such as lan- Start-up of the high-pressure nozzle system guage, time and date, type of control is restricted to HygroMatik staff or authorized signal and type of control). On this personnel only. screen the respective settings must be...
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Step 5: Monitor unit function and check for leakage » Let the high-pressure nozzle system operate for about 30 minutes with duct ventilator running humidity transport. » If leaks appear, switch off the unit. Step 6: Repair leaks and correct improper spray image »...
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Please send us the notification of readiness preferably 10 working days before the desired date. Best regards Your HygroMatik Service Team We confirm that the above connections are fully ready. Desired date for commissioning: ___________________________ If the comissioning cannot be performed due to on-site reasons such as lack of water, or power supply, the resulting travel costs and time will be charged.
11. Description of control and are looped from there to the mainboard. Fusing of the control voltage is made on the 11.1 General description mainboard by 2 2.5 A fast-blow fuses (F1, F2). The control is integrated into the high-pres- sure system housing and is operated via a The low voltage supply power für expansion 3.5"...
11.3 Mainboard The mainboard is "the heart" of the control. All logic functions and control operations for the high-pressure nozzle system are pro- vided here. For driving the main contactor, the flushing solenoid valve and the 2nd-load solenoid valve, three relays are located directly on the mainboard.
11.3.1 Connections on the main- 11.3.1.2 System-side interfaces board ST1: 11.3.1.1 Customer-side interfaces • 4-pin plug connection for the connec- tion of L1 and N and the interlock Inputs (safety) system, looped via ST1.2 of ST08: the expansion board • 05: control signal input 0...10 VDC ST11.1: •...
11.4 Expansion board The expansion board provides - besides fur- ther inputs - additional relays for the switch- ing of the water intake solenoid valve and the load (the 1 load is selected by default when humidification starts, the 2 load is switched on the main board).
11.4.1 Connections of the expansion 11.5 Connection terminals block board Inputs ST05: • 06: high pressure sensor (0...20 mA) • 08: higital input for switching between humidification/cooling (12 VDC) ST1.1: • 4-pin screw / plug connection for the connection of L1 and N and the inter- lock (safety) system ST1.2: •...
11.6 Electrical connection 11.6.2 Connection of interlock (safety) system The so-called interlock (safety) system is WARNING located between terminals 1 and 2 of the X1 Danger of electric shock! terminal block. Safety equipment can be Dangerous electric voltage! wired (also in series) into the interlock All work relating to the electrical installation (safety) system.
11.6.3 Terminal wiring for the various 11.6.3.1 Terminal wiring for supply modes of operation air humidification (standard delivery) Standard operating mode of the high-pres- sure nozzle system is „supply air humidifica- 1-step operation tion“. Optionally, a „combined unit“ that supports both modes of operation in a switch- able form may be ordered (for further infor- Terminal strip on ST08 mation concerning the various modes of...
11.6.3.2 Terminal wiring for a com- Please note bined unit (ordering option) Active humidity sensors require an external A combined unit allows for the alternative supply voltage. Terminal 3 provides +20 VDC operation of supply air humidification and for that purpose. exhaust air cooling.
Additionally, the parameter „Cooling“ (15:adi- Operation with active humidity sensor or abate/12) must be set to „1“ (only visible external controller when code „090“ was input). Terminal wiring of the mainboard is to be Parameter „Digital_input_function“ (10:func- made as for the standard unit (supply air tions/12) must be set to „51“...
12. Screen Active area Icons for status display Active screen area Main display for operating values, navigation using the scroll keys Scroll keys can be used to display the following operating values: • Pressure_actual_value [bar] • Pressure_set_value [bar] • Frequency_set_value [Hz] •...
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Active screen area In the event of a fault or a service message, the relevant display field is shown instead of the HygroMatik logo. Touching it opens the unit info screen (see Sec- tion 5.9). Störung (001) Service Unit info screen (see Section 5.9) for the display of error and service messages in 02: Information plain text.
In addition to operating the unit directly, it is possible to control it remotely via the building technology control system or a PLC, using the communication interface. Supplementary documentation is available from HygroMatik for this type of application. Screen views operating structure...
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Overview of the screens Content of screen page Presentation Sec. Screen 1 Used for the basic unit settings (e.g. user language) 12.2 Commissioning after the unit is switched on for the first time. This 01:Commissioning page is then closed. To do so, use the confirmation tick to exit it.
13.2 Screen 1 - Commissioning » Confirm the input and return to the "Initial operation" screen with the After connection to the mains supply and ini- green tick in the top right (cancel by tial actuation of the control switch, the com- touching "X").
13.2.3 Control settings The initial operation is now complete. If the initial operation screen was exited with the The type of unit control is specified in the confirmation tick, the main screen is automa- next step. The screen offers the most com- tically shown in the display.
13.2.4 Line-up of the commissioning parameters 01: Comissioning No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Language Selection Selection of language Deutsch Deutsch English...
13.3 Screen 2 - Main screen The values for the normal display brightness and the dimmed state can be adjusted by the user, as well as the duration after which the main screen is changed to the dimmed state (s. section 12.6.1). The main menu of the basic level and the Pressure_actual_value advanced level (screen 3) is accessed by...
Table of the read values available in the main screen and the humidity set value (only when PI-controller was selected) Mainscreen No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Pressure_acutal_value Read value The current system pressure in the unit in bar...
13.4 Password entry 13.5 Screen 3 - Main menu (basic level) The password determines if the main menu of the basic level or the advanced level is dis- played. The password codes in use are: After selecting the basic level, the icons of the submenus which are available without Code 000: The main menu of the basic level password entry are displayed:...
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Layout of screen page Example 2: Setting the screen brightness Touch "Screen_brightness normal" on the The input fields in which changes can be screen to call up the input mask: made are shown in italics. Depending on the parameter, the input has to be made by: •...
13.6.1 Settings submenu Table of settings parameters (basic level) 03: Settings No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Language Selection Selection of language see: 01-1 Language DD.MM.YY...
13.6.2 Read values submenu Read values table (visible on both the basic and the advanced levels) 04: Read_values No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Status_unit Read value Operating condition of unit...
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Read values continued Pressure_set_value Read value The set point of the system pressure in bar Frequency_set_value Read value The frequency set value for the frequency inverter Read value The current load situation in the spray system Load_actual The spraying system is not in operation 1st_load The spraying system works in single load mode 2_Load...
13.6.3 History submenu 13.6.3.1 Explanation of history ma- nagement The control stores 10 sets of error messages on a rolling basis. Once there are 10 records, the oldest record is overwritten by a current This submenu is identical on the basic and entry.
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Table of history layout continued Read value 4th memory entry: source of occurrence 4th fault entry see: 07-4 1st fault entry 5th fault_entry_date Read value 5. Memory entry: Date/time 5th fault_entry_message Read value 5. Memory entry: Error message see above see: 02-1 Fault_message_unit Read value 5.
13.7 Screen 3 - Main menu 13.8 Advanced level submenus (advanced level) By touching the respective icon, the operator accesses the screen page where the param- After the advanced level has been selected eters of the respective group are available for by entering the corresponding password selection, viewing or for making changes.
13.8.1 Settings submenu Table of settings parameters (advanced level) 03: Settings No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Language Selection Selection of language see: 01-1 Language...
13.8.3 Control submenu Table of control parameters 05: Control No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Selection Combinations of control type and input signal type/range Control_settings see: 01-4 Control_settings 25,0...
13.8.4 Service submenu Operating hours parameter „Operating_time_service“ (06:Service/3) holds the number of operating hours as a threshold value that leads to the display of the „Operating_time“ service mes- 13.8.4.1 Service messages sage (02:Information/4,7) when reached. The wear components of the unit are moni- After maintenance was accomplished, the tored continuously when the unit is in opera- service message must be reset by setting the...
13.8.4.2 Procedure for parameter USB connector on mainboard update The information below explains how to work with the "Update_function" parameter (see parameter row 26 in the table above). The update function makes it possible to overwrite parameter settings with a parame- ter set which is saved on an external USB flash drive.
13.8.6 Functions submenu Table of functions parameters 10: Functions No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Dead_leg_flushing Selection Solenoid valve of the water inlet and pump\flushing valve are switched on and off in parallel for dead leg flushing [27].
2 stop bits Modbus_timeout Timeout in s for software control commands [12] through communication interface [13] Physical address of a BACnet device within the network (s. separate HygroMatik BACnet_MacID documentation) 65535 Number for the unique addressing of an instance of a specific BACnet object (s.
13.8.7 Adiabate submenu Table of parameters for the adiabate functions 15: Adiabatic No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Selection Flush after waiting time and at the time specified in parameter 15/3.
13.8.8 Recording submenu USB connector on mainboard The control can record 10 data sets inter- nally on a rolling basis. For activation, the parameter „Recording“ (16:Recording/1) must be set to „1“ (activated). Snapshots of the unit status are then carried out at inter- vals of 10 s, which can be helpful for trouble- shooting.
Table of recording functions 16: Recording No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Selection Recording [93] of parameter sets Recording No recording Deactivated Activated...
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After an error or a status message has occurred, a display which provides informa- tion about the type of message appears in the main screen instead of the HygroMatik logo. The content of the message is described in Section 14.
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Entries on the unit info screen 02: Information No. Parameter Adjustment/value range Meaning/Comment Factory setting (FS) Bold [ ] explains the term in the glossary [ ] refers to a related explanation of the term Fault_message_unit Read value List of possible unit fault messages No_fault No fault Plug_ST09...
The relevant display field is then The majority of fault messages is additionally shown instead of the HygroMatik logo. The accompanied by the flashing of one or more display field shows a warning symbol, the icons, allowing for a first limitation of the „Fault“...
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The feed pressure of the zles pressurised water has • Overpressure protec- • Please contact exceeded 75 bar for a tion on high-pressure HygroMatik period of secs pump not properly set • Pressure hose leaky • Check pressure hose Min. pressure...
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• Motor cable short-cir- mentation of the cuited frequency inverter (may be requested • Error in the frequency from HygroMatik) inverter electronics • Earth fault of output terminals • Air inlets and outlets • Remove blockage(s) Motor temperature...
14.2 Service messages Service messages are shown (just as the fault messages) on the main screen in place of the HygroMatik logo, when the cause has occured. Service When tipping the display field, the unit info screen is shown with the messages in plain text.
Carry out a visual inspection of aero- Leakages occurring can be repaired by sol separators and clean if neces- replacing the seals. In such a case, contact sary. HygroMatik. » Check the high-pressure pump oil level. » Check the water filter cartridge upstream of the pump group for con- 15.1.1 Changing the oil in the high-...
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Risk of material damage to the high pres- sure pump caused by inadequate oil fill- ing! Only use mineral oil! » Add 15W40 motor oil (approx. 0.4 l) via the filler hole (1). » Check the oil level using the dipstick and close the filler hole.
15.1.2 Checking/replacing the mains » Set the control switch on the control water filter cabinet of the high-pressure nozzle system to „0“. The mains water filter must be checked » Close the supply water stopcock monthly for contamination and replaced upstream of the water filter.
15.1.4 Cleaning the high-pressure 15.1.5 Cleaning the aerosol separa- nozzles tors The aerosol separators should be checked every 4 weeks for possible contamination WARNING and cleaned if necessary. The aerosol sep- Risk of injury due to high pressure remai- arators should be thoroughly cleaned at least ning in the tubing.
15.1.6 Cleaning the spray system 15.1.8 Cleaning the humidification chamber » Clean the humidification chamber and the base tray as required with the cleaning agent that is recom- mended by the manufacturer of the humidification chamber. » After cleaning, rinse and let dry. Risk of material damage! When cleaning the spray system, do not aim the water jet at the aerosol separators.
15.2 Extended service instruc- » Dismantle the water connection lines of the high-pressure pump tions » Remove the 4 fixing screws (3) (2 15.2.1 Replacing the shaft sealing screws are hidden in fig.) of the cou- ring of the high-pressure pling bell and separate the coupling pump EH2009 bell with the pump from the motor...
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» Remount oil drain screw (2) paying attention to the sealing ring. Key and shaft sealing ring Filler hole, sight glas and drain screw Risk of material damage to the pump! When removing the shaft sealing ring, take care not to damage the seat and the shaft! »...
15.2.2 Replacing the valves The high-pressure-pump has 3 identical valves on the low-pressure and high-pres- sure side. If the pump can no longer build up the required pressure, worn valves may be the cause. To replace the valves, Replace- ment kit KIT123 is required which includes 6 valves and 6 O-rings.
15.2.4 Calibration work after repair or replacement of the high-pres- sure pumpstation 15.2.4.1 Setting of the overpressure protection Overpressure protection setting is restricted to a basic setting for the unit operator. Ceramic plungers » Carefully free the ceramic plungers (16) of seal deposits with the included polishing wool, check them for signs of wear and replace if nec- essary.
15.2.4.2 Setting of the optional by- pass valve on the distribu- tion manifold 1 - Distribution manifold 2 - Headless Allan screw 3 - By-pass valve 4 - Solenoid valves for pressure hoses 5 - Rinse valve Method » Apply control signal ≥ 1.5 V ->...
17. Spare parts HPS250 HPS500 Article. No. Description Electrical main assemby CN-07-00020 Mainboard [Modbus] CN-07-00021 Display Touch CN-07-00030 Extension board double cylinder units CN-07-00066 Main contactor 20A AC1 CN-07-00059 Main contactor 16A AC1 CN-07-00210 Circuit breaker B 16A, 1+N, 10kA...
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For ordering spare parts you find a template on the www.hygromatik.com website under the „Contact“ tab. Your spare parts order can also be sent directly per e-mail to hy@hygromatik.de. Please make sure to specify your unit model and serial number.
18. Technical specifications High-pressure nozzle system HPS Effective output power [kg/h] up to 250 up to 600 230/1/N/50 - 60 Electrical connection [V/Ph/Hz] Power rating [kW] 1,48 Nominal current 4,45 10,4 0 - 10 / 0 - 20 / 0 - 140 [V/mA/Ω] Control signal number of nozzles...
Modbus is a communications protocol for serial data transmission for the remote control of units, which is widely used in industry. HygroMatik controls use the MODBUS - RTU (remote terminal unit) variant. Separate documentation is available upon request from HygroMatik.
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Glossary ctd. (1) Floating max. limiter The floating max. limiter is an additional function when the control is operated with the internal PI controller. It serves for protection against excessive humidification of the channel. In case of the room sensor sending a demand while the channel has already reached its maximum humidity capacity, a floating max.
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Glossary ctd. (2) Switchover point Defined switching threshold for switchover from one load level [64] to an other depending on the input signal level. Virtual interlock (safety) system If control via àCommunication interface [13] was selected, software is used to place a logical switch in series with the hardware interlock (safety) system.
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Lise-Meitner-Str.3 • D-24558 Henstedt-Ulzburg Telefon 04193/ 895-0 • Fax -33 eMail hy@hygromatik.de • www.hygromatik.com Ein Mitglied der CAREL Gruppe Ein Unternehmen der Gruppe 100%...
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