HydroMatik HeaterCompact User manual

Electric Heater Steam Humidifier
HeaterCompact
Installation yellow
Plumbing blue
Electrics red
Maintenance green
General Information white
ÁHC.EN0È
HC.EN
Manual

Page 2
Warning, Hazardous Voltage: All work to be performed by trained personnel only.
All electrical installation and servicing of the electrical components of this unit to be
performed by qualified electricians only. Disconnect power supply before installation
and servicing!
© Copyright HYGROMATIK GmbH; HeaterCompact 08.09.2015
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

Page 3
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. Transport ............................................................................................................................ 9
3.1 Overwiew ........................................................................................................................... 9
3.2 Transport Size and Weigth ................................................................................................ 9
3.3 Packing .............................................................................................................................. 9
3.4 Interim Storage .................................................................................................................. 9
3.5 Check for Complete and Correct Delivery of Goods ......................................................... 9
3.6 Included in the Delivery ..................................................................................................... 10
4. Operation and Device Construction ................................................................................ 11
4.1 Mode of Action .................................................................................................................. 11
4.2 Installation and Method of Operation ................................................................................ 12
4.3 Internal Output Setting ...................................................................................................... 14
5. Mechanical Installation .....................................................................................................15
5.1 Steam Humidifier - environmental conditions .................................................................... 15
5.1.1 Equipment Dimensions HC ............................................................................................ 16
5.1.2 Fitting Measures ............................................................................................................. 18
5.2 Absorption Distance BN .................................................................................................... 19
5.2.1 Determining the Absorption Distance ............................................................................. 19
5.3 Fan Unit (option) ................................................................................................................ 21
5.3.1 Fan Unit Type VG ........................................................................................................... 21
5.3.2 Absorption Distance Nomogram .................................................................................... 23
5.4 Steam Manifold ................................................................................................................. 24
5.4.1 Notes on Installation ....................................................................................................... 24
5.5 Steam Line ........................................................................................................................ 28
5.6 Cover Plate ........................................................................................................................ 29
5.7 Drill Pattern ........................................................................................................................ 30
5.8 Condensate Hose .............................................................................................................. 32
5.9 Types of Installation .......................................................................................................... 32
5.10 Steam Solenoid Valves ................................................................................................... 34
5.11 Unit Installation Check ..................................................................................................... 34
6. Water Installation .............................................................................................................. 35
6.1 Water Quality ..................................................................................................................... 35
6.2 Water Supply (For Operation with Demineralized Water or Purified Condensate) ........... 36
6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ............. 37
6.3.1 Feed from Holding Tank ................................................................................................. 38

Page 4
6.4 Water Treatment ............................................................................................................... 38
6.5 Water Discharge ............................................................................................................... 39
6.6 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 ............................................................ 43
7.5.1 1-step control .................................................................................................................. 44
7.5.2 Proportional Control with an external control signal ....................................................... 44
7.5.3 Proportional Control with Built-In PI-Controller .............................................................. 46
7.6 Cable Connections ............................................................................................................ 47
7.7 Fan Unit ............................................................................................................................. 47
7.8 Wiring Diagram .................................................................................................................. 48
7.9 Electrical Installation Checklist ..........................................................................................48
8. Maintenance ....................................................................................................................... 49
8.1 Maintenance for Operation with Demineralized Water / Condensate ............................... 50
8.2 Maintenance for Operation with Tap Water or Partially Softened Water ........................... 51
8.3 Access to Control Unit ....................................................................................................... 52
8.4 Removing and Cleaning the Steam Cylinder .................................................................... 53
8.5 Maintenance of the Control Cylinder ................................................................................. 58
8.5.1 Cleaning the nozzle in the steam hose adapter ............................................................. 58
8.6 Replacing Heater Elements ............................................................................................... 58
8.7 Replacing Thermo Sensor (for Heater Element) ............................................................... 59
8.8 Unlocking of a Released Thermo Sensor (for heater element) ......................................... 60
8.9 Unlocking of a Released Thermo Sensor (for Solid State Relay) ..................................... 60
8.10 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ...................................... 61
8.11 Cleaning Blow-Down Pump ............................................................................................. 62
8.12 Cleaning connection hoses and cylinder base ................................................................ 63
8.13 Checking Cable Screw Connections, Heater Element Wires .......................................... 64
8.14 Operational Check ........................................................................................................... 64
8.15 Dismantling ...................................................................................................................... 64
9. Commissioning ................................................................................................................. 65
10. EC-Declaration of Conformity ........................................................................................ 66
11. Spare Parts ...................................................................................................................... 67
12. Fax Form - Order for spare parts ................................................................................... 71
13. Index ................................................................................................................................. 72
14. Technical Specifications ................................................................................................ 74
15. Exploded View ................................................................................................................. 76
16. View of Cabinet ................................................................................................................ 77

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
They will impre ss you with their safety, ease of use and econo-
mical operation.
In order to operate your HygroMatik steam humidifier safely, pro-
perly and efficiently, please read these operating instructions.
Employ yo ur ste am hu midifier only in sound condition a nd as
directed. Consider po tential hazards an d safety issues and fol-
low all the recommendations in these instructions.
If you have additional questions, please contact us:
Tel.: [phone] (Main Number)
Tel.: [phone] (Technical Support Hotline)
Fax: [phone]
e-mail: [email protected]
For all technical questions or spare parts orders, please be pre-
pared to provide unit type and serial number (see name plate on
the unit).
1.1 Typographic Distinctions
•preceded by a bullet: general specifications.
» preceded by an arrow: Procedures for servicing or
maintenance which should or must be performed in the
indicated order.
Installation step which must be checked off.
italics Terms used with graphics or drawings.
1.2 Documentation
Retention
Please ret ain th ese o perating instruction s in a secure, alwa ys
accessible location. If the product is resold, turn the documenta-
tion over to the new operator. If the documentation is lost, please
contact HygroMatik.
Versions in Other Languages
These operating instructions are available in several languages.
If interested, please contact HygroMatik or your HygroMatik dea-
ler.

Page 6
1.3 Directions for Use
The proven principle of heating wa ter by the use of electric
immersion heate rs is exploited to generate steam. Using diffe-
rent tap water q ualities or p artial sof tened water (all hu midifier
types) or fully demineralized wate r / conde nsate water (only for
humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim).
Warning: HygroMatik steam humidifiers emit steam with a tem-
perature o f 10 0°C. Th e steam may no t b e inhaled directly.
Proper usage also entails following HygroMatik's instructions for
installation, dismantling, reassembly, initial operation and opera-
tion and maintenance, as well as disposal procedures.
Only qu alified a nd authorised p ersonnel may opera te the unit.
Persons transporting or working on the unit , must have read
and unde rstood the corre sponding p arts of the Operation and
Maintenance Instruct ion and especially the chapter 2. „Sa fety
Notes“. Additionally, op erating personne l must be informed of
any possible dangers. You should place a copy of the Operation
and Maintenance Instruction at the unit‘s operational location (or
near the unit).
The steam humidifier is not qualified for exterior application.

Page 7
2. Safety Notes
2.1 Overview
These sa fety notes are required b y law . The y p romote work-
place safety and accident prevention.
Warnings and Safety Symbols
The safety symbols be low identify sections containing warnings
about hazards or potential da ngers. Please fa miliarize yourself
with these symbols.
Warning: Failure to o bserve this warning ma y result in serious
injury or death and/or damage to the unit.
Danger, Hazardous Voltage: Hazardous electrical current!
Fai-
lure to observe this warning may result in injury or even serious
injury or death.
Warning: Failure to follow these instructions may resu lt in
damage to the unit due to electrostatic discharge. The electronic
components of the humidifier control a re very sensitive t o elec-
trostatic discha rges. In orde r to safeguard these components
during installation and servicing, steps must be taken to protect
against ESD.
Reminder: Materials and consumables must be handled and/or
disposed of as required by law.
Note: App ears before explanations o r cross-refere nces which
refer to other sections of the operating instructions.
2.2 Guidelines for Safe Operation
Overview
Obey all safety notes and warnings present on the unit.
In case of a malfunction, switch off the unit immediately and pre-
vent a re start. Rep air malfun ctions promptly. Af ter any rep air
work, have qualified personnel check t he safe operation of the
unit.
Use original spare parts only. Additional national safety regulati-
ons also fully apply to the operation of this unit.
This unit is not designed for the use by persons (also children)
with limited physical, sensory and mental abilities - or without
knowledge and experience. Unless they are supervised or trai-
ned by a person, who is responsible for their safety.
Supervise children in orde r to ensure that they will not play with
the unit.
The unit is only allowed to work with connected steam hose that
safely leads the steam.
Caution
steam

Page 8
Accident Prevention Regulations
Attention: In t he e vent of leaky or faulty components un con-
trolled hot steam may flow.
HygroMatik steam humid ifiers a re 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 Pr evention Regulatio n Electrical
Systems and Equipment to prevent injury to yourself and others.
Operation of the Unit:
Do not pe rform any work which co mpromises the safety of the
unit. Regularly check that all sa fety and monitoring devices are
functioning normally. Do not remove or disable safety devices.
Installation, Di smantling, Maintenance and Re pair of the
Unit:
Disconnect unit components from power supply prior to mainte-
nance or repair work.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer.
Electrical
Work on the e lectrical syste m mu st be p erformed by q ualified
personnel.
Disconnect unit components from power supply prior to work.
It is not allowed to connect the unit to DC voltage supply.
In case of a malfunction in the electrical power supply, switch off
the unit immediately. Use only original fuses with the appropriate
amperage rating . Regularly check the unit's e lectrical e quip-
ment. Promptly repair any damage, such as loose connections,
burned wiring or defective electrical insulation. After proper elec-
trical installation or repair, test all safety mechanisms (such as
grounding resistance).
2.3 Disposal after Dismantling
Note: The operator is responsible for the disposal of unit compo-
nents as required by law.

Page 9
3. Transport
3.1 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.
3.2 Transport Size and Weigth
* Dimensions and weigths can vary insignificantly
3.3 Packing
Note: Observe the symbols affixed to the box.
3.4 Interim Storage
Keep the unit dry and protect from frost.
3.5 Check for Complete and Correct Delivery of
Goods
Upon receipt of the unit, make sure that:
•type and serial number on the name plate match what
is in the purchasing and delivery documents,
•equipment is complete and in perfect condition.
Note: In case of damage during shipment and/or missing parts,
immediately file a written claim with your carrier or supplier.
Type* depth
[cm]
higth
[cm]
width
[cm]
weigth
[kg]
HC02 33 47 46 14
HC03 36 65 51 16
HC06 36 65 51 16
HC09 36 65 51 16
HC06P 41 78 59 25
HC09P 41 78 59 25
HC12 41 78 59 26
HC18 41 78 59 26
HC27 41 78 59 27

Page 10
Time limits for filing freight claims with shipping companies are*:
* Subject to change without prior notice.
3.6 Included in the Delivery
The delivery includes:
• Unit of the selected humidifier type including selected con-
trol.
• Water installation hose.
• Manuals for the steam humidifier and the control.
• Ordered accessories (steam manifold, steam hose, con-
densate hose, etc.).
• Maintenance o-ring set for steam cylinder.
Transport Company After Receipt of Goods
Mail 24 hours at the latest
Rail 7 days at the latest
Truck and railway compa-
nies
4 days at the latest
Parcel Service immediatly

Page 11
4. Operation and Device Construction
4.1 Mode of Action
The Imersion Heater Principle
One to three heater eleme nts (Pos. 8 in the explo ded view,
please see co ver foldout) a re pla ced in a close d cylin der and
connected to a lternating current. The cylin der is filled with t ap
water, fully demineralized water or partially softened water. Heat
generated by the heater element increases water temperature to
approx. 100°C.
When fully demineralized water is used, the feed water is practi-
cally free of minerals. This ensures long life for the cylinder and
heater elements since virtually no mineral deposits can settle or
build up. Fully demineralized water minimizes the number of ser-
vice / maintenance checks.
When tap water is used, some of the minerals dissolved in the
water will settle in the cylinder as solids of various compositions.
Most of these scale deposits are removed by periodic flushing or
use of a h eavy-duty blow-down pump. See section "Se rvicing
During Operation with Tap Water".
The gen erated steam has a temperatu re of abo ut 100°C and
minimal po sitive pressure ("pressure less” steam). It is virtually
demineralized and germ-free.

Page 12
4.2 Installation and Method of Operation
By pressing the control switch („Pos. I”) the humidifier is turned
on. Wh en th e hygrost at or controller signals a demand for
humidification, the inlet solenoid valve (14) opens. The solenoid
valve is designed for pressures from 100 x 103 to 100 x 104 Pas-
cals (1 to 10 bar).
Water is fed into the cylinder.
The water level in the cylinder must be maintained within a spec-
ified range. If the water level is to o hig h, the ellbow act s as a
safety overflow for water drainage. If the water level is too low, it
could cause the heat er elemen t (8) to overhea t. Th erefore,
power supply to the heater element is shut off when water levels
are too low.
The cylinder water level is controlled by a level control (27). The
level control consists of a stainless steel cylinder with two float
switches and three reed contacts. The float switches indicate the
water level in the steam cylinde r: "Dry Run", "Humidification "
and "Max. Level". The control capsule is pressure-equalized.
At the standard setting, the inlet solenoid valve (14) opens when
the water level remains below “humidif ication” level for 10 sec-
onds. The water level then rises again to “humidification” level.
The steam cylinde r consist s of a to p (16) an d lower (9) p art
joined with a cylinder flange. The seal between the cylinder and
cylinder base (11), as well as between the top and lower part of
the cylinder, is maintained using an o-ring.

Page 13
General survey
The heater elements are equipped with a mechanical high tem-
perature sa fety. Th is mechanism provides a re dundant safety
system in the event of excessively low water levels (“Dry Run”).
The cylinder water is periodically flushed out with a hea vy-duty
blow-down pump (10).
Steam is fed into air-condition ing duct s through special steam
hoses a nd steam ma nifolds. Under normal condition s, t his
steam has virtually no heating effect on the air to be humidified.
Accumulated condensate can be returned to the steam cylinder
via a condensate hose.
Direct room humidification (without ducts) is performed using fan
units (with blower and n ozzle). T he st eam g enerator is con-
nected to the fan unit with steam and condensate hoses.

Page 14
Steam lines in steam ba th cabins employ special steam hoses
and piping (if required). Accumu lated condensate is n ormally
routed into the steam cabin. At a relative humidity of 100%, the
supplied steam is used to heat the steam bath.
Warning: Leakage of the steam cylinder can cause a serious
hazard, such as giving an electric shock.
Warning: During blow down hot wat er wit h a temperature of
about 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 th e hu midifier ca n be prop ortionally op erated across the
entire output range of 5% - 100% nominal capacity.

Page 15
5. Mechanical Installation
Warning: Installation of this unit should be performed by quali-
fied personnel only . HygroMatik accept no liability for d amage
due to faulty installation.
Obey all safe ty instructions and wa rnings on the unit. Durin g
installation the unit must be disconnected from its power supply.
Accessory equipment may not be installed on or in the unit with-
out prior written co nsent from Hygro Matik. Otherwise the war-
ranty is void.
Warning: If the installation of this unit is a ttempted by only one
person there is a risk that the unit will drop down. We propose to
carry out the installation by two persons.
5.1 Steam Humidifier - environmental con diti-
ons
Note: When selecting the location for steam hu midifier installa-
tion, be aware of the following:
•Ambient temperature must be between +5 and +40 °C.
•Relative humidity may not exceed 80% RH.
•Observe clearances specified in the diagrams below to
ensure adequate ventilation.
• An Installation in a closed room requires aeration and if
neccessary temperature conditioning in order to reach
the above mentioned environmental conditions.
•HygroMatik humidifiers are not suitable for direct out-
door installation.
•Install the steam humidifier as close as possible to the
steam manifold. Use only short lengths of steam and
condensate hose to ensure optimal performance.
•Hoses must be laid at a constant 5-10% grade to uni-
formly prevent sags and kinks.
•The back surface of the steam humidifier heats up dur-
ing operation (to max. 70°C). Take care that the con-
struction on which the unit is mounted is not made of
temperature-sensitive material.
•Place the steam humidifier so that the unit is easily
accessible with sufficient space to perform mainte-
nance.
•The unit’s protection class is IP20.

Page 16
5.1.1 Equipment Dimensions HC
c
a
e
l
j
m
k
o
n
d
b
h
f
i
g
View from below
Rear view
View from top
Water inlet
Waste water connection
Steam outlet
Condensate inlet
Cable entries

Page 17
HC02 HC03-09 HC06P-09P
HC12-HC27
a 390 562 707
b 394 427 490
c 260 257 306
d 320 382 445
e 351 513 657
f33 30 30
g 170 190 250
h48 35 50
i80 44 50
j 158 145 162
k 110 109 138
l 178 100 81
m 167 50 86
n43 56 56
o18 18 18
all dimensions in mm
General Survey

Page 18
5.1.2 Fitting Measures
Wall Distance
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 th e equipment is inst alled on
brackets which can be embedded in the floor.
(all dimensions in mm)
B
B

Page 19
5.2 Absorption Distance BN
The "ab sorption d istance" (BN) is defined as th e distance from
the steam feed to where the steam is completely absorbed in the
treated air. W ithin the ab sorption d istance, steam is visible as
mist in the air stream.
Condensation ma y occur o n anythin g inst alled within the
absorption distance.
Although st eam outside th e absorptio n dist ance (B N) is com-
pletely absorbed, it is not yet evenly diffused in the duct. If you
plan to inst all a ny p arts or device s in side the a bsorption dis-
tance, such a s sensors or elbows, we recommend increasing
the absorption distance using the formulae below. The absorp-
tion dist ances required for certain in stalled fittings are distin-
guished by separate symbols a nd calcula ted a s a multiplier of
the absorption distance BN.
The absorptio n dist ance has no fixe d value, but depe nds on
many factors. T hese are dep icted in th e absorptio n dist ance
nomogram below.
5.2.1 Determining the Absorption Distance
To determine the absorption distance, the following parameters
are required:
•Air humidity before humidification x1 in g/kg.
•Air temperature after humidification t2 in °C (with steam
humidifiers the change in air temperature due to humid-
ification may be disregarded t1 or t2).
•Specific increase in humidity x in g/kg (can be deter-
mined in the h,x diagram)
•quantity of steam introduced in kg/h.
•air speed wL in m/s in air duct
•Total length lD of the steam manifold installed in the air
duct
Absorption Distance
BNfor normal obstructions, such as se n-
sors, ventilators, outlets
Bc = (1,5...2) x BNfor fine filters, heat registers
Bs = (2,5...3) x BNfor particle filters
Bd = (2,5...3) x BNfor humidity sensors, duct humidistats
o
D
m

Page 20
Length ID of the usable steam manifold depends on the dimen-
sions of the air duct. Th e length of the absorption distance can
be reduced by using multiple st eam manifolds (also see section
on the steam manifold).
Method:
Graphically determine absorption distance BN using the absorp-
tion distance nomogram (also see Section „Absorption Distance
Nomogramm“). Enter the va lue of the p arameters enumerated
above into the respective quadrants. The resulting point of inter-
section ind icates the value of the desired absorption dist ance
BN.
Notes:
x1: _______________________________[g/kg]
t2: _______________________________[°C]
x:_______________________________[g/kg]
:_______________________________[kg/h]
wL: _______________________________[m/s]
lD: _______________________________[mm]
Air humidity before humidification
Air temperature after humidification
Specific increase in humidity
quantity of steam introduced
air speed t
Total length of the steam manifold
o
D
m