HygroMatik HeaterCompact HC02 User manual

Electric Heater Steam Humidifier
HeaterCompact
Installation yellow
Plumbing blue
Electrics red
Maintenance green
General Information white
ÁHC.EN0È
HC.EN
E-8881110
Manual

Page 2
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").
©Copyright HygroMatik GmbH
HeaterCompact [21.07.2017]
Current version of this manual can be found at: www.hygromatik.co.uk
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 con-
sent of HygroMatik GmbH.
Information in this manual is subject to change or alteration without prior notice.
Risk of electrical shock!
Hazardous electrical high voltage!
All electrical work to be performed by certified expert staff (electricians or expert personnel with
equivalent training) only.

Page 3
1. Introduction ....................................................................................................................... 5
1.1 Typographic Distinctions ...................................................................................................5
1.2 Documentation .................................................................................................................. 5
1.3 Intended Use ..................................................................................................................... 6
2. Safety Instructions ............................................................................................................ 7
2.1 Guidelines for Safe Operation ........................................................................................... 7
2.1.1 General ........................................................................................................................... 7
2.1.2 Unit control ..................................................................................................................... 7
2.1.3 Unit operation ................................................................................................................. 7
2.1.4 Mounting, dismantling, maintenance and repair of the unit ............................................ 8
2.2 Electrical ............................................................................................................................ 9
2.2.1 Disposal after dismantling ..............................................................................................9
3. Transport ............................................................................................................................ 10
3.1 Overwiew ........................................................................................................................... 10
3.2 Transport Size and Weigth ................................................................................................ 10
3.3 Packing .............................................................................................................................. 10
3.4 Interim Storage .................................................................................................................. 10
3.5 Check for Complete and Correct Delivery of Goods ......................................................... 10
3.6 Included in the Delivery ..................................................................................................... 11
4. Operation and Device Construction ................................................................................ 12
4.1 Mode of Action .................................................................................................................. 12
4.2 Installation and Method of Operation ................................................................................ 13
4.3 Internal Output Setting ...................................................................................................... 15
5. Installation ......................................................................................................................... 16
5.1 Steam Humidifier - environmental conditions .................................................................... 16
5.1.1 Equipment Dimensions HC ............................................................................................ 18
5.1.2 Fitting Measures ............................................................................................................. 20
5.2 Absorption Distance BN .................................................................................................... 21
5.2.1 Determining the Absorption Distance ............................................................................. 21
5.2.2 Absorption Distance Nomogram .................................................................................... 23
5.3 Fan Unit (optional) ............................................................................................................. 24
5.4 Steam Manifold ................................................................................................................. 26
5.4.1 Notes on Installation ....................................................................................................... 26
5.5 Steam Line ........................................................................................................................ 30
5.6 Cover Plate ........................................................................................................................ 31
5.7 Condensate Hose .............................................................................................................. 32
5.8 Types of Installation .......................................................................................................... 32
5.9 Steam Solenoid Valves .....................................................................................................34
5.10 Unit Installation Check ..................................................................................................... 34
6. Water installation .............................................................................................................. 35
6.1 Water Quality ..................................................................................................................... 36
6.2 Water Supply (For Operation with Demineralized Water or Purified Condensate) ........... 36

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6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ............. 37
6.4 Feed from Holding Tank .................................................................................................... 38
6.5 Water Treatment ............................................................................................................... 39
6.6 Water Discharge ................................................................................................................ 39
6.7 Water Connection Installation Checklist ............................................................................ 40
7. Electrical Installation ........................................................................................................ 41
7.1 Electrical Installation .......................................................................................................... 42
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 ............................................................ 44
7.5.1 1-step control .................................................................................................................. 44
7.5.2 Proportional Control with an external control signal ....................................................... 45
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
8.6 Replacing Heater Elements ............................................................................................... 59
8.7 Replacing the Heater Element Sealing .............................................................................60
8.8 Replacing Thermo Sensor (for Heater Element) ............................................................... 61
8.9 Unlocking of a Released Thermo Sensor (for heater element) ......................................... 62
8.10 Unlocking of a Released Thermo Sensor (for Solid State Relay) ................................... 62
8.11 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ......................................63
8.12 Cleaning Blow-Down Pump ............................................................................................. 64
8.13 Cleaning connecting hoses and cylinder base ................................................................ 65
8.14 Checking Cable Screw Connections, Heater Element Wires .......................................... 65
8.15 Functional Check ............................................................................................................. 65
8.16 Dismantling ...................................................................................................................... 66
9. Commissioning ................................................................................................................. 67
10. EC-Declaration of Conformity ........................................................................................ 69
11. Spare Parts ...................................................................................................................... 70
12. Technical Specifications ................................................................................................ 74
13. Exploded View ................................................................................................................. 76
14. 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 impress 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 your steam humidifier only in sound condition and as
directed. Consider potential hazards and safety issues and fol-
low all the recommendations in these instructions.
If you have additional questions, please contact us:
Tel.: [phone] / 895-0 (Main Number)
Tel.: [phone] / 895-293 (Technical Support Hotline)
Fax: [phone] / 895-33
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 retain these operating instructions in a secure, always
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 Intended Use
The HygroMatik steam generator serves for steam production
based on various water qualities or partially softened water
(valid for all of the HygroMatik humidifier models). With the Heat-
erLine, HeaterCompact/Kit and HeaterSlim familiy of products,
also fully desalinated water/cleaned condensate may be used.
Risk of scalding!
Steam with a temperature of 100°C is produced.
Do not inhalate directly.
Only qualified and authorised personnel may operate the unit.
Persons transporting or working on the unit must have read and
understood the respective parts of the Operation and Mainte-
nance Instruction and especially chapter 2, „Safety Notes“. Addi-
tionally, operating personnel must be informed of any possible
dangers. You should place a copy of the Operation and Mainte-
nance Instruction at the unit‘s operational location (or near the
unit).
The steam humidifier is not qualified for exterior installation.

Page 7
2. Safety Instructions
These safety instructions are required by law. They promote
workplace safety ans accident prevention.
2.1 Guidelines for Safe Operation
2.1.1 General
Comply with the accident prevention regulation „DGUV Regula-
tion 3“ to prevent injury to yourself and others. Beyond that,
national regulations apply without restrictions.
2.1.2 Unit control
Do not perform any work which compromises the safety of the
unit. Obey all safety notes and warnings present on the unit.
In case of a malfunction or power grid disruption, switch off the
unit immediately and prevent a restart. Repair malfunctions
promptly.
Restricted use.
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 order to ensure that they will not play with
the unit.
2.1.3 Unit operation
Risk of scalding!
In case of leaking or defective components, hot steam may exit
in an uncontrolled manner.
In case of malfunction or electrical power disruption, switch off
the unit immediately and prevent from restart.

Page 8
Risk of material damage!The unit may be damaged if switched
on repeatedly following a malfunction without prior repair.Rectify
defects immediately!
The unit must not be operated on a DC power supply.
The unit may only be used connected to a steam pipe that safely
transports the steam (not valid device type MiniSteam).
Regularly check that all safety and monitoring devices are func-
tioning normally. Do not remove or disable safety devices.
2.1.4 Mounting, dismantling, maintenance and repair
of the unit
The HygroMatik steam humidifier is IP20 protected. Make sure
that the unit is not object to dripping water in the mounting loca-
tion.
When installation is made in a room without a drain, safety pre-
cautions must be taken in order for to shut off the humidifier‘s
water supply in event of a leak.
Use genuine spare parts only.
After any repair work, have qualified personnel check the safe
operation of the unit.
Attaching or installing of additional components is permitted
only with the written consent of the manufacturer.

Page 9
2.2 Electrical
Risk of electrical shock!Hazardous electrical high voltage.Any
work on the electrical system may only be performed by quali-
fied personnel.Disconnect unit components from electrical
power supply prior to work.After electrical installation or repair
work, test all safety mechanisms (such as grounding resi-
stance).
Use only original fuses with the appropriate amperage
rating.Regularly check the unit‘s electrical equipment. Promptly
repair any damage such as loose connections or burned
wiring.Responsibility for intrinsically safe installation of the
HygroMatik steam humififiers (steam generators) is incumbent
on the installing specialist company.
2.2.1 Disposal after dismantling
The operator is responsible for the disposal of unit components
as required by law.

Page 10
3. Transport
3.1 Overwiew
Proceedcarefullywhentransportingthesteamhumidifierinorder
topreventdamagefromroughorcarelessloadingandunloading.
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
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.
In case of damage during shipment and/or missing parts, imme-
diately 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
Please note
Please note
Please note

Page 11
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
Carriers 4 days at the latest
Parcel Service immediatly

Page 12
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. 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 heavy-duty blow-down pump. See section "Servicing
During Operation with Tap Water".
The generated steam has a temperature of about 100°C and
minimal positive pressure ("pressureless” steam). It is virtually
demineralized and germ-free.

Page 13
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 103to 100 x 104Pas-
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 too high, the ellbow acts as a
safety overflow for water drainage. If the water level is too low, it
could cause the heater element (8) to overheat. Therefore,
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 cylinder: "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 “humidification” level for 10 sec-
onds. The water level then rises again to “humidification” level.
The steam cylinder consists of a top (16) and lower (9) part
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 14
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).
Steam is fed into air-conditioning ducts through special steam
hoses and steam manifolds. Under normal conditions, this
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 nozzle). The steam generator is con-
nected to the fan unit with steam and condensate hoses.
Steam lines in steam bath cabins employ special steam hoses
and piping (if required). Accumulated condensate is normally
routed into the steam cabin. At a relative humidity of 100%, the
supplied steam is used to heat up the steam bath. The mounting
location of the humidifier must always be outside of the steam
cabin.

Page 15
For maintenance purposes, the cylinder water may be drained
by pressing and holding the control switch in the „II“ position.
Risk of electrical shock!
Hazardous electrical high voltage.
In case of leakage from the humidifier, switch off the unit and
eliminate leakage.
Risk of scalding!
During blow down hot water with a temperature of about 95°C is
being drained. Avoid any contact with skin.
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 16
5. Installation
Installation of this unit to be accomplished only by qualified
personnel (persons with completed training in the plumbing
field and in the field of electrical installation work, respec-
tively) !
Obey all safety notes and warnings present on the unit.
Risk of electrical shock!
Hazardous electrical voltage.
During installation the unit must be disconnected from power
supply.
HygroMatik accepts no liability for damage due to faulty installa-
tion.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer, or else the war-
ranty is void.
Risk of foot injuries!
Unit may drop during mounting involving a single person.
Helping hand of a second person is required.
5.1 Steam Humidifier - environmental conditi-
ons
When selecting the location for steam humidifier installation, be
aware of the following:
• Ambient temperature must be between +5 and +40 °C
• 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 outdoor
installation
Please note

Page 17
• Install the steam humidifier as close as possible to the
steam manifold. Use only short lengths of steam and con-
densate hose to ensure optimal performance
• The back surface of the steam humidifier heats up during
operation (to max. 70°C). Take care that the construction
on which the unit is mounted is not made of temperature-
sensitive material
• Place the steam humidifier so that the unit is easily acces-
sible with sufficient space to perform maintenance
• The unit’s protection class is IP20

Page 18
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 19
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 20
5.1.2 Fitting Measures
Wall clearance
When determining the steam humidifier positioning, make use of
existing water connections (feed and drain).
Wall Mounting
To function properly, the steam humidifier must be installed verti-
cally.
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
brackets which can be embedded in the floor.
(all dimensions in mm)
Please note
B
B
Please note