HydroMatik LPS User manual

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

Page 2
Caution: Voltage: All work must be carried out by specialists. All electrical installa-
tion work and work on the device's electrical components must be carried out by
authorised electricians. Switch off devices and disconnect them from the mains sup-
ply first!
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").
Copyright © HygroMatik GmbH [2013.06.19]
LPS
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]. No other right is
granted under this licence. In particular and without prejudice to the generality of the foregoing,
the Work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in part
or in any manner or form other than as expressly granted here without the prior written consent of
HygroMatik GmbH.
Information in this manual is subject to change or alteration without prior notice.

Page 3
1. Introduction ....................................................................................................................... 5
1.1 Typographic markings .......................................................................................................5
1.2 Documentation .................................................................................................................. 5
1.3 Intended use ..................................................................................................................... 6
2. Safety instructions ............................................................................................................ 8
2.1 General information ........................................................................................................... 8
2.2 Operational safety instructions ..........................................................................................8
2.3 Disposal upon disassembly ............................................................................................... 9
3. Transport ............................................................................................................................ 10
3.1 General information ........................................................................................................... 10
3.2 Packaging .......................................................................................................................... 10
3.3 Temporary storage ............................................................................................................ 10
3.4 Inspecting for correctness and completeness ...................................................................10
3.5 Scope of delivery ............................................................................................................... 10
4. Function and design .........................................................................................................11
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 .................................................................................................... 15
4.3 Partial and Full-Load ......................................................................................................... 16
5. Connnections .................................................................................................................... 17
5.1 Water ................................................................................................................................. 17
5.2 Waste water ...................................................................................................................... 17
5.3 Pressure water .................................................................................................................. 17
5.4 Electrical ............................................................................................................................ 18
6. Interfaces to the HygroMatik nozzle system LPS ........................................................... 19
6.1 Air ...................................................................................................................................... 19
6.2 Humidification chamber .....................................................................................................19
7. Mechanical assembly ........................................................................................................ 21
7.1 Overview of the humidification chamber ........................................................................... 21
7.2 Vortex wall module assembly ............................................................................................ 22
7.3 Assembling the vortex module wall ................................................................................... 22
7.3.1 Guide rails for the vortex module wall: ........................................................................... 22
7.3.2 Examplary design of guide rails for a vortex module wall .............................................. 23
7.3.3 Side rails for the vortex module wall: .............................................................................. 23
7.3.4 Assembling of the side rails for the vortex module wall ..................................................23
7.4 Installation of the nozzles, distributor pipe and tubing ....................................................... 24
7.4.1 Nozzle Installation: ......................................................................................................... 25
7.4.2 Assembling the distributor pipe ...................................................................................... 26

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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. Water connection .............................................................................................................. 38
9.1 Overview Water connection .............................................................................................. 38
9.2 Water supply ..................................................................................................................... 39
9.3 Drainage ............................................................................................................................ 40
9.3.1 Water drain for the humidification chamber .................................................................... 40
9.4 Water Quality ..................................................................................................................... 41
9.5 Inspection the water supply ............................................................................................... 41
10. Hygiene ............................................................................................................................ 42
10.1 Ensuring hygiene (VDI 6022) .......................................................................................... 42
10.2 Automatic flushing ........................................................................................................... 42
11. Electrical connection ......................................................................................................43
11.1 Connection data .............................................................................................................. 44
11.2 System enabling / Safety chain ....................................................................................... 44
11.3 Circuit diagram ................................................................................................................ 45
11.4 Inspecting the electrical installation ................................................................................. 47
12. Commissioning ............................................................................................................... 48
13. Maintenance ..................................................................................................................... 49
13.1 Maintenance activities ..................................................................................................... 49
13.1.1 Inspection / replacement of the net-based water filter .................................................. 50
13.1.2 Cleaning the atomizer nozzle ....................................................................................... 51
13.1.3 Cleaning the droplet separators ................................................................................... 52
13.1.4 Cleaning the vortex module wall .................................................................................. 52
13.1.5 Cleaning the humidification chamber ........................................................................... 53
14. Control System ................................................................................................................ 54
14.1 Control and speed regulation .......................................................................................... 54
14.1.1 Full load and part load .................................................................................................. 55
14.1.2 Summer / winter mode ................................................................................................. 55
14.2 Description of the programmable controller (PLC) .......................................................... 56
14.2.1 General description ...................................................................................................... 56
14.2.2 Menu ............................................................................................................................ 58
14.2.3 Overview of error reports ..............................................................................................61
15. EC declaration of conformity ......................................................................................... 63
16. Spare parts ....................................................................................................................... 64
17. Fax Form - Order for spare parts ................................................................................... 66
18. Technical Specifications ................................................................................................ 67
19. Plant scheme ................................................................................................................... 68

Page 5
1. Introduction
Dear Customer,
Thank you for purchasing a LPS nozzle system.
The HygroMatik LPS nozzle system corresponds to the current
state of the art. It features exceptional operational reliability,
ease of use and cost-effectiveness.
To ensure the proper, safe and economical operation of your
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.
If you have further questions please contact us:
Tel.: [phone] (Switchboard)
Tel.: [phone] (Technical Hotline)
Fax: [phone]
Email: [email protected]
Please have your device data ready for queries or spare part
orders!
1.1 Typographic markings
•lists with items beginning with bullets: general lists
» lists with items beginning with arrows: work or operating
steps which should or must be carried out in the speci-
fied order
installation steps which must be checked
italics figure and plan names
1.2 Documentation
Storage
Please keep this operating manual in a safe place where it is
accessible at all times. If you sell the product, be sure to include
this manual. Please contact HygroMatik if the documentation is
lost.
Language versions
This operating manual is available in different languages. Please
contact your HygroMatik dealer or HygroMatik for details.

Page 6
1.3 Intended use
The HygroMatik LPS nozzle system is used for air humidification
and cooling with desalinated water having a conductivity of 5-20
µS/cm. The feed water should have a temperature of 5-15°C.
Caution: Proper use includes fulfilment of the assembly, disas-
sembly, reassembly, start-up, operating and maintenance condi-
tions specified by us as well as disposal measures.
Only appointed qualified staff may work on or with the system.
Persons transporting or working on or with the system must
have read and understood the relevant parts of this operating
manual, particularly the 'Safety instructions' section. Staff must
also be informed of possible hazards by the operating company.
Please keep a copy of the operating manual at the location
where the device is being used.
The HygroMatik LPS nozzle system is not frost-proofed and not
suitable for outdoor installation.
The room temperature should be between 5 and 40°C.
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. They can be found in such places as offices, store-
rooms, production halls, clean rooms, hospitals and concert
halls.
Note: Components installed in ventilation and air-conditioning
systems must be suitable for the intended use; i.e. they must be
corrosion-resistant, easy to clean, accessible and hygienic. Fur-
thermore, they must not facilitate growth of micro-organisms.
Improper use:
Hardware and software may not be modified.

Page 7
Exemptions of usage:
The HygroMatik nozzle system LPS is not frost resistant and is
unsuitable for outdoor installation.
The HygroMatik nozzle system LPS PLC control may not be
deviate from the preset programmed On-/Off Control (or only
after consultation with HygroMatik).
The default constant pressure level of the HygroMatik LPS noz-
zle system may not be changed (or only after consultation with
HygroMatik).
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 8
2. Safety instructions
2.1 General information
The safety instructions are prescribed by law. They are intended
to ensure health and safety at work and accident prevention.
Warnings and safety symbols
The following safety symbols are used in this manual to indicate
hazard and risk warnings. Please familiarise yourself with these
symbols.
Caution: Failure to heed this warning may result in injury or dan-
ger to life and limb and/or damage to the device.
Caution: Voltage: Dangerous electrical voltage! Failure to heed
this warning may result in injury or danger to life and limb.
Note: indicates materials and consumables which must be han-
dled and/or disposed of in accordance with statutory require-
ments.
Note: precedes explanations for or cross-references to other
places in the text.
2.2 Operational safety instructions
General information
Observe all safety instructions and warnings found on the sys-
tem.
If malfunctions occur switch the system off immediately and
secure it to prevent it from being switched on. Eliminate the mal-
functions immediately.
After maintenance work has been carried out, expert staff must
ensure that the system is safe to operate.
Only use original spare parts.
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.
Work on the high pressure components of the nozzle system is
only allowed if the unit is disconnected from the power supply.
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
trained by a person, who is responsible for their safety.

Page 9
Supervise children in order to ensure that they will not play with
the unit.
Accident prevention regulations
Caution: Heed the HSW (Health and Safety at Work) regulations
for electrical installations and equipment (VBG4/BGVA3).
By doing so you protect yourself and others from harm.
Operating the HygroMatik LPS nozzle system
Refrain from all work practices which compromise the safety of
the system.
Check all protection and warning devices at regular intervals to
ensure they are in perfect working order.
Do not remove or deactivate safety devices.
Assembling, disassembling, servicing and maintaining the
device
Disconnect system parts from the mains supply before servicing
or repairing them.
Mounting or insertion of additional devices is only permitted
with the written consent of the manufacturer.
The HygroMatik LPS nozzle system is protected to IP20. Ensure
that the devices are protected from dripping water and dust at
the installation location.
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.
Electrical equipment
Caution: Only a qualified electrician is permitted to work on the
electrical system and the control cabinet.
Disconnect system parts from the mains supply before working
on them. Switch off the system immediately if faults in the electri-
cal energy supply occur. Only use original fuses with the speci-
fied amperage. Inspect the system's electrical equipment at
regular intervals. Promptly eliminate deficiencies, such as loose
connections or melted cables. After carrying out the correspond-
ing electrical assembly or maintenance work, test all protective
measures used (e.g. earth resistance).
2.3 Disposal upon disassembly
Note: The operating company is responsible for disposal of the
system parts in accordance with statutory requirements.

Page 10
3. Transport
3.1 General information
Note: Take care when transporting the HygroMatik LPS nozzle
systemtopreventthedeviceandpackagingfrom beingdamaged
by impact or accidental loading or unloading.
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.
Note: Only clean components may be installed in a ventilation
duct.
3.4 Inspecting for correctness and complete-
ness
When you receive the goods, ensure that:
•the equipment is complete and all parts are in perfect
condition.
Note: Any transport damages and/or missing parts must be re-
ported immediately to the shipper or supplier.
The periods in which notification of the transport company must
occur for the purposes of identifying the damage are as follows*:
* Periods are subject to change without notice.
3.5 Scope of delivery
The following items are included in the delivery:
•vortex modules
•droplet separators (optional; Hygiene compliance
checks applies only to systems with droplet separators)
•pump station
•operating instructions for the system
•bushing/s for duct
Note: Hoses and nozzles are delivered at the time of start-up.
Transport company Time after receipt of
goods
Post no later than 24 hours
Rail 7 days at the latest
Rail and road transport
companies 4 days at the latest
Parcel services immediately

Page 11
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.
These nozzles generate a very fine spray mist which is taken up
by the air in the device chamber. The ambient air is cooled adia-
batically in the process.
4.2 Design and process
1: Pump group
2: Water feed
3: Vortex module wall
4: Viewing window (necessary according to VDI 6022)
5: 2-stage droplet separator
6: Humidification chamber or duct with service doors and water
tray
7: Water drain, siphoned
8: SPS-control

Page 12
4.2.1 Pump group
The vane pump generates a pressure of up to 16 bar. The main-
tenance-free asynchronous motor with variable frequency ena-
bles continuous operation up to 50 Hz.
4.2.2 Dimension drawing of HygroMatik LPS nozzle
system
Pump group Capacity [l/h] Max. speed
[rpm]
LPS 45 45 1350
LPS 72 72 1350
LPS 110 110 1350
H T B Weight
LPS 45-110 700 230 600 30 Kg
T
B
H

Page 13
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. For optimal
moisture absorption, the air velocity is 1.0-2.5 m/s. The vortex
module wall exhibits a low pressure drop of 10Pa at an air veloc-
ity of 2.0 m/s.

Page 14
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.
The atomising nozzle generates a spray cone with a wide open-
ing angle.
1: Nozzle opening
2: Nozzle body
Functioning:
The nozzle sets the flowing water in rotation and thereby it can
leave at high speed. This enables a very fine water spray. The
higher the operating pressure, the finer the droplets.
Material of the nozzle: corrosion-free stainless steel
2
1

Page 15
4.2.5 Droplet separators (optional)
There are no more atomised water droplets in the air stream
behind the HygroMatik LPS nozzle system (if the environmental
parameter specifications are complied with). The two wire-mesh
droplet separators arranged in series ensure this. The trap pads
exhibit a low pressure drop (75 Pa at air velocity of 2.0 m/s and
average air density of 1.2 kg/m³).
The air velocity should be between 0.9 m/s and 2.8 m/s. If it is
outside this range it can cause moisture breakthrough down-
stream of the droplet separators - in such cases please first con-
tact HygroMatik.
The droplet separators are inserted into the humidification
chamber via guide rails and are hence easy to remove for serv-
icing.
The traps are standardly delivered with corrosion-resistant metal
frames.
Note: Hygiene compliance checks applies only to systems with
droplet separators.
4.2.6 Humidification section
The section between the vortex module wall and the droplet sep-
arators is called the 'humidification section' in this system. It is
unobstructed and hence easy to monitor and clean.
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'.
droplet separators

Page 16
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.
Construction:
The vane pump has to exits for water - one is the water supply
for the nozzles for Partial load and the othe one is the water sup-
ply for the nozzles for Full load.
If the external control signal decreases below a special switching
point, the HygroMatik nozzle system LPS switches off the water
supply for half of the nozzles.

Page 17
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.
5.2 Waste water
Connection: Connecting piece DN 12 for
plastic hose (resistant to low
conductive water)
Fitting: with constant fall and free outlet
and siphon
5.3 Pressure water
Connection „Full-Load”: plug-in connection for 6/4
pressure hose
Connection „Cooling”: plug-in connection for 6/4
pressure hose
Connection „Partial-Load”: plug-in connection for 6/4
pressure hose

Page 18
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
6. Interfaces to the HygroMatik nozzle system
LPS
6.1 Air
Air purity: A Class F7 pre-filter is to be
placed upstream of the HygroMatik nozzle system LPS.
Air velocity: 0.9-2.8* m/s
If the air velocity is outside this range please contact HygroMa-
tik.
(*: under ideal conditions)
Pressure drop: Approx. 80 Pa (at an air velocity
of 2.0 m/s and with use of a vortex module wall and two dry
droplet separators).
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. This also
applies for systems with multi-stage ventilators.
Note: For humidification of rooms the humidified air must exhibit
a purity in terms of bacterial count in accordance with VDI 6022.
6.2 Humidification chamber
The humidification component should be designed with a floor
tray that has an inclination of at least 1.5° towards the trap and
to be waterproof.
The water drain must be at the end of the humidification section.
The ideal humificiation section length (distance between vortex
module wall and droplet separators) is 0.9 m. This corresponds
to a total installation length of 1.5 m (see schematic in section
entitled 'Overview of the humidification chamber'). Should this
installation length not be available please contact HygroMatik.
The humidification chamber should be aerosol-tight and it
should be able to withstand desalinated water.
Note: The guide rails for the vortex module wall and droplet sep-
arators are supplied by the manufacturer. The guide rails must
already be installed for the system to be started. The vortex
module wall and droplet separators must also already be
installed.

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.