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Summary of Contents for Hydromatic FlexLine FLH03
- Page 1 FlexLine Electric Heater Steam Humidifiers Manual ÁFLH.ENKÈ FLH.EN E-8881164...
- Page 2 Certain computer programs contained in this product [or device] were developed by HygroMatik GmbH ("the Work(s)"). Copyright © HygroMatik GmbH [09.12.2021] FlexLine FLH 03/06/09/15/25/30/40/50/80/100 EN All Rights reserved. Current version of this manual can be found at: www.hygromatik.co.uk 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].
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Page 3: Table Of Contents
1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation ........................5 1.3 Symbols in Use ......................... 5 1.3.1 Specific Symbols related to Safety Instructions ............. 5 1.3.2 General Symbols ......................5 1.4 Intended Use ........................6 2. Safety Instructions ......................7 2.1 Guidelines for Safe Operation ................... - Page 4 7.1 Electrical installation approach ..................27 7.2 Cable connections ......................28 7.3 Safety interlock ........................28 7.4 Connection diagram ......................29 7.5 Electrical installation check list ..................29 8. Commissioning ......................... 30 9. Maintenance ........................31 9.1 General ..........................31 9.1.1 Service messages ......................
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Page 5: Introduction
1. Introduction Retention Please retain these operating instructions in Dear Customer, a secure, always accessible location. If the Thank you for choosing a HygroMatik steam product is resold, turn the documentation humidifier. over to the new operator. If the documenta- tion is lost, please contact HygroMatik. -
Page 6: Intended Use
1.4 Intended Use HygroMatik electric heater steam humidifiers serve for steam production based on tap water, partially softened water or fully desali- nated water/cleaned condensate. Proper usage also comprises the adherence to the conditions specified by HygroMatik for: • installation •... -
Page 7: Safety Instructions
2. Safety Instructions 2.1.3 Unit Operation These safety instructions are required by law. They promote workplace safety and accident WARNING prevention. Risk of scalding! Uncontrolled hot steam escape in case of 2.1 Guidelines for Safe Opera- leaking or defective components possible. tion Switch off unit immediately. -
Page 8: Mounting, Dismantling, Maintenance And Repair Of The Unit
2.1.4 Mounting, dismantling, mainte- After electrical installation or repair work, test nance and repair of the unit all safety mechanisms (such as grounding resistance). The HygroMatik steam humidifier is IP20 pro- tected. Make sure that the unit is not object to Use only original fuses with the appropriate dripping water in the mounting location. -
Page 9: Transport
3. Transport Time limits for filing freight claims with ship- ping companies are*: Please note After receipt of Shipping company goods Proceed carefully when transporting the steam humidifier in order to prevent damage Carriers no later than 4 days due to stress or careless loading and unload- ing. -
Page 10: Functional Description And Device Composition
4. Functional Description and with a temperature of approx. 100 °C (212 °F) This steam is virtually mineral-free and germ- Device Composition free. 4.1 Mode of Action When fully desalinated water is used, the cy- linder water is almost totally clear of minerals. The immersion heater principle This situation guarantees a long lifetime of the Depending on the output rating, one, three or... -
Page 11: Operational Sequence
4.2 Operational sequence 4.3 Internal Output Setting The steam humidifier is switched on by Continuous control is achieved by propor- pressing the control switch on the front panel tional driving (pulse width modulation) of one to the „I“ position. If the safety chain is of the heater elements and phased addition of further elements. -
Page 12: Mechanical Installation
5. Mechanical installation • Installation in a closed room requires aeration and, eventually, temperature conditioning in order to meet the a.m. WARNING environmental conditions Risk of foot injuries! • steam humidifier should Prevent unit from dropping during installation! installed as close as possible to the Helping hand of a second person is advis- steam manifold. -
Page 13: Dimensions And Mounting Directions
5.1.1 Dimensions and Mounting Table of dimensions Directions Model X [mm/inch] Y [mm/inch] Z [mm/inch] A [mm/inch] B[mm/inch] FLH03-FLH09* 460/~18.1 535/~21 320/~12.6 310/~12.2 400/~15.7 FLH15-FLH25 540/~21.3 695/~27.4 320/~12.6 390/~15.4 560/~22 FLH30-FLH50 640/~25 785/~30.9 420/~16.5 490/~19.3 650/~25.6 FLH80-FLH100 1170/~46 785/~30.9 420/~16.5 1000/~39.4 660/~25.6 * Units with production date January 2022 and earlier: X:540 / A:390... - Page 14 Mounting principle Please note • To function properly, the steam humidi- fier must hang level and plumb. • When choosing the installation loca- tion, consider the necessary distance between the unit and existing desig- nated paths. This should be at least 60 •...
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Page 15: Unit Installation Check
5.2 Unit Installation Check Before start-up, pls. check proper unit instal- lation following the list below: Unit perpendicularly aligned in both the vertical and horizontal axis ? All clearances obeyed? Steam hose installed with a 5 - 10 % minimum incline/decline (see chap- ter "Steam line“) ? ... -
Page 16: Absorption Distance Bn
5.3 Absorption Distance B 5.3.1 Determining the Absorption Distance The "absorption distance" (B ) is defined as To determine the absorption distance, the fol- the distance from the steam feed to where lowing parameters are required: the steam is completely absorbed in the treated air. -
Page 17: 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 17... -
Page 18: Steam Manifold
5.4 Steam Manifold Water drain • We point out that according to the Ger- 5.4.1 General installation guidelines man Association of engineers (VDI) guideline VDI 6022, a water drain must When installing steam manifolds, pls. follow be provided within the absorption these guidelines: distance inside the air duct When increased airflow speed is encoun-... - Page 19 Minimum distance for condensation Air flow avoidance: direction = 210mm/8.3 inch: „Steam manifold - Next steam manifold“ distance = 120mm/4.7 inch: „Lowest steam manifold - Duct bottom plane“ distance = 120mm/4.7 inch: „Highest steam manifold - Duct ceiling plane“ distance Steam manifold arrangement for special air duct shapings flat...
- Page 20 Vertical steam manifold installation Steam manifold arrangement Air flow direction Steam supply Horizontal installation of the steam mani- folds is preferable. However, vertical installation into the air duct from below is also possible. Standard manifold dimensions [mm]/ [inch]***: 220/ 400/ 600/ 900/ 1200/...
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Page 21: Steam Line And Condensate Hose Layout
5.5 Steam line and condensate 5.5.2 Condensate hose layout hose layout (only for electrode steam humidifiers) The condensate hose may be run from the steam manifold back to the steam cylinder, Please note as depicted in the schematic drawing below Because of the high requirements on hose with concern to installation type 1. -
Page 22: Steam Line And Condensate Hose Installation Types
5.5.3 Steam line and condensate Installation type 2 hose installation types Steam manifold is positioned less than 500 mm above or below device upper Installation type 1 edge: Steam manifold is positioned more than 500 mm above device upper edge: Please note »... -
Page 23: Water Connection
6. Water connection The following applies to electrode steam humidifiers: • Use feed water without chemical addi- WARNING tives and with a conductivity between Risk of scalding! 200 and 800 µS/cm only. Beyond con- Very hot water to be found in and around the ductivity levels of 800µS/cm up to a steam humidifier during and after operation. -
Page 24: Operation Of Electrode Steam Humidifier With Softened Water
6.1 Operation of electrode steam 6.2 Water supply humidifier with softened water Foreign material in water supply pipe may cause premature wear of the solenoid Do not use softened water unless special valve. measures are taken! Flush the water supply pipe before making connection to the solenoid valve. -
Page 25: Water Discharge
6.3 Water discharge WARNING Risk of scalding! During blow down, up to 0.3 l/sec (08 gal./ sec) are being drained with a temperature of about 95 °C (203°F). Ensure that the drain hose is reliably fas- tened and wastewater can drain freely and pressureless. -
Page 26: Water Connections Final Check
6.4 Water connections final check Drain hose from Go down the following water installation checklist: Drain stub on All screws and clamps properly housng tightened? Grounding clips Water supply line flushed before making connections? Water connection properly installed? ... -
Page 27: Electrical Connection
7. Electrical connection 7.1 Electrical installation approach » Provide fuses with a contact gap of WARNING at least 3mm per pole. » Install a separate main connection Risk of electrical shock! for each steam cylinder including Hazardous electrical voltage. main circuit breaker, main switch All work related to electrical installation to be etc. -
Page 28: Cable Connections
7.2 Cable connections 7.3 Safety interlock The table below shows the number and dimensioning of the cable connections pro- WARNING vided by the various FlexLine housing types. Risk of electrical shock! Hazardous electrical voltage. Blind When standard wiring was made, terminal 1 Model with plug... -
Page 29: Connection Diagram
7.4 Connection diagram The device-specific wiring diagrams are included in the scope of delivery. Please use them for the installation and keep them in a safe place. 7.5 Electrical installation check list Check electrical installation with respect to customer-site requirements and local power supply regulations. -
Page 30: Commissioning
8. Commissioning Step 4: Trigger steam demand WARNING » Set control for commissioning check for permanent steam demand and Risk of operating error! close safety interlock. Start-up of the unit is restricted to expert staff The water inlet solenoid valve opens and only (electricians or expert personnel with feeds water into the steam cylinder equivalent training). -
Page 31: Maintenance
9. Maintenance 9.1 General • „Cycles_main_contactor x“ is indicated when the number of cycles pre-set for For the achievement of a long unit life span, main contactor „x“ (x = 1...5) is regular maintenance is a must. Maintenance reached. The main contactor should works to be performed refer to unit assem- then be replaced and the counter reset blies that underlie either mechanical or elec-... -
Page 32: Safety Instructions For Maintenance
9.2 Safety instructions for main- tenance Risk of electrical shock! Hazardous electrical voltage. Unit must be switched off and protected against restart by expert staff (electricians or expert personnel with equivalent training) before any mainte- nance work is commenced. Risk of skin burning! Hot steam cylinder during operation and for some time afterwards. -
Page 33: Maintenance When Unit Is Operated With Tap Water Or Partially Softened Water
9.3 Maintenance frame work Instructions on maintenance and cleaning intervals are entirely based on empirical data. when unit is operated with fully demin. water and con- densate Cycle time Maintenance work weeks after • Visual inspection of electrical and mechanical connections commissioning •... -
Page 34: Removal And Reinstallation Of The Steam Cylinder
9.5 Removal and reinstallation of If the steam hose is not to be disconnected, the steam hose adapter with the steam hose the steam cylinder still attached may be detached from the steam cylinder as shown in the next figures. 9.5.1 Removal of the steam cylinder »... -
Page 35: Cylinder Cleaning / O-Ring Replacement
» Lift steam the cylinder from the cylin- » Separate cylinder halves. der base. » Remove the used O-rings between the cylinder halves, in the base and in the steam hose adapter. 9.5.2 Cylinder cleaning O-ring replacement For cleaning, mechanical removal of the deposits is usually sufficient. -
Page 36: Cleaning The Connecting Hoses, Base Connections, Fine Filter And Drain Pump
» Clean both strainer. » When assembling the cylinder, make sure that the brackets and reinforce- ments are on top of each other. Risk of functional disruption! Use descaler or cleaning detergents only for cylinder and heater element cleaning. Do not introduce in cylinder base or apply to hoses! Prior to restarting the unit, make sure that the device assemblies in question are thoroughly... -
Page 37: Level Control Device Cleaning
9.5.4 Level control device cleaning » Insert the 2 screws remaining into the open level control device enclo- sure mounting holes while position- Hose connection ing the ground wire connection stub eyelet under the lower left screw. Mounting screws » Handtighten all of the screws. -
Page 38: Reinstallation Of The Steam Cylinder
9.5.6 Reinstallation steam » Affix the steam hose adapter with cylinder the clip. » Place the cylinder vertically in cylin- der base. » Follow the handling instructions in the section Leakage test. » Reconnect connector halves. Risk of functional disruption! Risk of material damage! Loose cable connections may result in increased transition resistance and contact... -
Page 39: Removal And Installation Of Unit Components
9.6 Removal and installation of » Push pump back into cylinder base and bolt to bottom plate encorporat- unit components ing the vibration buffer (42) and washers saved during removal. 9.6.1 Blow-down pump (removal, » Moisten O-ring (31) and insert into cleaning, reinstallation) adapter. -
Page 40: Solenoid Valve (Removal, Reinstallation)
9.6.2 Solenoid valve (removal, rein- stallation) Removal » Shut off water supply and disconnect tap water hose cap screw connection. » Remove connecting hose (20*) from cylinder base. » Detach electrical cable connector from solenoid valve (25*). » Unscrew solenoid valve mounting screws. -
Page 41: Heater Element Replacement
9.6.3 Heater element replacement 9.6.4 Thermo switch replacement (for heater elements) Removal » Remove and open steam cylinder as described in the Removal of the steam cylinder section. » Separate thermo switch capillary tube from heater element(s) by detaching the retainer clips. »... -
Page 42: Releasing A Thermo Switch That Has Triggered
Reinstallation Thermo switch(es) on steam cylinder cover. » Install replacement thermo switch with a new sealing. After the unit has cooled down, the thermo switch that has triggered may be identified by » Properly connect the capillary tube passage measurement, as long as it is a to the heater element. -
Page 43: Leak Test
9.7 Leak test 9.8 Functional check » Run the system with maximum out- put for a couple of minutes Risk of electrical shock! » Check hose connections and seals Hazardous electrical voltage! for leakage. Follow safety instruction for work on live com- ponents. -
Page 44: Dismantling
Dismantling Once the steam humidifier will no longer be used, dismantle (demolish or scrap) it by fol- lowing the installation procedures in reverse order. WARNING Dismantling of the unit may only be per- formed by qualified personnel. Electrical dis- mantling may only be performed by trained electricians. -
Page 45: Declaration Of Conformity
11. Declaration of Conformity Page 45... -
Page 46: Spare Parts
12. Spare Parts FLH03 FLH06 FLH09 FLH15 FLH25 FLH30 FLH40 FLH50 FLH80 FLH100 Article No. Description Steam generation 208-240 V SP-03-01100 Heating element CY08 3kg 208-240V, incl. gaskets SP-03-01101 Heating element CY08 6kg 208-240V, incl. gaskets SP-07-01100 Heating element CY17/45 5kg 208-240V, incl. gasket Steam cylinder with SuperFlush nozzle SP-03-01020 Steam cylinder FLH03 CY08 208-240V, compl. - Page 47 Spare parts (2) FLH03 FLH06 FLH09 FLH15 FLH25 FLH30 FLH40 FLH50 FLH80 FLH100 Article No. Description Steam generation 575-690 V SP-03-01104 Heating element CY08 6kg 575-690V, incl. gaskets SP-03-01107 Heating element CY08 9kg 575-690V, incl. gaskets SP-07-01103 Heating element CY17/45 5kg 575-690V, incl. gasket SP-07-01106 Heating element CY17/45 8,4kg 575-690V, incl.
- Page 48 Spare parts (3) FLH03 FLH06 FLH09 FLH15 FLH25 FLH30 FLH40 FLH50 FLH80 FLH100 Article No. Description Electrics CN-03-01000 Solid state relay for FLH03-09 208-480V incl. heatsink & temp. limiter CN-07-01000 Solid state relay for FLH15-50 208-480V incl. heatsink & temp. limiter B-2602009 Solid state relay for FLH80-100 380-480V incl.
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Page 52: Technical Specifications
13. Technical specifications FLH Steam Humidifier Climate Technical specifications FlexLine heater Unit type FLH03 FLH06 FLH09 FLH15 FLH25 Steam output [kg/h] 15,0 25,0 5,5 - - 6,5 2,7 - - 3,3 8,2 - - 9,8 13,7 - - 16,4 22,7 - - 27,1 220 - - 240V /1Ph /50-... - Page 53 Technical specifications FlexLine heater FLH06 Unit type FLH03 FLH09 FLH15 FLH25 Steam output [kg/h] 15,0 25,0 5,5 - - 6,5 2,7 - - 3,3 8,2 - - 9,8 13,7 - - 16,4 22,7 - - 27,1 220 - - 240V /1Ph /50- 220 - - 240V /1Ph /N Electrical connection...
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Page 54: Exploded View
14. Exploded view The index numbers in the figure corre- spond to the spare parts list. The figure following shows the FLH model composition. The number of cyl- inders and heater elements vary with respect to the complete FLH series. Page 54... -
Page 55: View Of Housing
15. View of housing FLH03 - FLH25 FLH40, FLH50 FLH30 FLH80, FLH100 Page 55... - Page 56 Lise-Meitner-Str.3 • D-24558 Henstedt-Ulzburg Phone +49(0)4193/ 895-0 • Fax -33 eMail hy@hygromatik.de • www.hygromatik.com member of CAREL Group Ein Unternehmen der Gruppe 100%...
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