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HydroMatik LPS Operating Manual

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LPS
Humidifies and Cools
Operating manual
ÁLPS.Ä4-&3Ö.ENhÈ
LPS.20130619.EN

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  • Page 1 Operating manual Humidifies and Cools ÁLPS.Ä4-&3Ö.ENhÈ LPS.20130619.EN...
  • Page 2 Certain computer programs contained in this product [or device] were developed by HygroMatik GmbH ("the Work(s)"). Copyright © HygroMatik GmbH [2013.06.19] 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].

  • Page 3: Table Of Contents

    4.1 Functioning ........................11 4.2 Design and process ......................11 4.2.1 Pump group ........................12 4.2.2 Dimension drawing of HygroMatik LPS nozzle system ..........12 4.2.3 Vortex modules ......................13 4.2.4 Atomising nozzles ......................14 4.2.5 Droplet separators (optional) ..................15 4.2.6 Humidification section ....................
  • Page 4 7.4.3 Piping ..........................27 7.5 Assembling the droplet separators ..................32 7.5.1 Examplary design of guide rails for the droplet separators ..........32 7.6 Pump station wall mounting ....................35 7.7 Checking the installation ....................36 8. Dimensions - Pump Station ....................37 9.

  • Page 5: Introduction

    HygroMatik LPS nozzle system, please read this operating man- ual. Only use the HygroMatik LPS nozzle system if it is in perfect condition and only for its intended purpose, considering all safety and risk aspects as well as all instructions in this manual.

  • Page 6: Intended Use

    At an altitude of over 1000 meters please contact your HygroMa- tik dealer or HygroMatik for details. Applications: The HygroMatik LPS nozzle system has a wide range of applica- tions. These systems are used wherever low-energy adiabatic humidification or cooling or systems with high-precision control are needed.
  • Page 7 The HygroMatik LPS nozzle system may only be used for the purpose of cold-water cooling after consultation with HygroMa- tik. The HygroMatik LPS nozzle system or may not be used in a ver- tical flow (or only after consultation with HygroMatik). Page 7...

  • Page 8: Safety Instructions

    National regulations beyond the scope of this manual apply with- out restriction for operation of this device. During operation of the HygroMatik LPS nozzle system it is not allowed to stay in the humidification chamber. The desalinated water used for feeding the HygroMatik LPS nozzle systemis unsuitable for drinking.

  • Page 9: Disposal Upon Disassembly

    If a HygroMatik LPS nozzle system is to be set up in an area without water drainage, safety measures which eliminate the possibility of water entering the system due to leaks must be taken.

  • Page 10: Transport

    3.2 Packaging Note: The HygroMatik LPS nozzle system is delivered on a pal- let. 3.3 Temporary storage Store the material in a clean dry place. The storage temperature should be 0-40°C.

  • Page 11: Function And Design

    4. Function and design 4.1 Functioning The HygroMatik LPS nozzle system is based on atomisation of water. Desalinated water is fed into a vane pump. With an operating pressure of up to 16 bar, the water then goes to the nozzles.

  • Page 12: Pump Group

    50 Hz. Pump group Capacity [l/h] Max. speed [rpm] LPS 45 1350 LPS 72 1350 LPS 110 1350 4.2.2 Dimension drawing of HygroMatik LPS nozzle system Weight LPS 45-110 30 Kg Page 12...

  • Page 13: Vortex Modules

    4.2.3 Vortex modules The vortex modules provide for effective mixing of the air and the water mist. Due to their special design, they generate turbulence and shear zones which lead to a homogeneous distribution of moisture along the humidification section (0.9 m). The vortex modules (dimensions: 150 x 150 mm) are delivered individually and can be assembled to form a wall.

  • Page 14: Atomising Nozzles

    4.2.4 Atomising nozzles Desalinated water at a pressure of up to 16 bar reaches the noz- zles where the water is atomised to form ultra-fine mist-like aero- sols. The aerosols enter the area of the vortexed air stream downstream of the vortex modules. The air and aerosols are mixed intensively here.

  • Page 15: Droplet Separators (Optional)

    For a total standard installation length of 1.5 m for the HygroMa- tik LPS nozzle system the humidification section should have a length of at least 0.9 m. The exact dimensions are described in the schematic in the section entitled 'Overview of the humidifica- tion chamber'.

  • Page 16: Partial And Full-Load

    4.3 Partial and Full-Load For optimal humidification control under various input conditions the HygroMatik nozzle system LPS can be equipped with a „Par- tial and Full-Load” control function. At Full-load all nozzles are fed with water. At Partial-load a sole- noid valve switches off the water supply for approximately half of the nozzles.

  • Page 17: Connnections

    5. Connnections 5.1 Water Connection: 3/4”-external thread (within the system) Conductivity: 5-20 µS/cm Pressure: 0.15-0.5 MPa (1.5-5 bar) Temperature: max. 15°C pH value: 7 +/- 1 Note: The supply water for the HygroMatik high-pressure nozzle system must comply with VDI 6022; i.e. from a microbiological point of view it must be of drinking water quality.

  • Page 18: Electrical

    5.4 Electrical Power supply: LNE 230 V AC, 50 Hz (a fixed socket (16 A) at the installation site is necessary) External control signal: 0-10 V DC 4-20 mA DC System enabling: via ext. potential-free contact Collective fault signal: potential-free contact (change over contact) Operating status signal: potential-free contact (NO)

  • Page 19: Interfaces To The Hygromatik Nozzle System Lps

    Air volume flow (for 'partial-load / full-load switching' option): If the HygroMatik nozzle system LPS is operated in systems with modifiable air volume flows (reduced air volume of less than 70% of the maximum air volume), the full-load solenoid valve is switched off and the partial-load mode is activated.
  • Page 20 Note: The guide rails must be designed such that - the vortex module wall and droplet separators can be removed (for servicing) - there cannot be any stagnant water. Note: When starting the system check again that the humidifica- tion chamber has been thoroughly cleaned. In particular the humidification chamber and the ventilation duct upstream of it must be free from metal swarfs to prevent corrosion.

  • Page 21: Mechanical Assembly

    7. Mechanical assembly Caution: The device may only be assembled by qualified staff. HygroMatik accept no liability for damages resulting from incor- rect assembly. Observe all safety instructions and warnings found on the device. The device must be de-energised during assembly. Mounting or insertion of additional devices is only permitted with the written consent of the manufacturer.

  • Page 22: Vortex Wall Module Assembly

    7.2 Vortex wall module assembly The vortex module wall provides firstly the air turbulence and secondly it holds the atomiser nozzles and water distributor. The vortex module wall is supplied as specified (please note the number of vortex modules in width and height), assembled in the accompanying nozzle assembly data sheet: »...

  • Page 23: Examplary Design Of Guide Rails For A Vortex Module Wall

    7.3.2 Examplary design of guide rails for a vortex module wall Pos. 1: upper guide rail Pos. 2: vortex module wall Pos. 3: spacer or direct connection floor of chamber Guide rail (cross section) Pos. 4: lower guide rail Pos. 5: humidification chamber Inner dimension of guide rail: 62 mm Hight: please see above sketch Material: 1.4301 stainless steel sheet, thickness: 1 mm...
  • Page 24 7.3.4 Assembling of the side rails for the vortex module wall Vortex module walls consisting of 11 or more vortex module rows are automatically equipped with side rails and self-tapping screws. The side rails have to be adapted to the right lenght by the installer.

  • Page 25: Installation Of The Nozzles, Distributor Pipe And Tubing

    7.4 Installation of the nozzles, distributor pipe and tubing 7.4.1 Nozzle Installation: » In accordance with the supplied nozzle assembly data sheet locate the vortex module to be equipped with a nozzle. » Then plug the nozzle body (1), as shown in the picture, on the upstream side of the vortex module, so that it protrudes about 1 cm on the other side »...

  • Page 26: Assembling The Distributor Pipe

    7.4.2 Assembling the distributor pipe The high-pressure water coming from pump station first enters a manifold and is routed from there to the nozzle. The manifold is mounted according to the nozzle assembly sheet (project specific) produced by HygroMatik on the vortex wall.

  • Page 27: Piping

    7.4.3 Piping Manifold - Nozzles » The supplied 4 / 2 Hose pipe is firmly fitted into one of the snap-connections on the manifold pipe. » Check connection by gently pulling on the hose. » Estimate the hose length (noting nozzle assembly plan) to the nozzle by observation.
  • Page 28 Manifold - Pump Station In the standard version a 6/4 hose leads from the pump station to a manifold. However, if the LPS nozzle system is equipped with a partial/full load switch, then there is a 6/4 hose line lead- ing to two manifolds.
  • Page 29 Assembly of the hose guide » Drill a hole with a diameter of 15mm. through the wall of the air conditioning duct, » Assemble snap connector (4), nut (3) and washer (2) to hose opening (1) and insert through the duct wall from the outside (see picture below).
  • Page 30 (only at full load operation) For standard version: The pump station has a hose leading to a manifold at the vortex wall. From the manifold, it goes to all the nozzles of the LPS noz- zle system. Additionally: »...
  • Page 31 » Check by gently pulling the tube. » Estimate the hose length from the snap-connector to the duct opening (external duct wall) to the manifold. Maximum bending radius 40mm. » Cut the hose at right angles with a hose cutter. »...

  • Page 32: Assembling The Droplet Separators

    7.5 Assembling the droplet separators The guide rails must be installed in a way that makes it possible to either pull out or lift up the vortex module wall. Detail B Detail A 7.5.1 Examplary design of guide rails for the droplet separators Detail A: Dimensions given in mm...
  • Page 33 Dimensions of guide rails for droplet separators Material used for upper guide rail: 1.4301 stainless steel sheet, thickness: 1 mm Detail B: Hight is variabel: pushed in droplet separators: 55 lifted in droplet separatosr: 30 The upper guide rail is directly attache to the ceiling of the humidification chamber (using screws, rivets or similar) Assembling two droplet separators in a stack For installation heights of above 1.5 m, two droplet separators...
  • Page 34 Detail C (side view): B1: Preliminary droplet separator B2: Final droplet separator B3: Angle bracket B4: Hose connection for drainage of waste water from upper droplet separator Perforated sheet metal (material: 1.4301) should be used for the lower guide rails for the droplet separators. Alternatively, sheet metal with several holes (at least 4 per metre) 8-10 mm in diam- eter can be used.The assembly must be made with 1.5% incline.

  • Page 35: Pump Station Wall Mounting

    7.6 Pump station wall mounting The installation of this unit must be carried out only by qualified personnel. We can assume no liability for damages caused by incorrect installation. Please observe all the safety instructions and warnings on the equipment. On the rear wall of the unit housing there are 4 mounting brack- ets (see also: Dimensions, pump station).

  • Page 36: Checking The Installation

    7.7 Checking the installation Assembling the vortex module wall  Have all electrical cable and plug connections been properly tightened?Is the vortex module wall in accor- dance with the nozzle arrangement data sheet? (please note the number of modules in width and height)? Vortex module wall assembly ...

  • Page 37: Dimensions - Pump Station

    8. Dimensions - Pump Station View from below Rear view Side view Page 37...

  • Page 38: Water Connection

    9. Water connection 9.1 Overview Water connection 1: Water supply 2: Water drainage 3: 12mm plastic tube (1.5 meter ): included 4: plastic hose DN12: on site 5: Water filter (input side: 3/4 external thread output side: 12mm snap-connector) 6: Mounting Bracket 7: Pump Station 8: External drain, siphoned (free entry must be assured) 9: Manometer, 0-10 bar...

  • Page 39: Water Supply

    Note: There must be a stopcock and a sampling valve in the immediate vicinity of the HygroMatik LPS nozzle system pro- vided. 9.2 Water supply Attention: Please observe during installation: • All work must only be performed by qualified personnel.

  • Page 40: Drainage

    9.3 Drainage At the bottom of the housing, a DN12 spout is sticking out. This is a drain and is used to: • empty and relieve the pressure lines to the vortex wall after removal of the module enable signal •...

  • Page 41: Water Quality

    9.4 Water Quality Conductivity: 5-20 µS/cm Pressure: 0,15-0,5 MPa (1,5-5 bar) Flow rate greater than max output of the nozzle sytem Temperature: 5-15°C PH value: 7 +/-1 9.5 Inspection the water supply Water supply  Is the supplied water filter installed to the water inlet for the pump station? ...

  • Page 42: Hygiene

    10.2 Automatic flushing If the HygroMatik nozzle system LPS is in „stand by mode” and there is no demand for work for 24 hours the system will periodi- cally run (every 24h) flush cycles.

  • Page 43: Electrical Connection

    It is the customer's responsibility to monitor qualifications. Caution: Voltage! All installation work must be completed before the HygroMatik nozzle system LPS is connected to the mains supply. Please observe all local regulations for electrical installation work.

  • Page 44: Connection Data

    Caution: The contacts which are placed on terminals X2.1 and X2.2 must be potential-free and suitable for switching 24 V DC / 100 mA. After the HygroMatik nozzle system LPS has been started, a standard voltage of 24 V DC is applied to terminal X2.1.

  • Page 45: Circuit Diagram

    11.3 Circuit diagram Page 45...
  • Page 46 Page 46...

  • Page 47: Inspecting The Electrical Installation

    11.4 Inspecting the electrical installation The electrical installation must be checked by an electrician in accordance with customer requirements and the regulations set out by the public electricity supply company:  Does the mains voltage match the voltage specified on the nameplate / delivery note? ...

  • Page 48: Commissioning

    12. Commissioning Note: The LPS nozzle system may only be operated by qualified personnel. Turning the LPS nozzle system off Note: Before the LPS nozzle system is put into operation, it must be clear how to switch the system off.

  • Page 49: Maintenance

    However, operational faults which can be traced back to inade- quate or improper maintenance may occur. Regular maintenance of the HygroMatik nozzle system LPS is indispensable for ensuring long service life. Caution: For maintenance work please bear in mind that: •...

  • Page 50: Inspection / Replacement Of The Net-Based Water Filter

    13.1.1 Inspection / replacement of the net-based water filter Water filter check Water filter must be checked for contamination 1 x monthly and if necessary replaced. If the white water filter cartridge changes its colour this means it is polluted. Pollution causes a higher flow resistance.

  • Page 51: Cleaning The Atomizer Nozzle

    8. Open the external stopcock. 9. Set the main switch to 'I'. 13.1.2 Cleaning the atomizer nozzle 1. Switch the HygroMatik LPS Nozzle System power supply to 0 2. Unscrew the nozzle from nozzle holder. Take care not to touch the impact pin.

  • Page 52: Cleaning The Droplet Separators

    13.1.3 Cleaning the droplet separators The droplet separators should be checked every 4 weeks for possible contamination and cleaned if necessary. The droplet separators should be thoroughly cleaned at least once a year. Cleaning the droplet separators: 1. Pull or lift the droplet separators out of the guide rails. 2.

  • Page 53: Cleaning The Humidification Chamber

    13.1.5 Cleaning the humidification chamber Clean the humidifier housing and the base tray as required with a cleaning agent, then rinse and dry them. For cleaning and disinfection we recommend INCIDUR pro- duced by Ecolab. When using other cleaning and disinfection agents please check material compatibility with all plastic materials used in the humid- ification chamber.

  • Page 54: Control System

    The water pressure may range between 5 and 16 bars. The main switch (Item 3), which is located at the top left-hand side, is for switching off the HygroMatik low-pressure nozzle system LPS. HygroMatik low-pressure nozzle system LPS Page 54...

  • Page 55: Full Load And Part Load

    Contact closed = Summer mode In summer mode, regulation of the HygroMatik low pressure nozzle system LPS is made solely by means of the safety chain (Terminals 1 and 2) in single-stage switching mode; as long as the safety chain is closed, the system operates at 100% humidification performance.

  • Page 56: Description Of The Programmable Controller (Plc)

    14.2 Description of the programmable controller (PLC) 14.2.1 General description The HygroMatik low pressure nozzle system LPS controller regulates the complete atomizing operation. The user interface for operating and regulating the function of the appliance is on the face of the PLC controller.
  • Page 57 Functional description of the display and LED: The display consists of 14 icons in 3 categories: 1. Operating modes 2. Values and dimensional units 3. Switching states Icon Description Color Error (Error codes F1...F8 are displayed; detailed description see below) Summer mode green (cooling)

  • Page 58: Menu

    System start After switching on the Hygromatik low pressure nozzle system LPS at the main switch, an initial flushing operation is carried out (default setting 10 sec.). The system is then in the main menu, i.e. the actual pressure is displayed.
  • Page 59 14.2.2.1 Reading level: The following reading parameters can be selected in the reading level: Actual value of pressure [bars] Actual value of the control signal Setpoint control signal Set value of performance limiter [%] Set value for the target humidity (only valid with PI control [%] Actual value of current humidity (only valid with PI control [%]...
  • Page 60 14.2.2.3 Operation If the HygroMatik low pressure nozzle system LPS is enabled, (i.e. the safety chain is closed) and a control signal greater than the activation threshold is put in, the system atomizes water. The LED 1 for status "Operating" is illuminated.

  • Page 61: Overview Of Error Reports

    14.2.3 Overview of error reports Fault Malfunction Description Possible cause Remedial action report Water inlet Water supply Water supply not Connect water inadequate. Inlet connected. supply with Pressure pressure must be adequate pressure. < 1bar between 1 to 5 bars. Temperature The temperature sensor The ventilator in the...
  • Page 62 14.2.3.1 Menu structure and parameter setting Page 62...

  • Page 63: Ec Declaration Of Conformity

    15. EC declaration of conformity Page 63...

  • Page 64: Spare Parts

    16. Spare parts Article no. pump station E-7800100 Motor LPS systems, 230V, 0,37kW E-7800202 Rotary vane pumpe LPS-100; LPS110 E-7800204 Rotary vane pumpe LPS72 E-7800206 Rotary vane pumpe LPS45 E-3720010 fan, axial, 230VAC E-7702200 protection grill, cabinet fan HDS, incl. filter inlay 120 x 120 mm B-7800400 Solenoid valve water inlet, incl.
  • Page 65 Artikel-Nr. Article no. Vortex-wall E-7701000 E-7701000 Vortex module E-7800400 E-7800400 LPS water distribution tube E-7601630 E-7601630 T-piece female 1/8" E-7601586 E-7601586 Double nipple G1/8" - G1/8" E-7800410 E-7800410 Sealing plug M5 E-7800412 E-7800412 Sealing plug male 1/8" E-7800414 E-7800414 Pipe fitting M5, 4mm hose...

  • Page 66: Fax Form - Order For Spare Parts

    17. Fax Form - Order for spare parts Fax Form Please copy, fill in and fax to Lise-Meitner-Str. 3 . +49(0)4193/895-33 Fax.No 24558 Henstedt-Ulzburg Tel. +4904193/895-0 Order of spare parts unit type *______________ serial no.* ___________________ commission: ______________ order no.: __________________ quantity article article no.

  • Page 67: Technical Specifications

    18. Technical Specifications LPS 45 LPS 72 LSP 110 Effective humidification capacity [l/h] Nominal power rating [kW] 0,15 0,16 0,18 Amps [A] Volts [V/Ph/Hz] 230/1/50 Control signals 0-10V / 4-20mA (other control signal levels on request) Nozzle number Humidification path, ideal [m]...

  • Page 68: Plant Scheme

    19. Plant scheme Option: Sommer-/ Winterschaltung summer-/ winter control Winter Teillast-Magnetventil Teillast winter part load valve partial load VE-Wasser Option: Deionised water 5 - 16 bar Teil-/ Volllast 1 - 5 bar part-/ full load 5 - 20μs/cm Winter Wassereinlassfilter Wassereinlass- Pumpe Volllast-Magnetventil...
  • Page 69 Page 69...
  • 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...

This manual is also suitable for:

Lps45Lps72Lps110

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