HygroMatik HeaterLine Series User manual

Electric Heater Steam Humidifier
ÁHL.CSAKÈ
HL.CSA
IMPORTANT: READ AND SAVE
THESE INSTRUCTIONS
Manual

Page 2
Risk of electrical shock by 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 02.09.2016
Information in this manual is subject to change or alteration without prior notice.
Current version of this manual can be found at: www.hygromatik.co.uk

Page 3
1. Introduction ....................................................................................................................5
1.1 Typographic Distinctions ................................................................................................5
1.2 Documentation ...............................................................................................................5
2. Safety Instructions .........................................................................................................7
2.1 Overview ........................................................................................................................7
2.2 Guidelines for Safe Operation ........................................................................................7
2.3 Disposal after Dismantling ..............................................................................................8
3. Transport .........................................................................................................................9
3.1 Overview ........................................................................................................................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. Functional description and device composition .........................................................12
4.1 Mode of operation ..........................................................................................................12
4.2 Structure and operation of the device ............................................................................12
4.3 Internal Output Setting ...................................................................................................14
5. Installation ......................................................................................................................15
5.1 Steam Humidifier Operating Environment ......................................................................15
5.1.1 Fitting Measures ..........................................................................................................17
5.1.2 Equipment Dimensions HL 06-45 ................................................................................18
5.2 Fan Units (options) .........................................................................................................19
5.2.1 Fan Units Type VG ......................................................................................................19
5.3 Absorption Distance BN .................................................................................................20
5.3.1 Determining the Absorption Distance ..........................................................................20
5.3.2 Absorption Distance Nomogram .................................................................................22
5.4 Steam Manifold ..............................................................................................................23
5.4.1 Notes on Installation ....................................................................................................23
5.5 Steam Line .....................................................................................................................27
5.6 Cover Plate .....................................................................................................................28
5.7 Drill Pattern .....................................................................................................................29
5.7.1 Types of Installation ....................................................................................................31
5.8 Condensate Hose ...........................................................................................................33
5.9 Steam Solenoid Valves ..................................................................................................35
5.10 Chimney-compartment ................................................................................................35
5.11 Unit Installation Check ..................................................................................................36
6. Water Installation ...........................................................................................................37
6.1 Water Quality ..................................................................................................................38
6.2 Water Supply (For Operation with Demineralized Water or Purified Condensate) ........39
6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ..........40

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6.3.1 Feed from Holding Tank ..............................................................................................41
6.4 Water Treatment ............................................................................................................41
6.5 Water Discharge .............................................................................................................42
6.6 Checklist .........................................................................................................................43
7. Electrical Installation .....................................................................................................44
7.1 Electrical Installation .......................................................................................................44
7.2 Cable Connections .........................................................................................................46
7.3 Safety Interlock ...............................................................................................................46
7.4 Wiring Diagram ...............................................................................................................47
7.5 Electrical Installation Checklist .......................................................................................47
8. Commissioning ..............................................................................................................48
9. Maintenance ....................................................................................................................50
9.1 Maintenance for Operation with Demineralized Water / Condensate ............................51
9.2 Maintenance for Operation with Tap Water or Partially Softened Water ........................52
9.3 Access to Control Unit ....................................................................................................53
9.4 Cleaning the Coarse Strainer in the Cylinder Base ........................................................53
9.5 Cleaning Steam Cylinder ................................................................................................55
9.6 Cleaning connection hoses, cylinder base and nozzle ...................................................57
9.7 Replacing Thermo Sensor (for Heater Element) ............................................................58
9.8 Unlocking of a Released Thermo Sensor (for a heater element) ...................................60
9.9 Unlocking of a Released Thermo Sensor (for a Solid State Relay) ...............................60
9.10 Unlocking of a Released Thermo Sensor (cylinder cover) ...........................................60
9.11 Cleaning Blow-Down Pump ..........................................................................................60
9.12 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ...................................61
9.13 Checking Cable Screw Connections, Heater Element Wires .......................................63
9.14 Operational Check ........................................................................................................63
9.15 Dismantling ...................................................................................................................63
10. CSA Certificate of Compliance ...................................................................................64
11. Spare Parts ...................................................................................................................66
12. Fax Form - Order for spare parts ................................................................................71
13. Exploded View ..............................................................................................................72
14. View of Cabinet .............................................................................................................73
15. Technical Specifications .............................................................................................74

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
They will impre ss 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 yo ur ste am hu midifier only in sound condition a nd as
directed. Consider po tential hazards an d safety issues and fol-
low all the recommendations in these instructions.
If you have additional questions, please contact us:
Tel.: [phone] (Main Number)
Tel.: [phone] (Technical Support Hotline)
Fax: [phone]
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 ret ain th ese o perating instruction s in a secure, alwa ys
accessible location. If the product is resold, turn the documenta-
tion over to the new operator. If the documentation is lost, please
contact HygroMatik.
Versions in Other Languages
These operating instructions are available in several languages.
If interested, please contact HygroMatik or your HygroMatik dea-
ler.

Page 6
Hot Steam!Do not inhalate!
HygroMatik steam humidifiers emit steam with a temperature of
100°C/212°F. The steam should 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.
HygroMatik steam humidifiers se rve for steam production using
different tap water qualities or partial softened water (all humidi-
fier types) or fully demine ralized wate r / cond ensate water (for
humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim
only).
Only qu alified a nd au thorised p ersonnel may opera te the unit.
Persons transporting or working on the unit must have read and
understood the corresponding parts of the Operation and Main-
tenance Instruction s and esp ecially the cha pter 2. „Safety
Notes“. Additionally, op erating personne l must be informed of
any possible dangers. You should place a copy of the Operation
and Maintenan ce Instructions at the unit‘s opera tional location
(or near the unit).
The steam humidifier is not qualified for exterior application.

Page 7
2. Safety Instructions
2.1 Overview
These sa fety instructions are required by law . They pro mote
workplace safety an d accident p revention. According to ANSI
Z535.6 the follwowing signal words are used in this document:
DANGER indicates a hazardo us 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 u sed to address prac tices no t relate d to physical
injury.
2.2 Guidelines for Safe Operation
Restricted Use
This unit is not designed for the use by persons (also children)
with limited physical, sensory and mental abilities - or without
knowledge and experience. Unless they are supervised or trai-
ned by a person, who is responsible for their safety.
Supervise children in order to ensure that they will n ot play with
the unit.
Accident prevention compliance
Comply with the Accident Prevention Regulation Electrical Sys-
tems and Equipment to prevent injury to yourself and others.
Additional national safety regulations also fully apply to the oper-
ation of this unit.
Operational Safety
In case of a malfunction, switch off the unit immediately and pre-
vent a restart. Repair malfunctions promptly.
The unit is only allowed to work with connected steam hose that
safely leads the steam.
Make sure that no ign itable gas mixtur e can get into the steam
cylinder.
Do not pe rform any work which co mpromises the safety of the
unit.

Page 8
Regularly check that all safety and monitoring devices are func-
tioning normally.
Do not remove or disable safety devices.
Safety instructions on product
Obey all safety instructions and warnings present on the unit.
Installation, Dism antling, Maintenance a nd Rep air of the
Unit
Disconnect unit components from power supply prior to mainte-
nance or repair work.
Use original spare parts only.
After any repair work, have qu alified personnel check th e safe
operation of the unit.
Electrical
Installation to be made in accordance with CEC and/or NEC!
Work on the ele ctrical system must be perfo rmed b y qua lified
personnel only.
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 e lectrical equipment. Promptly repair
any damage, such as loose co nnections o r b urned wiring or
defective electrical insulation. After prope r ele ctrical installation
or repair, test all safety me chanisms (such a s grounding resis-
tance).
Unit operating environment
HygroMatik ste am humidif iers are IP20-pro tected. 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.
Unit modifications
Attaching or installing additional components is permitted only
with the written consent of the manufacturer.
2.3 Disposal after Dismantling
The operator is responsible for the disposal of unit co mponents
as required by law.

Page 9
3. Transport
3.1 Overview
Proceed carefully when transporting the steam humidifier in order
to prevent damage due to stress or careless loading and unload-
ing.
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
Please note

Page 10
The h eating elemen t humidifiers type HeaterLine 60-9 0 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
Notice the symbols affixed to the box.
3.4 Interim Storage
Store the unit in a dry place and protect against frost.
3.5 Check for Complete and Correct Delivery of
Goods
Upon receipt of the unit, confirm that:
•the type and serial number on the name plate match
those specified in the order and delivery documents
and
•the equipment is complete and all parts are in perfect
condition.
In case of damage during shipment or missing parts, immediately
file a written claim with your carrier or supplier.
Time limits for filing freight claims with shipping companies are*:
* Time limits for some services subject to change.
Transport Company After Receipt of Goods
Carriers no later than 4 days
Parcel Service immediately
Please note
Please note

Page 11
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.

Page 12
4. Functional description and device compo-
sition
4.1 Mode of operation
The Immersion Heater Principle
One to five heater elements (8) are placed in a closed cylinder
and co nnected to alternating cu rrent. The cylinder (9 ) is filled
with t ap wate r, fully d emineralized water or partially sof tened
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 h eavy-duty blow-down pump. See section "Se rvicing
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 Structure and operation of the device
By pre ssing th e co ntrol switch („Pos. I” ) the h umidifier will be
turned on.
When the hygrostat or controller signals a demand for h umidifi-
cation, the inlet solenoid valve (14) opens. The solenoid valve is
designed for pre ssures from 1 bar min ., 10bar ma x. / 14.7 p si
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 to o hig h, the ellbow act s as a
safety overflow for water drainage. If the water level is too low, it
could cause th e he ater elements (8) to overhea t. Th erefore,
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 cylinde r: "Dry Run", "Humidification "
and "Max. Level". The control capsule is pressure-equalized.

Page 13
At the standard setting, the inlet solenoid valve (14) opens when
the water level remains below “humidif ication” 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 mad e 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 sa fety. Th is mechanism provides a re dundant safety
system in the event of excessively low water levels (“Dry Run”).
The cylinder water is periodically flushed out with a hea vy-duty
blow-down pump (10 ). Hyg romatik’s SUPER FL USH system
effectively assist s this op eration. The SUPER FLUSH me cha-
nism g enerates a st rong whirlpool effect in th e straine r 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-condition ing duct s through special steam
hoses a nd steam ma nifolds. Under normal condition s, t his
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 cap sule / W ater 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 h eater ele-
ments

Page 14
Direct room humidification (without ducts) is performed using fan
units (with blower and n ozzle). T he st eam g enerator is con-
nected to the fan unit with steam and condensate hoses.
Steam lines in stea m bath cabins employ special steam hoses
and piping (if required). Accumu lated condensate is n ormally
routed into the steam cabin. At a relative humidity of 100%, the
supplied steam is used to heat the steam bath.
For maintena nce th e cylind er can be draine d by pre ssing the
control switch „Pos.II”.
4.3 Internal Output Setting
Continuous control of th e Heate rLine 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.

Page 15
5. Installation
Installation of this unit to be attempted only by qualifie d
personnel!
All safety notes a nd warnings p resent on the un it must be
obeyed.
Risk of electrical shock by hazardous voltage!
During installation the unit must be disconnected from the power
grid.
HygroMatik accepts no liability for damage due to faulty installa-
tion.
Attaching or inst alling add itional compo nents is permitted only
with the written conse nt of the manu facturer, or else the wa r-
ranty is void.
Prevent unit from dropping during installation!
Helping hand of a second person is advisable.
5.1 Steam Humidifier Operating Environment
When selectin g the inst allation site fo r the ste am humidifier ,
take the following in account:
•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.
Please note
Please note
Please note

Page 16
•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 c a r e
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 17
5.1.1 Fitting Measures
Wall Distance
When selecting the stea m humidifier set-up location, make use
of existing connections (supply water and drain), if possible.
Wall Mounting
For proper functioning of the steam generator the plumb-vertical
installation is mandatory
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 th e equipment is inst alled on
brackets which can be embedded in the floor.
> 300mm/
> 500mm/
> 200mm/
> 50mm/
Please note
B
B
Please note

Page 18
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 19
5.2 Fan Units (options)
The fan units should be positioned in a way that avoids drafts. In
general, a minimum height of 6 ft 7 in (2 m) above floor is suffi-
cient. Install the fan units directly on a wall.
Risk of skin burning!
During operation and for some time afterwards the steam noz-
zles are hot!
Do not touch.
During operation hot steam discharges from the nozzle.
Avoid any contact in the field of the visible steam cloud.
Rotating parts!
During operation the cross-flow fan rotates.
Do not touch.
Do not introduce any matter through the fan grid.
5.2.1 Fan Units Type VG
•Install the fan units over the steam humidifier
•When employing multiple fan units, do not exceed a
maximum distance of 5 m from the steam humidifier
•Observe the clearances specified in the figs.
Technical specifications for fan units
Fan Unit VG08 VG17 VG30
Quantity of Steam [lb/h /kg/h] 17.6/8 37.5/17 66/30
Steam Inlet [In/mmφ] 0.98/25 0.98/25 1.57/40
Condensate Outlet [in/mmφ] 0.47/12 0.47/12 0.47/12
Airflow Capacity [ft3/hr /
cbm/h]
5297/
150
6533/
185
12360/
350
Nominal Output [W] 26 35 67
Nominal voltage [V] 230 230 230
Dimensions W [in/mm] 17.4/441 20/507 21.7/550
H [in/mm] 6.7/171 6.7/171 6.7/171
D [in/mm] 7.1/180 9.3/237 11/277
Weight [lb/kg] 7.9/3.6 13.2/6 15.4/7
Sound Level (3 f t 3.37
in/1m dist ance to the
source of noise)
[dB(A)] 52 54 57
Please note
Unit Type Fan Units
HL 6 VG 08
HL 9 VG 17
HL 18 - 30 VG 30
HL 36, 45, 60 2 x VG 30
HL 70, 80, 90 4 x VG 30
11.8/300 mm
minimum
39.4 in/
1000 mm
39.4 in/
1000 mm
Steam
approx. 0.8 in/20 mm 9.8 ft/3.0 m minimum
Front View Wall Installation
Side View Wall Installation

Page 20
5.3 Absorption Distance BN
The "ab sorption distance" (B N) is defined as th e distance from
the steam feed to where the steam is completely absorbed in the
treated air. W ithin the ab sorption d istance, steam is visible as
mist in the air stream.
Condensation ma y occur o n anythin g inst alled within the
absorption distance.
Although st eam outside th e absorptio n dist ance (B N) is com-
pletely absorbed, it is not yet evenly diffused in the duct. If you
plan to inst all a ny p arts or device s in side the a bsorption dis-
tance, such a s sensors or elbows, we recommend increasing
the absorption distance using the formulae below. The absorp-
tion dist ances required for certain in stalled fittings are distin-
guished by separate symbols a nd calcula ted a s a multiplier of
the absorption distance BN.
The absorptio n dist ance has no fixe d value, but depe nds on
many factors. T hese are dep icted in th e absorptio n dist ance
nomogram below.
5.3.1 Determining the Absorption Distance
To determine the absorption distance, the following parameters
are required:
•Air humidity before humidification x1 in g/kg.
•Air temperature after humidification t2 in °C (with steam
humidifiers the change in air temperature due to humid-
ification may be disregarded t1 or 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 wL in m/s in air duct
•Total length lD of the steam manifold installed in the air
duct
Absorption Distance
BNfor normal obstructions, such as se n-
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