HygroMatik HeaterLine Series User manual

Electric Heater Steam Humidifier
ÁHL.CSAKÈ
HL.CSA
E-8881708
IMPORTANT: READ AND SAVE
THESE INSTRUCTIONS
Manual

Page 2
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the work(s)").
©Copyright HygroMatik GmbH
HeaterLine CSA [01.02.2017]
Current version of this manual can be found at: www.hygromatik.de/us
All rights reserved.
HygroMatik GmbH grants the legal user of this product [or device] the right to use the work(s)
solely within the scope of the legitimate operation of the product [or device]. No other right is
granted under this licence. In particular and without prejudice to the generality of the foregoing,
the work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in part
or in any manner or form other than as expressly granted here without the prior written consent of
HygroMatik GmbH.
Information in this manual is subject to change or alteration without prior notice.
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. Disconnect power supply prior to work start

Page 3
1. Introduction ....................................................................................................................5
1.1 Typographic Distinctions ................................................................................................5
1.2 Documentation ...............................................................................................................5
1.3 Symbols in Use ..............................................................................................................6
1.3.1 Specific Symbols related to Safety Instructions ..........................................................6
1.4 Intended Use ..................................................................................................................6
2. Safety Instructions .........................................................................................................8
2.1 Guidelines for Safe Operation ........................................................................................8
2.1.1 General ........................................................................................................................8
2.1.2 Unit control ..................................................................................................................8
2.1.3 Unit operation ..............................................................................................................8
2.1.4 Mounting, maintenance, repair and dismantling of the unit .........................................9
2.1.5 Electrical ......................................................................................................................9
3. Transport .........................................................................................................................10
3.1 Overview ........................................................................................................................10
3.2 Transport Size and Weigth .............................................................................................10
3.3 Packing ...........................................................................................................................11
3.4 Interim Storage ...............................................................................................................11
3.5 Check for Complete and Correct Delivery of Goods ......................................................11
3.6 Included in the Delivery ..................................................................................................12
4. Functional description and device composition .........................................................13
4.1 Mode of operation ..........................................................................................................13
4.2 Structure and operation of the device ............................................................................13
4.3 Internal Output Setting ...................................................................................................15
5. Installation ......................................................................................................................16
5.1 Environment Parameters to be met and Mounting Recommendations ..........................16
5.1.1 Fitting Measures ..........................................................................................................18
5.1.2 Equipment Dimensions HL 06-45 ................................................................................19
5.2 Fan Units (options) .........................................................................................................20
5.2.1 Fan Units Type VG ......................................................................................................20
5.3 Absorption Distance BN .................................................................................................21
5.3.1 Determining the Absorption Distance ..........................................................................21
5.3.2 Absorption Distance Nomogram .................................................................................23
5.4 Steam Manifold ..............................................................................................................24
5.4.1 Guidelines for Installation ............................................................................................24
5.4.2 Recommendations for dimensioning ...........................................................................25
5.5 Steam line and condensate hose layout .......................................................................29
5.5.1 Guidelines for steam line design ................................................................................29
5.5.2 Condensate hose layout ..............................................................................................30
5.5.3 Steam line and condensate hose installation types ....................................................30
5.6 Chimney compartment ..................................................................................................33

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5.7 Unit Installation Check ....................................................................................................33
6. Water Installation ...........................................................................................................34
6.1 Water Quality ..................................................................................................................35
6.2 Water Supply (when unit is operated with demineralized water or purified condensate) 36
6.3 Water Supply (when unit is operated with tap water or partially/fully softened water) ...37
6.3.1 Steam Humidifier Feed from Holding Tank .................................................................39
6.4 Water Treatment ............................................................................................................39
6.5 Water Discharge .............................................................................................................40
6.6 Water Installation Checklist ............................................................................................41
7. Electrical Installation .....................................................................................................42
7.1 Electrical Installation .......................................................................................................42
7.2 Cable Connections .........................................................................................................44
7.3 Safety Interlock ...............................................................................................................44
7.4 Wiring Diagram ...............................................................................................................45
7.5 Electrical Installation Checklist .......................................................................................45
8. Commissioning ..............................................................................................................46
9. Maintenance ....................................................................................................................47
9.1 Maintenance for Operation with Demineralized Water / Condensate ............................48
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 ................................................................................................52
9.6 Cleaning connection hoses, cylinder base and nozzle ...................................................53
9.7 Replacing Heater Elements ............................................................................................53
9.8 Replacing Thermo Sensor (for Heater Element) ............................................................54
9.9 Replacing the Heater Element Sealing ..........................................................................56
9.10 Cleaning the Control Cylinder ......................................................................................56
9.11 Unlocking of a Released Thermo Sensor (for a heater element) .................................57
9.12 Unlocking of a Released Thermo Sensor (for a Solid State Relay) .............................57
9.13 Unlocking of a Released Thermo Sensor (cylinder cover) ...........................................57
9.14 Cleaning Blow-Down Pump ..........................................................................................58
9.15 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ...................................59
9.16 Checking Cable Screw Connections, Heater Element Wires .......................................61
9.17 Operational Check ........................................................................................................61
10. Dismantling ...................................................................................................................62
11. CSA Certificate of Compliance ...................................................................................63
12. Spare Parts ...................................................................................................................65
13. Fax Form - Order for spare parts ................................................................................70
14. Exploded View ..............................................................................................................71
15. View of Cabinet .............................................................................................................72
16. Technical Specifications .............................................................................................73

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
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.

Page 6
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.
1.4 Intended Use
HygroMatik steam humidifiers serve for steam production using
different tap water qualities or partial softened water (all humidi-
fier types) or fully demineralized water/cleaned condensate
(heater element humidifiers only).
Proper usage also comprises the adherence to the conditions
specified by HygroMatik for:
• installation
• dismantling
• reassembly
• commissioning
• operation
• maintenance
• disposal.

Page 7
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 Main-
tenance Instructions 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 Instructions at the unit‘s operational location
(or near the unit).
By construction, HygroMatik steam humidifiers are not qua-
lified for exterior application.
Risk of scalding!
Steam with a temperature of up to 212 °F is produced.
Do not inhalate steam directly in order to avoid respiratory
damage!

Page 8
2. Safety Instructions
These safety instructions are required by law. They promote
workplace safety and accident prevention.
2.1 Guidelines for Safe Operation
2.1.1 General
Comply with the accident prevention regulation „DGUV Regula-
tion 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 notes and warnings present on the unit.
In case of a malfunction or electrical power supply disruption,
switch off the unit immediately and prevent from restart. Repair
malfunctions promptly.
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 not play with
the unit.
2.1.3 Unit operation
Risk of scalding!
In case of leaking or defective components, hot steam may exit
in an uncontrolled manner.
Switch off unit immediately.
Risk of material damage!
The unit may be damaged if switched on repeatedly following a
malfunction without prior repair.
Rectify defects in return!
• The unit must not be operated on a DC power supply
• The unit may only be used connected to a steam pipe that
safely transports the steam (not valid device type Mini-
Steam)

Page 9
• Regularly check that all safety and monitoring devices are
functioning normally
• Do not remove or disable safety devices
2.1.4 Mounting, maintenance, repair and dismantling
of the unit
The HygroMatik steam humidifier is IP20 protected. Make sure
that the unit is not object to dripping water in the mounting loca-
tion.
When installation is made in a room without a drain, safety pre-
cautions must be taken in order for to shut off the humidifier‘s
water supply in event of a leak.
• Use genuine spare parts only
• After any repair work, have qualified personnel check the
safe operation of the unit
• Attaching or installing of additional components is per-
mitted only with the written consent of the manufacturer
• The operator is responsible for the disposal of unit compo-
nents as required by law
2.1.5 Electrical
Risk of electrical shock!
Hazardous electrical high voltage!
Any work on the electrical system must only be performed by
qualified personnel.
Disconnect unit components from electrical power supply prior
to work.
After electrical installation or repair work, test all safety mecha-
nisms (such as grounding resistance).
Only use 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.
Responsibility for intrinsically safe installation of the HygroMatik
steam humififiers (steam generators) is incumbent on the instal-
ling specialist company.

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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

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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
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 12
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 13
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 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 Structure and operation of the device
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. 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
float switches indicate the water level in the steam cylinder: "Dry
Run", "Humidification" and "Max. Level".

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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. During this procedure, steam
production is interrupted for a few minutes.
For maintenance the cylinder can be drained by pressing the
control switch „Pos.II”.
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 15
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.

Page 16
5. Installation
General risk of personal injury!
Personnel not familiar with professional installation methods
may sustain physical damage.
Installation of this unit to be accomplished only by qualified per-
sonnel (persons with completed training in the plumbing field
and in the field of electrical installation work, respectively)!
Risk of electrical shock!
Hazardous electrical high voltage!
Unit must be disconnected from electrical power supply during
installation.
Risk of foot injuries!
Unit may drop during mounting involving a single person.
Helping hand of a second person is required.
HygroMatik accepts no liability for damage due to faulty installa-
tion.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer, or else the war-
ranty is void.
5.1 Environment Parameters to be met and
Mounting Recommendations
When selecting the installation site for the steam humidifier, take
the following into account:
• The minimum clearances indicated in the fitting measures
section must be observed in order to ensure adequate unit
ventilation and allow for unobstructed access in case of
maintenance
• Protection class IP20
• By design, HygroMatik steam humidifiers are not qualified
for outdoor installation (electronical components and
water-bearing parts may be damaged)
Please note
Please note

Page 17
• Ambient temperature must lie between +41 and +104 °F in
order to protect the unit electronics against damage; frost
may damage the steam cylinder
• Relative humidity must not exceed 80 % r.h., since values
beyond may lead to electronic malfunction or damage
• Installation in a closed room requires aeration and, even-
tually, temperature conditioning in order to meet the a.m.
environmental conditions
• The steam humidifier should be installed as close as pos-
sible to the steam manifold. Optimum performance is only
guaranteed when steam and condensate hoses are kept
short
• Make use of existing water connections for supply and
draining
• Hoses must be laid at a consistent 5 to 10 % incline/
decline in order to definitely prevent sagging and kinking
• Mount the unit on a stable, preferably solid wall offering
the bearing capacity required (s. unit technical specificati-
ons). If such a wall is not at hand, the unit may be attached
to a stand bracket firmly bolted to the floor
• Mounting the unit must be perpendicularly aligned in both
the vertical and horizontal axis (plumb and level) in order
to achieve uniform immersed surface areas for the electro-
des
• The steam humidifier rear panel heats up during operation
(to a maximum of 158 °F). Take care that the construction
on which the unit is to be mounted is not made of tempera-
ture-sensitive material

Page 18
5.1.1 Fitting Measures
Wall Distance
When determining the steam humidifier positioning, 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 the equipment is installed on
brackets which can be embedded in the floor.
> 300mm/
> 500mm/
> 200mm/
> 50mm/
Please note
B
B
Please note

Page 19
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 20
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 or scalding!
During operation and for at least 10 mins afterwards the steam
nozzles are hot. Do not touch!
During operation hot steam discharges from the nozzles.
Avoid any contact in the field of the visible steam cloud.
Due to improper installation or contamination hot water may drip
from the nozzles. Do not reside in the area directly under the
nozzles.
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] 0.55/14 0.47/12 0.47/12
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 ft 3.37
in/1m distance 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