HygroMatik DDS Series User manual

FlexLine
MANUAL
ÁDDS.ENZÈ
DDS.EN
E-8881128
Steam Injection Humidifiers DDS
for existing steam systems

Page 2
Risk of electrical shock!
Hazardous electrical high voltage!
All electrical work to be performed by certified expert staff (electricians or expert personnel with
eqivalent training) only.
Copyright © HygroMatik GmbH [19.07.2021]
Steam Injection Humidifiers / DDS EN
Information in this manual is subject to change or alteration without prior notice.
WARNING
!

Page 3
1. Introduction ....................................................................................................................... 5
1.1 Typographic Distinctions ...................................................................................................5
1.2 Documentation .................................................................................................................. 5
1.3 Symbols in Use ................................................................................................................. 5
1.3.1 Specific Symbols related to Safety Instructions ............................................................. 5
1.3.2 General Symbols ............................................................................................................ 5
1.4 Intended Use ..................................................................................................................... 6
2. Safety Instructions ............................................................................................................ 7
2.1 Guidelines for Safe Operation ........................................................................................... 7
2.1.1 Scope ............................................................................................................................. 7
2.1.2 Unit control ..................................................................................................................... 7
2.1.3 Mounting, dismantling, maintenance and repair of the unit ............................................ 8
2.1.4 Electrical ......................................................................................................................... 8
2.2 Disposal after dismantling ................................................................................................9
3. Transport ............................................................................................................................ 10
3.1 Overview ........................................................................................................................... 10
3.2 Packing .............................................................................................................................. 10
3.3 Interim Storage .................................................................................................................. 10
3.4 Check for Complete and Correct Delivery of Goods ......................................................... 10
4. Function and Assembly .................................................................................................... 11
4.1 Areas of application ........................................................................................................... 11
4.2 Function ............................................................................................................................. 11
4.3 Components ...................................................................................................................... 13
4.3.1 Separator ........................................................................................................................ 13
4.3.2 Strainer ........................................................................................................................... 14
4.3.3 Control Valve and Actuator ............................................................................................ 14
4.3.4 Start-up safety switch ..................................................................................................... 16
4.3.5 Steam Lances ................................................................................................................ 17
4.3.6 Pressure Gauge Station ................................................................................................. 18
4.3.7 Ball Float Steam Trap ..................................................................................................... 19
4.3.8 Thermostatic Capsule Steam ......................................................................................... 20
5. Humidification Output .......................................................................................................21
5.1 Output Graphs ................................................................................................................... 21
5.2 Determining the control valve Kvs-Value .......................................................................... 21
5.3 Separator Type 20 with one steam lance ........................................................................ 22
5.4 Separator Type 20 with multiple steam lances .................................................................. 23
5.5 Separator Type 40 with one steam lance .......................................................................... 24
5.6 Separator Type 40 with multiple steam lances .................................................................. 25
6. Graph for Determing Absorption Distance ..................................................................... 26
7. Mechanical installation .....................................................................................................27
7.1 Allowable environmental parameters ................................................................................ 27
7.2 Attaching steam pipes ....................................................................................................... 27
7.3 Water hammer prevention ................................................................................................. 28

Page 4
7.4 Separator ........................................................................................................................... 29
7.5 Control Valve and Actuator ............................................................................................... 29
7.6 Pneumatic Start-up safety feature ..................................................................................... 30
7.7 Steam Lances ................................................................................................................... 30
7.7.1 Duct mounting set for steam lance ................................................................................. 31
7.7.2 Installation Examples ..................................................................................................... 32
7.8 Steam Lance Heating System ........................................................................................... 35
7.9 Check List .......................................................................................................................... 36
8. Electrical connection ........................................................................................................ 37
9. Commissioning ................................................................................................................. 38
10. Maintenance ..................................................................................................................... 40
10.1 Strainer ............................................................................................................................ 40
10.2 Ball float condensate drain .............................................................................................. 41
10.3 Thermostatic Capsule Steam trap Type MST21 ............................................................. 41
11. Malfunctions .................................................................................................................... 42
12. Dimensions and Installation Schematic ........................................................................ 44
13. Spare Parts ...................................................................................................................... 46
14. Technical Data ................................................................................................................. 50

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam
injection humidifier.
HygroMatik steam humidifiers represent the
latest in humidification technology.
In order to operate your HygroMatik steam
injection humidifier safely, properly and effi-
ciently, please read these operating instruc-
tions.
Employ your steam injection humidifier only
in sound condition and as directed. Consider
potential hazards and safety issues and fol-
low all the recommendations in these instruc-
tions.
If you have additional questions, please con-
tact your expert dealer.
For all technical questions or spare parts
orders, please be prepared to provide unit
type and serial number (see name plate on
the unit).
1.1 Typographic Distinctions
•Preceded by a bullet: general speci-
fications
» 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 documentation
over to the new operator. If the documenta-
tion is lost, please contact HygroMatik.
Versions in Other Languages
These operating instructions are available in
several languages. If interested, please con-
tact HygroMatik or your HygroMatik dealer.
1.3 Symbols in Use
1.3.1 Specific Symbols related to
Safety Instructions
According to ANSI Z535.6 the following
signal words are used within this document:
DANGER indicates a hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE is used to address practices not
related to physical injury.
1.3.2 General Symbols
This symbol is used whenever a situation
requires special attention beyond the scope
of safety instructions.
DANGER
!
WARNING
!
CAUTION
!
NOTICE
Please note

Page 6
1.4 Intended Use
Areas of application:
The HygroMatik steam injection humidifier
(SIH) uses existing pressurized steam for air
humidification. The SIH humidifies with con-
densate-free saturated steam and offers the
shortest possible humidification distances.
They are used e.g. in clean rooms and hospi-
tals.
Proper usage also comprises the adherence
to the conditions specified by HygroMatik for:
• installation
• dismantling
• reassembly
• commissioning
• operation
• maintenance
• disposal
Only qualified and personnel may work on or
with the system (a supplementary qualifica-
tion according to VDI 6022 Part B or an
equivalent qualification is recommended).
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 haz-
ards by the operating company. Please keep
a copy of the operating manual at the loca-
tion where the device is being used.
Components installed in ventilation and air-
conditioning systems must be suitable for the
intended use; i.e., according to VDI 6022 or
equivalent, they must be corrosion-resistant,
easy to clean, accessible and hygienic. Fur-
thermore, they must not facilitate growth of
micro-organisms.
By construction, HygroMatik steam injection
humidifiers are not qualified for exterior appli-
cation.
The room temperature during operation of
the system should be between 5 and 40 °C.
Improper use:
Any other use not compatible with the
intended use outlined above is not allowable.
Improper use as well as changes in hardware
or software that are not authorized by Hygro-
Matik will lead to the total loss of guarantee
and warranty claims.
NOTICE
NOTICE

Page 7
2. Safety Instructions
These safety instructions are required by law.
They promote workplace safety and accident
prevention.
2.1 Guidelines for Safe Opera-
tion
2.1.1 Scope
Comply with the accident prevention regula-
tion „DGUV Regulation 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 instruc-
tions and warnings present on the unit.
In case of a malfunction or electrical power
disruption, switch off the unit immediately and
prevent a restart. Repair malfunctions
promptly. Close the steam supply line and
secure it against unauthorized reopening.
After repair work, ensure the operational
safety of the steam injection humidifier by
qualified personnel. Regularly check that all
safety and monitoring devices are functioning
normally. Do not remove or disable safety
devices.
Risk of material damage!
The unit may be damaged if switched on
repeatedly following a malfunction without
prior repair.
Rectify defects immediately!
Use only original spare parts.
Restricted use.
According to IEC 60335-2-98 the following
applies: Very young children must not use the
device. Children are not allowed to play with
the device, this must be ensured by a super-
visor. Children are not allowed to do cleaning
and user maintenance without a supervision.
NOTICE
WARNING
!

Page 8
2.1.3 Mounting, dismantling, mainte-
nance and repair of the unit
• Use only steam with a minimum pres-
sure of 0,5 barg and a maximum pres-
sure of 4,5 barg at the entry point of the
steam injection humidifier.
• Steam pipes are hot and care must be
taken accordingly.
• Use only steam without chemical addi-
tives.
• Steam supply must be dimensioned so
that the steam velocity does not exceed
25 m/s.
• The control valves are not stop valves.
They have been optimised to control
the necessary steam supply. They are
metal to metal sealed according to IEC
534-4 Class IV and can, therefore,
show a leakage of 0.01 % when sup-
plied. We recommend the use of a stop
valve in order to ensure that the steam
supply is completely shut off.
• There may be impurities in the steam
supply. In order to prevent valve dam-
age there must be a filter installed with
a pore diameter of <0.16 mm.
• During maintenance or installation
work, the device must be disconnected
from the power supply and secured
against being switched on again. The
absence of voltage must be ensured by
a measurement.
• To enable constant and steady humidi-
fication, the humidity sensors should
not be mounted in the supply air duct.
• Use genuine spare parts only.
• After electrical installation or repair
work, test all safety mechanisms (such
as grounding resistance) and ensure
operational safety through competent
and qualified staff.
• Attaching or installing of additional
components is permitted only with the
written consent of the manufacturer.
Water leaks caused by defective connec-
tions or malfunctions are possible.
Water is constantly and automatically filled
and drained in the humidifier. Connections
and water-carrying components must be
checked regularly for correct operation.
Do not install HygroMatik steam generators
above electrical equipment such as fuse
boxes, electrical appliances, etc. In the case
of a leakage, leaking water can damage the
underlying electrical equipment.
2.1.4 Electrical
Risk of electrical shock!
Hazardous electrical voltage!
• Any work on the electrical system to be
performed by certified expert staff
(electricians or expert personnel with
comparable training) only.
• During maintenance or installation
work, the device must be disconnected
from the power supply and secured
against being switched on again. The
absence of voltage must be ensured by
a measurement.
• After electrical installation or repair
work, test all safety mechanisms (such
as grounding resistance).
CAUTION
!
NOTICE
WARNING
!

Page 9
• Use only original fuses with the appro-
priate amperage rating.
• Regularly check the unit‘s electrical
equipment. Promptly repair any dam-
age such as loose connections or
burned wiring.
• Responsibility for intrinsically safe
installation of the HygroMatik steam
humidifiers is incumbent on the install-
ing specialist company.
2.2 Disposal after dismantling
The humidifier is made up of metal parts and
plastic parts. In reference to European Union
directive 2012/19/EU issued on 4 July 2012 and
the related national legislation, please note that:
The components of the electrical and electronic
devices must not be disposed of as municipal
waste, and therefore the method of waste sepa-
ration must be applied. The public or private
waste collection systems defined by local legis-
lation must be used.
The operator is responsible for the disposal
of unit components as required by law.
NOTICE
NOTICE

Page 10
3. Transport
3.1 Overview
Proceed carefully when transporting the
steam injection humidifier in order to prevent
damage due to stress or careless loading
and unloading.
3.2 Packing
The type of packaging depends on the series
and type of the delivered device.
Accessories (e.g. steam traps) are packed
separately.
If the control valve is included in the scope of
delivery, it is delivered mounted with the actu-
ator and connected to the steam dryer. Addi-
tional fittings are packed separately.
The steam lances are delivered in special
protective coatings.
3.3 Interim Storage
Store the unit in a dry place and protect from
frost and strong sunlight.
Only clean components are permitted to be
installed in a ventilation duct.
3.4 Check for Complete and Cor-
rect Delivery of Goods
Upon receipt of the unit, confirm that:
•model and serial number on the
name plate match those specified in
the order and delivery documents
•the equipment is complete and all
parts are in perfect condition
In case of damage from shipment and/or
missing parts, immediately notify the carrier
or supplier in writing.
Time limits for filing freight claims with ship-
ping companies are*:
* Time limits for some services subject to
change.
Please note
Please note
Shipping company After receipt of
goods
Carriers no later than 4 days
Parcel service immediately
Please note

Page 11
4. Function and Assembly
4.1 Areas of application
The typical use of the HygroMatik DDS pres-
surized steam humidifier is for supply air
humidification. The system is connected to
an existing steam network and humidifies
with condensate-free saturated steam. It thus
offers the shortest possible humidification
distances.
The HygroMatik DDS offers four components
in one unit: Separator, strainer condensation
drain and start-up safety switch.
SIH Version C
(MaterialMix)
4.2 Function
Steam flows through a dirt particle trap (1)
over the Separator interface (2) into the
Separator (3). The separator separates con-
densation from the steam.
Condensation is drained using the float con-
trolled condensation drainage (4). The
Start-up safety feature (5) measures the
temperature at the condensation return.
Operation switch (11) is activated when the
switch temperature has reached approx.
80°C.
Now the main portion of the steam flows
through the control valve (7). The amount of
steam is regulated over the operation switch
(11).
Steam lance (s) (8) are flanged or screwed
onto the valve exit side.
Dried steam is blown out through the spe-
cially formed nozzles (9) that take the dried
steam from the pipe centre. The nozzles are
press-fitted into the steam lances.
The steam lance heating system is fed over
connection (6) on the separator. Alterna-
tively there is the possibility to seal the sep-
arator connection and operate the steam
lance heating system from a separate steam
reservoir. A thermic Capsule Condensation
Drain (10) ensures that condensation in the
steam lance heating system is drained off.
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SIH Version C (Material Mix)
SIH Version A (stainless steel)
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SIH Version C (MaterialMix)
7- control valve
8 - Steam lance (s)
9 - Nozzles
10 - Thermic Capsule Condensation Drain
11 - Operation switch
12 - steam lance heating system
1 - dirt particle trap
2 - Separator interface
3 - Separator
4 - Float controlled Condensation Drain
5 - Start-up safety feature
6 - connection
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4.3 Components
The HygroMatik pressure steam humidifier
consists of 4 basic elements:
• Seperator
• Control valve with or without actuator
• Steam Plants
• Accessories
The system is available completely in stain-
less steel (A) or as a material-mix version (C).
4.3.1 Separator
The stainless steel separator is the essential
component for moisture separation. The sep-
arator is available in versions 20 and 40. The
separator size is dependent upon the desired
steam output and available steam pressure.
Separator Version C
Separator Version A
Function
Steam flows through the pipe union (1) into
the separator.
Steam and condensate are separated by the
joint action of the inlet pipe (2) and the spi-
ral-shaped flow system.
The aerosole droplets present in the steam
are thrown against the outer wall by centrifu-
gal force which separates them from the
steam phase. The droplets are conveyed
through the drain (3) into the condensate
return. This prevents droplets from being
transported by the steam.
Steam is conveyed into the upper part of the
separator chamber via a supply pipe (4) or
directly to the valve.
A certain amount of steam flows through the
connector (5) and feeds the steam lance
heating system.
The bulk of the steam exits the separator
through the outlet connection (6) and flows
through the control valve.
Separator Version A
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
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Page 14
4.3.2 Strainer
There should be a strainer installed in the
steam supply line directly in front of every
separator. Only if this is done there is guaran-
tee that no foreign particles enter the humidi-
fier unit.
Valve cone and valve face in both the control
valve and steam trap are sensitive to fouling.
Dirt particles between the face and the cone
prevent normal closure and have a corrosive
effect.
Function
Steam flows through the inlet in the cylindri-
cal version (type C) or the conical strainer
(type A) and through the holes to the exit.
Foreign matter is retained by the strainer.
4.3.3 Control Valve and Actuator
The desired steam quantity is set over a con-
trol valve, which is located between separator
and steam lance. The control valve itself is
controlled by an electrical or pneumatic actu-
ator.
If control valve and actuator are included in
the delivery the relevant operating and instal-
lation instructions will be enclosed.
If control units from other manufacturers are
used the customer must check whether these
are compatible with the steam injection
humidifier.
Control valve
The control valve regulates the steam quan-
tity by means of the valve lift. When the valve
is closed the valve cone rests against the
valve face. When the valve rods lift the cone
there is a resultant gap through which the
desired quantity of steam flows. The gap can
be widened or narrowed as required.
As a general rule the customer is free to use
any typical control valve which is approved
for steam control.
Standard are the Spirax-Sarco Valves from
HygroMatik. Alternative suppliers can be
listed on application.
Control valves ARI type BR440
SIH Type A Principle description
SIH Type C
Flanged A B Kvs-Value [m³/h]
DN15 130 118 0.25, 0.4, 0.63, 1.0, 1.6, 4.0
DN20 150 118 6.3
DN25 160 126 10.0
DN32 180 126 16.0
DN40 200 133 25.0

Page 15
Actuator
The actuator controls the valve cone posi-
tioning against the valve face. Through con-
tinuous actuation a specific control signal can
be assigned to every position of the valve
cone.
To prevent air-duct over-saturation all actua-
tors, even pneumatically operated ones,
should be equipped with a fail-safe. This fail-
safe closes the control valve immediately in
the case of power failure or pressure loss.
Typ Spirax Sarco PN9000
Electrical Actuator
The spindle and valve cone are set in motion
by the electrical actuator by means of a
motor.
Electrical Actuators typically require a 24V
AC/DC supply voltage and a control signal of
0-10 V.
Actuators with a 3 position control for modu-
lated control voltages are also available.
In order to comply with DIN 32 730 an electri-
cal actuator must have a fail-safe function so
that in the case of a power failure the control
valve is reset into a safe position (fully
closed)
Typ Hygromatik E- 4111680
Pneumatic Actuator
Pneumatic Actuators are controlled using
compressed air (e.g. 0,2-1barg).
Compressed air is supplied over a com-
pressed air supply (3) to a diaphragm (2).
As soon as the supply pressure exceeds the
spring (1) strength the diaphram is pushed
upwards. This pulls the two actuator spin-
dles (4) and control valve (5) upwards and
the actuator opens.
If control pressure drops the spring lowers
the spindle again. In the case of a total pres-
sure loss the spring immediately causes the
control valve to close.
Mögliche Regelsignale für Stellventil
pneumatical 0,2 - 1,0 bar
electrical 3-Position 24V AC
(230V on request)
electrical 0 (2) - 10 V, continuous
Supply voltage 24V AC
electrical
0 (4) - 20 mA, continuous
Supply voltage 24V AC
The 500 Ohm (or 2x1K
Ohm parallel) resistor is
connected to over connec-
tors 1 and 3. The resistor is
attached under the cover.

Page 16
4.3.4 Start-up safety switch
The start-up safety switch ensures that no
condensate from the steam network has
entered the air conditioning duct over the
steam lances.
electrical Start-up safety switch E-4111952
Electrical Start-up safety switch
With an electrical actuator the supply voltage
is looped through the start-up safety switch.
The start-up safety switch is set to allow the
supply voltage through only when a specified
temperature (in this case 80°C) is reached.
If the temperature remains below this level
the fail-safe function is triggered.
Pneumatic Start-up safety switch
The pneumatic start-up safety switch keeps
an exhaust valve open for compressed air as
long as the specified temperature has not
been reached.
This prevents control air from entering the
actuator.
If no start-up safety switch is available it is
advisable to let the unit run a few minutes
before switching the control on. This allows
time for the steam lance heating system to
heat the lances.
relief valve
capillary
tube
screw 1/2”
temperature
sensor
NOTICE

Page 17
4.3.5 Steam Lances
In the steam lances dry steam is blown out of
specially formed nozzles. They are designed
for low noise steam emission. The nozzles
take steam from the driest area in the steam
lance centre.
In order to prevent accumulated condensate
or aerosol droplets from being transported
with the steam, the steam lances are pro-
vided with a steam lance heating system.
Due to this system such droplets either evap-
orate or cannot form in the first place.
The steam lance heating system can be fed
by the separator or from a separate steam
reservoir.
Steam pressures of 1 barg or higher have an
optimum heating effect on the steam lances.
With less pressure the pre-heating and re-
evaporation times may be lengthened.
Re-evaporation
In some cases condensate remains in the
steam lances immediately following control
valve closure. This condensate is evaporated
by the steam lance heating system and exits
the steam lances as pressureless steam. Re-
evaporation of residual condensate can take
up to 20 minutes. The higher the steam pres-
sure the better is the performance of the
steam lance heating system and the shorter
the evaporation time.
Number of steam lances
The steam lance system may comprise multi-
ple steam lances.
With a duct height of more than 1000 mm
multiple lances should be positioned horizon-
tally one on top of the other. This ensures an
even steam distribution. See table for number
of steam lances recommended for various
duct heights.
NOTICE
Duct height Number of l a nces
up to 1000 mm 1
1000 - 1700 mm 2
1700 - 2200 mm 3
2200 - 2600 mm 4
over 2600 mm 5

Page 18
Check number of steam lances when the
following factors apply:
• duct air speed exceeds 5 m/s.
• Duct air temperature under 21°C.
• Last fine mesh filter located less than 3
m behind steam lance.
• Air flow branching occurs less than 1 m
behind steam lance.
Depending upon additional parameters such
as pre-defined steam output, existing or
desired absorbtion distance or rise in humid-
ity the installation of additional lances may
improve efficiency.
Steam lance piping for multiple steam
lances.
HygroMatik standard supply is for lengths of
300 mm and 450 mm. Distances are
approximate and can vary from installa-
tion to installation. Piping should be
installed for even lance distribution along the
duct height. Distance between duct floor and
ceiling should not exceed 250 mm.
4.3.6 Pressure Gauge Station
Installation of a pressure gauge on the steam
injection unit ensures immediate detection of
pressure drops or fluctuations.
The HygroMatik Pressure gauge station con-
sists of a tubular spring pressure gauge (0-6
bar), a T-junction and a dual nipple.
The pressure gauge is temperature resistant
up to 200° C.
Pressure gauge shut-off valves and siphons
are available on request.
The pressure gauge station is to be installed
upstream of the steam injection unit.
NOTICE
NOTICE

Page 19
4.3.7 Ball Float Steam Trap
After separation from the steam inside the
separator condensate is drained out through
a ball float steam trap.
Function
The discharge valve is controlled by the ball
float dependent upon the density of the
incoming medium.
During installation, it is important to ensure
that the marking "TOP" is in the correct instal-
lation direction. The sideway arrow shows
the flow direction.
Water hammers can severely damage the
ball float, condensate loads in outdoor instal-
lations increase the risk of freezing.
sectional view Ball Float Steam Trap
Please note
NOTICE
95

Page 20
4.3.8 Thermostatic Capsule Steam
Condensate that has collected in the steam
lance heating system is discharged through a
thermostatic capsule steam trap.
Function
The discharge valve is controlled dependent
upon the capsule volume and the tempera-
ture and pressure of the incoming medium.
The capsule contains a liquid whose satura-
tion curve parallels that of steam. However,
the liquid boiling point is always somewhat
less than that of water.
During installation, it is important to ensure
that the marking showing the correct installa-
tion direction is taken care of. The sideway
arrow shows the flow direction.
Do not insulate the thermic capsule steam
trap.
The minimum connection pipe length of
1.0 m (L3) between the lance connection and
the drain is absolutely mandatory.
Please note
NOTICE
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