HygroMatik HPS250 User manual

HPS
Adiabatic humidification and
cooling system
ÁHPS.ENvÈ
HPS.EN
E-8881140
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 [13.03.2019]
HPS EN
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 consent of HygroMatik GmbH.
Information in this manual is subject to change or alteration without prior notice.

Page 3
1. Introduction ....................................................................................................................... 6
1.1 Typographic markings ....................................................................................................... 6
1.2 Documentation .................................................................................................................. 6
1.3 Intended use ..................................................................................................................... 7
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 High-pressure pump group ............................................................................................. 12
4.2.2 Dimension drawing of HygroMatik high-pressure nozzle system ................................... 12
4.2.3 Vortex modules .............................................................................................................. 13
4.2.4 Atomising nozzles .......................................................................................................... 14
4.2.5 Aerosol separators ......................................................................................................... 15
4.2.6 Humidification section .................................................................................................... 15
5. Connnections .................................................................................................................... 16
5.1 Water ................................................................................................................................. 16
5.2 Waste water ...................................................................................................................... 16
5.3 High pressure water .......................................................................................................... 16
5.4 Electrical ............................................................................................................................ 17
6. Interfaces to the HygroMatik high-pressure nozzle system .......................................... 18
6.1 Air ...................................................................................................................................... 18
6.2 Humidification chamber ..................................................................................................... 18
7. Mechanical assembly ........................................................................................................19
7.1 Overview on the humidification chamber .......................................................................... 19
7.2 Housing of the high pressure nozzle system .................................................................... 20
7.3 Assembling the vortex module wall ................................................................................... 20
7.3.1 Guide rails for the vortex module wall ............................................................................ 20
7.3.2 Examplary design of guide rails for a vortex module wall) ............................................. 21
7.3.3 Side rails for the vortex module wall ............................................................................... 22
7.3.4 Assembling of the side rails for the vortex module wall .................................................. 22
7.4 Assembling the aerosol separators ................................................................................... 23
7.4.1 Examplary design of guide rails for the aerosol separators ........................................... 23
7.4.2 Assembling two aerosol separators in a stack ............................................................... 24
7.5 Assembling of the distribution pipe .................................................................................... 25

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8. Water connection .............................................................................................................. 27
8.1 Connection ........................................................................................................................ 27
8.2 Water quality ..................................................................................................................... 27
8.3 Water inlet ......................................................................................................................... 28
8.4 Water drain ........................................................................................................................ 28
8.4.1 Design of the water drain ...............................................................................................28
8.4.2 Water drain for the humidification chamber .................................................................... 29
9. Water connection .............................................................................................................. 30
9.1 Overview on water connection .......................................................................................... 30
9.2 Water supply ..................................................................................................................... 31
9.3 Drainage ............................................................................................................................ 32
9.4 Water drain for the humidification chamber ....................................................................... 32
9.5 Water Quality ..................................................................................................................... 33
9.6 Inspection of water supply ................................................................................................. 33
10. Hygiene ............................................................................................................................ 34
10.1 Ensuring hygiene (VDI 6022) .......................................................................................... 34
10.2 Automatic flushing ........................................................................................................... 34
11. Electrical connection ...................................................................................................... 35
11.1 Connection data .............................................................................................................. 36
11.2 System enabling / Safety chain ....................................................................................... 36
11.3 Circuit diagram ................................................................................................................ 37
11.4 Inspecting the electrical installation ................................................................................. 38
12. Commissioning ............................................................................................................... 39
13. Device Control ................................................................................................................ 40
13.1 Electrical and electronical components of the device ..................................................... 40
13.2 Control options (modes of operation) ............................................................................. 41
13.3 Description of the control functions ................................................................................ 43
13.3.1 Display and control unit ................................................................................................ 43
13.3.2 Switch on system ......................................................................................................... 44
13.3.3 Menu structure ............................................................................................................. 44
13.3.4 Reading values ............................................................................................................. 45
13.3.5 Settings ........................................................................................................................ 45
13.3.6 Set time and date ......................................................................................................... 46
13.3.7 Set language ................................................................................................................ 47
13.3.8 Enter password (code) ................................................................................................. 47
13.3.9 Parameters (Code 010) ................................................................................................ 47
13.3.10 Fault history (Code 010) ............................................................................................. 49
13.4 Overview of error messages .......................................................................................... 49
13.5 Menu set-up and parametrisation ................................................................................... 51
14. Maintenance ..................................................................................................................... 52
14.1 Maintenance activities ..................................................................................................... 52
14.1.1 Changing the oil in the high-pressure pump ................................................................. 53
14.1.2 Checking/replacing the mains water filter ..................................................................... 54

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14.1.3 Flushing the mains water system ................................................................................. 55
14.1.4 Cleaning the high-pressure nozzle ............................................................................... 56
14.1.5 Cleaning the aerosol separators .................................................................................. 57
14.1.6 Cleaning the vortex module wall .................................................................................. 57
14.1.7 Cleaning the mounting profiles ..................................................................................... 57
14.1.8 Cleaning the humidification chamber ........................................................................... 58
14.2 Extended HPS Service Manual ....................................................................................... 59
14.2.1 Replacing the shaft sealing ring of the high-pressure pump EH2009 .......................... 59
14.2.2 Replacing the valves .................................................................................................... 61
14.2.3 Replacing the seals on the water side .......................................................................... 62
15. EC declaration of conformity ......................................................................................... 63
16. Fax Form - Order for spare parts ................................................................................... 64
17. Spare parts ....................................................................................................................... 65
18. Plant scheme ................................................................................................................... 68
19. Technical data ................................................................................................................. 69

Page 6
1. Introduction
Dear Customer,
Thank you for purchasing a HygroMatik high-pressure nozzle
system HPS.
The HygroMatik high-pressure nozzle system HPS 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 high-pressure nozzle system HPS, please read this
operating manual.
Only use the HygroMatik high-pressure nozzle system HPS if it
is in perfect condition and only for its intended purpose, consid-
ering 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 7
1.3 Intended use
The HygroMatik high-pressure nozzle system HPS is used for
air humidification and cooling with desalinated water having a
conductivity of 5-20 µS/cm. The feed water should have a tem-
perature 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 high-pressure nozzle system HPS is not frost-
proofed and not suitable for outdoor installation.
The room temperature should be between 5 and 40°C.
Applications:
The HygroMatik high-pressure nozzle system HPS has a wide
range of applications. 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, storerooms, 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 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.
Caution: Failure to heed this warning may result in damage to
the device from electrostatic discharge. The electronic compo-
nents of the control system are highly sensitive to electrostatic
discharge. To protect these components from damage by elec-
trostatic discharge, special measures (ESD protection) must be
taken during all installation work.
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 high-pressure nozzle system
it is not allowed to stay in the humidification chamber.
The desalinated water used for feeding the HygroMatik high-
pressure nozzle system is unsuitable for drinking.

Page 9
Work on the high pressure components of the nozzle system is
only allowed if the unit is disconnected from the power supply.
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 high-pressure 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.
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 electrical
energy supply occur.
Only use original fuses with the specified amperage.
Inspect the system's electrical equipment at regular intervals.
Promptly eliminate deficiencies, such as loose connections or
melted cables. After carrying out the corresponding electrical
assembly or maintenance work, test all protective measures
used (e.g. earth resistance).
The HygroMatik high-pressure nozzle system is protected to
IP22. Ensure that the devices are protected from dripping water
at the installation location.
If a HygroMatik high-pressure 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.
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 high-pres-
sure nozzle system to prevent the device and packaging from be-
ing damaged by impact or accidental loading or unloading.
3.2 Packaging
Note: The HygroMatik high-pressure nozzle system is delivered
on a pallet.
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
•aerosol separators
•high-pressure pump station
•operating instructions for the system.
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 high-pressure nozzle system is based on atom-
isation of water.
Desalinated water is fed into a high-pressure piston pump. With
an operating pressure of up to 75 bar, the water is atomized by
means of high-pressure nozzles. These nozzles generate a very
fine spray mist which is taken up by the air in the humidification
chamber. The ambient air is cooled adiabatically 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 aerosol separator
6: Humidification chamber or duct with service doors and water
tray
7: Water drain, siphoned
8: SPS-control
Note: The swept area of the control cabinet door may not be
changed.
8
1
2
67
5
4
3
7

Page 12
Note: Short piping distances:
To avoid loss of pressure, the piping path for the water should
be as short as possible and have the lowest possible height dif-
ference.
4.2.1 High-pressure pump group
The high-pressure piston pump generates a pressure of up to 75
bar. The maintenance-free asynchronous motor with variable
frequency and voltage enables continuous 9-50 Hz opera-
tion.
*: with an efficiency rate of 98%
4.2.2 Dimension drawing of HygroMatik high-pres-
sure nozzle system
Pump group Humidification output*
[kg/h]
Max. speed
[rpm]
HPS250 46-250
(14-180 with Bypass)
1400
HPS500 90-500
(65-390 with Bypass)
1400
HTB
HPS250 990 480 850 approx 60 Kg
HPS500 990 480 850 approx 80 Kg

Page 13
4.2.3 Vortex modules
The vortex modules provide for effective mixing of the air and
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 20 Pa at an air
velocity of 2.0 m/s.

Page 14
4.2.4 Atomising nozzles
Desalinated water at a pressure of 25-75 bar reaches the high-
pressure nozzles where the water is atomised to form ultra-fine
mist-like aerosols. The aerosols enter the area of the vortexed
air stream downstream of the vortex modules. The air and aero-
sols are mixed intensively here.
Normally two different types of atomising nozzles are used: On
the one hand there are atomising nozzles with an aperture angle
of 120°, on the other hand atomising nozzles for the edge area
of the vortex module wall with an aperture angle of 60° exist.
1: Nozzle body
2: Nozzle opening
Functioning:
Water is forced with high velocity into circulation by the swirl
insert of the nozzle. Thereby the required atomisation of water
into extremely fine aerosols takes place at the outlet opening.
The high operating pressure of the water (up to 75 bar) is nearly
completely translated into the exit velocity from the nozzle. The
higher the operating pressure the finer the droplets.
High-pressure nozzle material: stainless steel 1.4404
1
2

Page 15
Spray characteristics at operating pressure of 75 bar
Volumetric flow rate: [l/h] 7,1*
Most droplets with diameter between 6-35µm at 75bar.
(*: Information is subject to change or alteration without prior
notice)
4.2.5 Aerosol separators
There are no more atomised water droplets in the air stream
behind the HygroMatik high-pressure nozzle system (if the envi-
ronmental parameter specifications are complied with). The two
wire-mesh aerosol separators arranged in series ensure this.
The trap pads exhibit a low pressure drop (60 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 aerosol separators - in such cases please first con-
tact HygroMatik.
The aerosol separators are inserted into the humidification
chamber via guide rails and are hence easy to remove for ser-
vicing.
4.2.6 Humidification section
The section between the vortex module wall and the aerosol
separators 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 high-pressure nozzle system the humidification section
should have a length of at least 0.9 m. The exact dimensions are
shown in the schematic in the section entitled 'Overview of the
humidification chamber'.
aerosol separators

Page 16
5. Connnections
5.1 Water
Connection: 3/4”-external thread
Conductivity: 5-20 µS/cm
Pressure: 0.1-0.5 MPa (1-5 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: Plastic hose DN 12
Fitting: with constant fall and with
siphon
5.3 High pressure water
Connections for loads: 3/8”-external thread for
high-pressure hose

Page 17
5.4 Electrical
Power supply: LNE 230 V AC, 50 Hz
External control signal: 0-10 V 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 18
6. Interfaces to the HygroMatik high-pressure
nozzle system
6.1 Air
Air purity: A Class F7 pre-filter is to be
placed upstream of the HygroMatik high-pressure nozzle sys-
tem.
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 aer-
osol separators).
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 in the way of
a scrubber housing featuring an inclination of at least 1.5°
towards the trap and being waterproof.
The water drain must be situated at the end of the humidification
section.
The ideal humificiation section length (distance between vortex
module wall and aerosol 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 feasable, 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 aerosol
separators must be supplied by the manufacturer. The guide
rails must already be installed before system start-up. Also, the
vortex module wall and aerosol separators must already be
installed.
Note: The guide rails must be designed such that the vortex
module wall and aerosol separators can be removed (for servic-
ing).
Note: Before start-up of the system check again that the humidi-
fication chamber has been thoroughly cleaned. In particular the
humidification chamber and the ventilation duct upstream must
be free from metal swarfs to prevent corrosion.

Page 19
7. Mechanical assembly
Caution: The device may only be assembled by qualified staff.
HygroMatik accept no liability for damages resulting from incor-
rect assembly.
Observe all safety instructions and warnings found on the
device. The device must be de-energised during assembly.
Mounting or insertion of additional equipment is only permitted
with the written consent of the manufacturer. Otherwise the
guarantee and warranty will become void.
7.1 Overview on the humidification chamber
1: Vortex module wall with spray system
2: Aerosol separators
3: Upper guide rails for aerosol separators
4: Lower guide rails for aerosol separators
5: Collection tray
6: Drain with trap
7. Upper guide rails for vortex module wall
8. Lower guide rails for vortex module wall
9. Two M32 cable glands (for partial-load / full-load switching) for
connecting high-pressure hoses. Only one cable gland is
needed for the standard model.
10. Distribution pipe
Note: In front of the vortex module wall and from the aerosol
separators a minimum distance of 0.3 m to other installed com-
ponents must be maintained (see above schematic). Tempera-
tures higher than 60°C may destroy the vortex modules.
12
3
4
5
5
6
6
7
9
10
8

Page 20
Note: Between vortex module wall or droplet separator and a
fan, a minimum distance of 1 m has to be observed. The air flow
must be laminar.
7.2 Housing of the high pressure nozzle sys-
tem
Screwing the housing of the high pressure nozzle system to the
floor ensures a stable stand. For this purpose use the 12 mm
drillings located in the four corners of the housing. A connection
set is included in the scope of the delivery.
7.3 Assembling the vortex module wall
Two guide rails are required for the assembly of the vortex mod-
ule wall.
We recommend to have an air gap sideways between the vortex
module wall and the housing wall as it generates a laminar air
flow and prevents moisture build-up on the walls.
7.3.1 Guide rails for the vortex module wall
In order to position the vortex module wall in the humidification
chamber guide rails are required. The guide rails are fixed to the
ceiling and the side walls of the humidification chamber.
The guide rails must be installed in a way that allows for lifting-
up the vortex module wall.
Ensure that after installation the humidification chamber is leak-
age-free.