HygroMatik HeaterLine Series User manual

Electric Heater Steam Humidifier
ÁHL.CSAKÈ
HL.CSA
IMPORTANT: READ AND SAVE
THESE INSTRUCTIONS
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
CSA HeaterLine 08.09.2015
Information in this manual is subject to change or alteration without prior notice.
Current version of this manual can be found at: www.hygromatik.de

Page 3
1. Introduction ....................................................................................................................5
1.1 Typographic Distinctions ................................................................................................5
1.2 Documentation ...............................................................................................................5
1.3 Directions for Use ...........................................................................................................6
2. Safety Notes ....................................................................................................................7
2.1 Overview ........................................................................................................................7
2.2 Guidelines for Safe Operation ........................................................................................7
2.3 Disposal after Dismantling ..............................................................................................8
3. Transport .........................................................................................................................9
3.1 Overwiew ........................................................................................................................9
3.2 Transport Size and Weigth .............................................................................................9
3.3 Packing ...........................................................................................................................10
3.4 Interim Storage ...............................................................................................................10
3.5 Check for Complete and Correct Delivery of Goods ......................................................10
3.6 Included in the Delivery ..................................................................................................11
4. Operation and Installation .............................................................................................12
4.1 Mode of Action ...............................................................................................................12
4.2 Installation and Method of Operation .............................................................................12
4.3 Internal Output Setting ...................................................................................................14
5. Installation ......................................................................................................................15
5.1 Steam Humidifier Operating Environment ......................................................................15
5.1.1 Fitting Measures ..........................................................................................................16
5.1.2 Equipment Dimensions HL 06-45 ................................................................................17
5.2 Absorption Distance BN .................................................................................................18
5.2.1 Determining the Absorption Distance ..........................................................................18
5.2.2 Absorption Distance Nomogram .................................................................................20
5.3 Steam Manifold ..............................................................................................................21
5.3.1 Notes on Installation ....................................................................................................21
5.4 Steam Line .....................................................................................................................25
5.5 Cover Plate .....................................................................................................................26
5.6 Drill Pattern .....................................................................................................................27
5.6.1 Types of Installation ....................................................................................................29
5.7 Condensate Hose ...........................................................................................................31
5.8 Steam Solenoid Valves ..................................................................................................33
5.9 Chimney-compartment ..................................................................................................34
5.10 Unit Installation Check ..................................................................................................34
6. Water Installation ...........................................................................................................35
6.1 Water Quality ..................................................................................................................35
6.2 Water Supply (For Operation with Demineralized Water or Purified Condensate) ........36
6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ..........37
6.3.1 Feed from Holding Tank ..............................................................................................38

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6.4 Water Treatment ............................................................................................................38
6.5 Water Discharge .............................................................................................................39
6.6 Checklist .........................................................................................................................40
7. Electrical Installation .....................................................................................................41
7.1 Electrical Installation .......................................................................................................41
7.2 Cable Connections .........................................................................................................43
7.3 Control Connection .........................................................................................................43
7.4 Safety Interlock ...............................................................................................................43
7.5 Wiring Diagram ...............................................................................................................44
7.6 Electrical Installation Checklist .......................................................................................44
8. Commissioning ..............................................................................................................45
9. Maintenance ....................................................................................................................46
9.1 Maintenance for Operation with Demineralized Water / Condensate ............................47
9.2 Maintenance for Operation with Tap Water or Partially Softened Water ........................48
9.3 Access to Control Unit ....................................................................................................49
9.4 Cleaning the Coarse Strainer in the Cylinder Base ........................................................49
9.5 Cleaning Steam Cylinder ................................................................................................51
9.6 Cleaning connection hoses, cylinder base and nozzle ...................................................52
9.7 Replacing Thermo Sensor (for Heater Element) ............................................................53
9.8 Unlocking of a Released Thermo Sensor (for heater element) ......................................55
9.9 Unlocking of a Released Thermo Sensor (for Solid State Relay) ..................................55
9.10 Unlocking of a Released Thermo Sensor (cylinder cover) ...........................................55
9.11 Cleaning Blow-Down Pump ..........................................................................................55
9.12 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ...................................56
9.13 Checking Cable Screw Connections, Heater Element Wires .......................................58
9.14 Operational Check ........................................................................................................58
9.15 Dismantling ...................................................................................................................58
10. CSA Certificate of Compliance ...................................................................................59
11. Spare Parts ...................................................................................................................61
12. Fax Form - Order for spare parts ................................................................................66
13. Exploded View ..............................................................................................................67
14. View of Cabinet .............................................................................................................68
15. Technical Specifications .............................................................................................69

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1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
They will impress you with their safety, ease of use and econo-
mical operation.
In order to operate your HygroMatik steam humidifier safely, pro-
perly and efficiently, please read these operating instructions.
Employ your steam humidifier only in sound condition and as
directed. Consider potential hazards and safety issues and fol-
low all the recommendations in these instructions.
If you have additional questions, please contact us:
Tel.: [phone] / 895-0 (Main Number)
Tel.: [phone] / 895-293 (Technical Support Hotline)
Fax: [phone] / 895-33
e-mail: [email protected]
For all technical questions or spare parts orders, please be pre-
pared to provide unit type and serial number (see name plate on
the unit).
1.1 Typographic Distinctions
•preceded by a bullet: general specifications.
» preceded by an arrow: Procedures for servicing or
maintenance which should or must be performed in the
indicated order.
Installation step which must be checked off.
italics Terms used with graphics or drawings.
1.2 Documentation
Retention
Please retain these operating instructions in a secure, always
accessible location. If the product is resold, turn the documenta-
tion over to the new operator. If the documentation is lost, please
contact HygroMatik.
Versions in Other Languages
These operating instructions are available in several languages.
If interested, please contact HygroMatik or your HygroMatik dea-
ler.

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1.3 Directions for Use
The proven principle of heating water by the use of electric
immersion heaters is exploited to generate steam. Using diffe-
rent tap water qualities or partial softened water (all humidifier
types) or fully demineralized water / condensate water (only for
humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim).
Warning: HygroMatik steam humidifiers emit steam with a tem-
perature of 100°C/212°F. The steam may not be inhaled directly.
Proper usage also entails following HygroMatik's instructions for
installation, dismantling, reassembly, initial operation and opera-
tion and maintenance, as well as disposal procedures.
Only qualified and authorised personnel may operate the unit.
Persons transporting or working on the unit , must have read
and understood the corresponding parts of the Operation and
Maintenance Instruction and especially the chapter 2. „Safety
Notes“. Additionally, operating personnel must be informed of
any possible dangers. You should place a copy of the Operation
and Maintenance Instruction at the unit‘s operational location (or
near the unit).
The steam humidifier is not qualified for exterior application.

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2. Safety Notes
2.1 Overview
These safety notes are required by law. They promote work-
place safety and accident prevention.
Warnings and Safety Symbols
The safety symbols below identify sections containing warnings
about hazards or potential dangers. Please familiarize yourself
with these symbols.
Warning: Failure to observe this warning may result in serious
injury or death and/or damage to the unit.
Danger, Hazardous Voltage: Hazardous electrical current!
Failure to observe this warning may result in injury or even seri-
ous injury or death.
Warning: Failure to follow these instructions may result in dam-
age to the unit due to electrostatic discharge. The electronic
components of the humidifier control are very sensitive to elec-
trostatic discharges. In order to safeguard these components
during installation and servicing, steps must be taken to protect
against ESD.
Reminder: Materials and consumables must be handled and/or
disposed of as required by law.
Note: Appears before explanations or cross-references which
refer to other sections of the operating instructions.
2.2 Guidelines for Safe Operation
Overview
Obey all safety notes and warnings present on the unit.
In case of a malfunction, switch off the unit immediately and pre-
vent a restart. Repair malfunctions promptly.
After any repair work, have qualified personnel check the safe
operation of the unit.
Use original spare parts only.
Additional national safety regulations also fully apply to the oper-
ation of this unit.
This unit is not designed for the use by persons (also children)
with limited physical, sensory and mental abilities - or without
knowledge and experience. Unless they are supervised or trai-
ned by a person, who is responsible for their safety.
Supervise children in order to ensure that they will not play with
the unit.
The unit is only allowed to work with connected steam hose that
safely leads the steam.

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Warning: Make sure that no ignitable gas mixture can get into
the steam cylinder.
Accident Prevention Regulations
Comply with the accident prevention regulation
Accident Prevention Regulation Electrical Systems and Equip-
ment to prevent injury to yourself and others.
Operation of the Unit
Do not perform any work which compromises the safety of the
unit.
Regularly check that all safety and monitoring devices are func-
tioning normally.
Do not remove or disable safety devices.
Installation, Dismantling, Maintenance and Repair of the
Unit
Disconnect unit components from power supply prior to mainte-
nance or repair work.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer.
Electrical
Installation in accordance with CEC and/or NEC!
Work on the electrical system must be performed by qualified
personnel.
Disconnect unit components from power supply prior to work
In case of a malfunction in the electrical power supply, switch off
the unit immediately.
Use only original fuses with the appropriate amperage rating.
Regularly check the unit's electrical equipment. Promptly repair
any damage, such as loose connections or burned wiring or
defective electrical insulation. After proper electrical installation
or repair, test all safety mechanisms (such as grounding resis-
tance).
HygroMatik steam humidifiers are IP20-protected. Make sure
that the unit is protected from drips in its installed location.
Installing a humidifier in a room without water discharge requires
safety devices to protect against water leakages.
2.3 Disposal after Dismantling
Note: The operator is responsible for the disposal of unit compo-
nents as required by law.

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3. Transport
3.1 Overwiew
Note:Proceedcarefullywhentransportingthesteamhumidifierin
order to prevent damage from rough or careless loading and un-
loading.
3.2 Transport Size and Weigth
* Dimensions and weigths can vary insignificantly
Type* Heigth
[cm]/
[inch]
depth
[cm]/
[inch]
width
[cm]/
[inch]
weigth
[kg]/[lb]
HL 6 93/
36.6 42/ 16.5 74/ 29.1 39/ 86.0
HL 9 93/
36.6 42/ 16.5 74/ 29.1 39/ 86.0
HL 12 93/
36.6 42/ 16.5 74/ 29.1 40/ 88.2
HL 18 93/
36.6 42/ 16.5 74/ 29.1 40/ 88.2
HL 24 93/
36.6 42/ 16.5 74/ 29.1 42/ 92.6
HL 27 93/
36.6 42/ 16.5 74/ 29.1 42/ 92.6
HL 30 95/
37.4 48/ 18.9 80/ 31.5 50/ 110.2
HL 36 95/
37.4 48/ 18.9 80/ 31.5 49/ 108.0
HL 45 95/
37.4 48/ 18.9 80/ 31.5 50/ 110.2

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The heating element humidifiers type HeaterLine 60-90 are
double units - they consist of two separate units.
HL 60 = HL 30 + HL 30 (Slave)
HL 70 = HL 36 + HL 36 (Slave)
HL 80 = HL 45 + HL 36 (Slave)
HL 90 = HL 45 + HL 45 (Slave)
3.3 Packing
Note: Observe the symbols affixed to the box.
3.4 Interim Storage
Keep the unit dry and protect from frost.
3.5 Check for Complete and Correct Delivery of
Goods
Upon receipt of the unit, make sure that:
•type and serial number on the name plate match what
is in the purchasing and delivery documents,
•equipment is complete and in perfect condition.
Note: In case of damage during shipment and/or missing parts,
immediately file a written claim with your carrier or supplier.

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Time limits for filing freight claims with shipping companies are*:
* Subject to change without prior notice.
3.6 Included in the Delivery
The delivery includes:
• Unit of the selected humidifier type including selected con-
trol.
• Water installation hose.
• Manuals for the steam humidifier and the control.
• Ordered accessories (steam manifold, steam hose, con-
densate hose, etc.).
• Maintenance o-ring set for steam cylinder.
Transport Company After Receipt of Goods
Mail 24 hours at the latest
Rail 7 days at the latest
Truck and railway compa-
nies 4 days at the latest
Parcel Service immediatly

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4. Operation and Installation
4.1 Mode of Action
The Imersion Heater Principle
One to five heater elements (8) are placed in a closed cylinder
and connected to alternating current. The cylinder (9) is filled
with tap water, fully demineralized water or partially softened
water. Heat generated by the heater elements increases water
temperature to approx. 100°C/212°F.
When fully demineralized water is used, the feed water is practi-
cally free of minerals. This ensures long life for the cylinder and
heater elements since virtually no mineral deposits can settle or
build up. Fully demineralized water minimizes the number of ser-
vice / maintenance checks.
When tap water is used, some of the minerals dissolved in the
water will settle in the cylinder as solids of various compositions.
Most of these scale deposits are removed by periodic flushing or
use of a heavy-duty blow-down pump. See section "Servicing
During Operation with Tap Water".
The generated steam has a temperature of about 100°C/212°F
and minimal positive pressure ("pressureless” steam). It is virtu-
ally demineralized and germ-free.
4.2 Installation and Method of Operation
By pressing the control switch („Pos. I”) the humidifier will be
turned on.
When the hygrostat or controller signals a demand for humidifi-
cation, the inlet solenoid valve (14) opens. The solenoid valve is
designed for pressures from 1bar min., 10bar max. / 14.7 psi
min., 147 psi max.
Water is fed into the cylinder (9).
The water level in the cylinder must be maintained within a spec-
ified range. If the water level is too high, the ellbow acts as a
safety overflow for water drainage. If the water level is too low, it
could cause the heater elements (8) to overheat. Therefore,
power supply to the heater elements is shut off when water lev-
els are too low.
The cylinder water level is controlled by a level control (6). The
level control consists of a stainless steel cylinder with two float
switches and three reed contacts. The float switches indicate the
water level in the steam cylinder: "Dry Run", "Humidification"
and "Max. Level". The control capsule is pressure-equalized.

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At the standard setting, the inlet solenoid valve (14) opens when
the water level remains below “humidification” level for 10 sec-
onds. The water level then rises again to “humidification” level.
For more information, also see section “Exploded View.”
The steam cylinder (9) is made of stainless steel. The cover (5)
is attached to the steam cylinder using a clamping ring (7). Up to
5 heater elements (8) are mounted on the cover.
The heater elements are equipped with a mechanical high tem-
perature safety. This mechanism provides a redundant safety
system in the event of excessively low water levels (“Dry Run”).
The cylinder water is periodically flushed out with a heavy-duty
blow-down pump (10). Hygromatik’s SUPER FLUSH system
effectively assists this operation. The SUPER FLUSH mecha-
nism generates a strong whirlpool effect in the strainer basket
which aids removal of scale deposits during the blow-down pro-
cess. During this procedure, steam production is interrupted for
a few minutes.
Steam is fed into air-conditioning ducts through special steam
hoses and steam manifolds. Under normal conditions, this
steam has virtually no heating effect on the air to be humidified.
Accumulated condensate can be returned to the steam cylinder
via a condensate hose.
Position Discription
2 Steam hose adapter
3 Connection control capsule
4 O-ring, steam hose adapter
5 Cover, cylinder
6 Control capsule / Water level
control
7 Clamping ring
8 Electrical Heater
9 Cylinder
10 Blow-down pump
11 Base
12 strainer insert
13 O-ring, base
14 Water inlet solenoid valve
15 O-ring, base
16 Pressure plate for heater ele-
ments

Page 14
Direct room humidification (without ducts) is performed using fan
units (with blower and nozzle). The steam generator is con-
nected to the fan unit with steam and condensate hoses.
Steam lines in steam bath cabins employ special steam hoses
and piping (if required). Accumulated condensate is normally
routed into the steam cabin. At a relative humidity of 100%, the
supplied steam is used to heat the steam bath.
For maintenance the cylinder can be drained by pressing the
control switch „Pos.II”.
4.3 Internal Output Setting
Continuous control of the HeaterLine Type steam humidifier is
achieved by proportional control ( pulse-width modulation) of the
heater elements. In this way the humidifier can be proportionally
operated across the entire output range of 5% - 100% nominal
capacity.

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5. Installation
Warning: Installation of this unit to be attempted only by quali-
fied personnel. We accept no liability for damage due to faulty
installation.
Obey all safety notes and warnings present on the unit.
During installation the unit must be disconnected from its power
supply.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer, or else the war-
ranty is void.
Warning: If the installation of this unit is attempted by only one
person there is a risk that the unit drops down. We propose to
carry out the installation by two persons.
5.1 Steam Humidifier Operating Environment
Note: When selecting the installation site for the steam humidi-
fier, note that:
•Ambient temperature must be between +5 and +40°C /
41 and 104°F.
•Relative humidity must not exceed 80% r.h. .
•An installation in a closed room requires aeration and if
neccessary temperature conditioning in order to reach
the above mentioned environmental conditions.
•The minimum clearances indicated in the diagram
below must be observed; these are necessary to
ensure adequate ventilation for the housing.
•HygroMatik humidifiers are not suitable for direct out-
door installation.
•The steam humidifier should be installed as close as
possible to the steam manifold. Optimal performance is
guaranteed only with short lengths of steam and con-
densate hose.
•Hoses must be laid at a consistent 5 -10% incline to
prevent sagging and kinking.
•The rear panel of the steam humidifier heats up during
operation (to a maximum of 60°C/140°F). Take care
that the construction on which the unit is mounted is not
made of temperature-sensitive material.
•Do not mount to duct or pleneum.
•Place the steam humidifier so that the unit is easily
accessible with sufficient space to perform mainte-
nance.
•The steam humidifier is not qualified for exterior appli-
cations.

Page 16
5.1.1 Fitting Measures
Wall Distance
Note: It is often advantageous to use existing water connections
(feed and drain) when selecting the steam humidifier.
Wall Mounting
Note: To function properly the steam humidifier must be
installed vertically.
Measures for drills for wall mounting please see table (measures
d and e) in chapter „Equipment Dimensions”.If there is no suit-
able wall, it is recommended that the equipment is installed on
brackets which can be embedded in the floor.
> 300mm/
> 500mm/ > 200mm/
> 50mm/
B
B

Page 17
5.1.2 Equipment Dimensions HL 06-45
View from below
Rear view
View from top
HL 06-27
[mm]/
[inch]
HL 30-45
[mm]/
[inch]
a 830/
32.7 855/ 35.0
b 645/
25.4 688/ 27.1
c 325/
12.8 395/ 15.6
d 591/
23.3 634/ 25.0
e 771/
30.4 795/ 31.3
f38/
1.5 38/ 1.5
g 268/
18.6 310/ 12.2
h51/
2.0 51/ 2.0
i40/
1.6 40/ 1.6
j 167/
6.6 197/ 7.8
k 161/
6.3 204/ 8.0
l76/
3.0 76/ 3.0

Page 18
5.2 Absorption Distance BN
The "absorption distance" (BN)is defined as the distance from
the steam feed to where the steam is completely absorbed in the
treated air. Within the absorption distance, steam is visible as
mist in the air stream.
Condensation may occur on anything installed within the
absorption distance.
Although steam outside the absorption distance (BN) is com-
pletely absorbed, it is not yet evenly diffused in the duct. If you
plan to install any parts or devices inside the absorption dis-
tance, such as sensors or elbows, we recommend increasing
the absorption distance using the formulae below. The absorp-
tion distances required for certain installed fittings are distin-
guished by separate symbols and calculated as a multiplier of
the absorption distance BN.
The absorption distance has no fixed value, but depends on
many factors. These are depicted in the absorption distance
nomogram below.
5.2.1 Determining the Absorption Distance
To determine the absorption distance, the following parameters
are required:
•Air humidity before humidification x1in g/kg.
•Air temperature after humidification t2in °C (with steam
humidifiers the change in air temperature due to humid-
ification may be disregarded t1or t2).
•Specific increase in humidity x in g/kg (can be deter-
mined in the h,x diagram)
•quantity of steam introduced in kg/h.
•air speed wLin m/s in air duct
•Total length lD of the steam manifold installed in the air
duct
Absorption Distance
BNfor normal obstructions, such as sen-
sors, ventilators, outlets
Bc= (1,5...2) x BNfor fine filters, heat registers
Bs= (2,5...3) x BNfor particle filters
Bd= (2,5...3) x BNfor humidity sensors, duct humidistats
o
D
m

Page 19
Length IDof the usable steam manifold depends on the dimen-
sions of the air duct. The length of the absorption distance can
be reduced by using multiple steam manifolds (also see section
on the steam manifold).
Method:
Graphically determine absorption distance BNusing the absorp-
tion distance nomogram (also see Section „Absorption Distance
Nomogramm“). Enter the value of the parameters enumerated
above into the respective quadrants. The resulting point of inter-
section indicates the value of the desired absorption distance
BN.
Notes:
x1: _______________________________[g/kg]
t2: _______________________________[°C]
x:_______________________________[g/kg]
:_______________________________[kg/h]
wL: _______________________________[m/s]
lD: _______________________________[mm]
Air humidity before humidification
Air temperature after humidification
Specific increase in humidity
quantity of steam introduced
air speed t
Total length of the steam manifold
o
D
m

Page 20
5.2.2 Absorption Distance Nomogram
Source: Henne, Erich: Luftbefeuchtung (Air Humidification), 3rd Edition 1984 (Page 101), Olden-
bourg Industrieverlag, Munich