HygroMatik StandardLine Manual
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HygroMatik StandardLine Manual

Electrode steam humidifier
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FlexLine
StandardLine
Electrode Steam Humidifier
Manual
ÁSLE.ENOÈ
SLE.EN
E-8881152

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Summary of Contents for HygroMatik StandardLine

  • Page 1 FlexLine StandardLine Electrode Steam Humidifier Manual ÁSLE.ENOÈ SLE.EN E-8881152...
  • Page 2 Current version of this manual to be found on: www.hygromatik.com 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.

  • Page 3: Table Of Contents

    1. Introduction ........................6 1.1 Typographic Distinctions ....................6 1.2 Documentation ........................6 1.3 Symbols in Use ......................... 6 1.3.1 Specific Symbols related to Safety Instructions ............. 6 1.3.2 General Symbols ......................6 1.4 Intended Use ........................7 2. Safety Instructions ......................8 2.1 Guidelines for Safe Operation ...................
  • Page 4 7. Electrical connection ......................28 7.1 Electrical installation approach ..................28 7.2 Cable connections ......................29 7.3 Safety interlock ........................29 7.4 Control signal ........................30 7.4.1 1-step operation ......................30 7.4.2 Operation with an active humidity sensor or external controller ........30 7.4.3 Wiring for control signal and safety (interlock) system for multiple units ......
  • Page 5 11.8 Detailed description of the user level reading values and settings ........60 11.9 Detailed parameter descriptions ..................64 12. Trouble shooting ......................70 12.1 Error handling ........................70 12.1.1 Table of possible faults and related error codes ............70 12.2 Table of functional disrup-tions ..................

  • Page 6: 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 7: Intended Use

    Pls. refer to parameter „2-1“ and „2- 2“ explanations given in the „Detailed param- eter descriptions“ section. The following applies to the StandardLine device series: Please read the explanations of parameters "2-1" and "2-2" in the section "Detailed parameter descriptions" in this manual.

  • Page 8: Safety Instructions

    2. Safety Instructions 2.1.3 Unit Operation These safety instructions are required by law. WARNING They promote workplace safety and accident 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 9: Mounting, Dismantling, Maintenance And Repair Of The Unit

    (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 10: Transport

    3. Transport Time limits for filing freight claims with ship- ping companies are*: 3.1 Overview After receipt of Shipping company Please note goods Proceed carefully when transporting the Carriers no later than 4 days steam humidifier in order to prevent damage Parcel service immediately due to stress or careless loading and unload-...

  • Page 11: Functional Description And Device Composition

    4. Functional Description and 4.2 Mechanical Construction Device Composition The StandardLine humidifiers are designed for wall mounting. For maintenance pur- poses, the steam cylinders are separable in 4.1 Mode of Action the middle. Making use of the frictional heat caused...

  • Page 12: Operating Sequence

    4.3 Operating sequence With normal water quality the blow-down loss rate lies between 7 and 15 % of the amount of steam produced. Depending on water By pressing the control switch („Pos. I”) the quality, a full steam cylinder blow-down is run humidifier is turned on.

  • Page 13: Mechanical Installation

    • Protection class IP20 • By design, HygroMatik steam humidi- fiers 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...

  • Page 14: Dimensions And Mounting Directions

    370/~14.6 695/~27.4 SLE45-SLE65 590/~23.2 790/~31.1 415/~16.3 535/~21 787/~31 Detailed measurements under https://www.hygromatik.com/files/pdf/hygromatik-standardline-dimensionsv11.pdf 3D models under https://www.hygromatik.com/en/downloads Wall clearances When mounting the steam humidifier, the wall clearanc- es shown in the fig. below must be obeyed:: 5 cm / 2,0 inch...
  • Page 15 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 designa- ted paths. This should be at least 60 •...

  • Page 16: 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 17: Absorption Distance Bn

    5.3 Absorption Distance B • quantity of steam introduced The "absorption distance" (B ) is defined as kg/h. the distance from the steam feed to where the steam is completely absorbed in the • air speed w in m/s in air duct treated air.

  • Page 18: 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 18...

  • Page 19: 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 Positioning within duct...
  • Page 20 Minimum distance for condensation avoidance: = 210mm/8.3 inch: „Steam manifold - Next steam manifold“ distance Air flow direction = 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 21 Vertical steam manifold installation 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/ 1450/ 15.7 23.6 35.4 47.2 57.1...

  • Page 22: Steam Line And Condensate Hose Layout

    HygroMatik steam humidifier (do not with a ANSI drill size „O“ drill. To do so, the restrict the cross-section, otherwise...

  • Page 23: 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 24: Water Connection

    6. Water connection • As installation or retrofit option, the DVGW-conform HyFlow system sepa- rator is available for the HygroMatik WARNING electrode steam humidifiers (except SLE 02). Risk of scalding! Very hot water to be found in and around the •...

  • Page 25: Operation Of Electrode Steam Humidifier With Softened Water

    Even if the HygroMatik steam humidifier is Flush the water supply pipe before making supplied with partially softened water, the connection to the solenoid valve. This is of...

  • Page 26: Water Discharge

    Guidelines for water discharge composi- 3/4” connection tion the numbers refer to the exploded view in the chapter with the same name. • Use original HygroMatik water drain hose • Do not buckle drain hose • Use a drain pipe and outlet pipe made...

  • Page 27: Water Connections Final Check

    1000 mm (10 to 40 inch) length into HyCool (not available for FLP-XX-TPRO a pressure-free outlet according to units), HygroMatik offers an option for limi- DIN EN 1717. The hose must be ting the steam humidifier wastewater temper- guided sideways of the humidifier to...

  • Page 28: Electrical Connection

    Do not connect the steam humidifier to the live power supply before all installation work has been completed. Main connection For the StandardLine steam humidifiers in the standard version, main connection can be found in the Technical Data (in the chapter of Please note...

  • Page 29: 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 StandardLine housing Risk of electrical shock! types. Hazardous electrical voltage! When standard wiring was made, terminal 1 Housing shows 230 VAC after commisioning.

  • Page 30: Control Signal

    7.4 Control signal Please note As described in the „Unit Control“ chapter, Active r.h. sensors need an external supply section „Provider level submenue and its voltage. For that purpose, terminal 3 has a parameters“, the unit control type is deter- +20 VDC offering.

  • Page 31: Wiring Diagram

    7.5 Wiring 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. 7.6 Electrical installation check list Check electrical installation with respect to customer-site requirements and local power supply regulations.

  • Page 32: Commissioning

    8. Commissioning Step 5: Monitor unit function and check for leakage » Let unit operate for 15 to 30 minutes. WARNING » If leaks appear, switch off the unit. Risk of operating error! Start-up of the unit is restricted to expert staff only (electricians or expert personnel with equivalent training).

  • Page 33: Maintenance

    9. Maintenance Since steam and condensate hoses are sub- ject to wear as well, hoses must also be 9.1 General checked regularly. For the achievement of a long unit life span, Seals are wear parts. As such, seal integrity regular maintenance is a must. Maintenance checks and replacement, if required, is also a works to be performed refer to unit assem- part of the regular maintenance work.

  • Page 34: Maintenance Frame Work

    9.2 Maintenance frame work Mineral deposits precipitate and crystallize Very seldomly, water pretreatment may be very differently in different types of water, necessary (softening by dilution to approx. 4 - even when two types have the same conduc- 8 °gH; decarbonization/partial desalination to tivity and hardness levels (the various con- achieve target reductions in carbonate hard- stituents in the water interact differently).

  • Page 35: Removal And Reinstallation Of The Steam Cylinder

    9.3 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. 9.3.1 Removal of the steam cylinder »...

  • Page 36: 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. 9.3.2 Cylinder cleaning O-ring replacement For cleaning, mechanical removal of the deposits is usually sufficient.
  • Page 37 » Clean the strainer. » Replace the O-rings of the elec- trodes. » Install new electrodes (48). Make sure that the electrodes are positioned cor- rectly (see exploded view). The deposits in the upper part of the cylinder can be conductive and lead to unwanted cur- rents between the electrode connections and the sensor electrode and thus to the message "cylinder full".

  • Page 38: Cleaning The Connecting Hoses, Base Connections, Fine Filter And Drain Pump

    9.3.4 Cleaning the vent hole on the » Put the cylinder halves together and pipe elbow reconnect them with the flange clamps. The pipe elbow is only accessible when the steam cylinder is removed. Risk of functional disruption! We generally advise against using limescale removers or other cleaners.

  • Page 39: Reinstallation Of The Steam Cylinder

    9.3.5 Reinstallation of the steam cyl- inder Risk of functional disruption! » Place the cylinder vertically in cylin- Risk of material damage! der base. Loose cable connections may result in increased transition resistance and contact area overheating. » Reattach Super Flush solenoid hose (if applicable) to steam cylinder bot- tom stub.

  • Page 40: Removal And Installation Of Unit Components

    9.4 Removal and installation of Reinstallation unit components » Moisten the new O-ring (33) and insert into cylinder base (37) hori- zontal stub. 9.4.1 Blow-down pump (removal, cleaning, reinstallation) » Push pump back into cylinder base and bolt to bottom plate encorporat- Removal and cleaning ing the vibration buffer (42) and washers saved during removal.

  • Page 41: Solenoid Valve (Removal, Reinstallation)

    9.4.2 Solenoid valve (removal, rein- 9.4.3 Electrode replacement stallation) » Remove the cylinder and open it Removal (see also chapter Removal of the steam cylinder). » Shut off water supply and disconnect tap water hose cap screw connection. Please note »...
  • Page 42 In case of the electrodes being burned-off to less than one third to half of their genuine length, electrode replacement should be made. Genuine electrode length HygroMatik large area electrodes made from stainless steel have the following genuine Please note lengths: When cylinder water maximum level is...

  • Page 43: Leak Test

    9.5 Leak test 9.6 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: Unit Control

    PCB. Another relay serves for sig- nalling purposes (factory setting is „collective Operation of the HygroMatik steam humidifier fault“). is under microprocessor control. As an ordering option, for provision of 2 addi-...
  • Page 46 Intrinsic safety HygroMatik steam humidifiers comply with intrinsic safety requirements in that the elec- trical power supply may be cut by two devices.

  • Page 47: Wiring Diagrams

    11.2 Wiring Diagrams 11.2.1 SLE Page 47...
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  • Page 50 Page 50...

  • Page 51: Mainboard Inputs And Outputs

    11.2.2 Mainboard inputs and outputs System interfaces Customer side interfaces Power supply and safety interlock Inputs ST01: ST08: • 4-pin plug connection with screw terminal adaptor for L and N power connection • Control signal 0...10 VDC and safety interlock („Terminals 1/2“) •...

  • Page 52: Control Operation

    11.3 Control operation User level 11.3.1 Principal user guidance From standard display (actual steam output), user level may be accessed by pressing any On powering up the steam humidifier, the key on the control panel. On user level, software version is shown in the display for a among other information, reading values r01 few seconds.

  • Page 53: Menu Tree

    11.3.3 Menu tree User level Provider level r01 Status 1-1 Power reduction r02 Error 1-2 Control signal r03 Act. steam output [kg/h] 1-Control 1-3 Correction of input stage r04 Act. steam output [lb/h] 1-4 Filter input stage r05 Actual current [A] r06 Filling level [mm] r07 Internal demand [%] 2-1 Corr.

  • Page 54: The Control Panel

    11.4 The control panel Icons state table permanently lit flashing Steam produc- Cylinder full tion active In conjunction with error icon: Fault steam pro- duction Main contactor Fault main con- active tactor The control panel comprises 3 sections: • the ESC, SET, control keys Filling active Fault filling...

  • Page 55: Navigation Within A Menu

    11.5 Navigation within a menu Provider level code entry and setting a parameter „ / “ » Using the keys, scroll until User level entry „P00“ is displayed and confirm with the SET key. „00“ is displayed. Standard display during normal operation is »...

  • Page 56: Tabular Representation Of Reading Value List And Provider Level Submenus

    11.6 Tabular representation of Reading Description reading value list and pro- value vider level submenus index For a detailed description, pls. refer to the Status respective sections within this chapter. Fault Actual steam output [kg/h] 11.6.1 The reading value list Actual steam outpt [lb/h] (only From normal operation, the user may access when imperial units were...
  • Page 57 Submenu „Blow-down“ (Group 2) Par. Denomination Setting options Code Correction partial blow-down -5...+5 Fs = 0 Correction full blow-down -5...+5 Fs = 0 Switch stand-by blow-down 0=off, 1=on Fs = 1 Waiting time stand-by blow-down 0.1...48.0 Fs = 24.0 Switch dead leg flushing 0=off, 1=on Fs = 0 Interval dead leg flushing [h]...
  • Page 58 Submenu „Functions“ (Group 5) Par. Denomination Setting options Code Switch stand-by heating 0=off, 1=on Fs = 0 Interval stand-by heating [min] 1...999 Fs = device dependant Stand-by heating [s] 1...999 Fs = device dependant Basic relay 0 = collective fault 1 = stand-by 2 = no demand 3 = humidifying...

  • Page 59: Exemplary Variation Of A Parameter Setting

    11.7 Exemplary variation of a parameter setting Example: Control signal is to be changed from „Ext. controller, 0 ...10V“ („1-2“ = „1“) to „PI controller, 0 ...10V“ („1-2“ = „4“). Please note The steps below make an essential change to a control parameter. If this is not intended, be sure to reestablish the original setting after changing it for exercising purposes.

  • Page 60: Detailed Description Of The User Level Reading Values And Settings

    20 s time frame, „No Modbus“ is shown as the device status and steam production is stopped (for details, see dedicated Modbus docu- mentation available from HygroMatik GmbH). Stand-by When in stand-by heating mode, status code 07 is heating displayed during steam production.
  • Page 61 Reading value Explanation Blow-down cate- Initial blow- After switching the device on, a blow-down gory down sequence is run with the parameter set for partial blow-down. Partial blow- A partial blow-down is run in order to achieve cylin- down der water concentration reduction. In order to dilute the concentration of the cylinder water, the control performs regular partial blow-downs.The blow-down icon in the display is lit.
  • Page 62 Reading value Explanation Service category Service The service threshold for the steam amount pro- steam duced as preset in 3-3 (SI units) or 3-4 (imperial amount units) was exceeded. The service icon in the display is permanently lit for the time the message is active. The status message may be reset by setting param- eter 3-1 to „1“.
  • Page 63 Reading value Explanation r14 mA-Signal Input signal measured at terminal ST806 [mA] r15 Ω-Signal Input signal measured at terminal ST807 [Ω] Set value Explanation P00 Code level Allows provider level access by code input (Code „10“) or limitation to user level (Code „0“). Provider level is exited automatically after 10 mins without a keystroke.

  • Page 64: Detailed Parameter Descriptions

    11.9 Detailed parameter descrip- tions Group Par. Denomina- Description tion Control Steam output Steam output limitation allows scaling down the max. limitation (steam) output within a range of 25 to 100 %, which may be necessary for a better control performance. The actual steam output is determined by the control sig- nal.The steam output can be set to a value between 25% and 100% of nominal output using the steam generation...
  • Page 65 Group Par. Denomina- Description tion Blow-down Correction full see correction partial blow-down blowdown (contd.) Switch stand- Should steam humidifier operation be prospectively by blow-down halted for a longer period of time, blowing-down the cyl- inder water is advisable in order to comply with the VDI 6022 hygiene regulations prescribing the prevention of microbial contamination of residual water.
  • Page 66 Group Par. Denomina- Description tion Service Reset steam- On finishing maintenance work, the service interval is to service inter- be reset (the service icon is blanked if it was illuminated before).After maintenance, reset the service interval as shown below (green LED is still blinking): Reset K1 Main contactor switching cycles are monitored and com- service inter-...
  • Page 67 Group Par. Denomina- Description tion Functions Switch stand- Stand-by heating is enabled or not (0= off, 1=on). by heating Interval Parameter 5-2 determines the interval time between stand-by heating phases when stand-by heating was enabled. heating On-time Parameter 5-3 sets the heating on-time when stand-by Stand-by heating was enabled.
  • Page 68 Group Par. Denomina- Description tion Functions Basic relay (60) Blow-down off: Relay is energized when not pump- allocation ing. (contd.) (61) Blow-down on: Relay is energized when pumping takes place. (62) Partial blow-down: Relay is energized when a partial blow-down is run. (63) Full blow-down: Relay is energized when a full blow- down is run.
  • Page 69 Group Par. Denomina- Description tion Settings Buzzer The control panel features a buzzer for prompting key strokes. Parameter 6-1 allows for muting the prompt. Time-Out Unit control switches the display back to actual steam output presentation after the time set in 6-2. Factory set- ting is „2 minutes“.

  • Page 70: Trouble Shooting

    12. Trouble shooting 12.1 Error handling On occurance of a fault, steam production is stopped. The control panel display is switched to error code output. In the same instance, the general fault icon starts flashing. On „Steam production“, „Main contactor“, „Filling“...
  • Page 71 Icons Error message Possible cause Counter measure Filling • Soleneoid valve or water • Clean water supply line supply line contaminated or and/or solenoid valve; Filling was not successful, defective replace solenoid valve, if i.e. the expexted filling defective level was not achieved •...
  • Page 72 Icons Error message Possible cause Counter measure Cylinder full • Check blow-down pump, • Check feed water qual- Sensor electrode conti- drainage system and steam nously signals full cylinder cylinder for hardeners and for 60 mins clean • Electrodes used up •...

  • Page 73: Table Of Functional Disrup-Tions

    12.2 Table of functional disrup- tions Problem Possible cause for faulty situation Counter measure • Output limitation parameter setting im- • Check 1-1 parameter setting Set humidity level not reached peds full power output • Nominal unit output insufficient • Check unit technical data, air- flow and secondary airflow •...
  • Page 74 Problem Possible cause for faulty situation Counter measure • Hose clamps on steam and/or conden- • Tighten clamps Water leaks from steam cylinder sate hose not tightened upper part • Steam hose adapter not properly fit or • Replace O-ring (if required) and O-ring not replaced ensure proper adapter installa- tion...
  • Page 75 Problem Possible cause for faulty situation Counter measure • • No steam exit Steam pipe improperly laid (water bag). Rerun steam hose according to from steam mani- guide lines fold • • Water exits peri- Excess pressure in duct system (max. Consult your expert dealer if odically from overpressure is 1200 Pa)

  • Page 76: Declaration Of Conformity

    13. Declaration of Conformity Page 76...

  • Page 77: Spare Parts

    14. Spare Parts SLE02 SLE05 SLE15 SLE20 SLE30 SLE45 SLE65 Article No. Description SLE10 Steam generation SP-01-00000 Steam cylinder CY2 complete SP-03-00000 Steam cylinder CY08 complete SP-04-00002 Steam cylinder CY17 complete w ith 3 electrodes SP-04-00000 Steam cylinder CY17 complete w ith 3 electrodes SP-04-00100 Steam cylinder CY17 complete w ith 6 electrodes SP-06-00000 Steam cylinder CY45/2 complete w ith 6 electrodes B-3204043 Electrodes w ithout hand nuts, set=2pcs...
  • Page 78 „Contact“ tab. Your spare parts order may as well be directed per e-mail to the HygroMatik main office using the address hy@hygromatik.de. Please make sure to specify your unit model and serial number.
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  • Page 81: Technical Specifications

    3 x 40 3 x 63 3 x 80 Fuse [A] Terminals max. [mm²] Number of steam cylinder StandardLine mainboard with capacitive touch display Control 220 - 240V 1,6A Separate control voltage 1 x 25 1 x 40 2 x 40...

  • Page 82: Exploded View

    16. Exploded view The number of steam outlets and the size of their connections can be found in the technical data. Page 82...

  • Page 83: View Of Housing

    17. View of housing This figure shows an example of one of the smaller unit sizes of the StandardLine series. Page 83...
  • Page 84 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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