HygroMatik DDS User manual

Steam Injection Humidifiers DDS
for existing steam nets
Manual

Page 2
Warning, Hazardous Voltage: All work to be performed by trained personnel only.
All electrical installation and servicing of the electrical components of this unit to be
performed by qualified electricians only. Disconnect power supply before installation
and servicing!
Copyright HygroMatik GmbH
DDS January 2011
Information in this manual is subject to change or alterate without prior notice.

Page 3
1. Introduction ....................................................................................................................... 5
1.1 Directions for Use .............................................................................................................. 5
1.2 TypographicsTypographic Distinctions .............................................................................. 5
2. Safety Instructions ............................................................................................................ 6
2.1 Operational Safety Instructions ......................................................................................... 6
2.2 Disposal after de-installation ............................................................................................. 7
3. Transport ............................................................................................................................ 8
3.1 Packing .............................................................................................................................. 8
3.2 Temporary storage ............................................................................................................ 8
3.3 Checking for correct and complete delivery ...................................................................... 8
4. Function and Assembly .................................................................................................... 9
4.1 Function ............................................................................................................................. 9
5. Strainer ............................................................................................................................... 10
5.1 Technical Data .................................................................................................................. 10
6. Separator ............................................................................................................................ 11
6.1 Function ............................................................................................................................. 11
6.2 Technical Data .................................................................................................................. 11
7. Control Valve and Actuator .............................................................................................. 12
7.1 Control Valve ..................................................................................................................... 12
7.2 Actuator ............................................................................................................................. 13
8. Start-up safety switch ....................................................................................................... 14
9. Steam Lances .................................................................................................................... 15
9.1 Technical Data ................................................................................................................. 16
9.2 Number of steam lances ................................................................................................... 16
10. Pressure Gauge Station .................................................................................................. 18
11. Ball Float Steam Trap ..................................................................................................... 19
11.1 Function ........................................................................................................................... 19
11.2 Technical Data ................................................................................................................ 20
11.2.1 KS-Condensate Drain for DDS Type A ....................................................................... 20
11.2.2 KS-Condensate Drain for DDS Type C ........................................................................ 20
12. Thermostatic Capsule Steam Trap ................................................................................ 21
12.1 Function ........................................................................................................................... 21
12.2 Technical Data ................................................................................................................ 22
13. Humidification Output ..................................................................................................... 23
13.1 Output Graphs ................................................................................................................. 23
13.2 Determining the control valve Kvs-Value ....................................................................... 23
13.3 Separator Type 20 with one steam lance ....................................................................... 25
13.4 Separator Type 20 with multiple steam lances ............................................................... 26
13.5 Separator Type 40 with one steam lance ....................................................................... 27
13.6 Separator Type 40 with multiple steam lances .............................................................. 28
14. Graph for Determing Absorption Distance ................................................................... 29

Page 4
15. Installation ....................................................................................................................... 30
15.1 Attaching steam pipes ..................................................................................................... 31
15.2 Electrical Installation ........................................................................................................ 32
15.3 Separators ....................................................................................................................... 33
15.4 Control Valve and Actuator ............................................................................................. 34
15.5 Pneumatic Start-up safety feature ................................................................................... 35
15.6 Steam Lances ................................................................................................................. 36
15.7 Installation Examples ...................................................................................................... 39
15.8 Steam Lance Heating System ......................................................................................... 41
15.9 Check List ........................................................................................................................ 42
16. Initial Operation ............................................................................................................... 43
17. Maintenance ..................................................................................................................... 45
17.1 Maintenance work ........................................................................................................... 45
17.2 Strainer ............................................................................................................................ 45
17.3 Ball float condensate drain .............................................................................................. 46
17.4 Thermostatic Capsule Steam trap type MST21 ............................................................ 47
18. Malfunctions .................................................................................................................... 48
19. Dismantling ...................................................................................................................... 50
20. Steam Injection System dimensions and Installation Schematic. .............................. 51
21. Spare Parts ...................................................................................................................... 52
22. Fax Form - Order for spare parts ................................................................................... 54

Page 5
1. Introduction
Dear Customer,
HygroMatik steam Injection humidifiers, produce dry steam for
humidification in A/C ducting and other applications.
Your steam injection humidifier comprises steam separators,
steam lances, steam trap, control valve and actuator. It is
extremely economical, safe in operation and easy to use.
In order to operate the HygroMatik steam injection humidifier in
a safe, orderly and economical fashion please take the time to
read this operating manual.
Please use the steam injection humidifier in a proper condition,
use only as it is intended and with regard to all the safety and
hazard indications and notes in this manual.
If you have any queries at all please get in touch as follows:
Tel.: [phone] (Switchboard)
Tel.: [phone] (Technical Hotline)
Fax: [phone]
E-Mail: [email protected]
1.1 Directions for Use
Your HygroMatik steam injection humidifier makes use of exist-
ing live steam for humidification purposes.
Proper usage involves strict adherence to our installation, de-
and re-installation, commissioning, operation and maintenance
requirements as well as proper disposal procedures.
Only qualified and authorised personnel may operate or service
the unit. Persons having to do with transport or any work on and
with the unit must previously have read and understood the rele-
vant parts of the manual, especially the section on safety
requirements. Additionally, the operator must inform such per-
sonnel about any possible hazards. Please place an example of
the operating instructionsl, clearly visible, at or near the installed
unit.
1.2 TypographicsTypographic 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.

Page 6
2. Safety Instructions
Overview
Adherence to these safety instructions are required by law. They
are there for your safety and for the prevention of industrial acci-
dents .
Warnings and Safety symbols
The following safety symbols indicate texts that contain warnings
concerning possible hazards. Please familiarise yourself with
these symbols.
Warning: Ignoring this warning may result in bodily injury and/or
damage to the unit.
Warning, High Voltage: Dangerous electrical voltage. Ignoring
this warning may cause serious bodily injury.
Note: Materials or other items that must be disposed of accord-
ing to the law.
Note: Indicates explanations or cross references to other parts
of the manual.
2.1 Operational Safety Instructions
Overview
In the case of malfunction shut off steam supply and make sure
it cannot be opened by unauthorised personnel. Correct mal-
function immediately.
After repair, operational safety must be checked out by autho-
rised personnel.
Use only original spare parts.
National laws also fully apply to the use of this steam injection
humidifier.
Accident prevention laws
Please comply with accident prevention laws:
See UVV Electical Appliances and associated units (VBG 4).
This can prevent injury to yourself and others.
Operating the Steam Injection Humidifier
Please do not do any work in such a way as to endanger the
safe operation of the unit.
Check all safety and monitoring elements regularly for correct
functioning.
Do not remove disable or de-install any safety-relevant items.

Page 7
Installation, de-installation, servicing and repair
Steam injection humidifier parts on which maintenance or repair
work is to be done must be disconnected from voltage and the
steam supply shut off. Installation of any additional parts is
allowed only after written permission from the manufacturer.
Electrical
Only qualified electricians may carry out electrical work on the
unit.
Remove voltage from any components being worked on. If the
energy supply is malfunctioning switch off the unit immediately .
After electrical work or repair is carried out all safety elements
must be tested for proper functioning.
Attention: Use only steam with a minimum pressure of 0,5 bar
and a maximum pressure of 4 bar at the entry point of the steam
injection humidifier.
Attention: Steam pipes are hot and care must be taken accord-
ingly.
Attention: use only steam without chemical additives.
Attention: Steam supply must be dimensioned so that the
steam velocity does not exceed 25 m/s.
Attention: 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 supplied. We recom-
mend the use of a stop valve in order to ensure that the steam
supply is completely shut off.
Attention: There may be impurities in the steam supply. In order
to prevent valve damage there must be a filter installed with a
pore diameter of <0.16 mm.
Attention: In order to maintain a continuous and constant
humidification the humidity sensors should not be fitted in the
supply duct.
2.2 Disposal after de-installation
Note: The operator is responsible for the lawful disposal of the
steam injection humidifier components.

Page 8
3. Transport
Overview
Note: If there is any transport damage and/or missing items
please get in touch with the transport company or supplier
immediately.
3.1 Packing
Note: Please observe the pictures on the packing.
The kind of packing used is dependent upon the type of unit sup-
plied. .
Accessories, such as steam traps, that can be part of the com-
plete order are packed separately.
If the control valve is part of the delivery it will be delivered
already installed on the steam separator. Additional screw fit-
tings are packaged separately.
Steam lances are delivered in special protective wrappings.
3.2 Temporary storage
The steam injection humidifier must be stored in a dry and frost
free area.
3.3 Checking for correct and complete delivery
On delivery please check that:
• the delivery corresponds to the order and delivery note.
• The data on the manufacturer‘s name plate corresponds to
the order and supply note
• All delivered components are in a proper condition
Note: Take care when transporting the steam injection humidi-
fier in order to prevent damage especially when loading and
unloading.
Take note of time limits for reporting damaged deliveries and
damage assessment. Here is a list of time limits :
Transport organisation after delivery
Post latest 24 hours.
Rail latest 7 days
Rail and road latest 4 days
Package services immediate

Page 9
4. Function and Assembly
The HygroMatik Steam Injection Humidifier comprises 4 basic
elements:
• Separator
• Control valve with or without control operation
• Steam Lances
• Additional materials
There is a stainless steel version Type A
and a mixed material version Type C
4.1 Function
Steam flows through a dirt particle trap (1) over the Separator
interface (2) into the Separator (3). The separator separates
condensation from the steam.
Condensation is drained using the float controlled condensa-
tion drainage. The Start-up security 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 lances (n) (8) are flanged or screwed onto the valve exit
side.
Dried steam is blown out through the specially 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. Alternatively there is the possibility to seal the
separator connection and operate the steam lance heating sys-
tem from a separate steam reservoir. A thermic Capsule Con-
densation Drain (10) ensures that condensation in the steam
lance heating system is drained off.
HygroMatik DDS Type A
*all stainless steel contruction
HygroMatik DDS Type C
*dirt trap, KS-Condensation drain and Valve as castings

Page 10
5. Strainer
There should be a strainer installed in the steam supply line
directly in front of every separator. Only if this is done can it be
guaranteed that there are no foreign particles in the humidifier
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 cylindrical version (type C)
or the conical strainer (type A) and through the holes to the exit.
Foreign matter is retained by the strainer.
5.1 Technical Data
Strainer 12.1 for type C Vers .20 Vers. 40
Nominal pressure setting PN 25
Female thread 3/4“ 1 1/2“
Weight 0,60 kg 2,4 kg
Dimensions A
B
C
D
93mm
65mm
110mm
38mm
153mm
115mm
190mm
62mm
Materials
Housing
Filter fitting
Seal
Coarse strainer
GGG40
GGG40
Graphite, reinforced
with nickel
Stainless steel 316L
pore size, coarse strainer 0,16mm
Strainer type A
*installed in the entry flange
Strainer type C
*Principle only; delivery in screwed
version

Page 11
6. Separator
The stainless steel separator is the essential component for
moisture separation. The separator is available in versions 20
and 40. The separator size is dependent upon the desired
steam output and available steam pressure.
6.1 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 spiral-shaped flow system.
The aerosole droplets present in the steam are thrown against
the outer wall by centrifugal 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.
6.2 Technical Data
Separator DDS20 DDS40
Type A Type C Type
A
Type
C
Thread connections B
C
D
1/4“
1/2“
DN25
1/4“
1/2“
3/4“
1/4“
1/2“
DN40
1/4"
1"
1 1/2"
Weight [kg] 3,6 1,46 7,3 3,70
Dimensions [mm] c
d
e
f
45
-
235
89
62
43
208
105
60
-
340
122
79
70
316
152
Materials Housing
internal
CrNiMo
Steel
1.4301
1.4301
VA
CrN-
iMo
Steel
1.4301
1.4301
VA
Max. Humidifica-
tion output
270 180 770 730
Steam Pressure max. 4 bar ü
Separator Type A
Separator Type C

Page 12
7. Control Valve and Actuator
The desired steam quantity is set over a control valve, which is
located between separator and steam lance. The control valve
itself is controlled by an electrical or pneumatic actuator.
If control valve and actuator are included in the delivery the rele-
vant operating and installation instructions will be enclosed.
If control units from other manufacturers are used the customer
must check whether these are compatible with the steam injec-
tion humidifier.
7.1 Control Valve
The control valve regulates the steam quantity 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 resul-
tant 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. Alterna-
tive suppliers can be listed on application.
Spirax-Sarco control valves Type LE33; KE63
Flanged A B C Kvs-value [m³/h]
DN15 130 103 69 0.2, 0.4, 0.5, 1.0,
1.6, 4.0
DN20 150 103 69 6.3
DN25 160 103 69 10.0
DN32 180 132 69 16.0
DN40 200 132 69 25.0

Page 13
7.2 Actuator
The actuator controls the valve cone positioning against the
valve face. Through continuous actuation a specific control sig-
nal can be assigned to every position of the valve cone.
To prevent air-duct over-saturation all actuators, even pneumati-
cally 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.
Electrical Actuator
The spinde and valve cone are set in motion by the electrical
actuator by means of a motor.
Electrical Actuators typically require a 24 V AC supply voltage
and a control signal of 0-10 V.
Actuators with a 3 position control for modulated control voltages
are also available.
In order to comply with DIN 32 730* an electrical 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).
Pneumatic Actuator
Pneumatic Actuators are controlled using compressed air (e.g.
0,2-1bar).
Compressed air is supplied over a compressed 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 spindles (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 pressure loss the spring immediately causes
the control valve to close.
Control valve signal options
pneumatic 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 500Ohm (or 2x1KOhm parallel) resisi-
tor is connected to over connectors 1 and 3.
The resistor is attached under the cover.
Type Hygromatik B-4115001
Type Spirax Sarco PN9000

Page 14
8. 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
steaml lances.
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 tempera-
ture (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.
Note: 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.
Electrical Safety switch
E-4111952
capillary
tube
relief valve
screw 1/2”
temperature sen-
sor
1/8”

Page 15
9. Steam Lances
In the steam lances (1) dry steam is blown out of specially
formed nozzles (2). 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
provided with a steam lance heating system (3). Due to this
system such droplets either evaporate or cannot form in the first
place.
The steam lance heating system can be fed by the separator or
from a separate steam reservoir.
Note: Steam pressures of 1 bar 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 immedi-
ately following control valve closure. This condensate is evapo-
rated by the steam lance heating system and exits the steam
lances as pressureless steam. Re-evaporation of residual con-
densate 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.
Steam Lances
Inside thread M10
casting rustfree steel casting BS 3146/1.4550
Heating pipe Stainless steel 1.4404/1.4306
Main pipe Stainless steel 1.4306
Sealing cap Stainless steel 1.4306
Clip Stainless steel 1.4435
Nozzle Stainless steel 1.4301

Page 16
9.1 Technical Data
*h - installation length
*j - total length
*X- Installation length min. 1m (see Steam Lance heating system)
Steam lances are available as type 20 and 40 in various
lengths, suitable for duct widths from 280mm to 3855 mm.
*Duct width is internal dimension
9.2 Number of steam lances
The steam lance system may comprise multiple steam lances.
With a duct height of more than 1000 mm multiple lances should
be positioned horizontally one on top of the other. This ensures
an even steam distribution. See table for number of steam
lances recommended for various duct heights.
Type 20 Type 40
Lance-
code
h
[mm]
j
[mm]
Weight
[kg]
h
[mm]
j
[mm]
Weight
[kg]
1 218 338 0,88 218 345 1,54
1,5 392 512 1,14 392 519 1,97
2 568 688 1,40 568 695 2,39
3 838 958 1,80 838 965 3,03
4 1148 1268 2,26 1148 1275 3,78
5 1408 1528 2,65 1408 1535 4,40
6 1718 1838 3,11 1718 1845 5,15
7 2018 2138 3,55 2018 2145 5,87
8 2318 2438 4,00 2318 2445 6,59
9 2628 2748 4,46 2628 2755 7,34
10 2938 3058 4,92 2938 3065 8,08
11 3238 3358 5,37 3238 3365 8,80
12 3548 3668 5,83 3548 3675 9,55
Inst. length h mm 218 390 568 838 1148 1408 1718 2018 2318 2628 2938 3238 3548
Duct width (max.)* mm 390 565 835 1130 1405 1715 2015 2315 2625 2935 3245 3545 3855
Duct width (min.)* mm 220 395 570 840 1150 1410 1720 2020 2320 2630 2940 3240 3550
Lance code 1 1,5 2 3 4 5 6 7 8 9 10 11 12
Duct height No. of Lancesl
up to 1000 mm 1
1000 - 1700 mm 2
1700 - 2200 mm 3
2200 - 2600 mm 4
over 2600 mm 5

Page 17
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
humidity the installation of additional lances may improve effi-
ciency.
Steam lance piping for multiple steam lances .
HygroMatik standard supply is for lengths of 300 mm und 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.

Page 18
10. 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 consists of an up to
200°C temperature-tested, tubular spring pressure gauge (0-
6bar), a T-junction and a dual nipple.
Pressure gauge shut-off valves and fluid-sack pipes are avail-
able on request.
Note: The pressure gauge station is installed in front of the
steam injection unit.

Page 19
11. Ball Float Steam Trap
After separation from the steam inside the separator condensate
is drained out through a ball float steam trap.
11.1 Function
The discharge valve is controlled by the ball float dependent
upon the density of the incoming medium.
Starting Position / Air
When the unit starts, air present in the system is discharged
through the thermostatic air extractor fan.
Normal Operating Conditions / Condensate
As soon as incoming condensate causes the float to rise, it flows
through the valve and extractor fan into the condensate network.
Hot condensate closes the thermostatic extractor but the con-
densate can continue to flow out through the valve.
Steam
If steam enters, the thermostatic extractor closes and the float
descends until the valve closes.
Warning: Water hammers can severely damage the ball float.
condensate loads in outdoor installations increase the risk of
freezing.
Water Hammers: Condensate accumulates in depressions.
During start-up, steam flows over the condensate causing it to
vibrate. This can continue until a certain amount of condensate
is carried off. At the next flow bifurcation this condensate hits the
first available object at a velocity of up to 25m/s. This impact is
known as a water hammer. .
Condensate load: Accumulated condensate which cannot drain
due to a depression.

Page 20
11.2 Technical Data
11.2.1 KS-Condensate Drain for DDS Type A
The KS-Condensate Drain for Type A is integrated into the sepa-
rator.
11.2.2 KS-Condensate Drain for DDS Type C
The KS-Condensate Drain for Type C is an additional unit that is
connected to the separator condensate drain over a connecting
piece.
Screwfitting : 1/2“ external thread
Materials:
Clip 1 Stainless steel 1.4404
Float 2 Stainless Steel 1.4404
Flange seal 3
Soft seal 4
Adjust. screw 5 Stainless Steel 1.4404
Housing 6 Stainless Steel 1.4404
Type Spirax Sarco FT14-4,5
Nominal pressure setting PN16
Screw fitting 1/2“ Internal thread
Dimensions : A 121 mm
B 107 mm
C 67 mm
D 147 mm
E 105 mm
Materials:
Cover 1 Nodular Cast Iron GGG40.3
Screws 2 Steel 8.8
Cover seal 3 nickel-graphite
Housing 4 Nodular Cast Iron GGG40.3
Mainvalve face 5 Stainless Steel 1.4057
Float 6 Stainless Steel 1.4301
Fan 7 Stainless Steel1.4541+1.4057
version type C
version type A