HygroMatik HeaterCompact Manual

HygroMatik HeaterCompact Manual

Electric heater steam humidifier
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Manual
Electric Heater Steam Humidifier
HeaterCompact
Installation yellow
Plumbing blue
Electrics red
Maintenance green
General Information white

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Summary of Contents for HygroMatik HeaterCompact

  • Page 1 Manual Electric Heater Steam Humidifier HeaterCompact Installation yellow Plumbing blue Electrics red Maintenance green General Information white...
  • Page 2  Copyright HYGROMATIK GmbH; HeaterCompact January 2012 Information in this manual is subject to change or alteration without prior notice. Current version of this manual can be found at: www.hygromatik.co.uk Warning, Hazardous Voltage: All work to be performed by trained personnel only.
  • Page 3: Table Of Contents

    1. Introduction ........................5 1.1 Typographic Distinctions ....................5 1.2 Documentation ........................5 1.3 Directions for Use ......................6 2. Safety Notes ........................7 2.1 Overview ........................... 7 2.2 Guidelines for Safe Operation ................... 7 2.3 Disposal after Dismantling ....................8 3.
  • Page 4 6.4 Water Discharge ....................... 39 6.5 Checklist ..........................40 7. Electrical Installation ......................41 7.1 Electrical Installation ......................41 7.2 Safety Interlock ........................42 7.3 Control Connection ......................43 7.4 Control Connection - Steam Bath Application ..............43 7.4.1 Temperature Sensor Connection ................... 43 7.5 Control Connection - Air Conditioning Application ............
  • Page 5: Introduction

    They will impress you with their safety, ease of use and econom- ical operation. In order to operate your HygroMatik steam humidifier safely, properly and efficiently, please read these operating instructions. Employ your steam humidifier only in sound condition and as directed.
  • Page 6: Directions For Use

    / condensate water (only for humidifier type HeaterLine, HeaterCompact and HeaterSlim). Warning: HygroMatik steam humidifiers emit steam with a tem- perature of 100° C. The steam may not be inhaled directly. Only qualified and authorised personnel may operate the unit.
  • Page 7: Safety Notes

    2. Safety Notes 2.1 Overview These safety notes are required by law. They promote work- place safety and accident prevention. Warnings and Safety Symbols The safety symbols below identify sections containing warnings about hazards or potential dangers. Please familiarize yourself with these symbols.
  • Page 8: Disposal After Dismantling

    HygroMatik steam humidifiers are IP20-protected. Make sure that the unit is protected from drips in its installed location. Installing a humidifier in a room without water discharge requires safety devices to protect against water leakages. Accident Prevention Regulations Comply with the Accident Prevention Regulation Electrical Sys- tems and Equipment to prevent injury to yourself and others.
  • Page 9: Transport

    3. Transport Overwiew Note:Proceed carefully when transporting the steam humidifier in order to prevent damage from rough or careless loading and un- loading. If the transport of this unit is attempted by only one person there is a risk that the unit will drop down. We propose to transport the unit by two persons.
  • Page 10: Included In The Delivery

    Time limits for filing freight claims with shipping companies are*: Transport Company After Receipt of Goods Mail 24 hours at the latest Rail 7 days at the latest Truck and railway compa- 4 days at the latest nies Parcel Service immediatly * Subject to change without prior notice.
  • Page 11: Operation And Device Construction

    4. Operation and Device Construction 4.1 Mode of Action The Imersion Heater Principle One to three heater elements (Pos. 8 in the exploded view, please see cover foldout) are placed in a closed cylinder and connected to alternating current. The cylinder is filled with tap water, fully demineralized water or partially softened water.
  • Page 12: Installation And Method Of Operation

    4.2 Installation and Method of Operation By pressing the control switch („Pos. I”) the humidifier is turned on. When the hygrostat or controller signals a demand for humidification, the inlet solenoid valve (14) opens. The solenoid valve is designed for pressures from 100 x 10 to 100 x 10 Pas- cals (1 to 10 bar).
  • Page 13 General survey The heater elements are equipped with a mechanical high tem- perature safety. This mechanism provides a redundant safety system in the event of excessively low water levels (“Dry Run”). The cylinder water is periodically flushed out with a heavy-duty blow-down pump (10).
  • Page 14: Internal Output Setting

    95°C is being drained. This can cause burns to the skin at direct contact. 4.3 Internal Output Setting Continuous control of the HeaterCompact Type steam humidifier is achieved by proportional control of the heater elements. In this way the humidifier can be proportionally operated across the entire output range of 5% - 100% nominal capacity.
  • Page 15: Mechanical Installation

    5. Mechanical Installation Warning: Installation of this unit should be performed by quali- fied personnel only. Hygromatik accept no liability for damage due to faulty installation. Obey all safety instructions and warnings on the unit. During installation the unit must be disconnected from its power supply.
  • Page 16: Equipment Dimensions Hc

    5.1.1 Equipment Dimensions HC View from below Water inlet Cable entries Rear view Waste water connection Condensate inlet Steam outlet View from top Page 16...
  • Page 17 HC03-09 HC06P-09P HC12-HC27 all dimensions in mm General Survey Page 17...
  • Page 18: Fitting Measures

    5.1.2 Fitting Measures Wall Distance (all dimensions in mm) Note: It is often advantageous to use existing water connections (feed and drain) when selecting the steam humidifier. Wall Mounting Note: To function properly the steam humidifier must be installed vertically. Measures for drills for wall mounting please see table (measures d and e) in chapter „Equipment Dimensions”.If there is no suit- able wall, it is recommended that the equipment is installed on...
  • Page 19: Absorption Distance Bn

    5.2 Absorption Distance B The "absorption distance" (B ) is defined as the distance from the steam feed to where the steam is completely absorbed in the treated air. Inside the absorption distance, steam is visible as mist in the air stream. Condensation may collect on anything installed inside the absorption distance.
  • Page 20 Length I of the usable steam manifold depends on the dimen- sions of the air duct. The length of the absorption distance can be reduced by using multiple steam manifolds (also see section on the steam manifold). Method: Graphically determine absorption distance B using the absorp- tion distance nomogram (also see Section „Absorption Distance Nomogramm“).
  • Page 21: Fan Unit (Option)

    5.3 Fan Unit (option) Note: The fan unit should be positioned to avoid drafts. A mini- mum height of 2 m is generally sufficient.  Install the fan unit directly on a wall. Type Fan Unit HC03, VG 08 HC06(P) HC09(P), VG 17 HC12...
  • Page 22 Fan unit, wall installation Side view, wall-mounted fan unit Technical Specifications Fan Unit VG Fan Unit VG08 VG17 VG30 Quantity of Steam [kg/h] Steam Inlet [mm] Condensate Outlet [mm] Airflow Capacity [cbm/h] Nominal Output Nominal voltage Dimensions W [mm] H [mm] D [mm] Weight [kg]...
  • Page 23: 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 23...
  • Page 24: Steam Manifold

    5.4 Steam Manifold 5.4.1 Notes on Installation These notes are based on a homogeneous Horizontal installation of Standard steam manifold installation: steam manifold Duct Steam Manifold Air flow L1=L2=L3 An even distribution of steam manifolds ensures a uniform steam distribution. Please use the total hight of the duct! Steam Manifold Air flow...
  • Page 25 Air duct Positioning of steam manifolds Sample flat Staggered vertically and laterally Air flow very flat By tilting the steam manifold 30 - 45° very flat duct towards the air flow direction, the mini- mum upper clearance can be reduced to 70mm.
  • Page 26 With high-pressure air-conditioning systems, the unit's drain hose system must be modified depending on the over pressure. When this is the case please consult HygroMatik. • Install the steam manifold as close as possible to the steam humidifier in order to minimize steam loss through condensation.
  • Page 27 2x(2xDN40) 2x(1xDN40) 2x(1xDN12) * For units HL 6 - 12 and HC3-12 HygroMatik delivers one adapter DN40 / 25 (but not for SPA applications).. ** For units HL 36 - 45 HygroMatik delivers one t-connector for separating the steam on two steam manifolds.
  • Page 28: Steam Line

    Note: When installing the steam hose, please pay attention to the following: • The steam hose diameter may not be smaller than the steam outlet of the HygroMatik steam humidifier (do not restrict the cross-section, otherwise back pressure will increase). •...
  • Page 29: Cover Plate

    5.6 Cover Plate HygroMatik flange plates may be used to neatly complete instal- lation of the steam humidifier in the air duct. Two-piece flange plates are available for the DN25 and DN40 steam manifolds. flange plate DN25 E-2604260 flange plate DN40 E-2604410...
  • Page 30: Drill Pattern

    5.7 Drill Pattern Drill Pattern not to scale DN25 ( Note: Due to variable print media the dimensions are not to scale. Page 30...
  • Page 31 Drill Pattern not to scale DN40 ( Note: Due to variable print media the dimensions are not to scale. Page 31...
  • Page 32: Condensate Hose

    5.8 Condensate Hose Note: When installing the condensate hose, please pay atten- tion to the following: Warning: To keep condensate from accumulating in the duct, make sure condensate can drain freely. If the steam manifold is positioned higher than 500 mm above the steam humidifier: »...
  • Page 33 » If enough space is available, lay a loop as a vapor trap. The steam manifold must be at least 500 mm from the loop. If the steam manifold is positioned lower than 500 mm above the steam humidifier: » Lay steam hose at a height of at least 400 mm above unit and then connect to the steam manifold with a con- stant fall.
  • Page 34: Steam Solenoid Valves

    5.10 Steam Solenoid Valves When humidifying a number of loads, which are to be controlled separately, using a single steam humidifier, steam solenoid valves can be included in the steam hoses. Valve control has to provided by the customer. • Install the vertical risers with flow from bottom to top.
  • Page 35: Water Installation

    When employing demineralized water or purified conden- sate, do not use copper or brass in the supply or drain lines of the HeaterCompact unit. These materials can be corroded by demineralized water or purified condensate. Instead, use stainless steel or temperature-resistant pla- stic pipes.
  • Page 36 Make sure that a backflow preventer is installed in the water supply line. Note: Shut-off valve (AV), water filter (WF) and backflow pre- venter are not provided by HygroMatik. Install as follows: » Check whether the valve strainer has been inserted in the solenoid valve.
  • Page 37: Water Supply (For Operation With Tap Water Or Partially Softened Water)

    Note: Shut-off valve (SV) and water filter (WF) are not supplied with the unit » HygroMatik provides a water hose (56) with a cap nut at both ends which can be used for water installation. Install as follows: »...
  • Page 38: Feed From Holding Tank

    6.3 Water Treatment For water treatment system specifications, use the following table. The figures below assume that the humidifier has been running for 24 hours at 100% output. HeaterCompact Max. Water Consump- tion in over24 h [l] HeaterSlim Max. Water Consump-...
  • Page 39: Water Discharge

    Water Discharge Warning: Please pay attention to free and non-pressure drain- age of the water! During blow down up to 0,3L/s is being drained. For water discharge, we recommend installation of a flexible water drain hose. Humidifier and waste water discharge must be on the same pressure level.
  • Page 40: Checklist

    and the inner surface of the cabinet drain connection. If water collects on the base plate, it will flow through this gap into the drainage system. 6.5 Checklist Verify correct system installation using the checklist below:  Can flushed-out water drain freely? ...
  • Page 41: Electrical Installation

    7. Electrical Installation Warning, Hazardous Voltage! All work related to electrical installation may be performed by authorized personnel only (electricians or professionals with equivalent training). The cus- tomer is responsible for checking qualifications.Warning, Haz- ardous Voltage! Do not connect the steam humidifier to the power grid until after all installation work has been completed.
  • Page 42: Safety Interlock

    We recommend using a main fuse with medium blow rating (applies only to the mains voltages above.) See table below indi- cating maximum power consumption corresponding to each type of circuit protection: Type Power Supply Power Con- Fuses sumption HC03 230V/1Phases/N 9,8 A 1x10A...
  • Page 43: Control Connection

    7.4.1 Temperature Sensor Connection Connect the temperature sensor cable to the designated termi- nals 6 and 7 on the HygroMatik steam generator. The factory setting for the value for the set point of steam bath temperature is 45°C. After switching the main switch to I (=ON)
  • Page 44: 1-Step Control

    7.5.1 1-step control With 1-Step Controls, the external control hygrostat or control switch is wired in series with the contacts of the safety interlock. 230V int. Warning: Contacts laid between terminals 1 and 2 must be potentialfree and rated for 230V switches By the use of a Basic control: For 1-step controls the jumpers must be set as indicated below: Basic Control...
  • Page 45 The factory setting is a control signal of 0-10V. Controller Humidifier Terminals By the use of a Basic control: For a Proportional Control with an external control signal the jumpers must be set as indicated below: Setting for External Control Signal: 0(2) - 10 V DC Basic Control...
  • Page 46: Proportional Control With Built-In Pi-Controller

    7.5.3 Proportional Control with Built-In PI-Controller Upon request, HygroMatik will provide an active sensor with a control signal of 0-10 V DC. Sensors with other control signals can also be used; the control (only available at Comfort or Com- fort-Plus Control) need only be set to them.
  • Page 47: Cable Connections

    7.6 Cable Connections The table below shows the cable connections provided in HeaterLine steam humidifiers: Unit Connection Connection Connection HC03 - 09 HC06P-HC09P HC12 - HC27 Characteristics of metric cable connections: Thread for cable diameter across-flats [mm] dimensions [mm] M16x1,5 4,5 - 10 M25x1,5 9 - 17...
  • Page 48: Wiring Diagram

    Every steam humidifier comes with a unit-specific technical manual and a manual for the control. In addition, you will find downloadable wiring diagrams and technical manuals at www.hygromatik.de. 7.9 Electrical Installation Checklist Perform electrical installation checks in compliance with cus- tomer site requirements and public power utility regulations: ...
  • Page 49: Maintenance

    Maintenance The HygroMatik steam humidifier is easy to maintain. Neverthe- less, inadequate or improper maintenance can lead to opera- tional malfunctions. Perform regular maintenance to give your unit a long life span. Warning: When performing maintenance work, please follow these instructions: ...
  • Page 50: Maintenance For Operation With Demineralized Water / Condensate

    Maintenance for Operation with Demineralized Water / Condensate Instructions for maintenance and cleaning intervals are based exclusively on typical, empirically determined values. Cycle Maintenance Task 4 Weeks after Visual check of electrical and mechanical Initial Operation connections. Visual check of water level control. Visual check of steam cylinder interior.
  • Page 51: Maintenance For Operation With Tap Water Or Partially Softened Water

    It is advisable to adjust the frequency of maintenance to the specific operational application. HYGROMATIK recommends to open and check the steam cyl- inder two weeks after commissioning. Ongoing maintenance intervals can be estimated based on the amount and type of res- idue found in the steam cylinder.
  • Page 52: Access To Control Unit

    8.3 Access to Control Unit » Remove cover (or electric compartment cover) and lift display panel (A) out of its guide. » Turn display panel (see drawing) and hang display panel on the humidifier cabinet (B) by placing the two guide pins in the two front guides.
  • Page 53: Removing And Cleaning The Steam Cylinder

    8.4 Removing and Cleaning the Steam Cylinder Warning: Please follow the detailed instructions in these operat- ing instructions! The unit is only to be serviced by qualified, authorized personnel. Note the warnings and safety notes in the operating instructions. Failure to observe warnings and safety notes may result in injury, serious injury or death, and/or dam- age to the unit.
  • Page 54 Page 54...
  • Page 55 detach connecting cable for heater element(s) clean the two strainers Cleaning of Steam Cylinder and Cylinder base When using mineral deposit removers or cleaners to clean the cylinder and heater elements, make sure you thoroughly rinse the unit before returning reassembling it. Use mineral deposit removers only for cylinder and heater elements.
  • Page 56 » Remove all deposits. However, small amounts of scale deposits on the heater elements (8) are harmless. » Cylinder base (11) and the connections have also to be checked for deposits and cleaned if necessary. Cleaning of the Control Cylinder The control cylinder (27, 28, 29) monitors the water level.
  • Page 57 Note: When putting the cylinder back together, the joints and reinforcements of both sections must fit together snugly. install connecting cable for heater element(s) Switch on the unit and check for leaks after 15-30 minutes of operation. Page 57...
  • Page 58: Maintenance Of The Control Cylinder

    8.5 Maintenance of the Control Cylinder When cleaning the steam cylinder the control cylinder should also be cleaned. As the access to the control cylinder is only possible if the steam cylinder is removed one can find the sub chapter „Cleaning of the Control Cylinder”...
  • Page 59: Replacing Thermo Sensor (For Heater Element)

    8.7 Replacing Thermo Sensor (for Heater Ele- ment) Removal » Remove and open the steam cylinder as described above in section “Removing and Cleaning the Steam Cylinder.” » Loosen clips of capillary tube (T). » Disconnect capillary (T) tube from the heater elements (8).
  • Page 60: Unlocking Of A Released Thermo Sensor (For Heater Element)

    8.8 Unlocking of a Released Thermo Sensor (for heater element) If a thermo sensor (for heater element) has released due to a too high temperature the red release button (P) is some millimetres above the level of the top of its holder. Additional the control reports a failure „thermo sensor activated“.
  • Page 61: Removing Inlet Solenoid Valve And Cleaning Fine Mesh Filter

    8.10 Removing Inlet Solenoid Valve and Clean- ing Fine Mesh Filter Removal » Remove and open the steam cylinder as described above in section “Removing and Cleaning the Steam Cylinder - Removal.” » Seal off water supply and remove screw joint from fresh water connection.
  • Page 62: Cleaning Blow-Down Pump

    8.11 Cleaning Blow-Down Pump Removal » Remove and open the steam cylinder as described above in section “Removing and Cleaning the Steam Cylinder - Removal.” » Detach electrical connector from the pump (10). » Detach union adapter (E) from the pump. »...
  • Page 63: Cleaning Connection Hoses And Cylinder Base

    8.12 Cleaning connection hoses and cylinder base All connection hoses should be free of deposits and under good conditions. As well check all connections of the cylinder base (11) and the steam hose adapter (2) for deposits and remove if neccessary. Page 63...
  • Page 64: Checking Cable Screw Connections, Heater Element Wires

    8.13 Checking Cable Screw Connections, Heater Element Wires » Check that all cable screw connections are securely tightened » Ensure that heating element cable is not dammaged. Warning: Loose cable connections cause excessive contact resistance and overheating of contact surfaces. 8.14 Operational Check »...
  • Page 65: Commissioning

    9. Commissioning Warning: This unit is only to be started by qualified personnel. Switching off steam humidifier Warning: Before starting up the unit, make sure you know how to switch it off. » Switch off unit by setting control switch to “0” »...
  • Page 66: Ec-Declaration Of Conformity

    10. EC-Declaration of Conformity Page 66...
  • Page 67: Spare Parts

    11. Spare Parts HC03 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Article No. Description Cabinet HC B-2129007 Cabinet HC03-09 B-2129009 Cabinet HC06P-27 Steam Generation B-2205483 Cylinder compl., with 1 heater element 2,25kW, 1 thermal sensor and terminal, 230V B-2205455 Cylinder compl. Incl 1 heater element 4.5kW, 1 thermal sensor and terminal B-2205459 Cylinder compl.
  • Page 68 HC0 3 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Article No. Description Water feed B-2304 061 double solenoid valve, 0.2-10 bar, 200- 240VAC, 2.5 l/mi n B-2304 069 double solenoid valve, 0.2-10 bar, 200- 240VAC, 3.5 l/mi n E-2304 024 fine filter in solenoid valve inlet E-2304 103 captive coupl ing ring for so lenoid valve 3/4 "...
  • Page 69 HC03 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Article No. Description Control B-2507041 main contactor 20A, DILM7 , coil voltage.230VAC B-2507061 main contactor 35A, DILM1 7, coil voltage 230VAC B-2502412 control button 2 pole Basic, L3/DS, middle 0 B-2602001 soli d state relai s 25 A, 1ph., cooling device 150 x 50 mm, thermal circuit breaker B-2602103 soli d state relai s 50 A, 2ph., cooling device...
  • Page 70 HC03 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Article No. Description Accessories E-2604034 Reducing piece DN40/DN25 for steam hose E-2604012 Steam hose DN25, per m E-2604013 Steam hose DN40, per m E-2604002 Conde nsate hose DN1 2, per m E-2404004 Steam hose clamp DN25 E-2604016 Steam hose clamp DN40...
  • Page 71: Fax Form - Order For Spare Parts

    12. Fax Form - Order for spare parts Fax Form Please copy, fill in and fax to HygroMatik . +49(0)4193/895-31 Lise-Meitner-Str. 3 Fax.No 24558 Henstedt-Ulzburg Tel. +4904193/895-0 Order of spare parts unit type *______________ serial no.* ___________________ commission: ______________ order no.: __________________...
  • Page 72: Index

    Exploded View Fan Unit ..................21 Installation Equipment Dimensions HC ..........16 ..............18 Fitting Measures ..........15 Installation of a HeaterCompact Internal Output Setting ............. 14 ................49 Maintenance Blow Down Pump ............... 62 ..............56 Control Cylinder ..............58...
  • Page 73 ............74 Technical Specification Unlocking Thermo Sensor (for heater element) ...... 60 ....60 Unlocking Thermo Sensor (for Solid State Relais) View of Cabinet ................ 77 ..............35 Water Installation Water Supply ................36 Page 73...
  • Page 74: Technical Specifications

    14. Technical Specifications HeaterCompact HC Type HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Steam Output [kg/h] Electrical Supply* 230V/1/N 400V/3/N 50-60Hz Power Rating [kW] 2,25 13,5 20,3 Power Consumption [A]** 19,6 11,3 16,9 11,3 16,9 19,5 29,3 29,3...
  • Page 75 HeaterCompact HC for SPA HC03..-DS - HC27..-DS Type HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27 Steam Output [kg/h] Electrical Supply* 230V/1/N 400V/3/N 50-60Hz Power Rating [kW] 2,25 13,5 20,3 Power Consumption [A]** 19,6 11,3 16,9 11,3 16,9 19,5...
  • Page 76: Exploded View

    15. Exploded View Page 76...
  • Page 77: View Of Cabinet

    16. View of Cabinet Page 77...
  • Page 78 Lise-Meitner-Str.3 D-24558 Henstedt-Ulzburg Phone +49(0)4193/ 895-0  Fax -33 eMail hy@hygromatik.de  www.hygromatik.com 12/2004 A member of the Group...

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