HygroMatik HyLine Series User manual

Electrode Steam HumidifierElectrode Steam Humidifier
ÁHYL.CSA9È
HYL.CSA
E-8881700
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
HyLine CSA [16.02.2017]
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 con-
sent 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
1.3.2 General Symbols ............................................................................................................ 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 Carton outer Size and Weight ........................................................................................... 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 ..................................................................................................... 11
4. Functional description and device composition ............................................................ 12
4.1 Mode of Operation ............................................................................................................. 12
4.2 Structure and operation of the device ............................................................................... 12
5. Installation ......................................................................................................................... 13
5.1 Environment Parameters to be met and Mounting Recommendations ............................. 13
5.1.1 Fitting measures ............................................................................................................. 15
5.1.2 Unit Dimensions HY05-HY45 ......................................................................................... 17
5.1.3 Unit Dimensions HY60-HY116 ....................................................................................... 19
5.2 Fan Units (Options) ........................................................................................................... 21
5.2.1 Fan Unit Type VG ........................................................................................................... 21
5.2.2 Fan Unit Cover ............................................................................................................... 22
5.3 Absorption Distance BN .................................................................................................... 23
5.3.1 Determining the Absorption Distance ............................................................................. 23
5.3.2 Absorption Distance Nomogram .................................................................................... 25
5.4 Steam Manifold ................................................................................................................. 26
5.4.1 Guidelines for Installation ............................................................................................... 26
5.4.2 Recommendations for dimensioning .............................................................................. 27
5.5 Steam line and condensate hose layout .......................................................................... 31
5.5.1 Guidelines for steam line design ................................................................................... 31
5.5.2 Condensate hose layout ................................................................................................. 32
5.5.3 Steam line and condensate hose installation types ....................................................... 32

Page 4
5.6 Unit Installation Check ....................................................................................................... 35
6. Water Installation .............................................................................................................. 36
6.1 Operation with Softened Water ......................................................................................... 37
6.2 Water Supply ..................................................................................................................... 38
6.3 Water discharge ................................................................................................................ 39
6.4 HyFlow Provision (Special order unit types) ...................................................................... 40
6.5 Water Installation Checklist ...............................................................................................41
7. Electrical Connection ........................................................................................................ 42
7.1 Electrical Installation .......................................................................................................... 42
7.2 Cable Connections ............................................................................................................ 44
7.3 Safety Interlock .................................................................................................................. 45
7.4 Wiring Diagram .................................................................................................................. 45
7.5 Electrical Installation Checklist ..........................................................................................45
8. Commissioning ................................................................................................................. 47
9. Maintenance ....................................................................................................................... 48
9.1 Maintenance Work ............................................................................................................ 49
9.2 Access to Electrical Enclosure .......................................................................................... 50
9.3 Removing and Cleaning the Steam Cylinder .................................................................... 50
9.4 Electrode wear .................................................................................................................. 57
9.4.1 Original Electrode Lengths ............................................................................................. 57
9.4.2 Uneven Electrode Lengths ............................................................................................. 58
9.5 Replacing Electrodes ........................................................................................................ 58
9.6 Cleaning the blow- down pump ......................................................................................... 60
9.7 Cleaning the Water Inlet Solenoid Valve ........................................................................... 60
9.8 Cleaning the Water Inlet Solenoid Valve and HyFlow System Separator (special models only)
61
9.9 Checking Cable Connections and Electrode Cables ......................................................... 62
9.10 Checking Hoses .............................................................................................................. 63
9.11 Checking Operation ......................................................................................................... 63
10. Dismantling ...................................................................................................................... 64
11. CSA Certificate of Compliance ...................................................................................... 65
12. Spare Parts ...................................................................................................................... 68
13. Fax Form - Order for spare parts ................................................................................... 77
14. Exploded View ................................................................................................................. 79
15. View of housing ............................................................................................................... 80
16. Technical Specification .................................................................................................. 81

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 your expert dealer.

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.
1.3.2 General Symbols
This symbol is used whenever a situation requires special atten-
tion beyond the scope of safety instructions.
1.4 Intended Use
The HygroMatik steamgenerator serves for steam production
based on various water qualities or partially softened water
(valid for all of the HygroMatik humidifier models). With the Hea-
terLine, HeaterCompact/Kit and HeaterSlim familiy of products,
also fully desalinated water/cleaned condensate may be used.
Only use supply water featuring a conductivity of 125 to
1250 µS/cm.
Please note

Page 7
D1: Lower threshold
C1: Range of reduced conductivity (adjustments recommended)
A: Normal tap water
B: Range of heightened conductivity
C2: Range of high conductivity (adjustments recommended)
D2: Upper threshold
Proper usage also comprises the adherence to the conditions
specified by HygroMatik for:
• installation
• dismantling
• reassembly
• commissioning
• operation
• maintenance
• disposal.
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.

Page 10
3. Transport
3.1 Overview
Proceed carefully when transporting the steam humidifier in
order to prevent damage due to stress or careless loading and
unloading.
3.2 Carton outer Size and Weight
HyLine:
CompactLine:
MiniSteam:
* Dimensions and weights may vary slightly.
Type* Height
[cm]/[inch]
Width
[cm]/[inch]
Depth
[cm]/[inch]
Weight
[kg]/[lbs]
HY05- 08 58/22.8 56/22.0 32/12.6 16/35.3
HY13- 17 75/29.5 63/24.8 37/15.6 24/52.9
HY23 75/29.5 63/24.8 37/15.6 25/55.1
HY30 81/31.9 67/26.4 41/16.1 33/72.8
HY45 88/34.6 76/29.9 48/18.9 46/101.4
HY60 80/31.5 104/40.9 41/16.1 54/119.0
HY90- 116 90/35.4 117/46.1 48/18.9 77/169.8
Type* Height
[cm]/[inch]
Width [cm]/
[inch]
Depth [cm/
[inch]]
Weight [kg]
C01 46/18.1 45/17.7 26/10.2 11/24.3
C02 48/18.9 44/17.3 31/12.2 12/26.5
C06 52/20.4 50/19.7 28/11.0 13/28.7
C10 58/22.8 51/20.1 31/12.2 14/30.9
C17 75/29.5 54/21.3 37/14.6 22/48.5
C22 75/29.5 54/21.3 37/14.6 22/48.5
C30 75/29.5 58/22.8 37/14.6 23/50.7
C45 81/33.1 63/24.8 41/16.1 25/55.1
C58 90/35.4 72/28.3 48/18.2 36/79.4
Type*
*
Height
[cm]/[inch]
Width [cm]/
[inch]
Depth [cm]/
[inch]
Weight[kg]
MS 5 59/23.2 48/18.9 28/11.0 13/28.7
MS 10 68/26.8 51/20.1 31/12.2 15/33.1
Please note

Page 11
3.3 Packing
Notice the symbols affixed to the packing 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, immedi-
ately notify the carrier or supplier in writing.
Time limits for filing freight claims with shipping companies are*:
* Time limits for some services subject to change.
3.6 Included in the Delivery
The delivery includes:
•Unit of the selected humidifier type including selected
control.
•Water installation hose 0,6m/23.6inch, 3/4".
•Mounting set with anchors and screws. For HyLine
types HY45 to HY116, extra mounting bar.
•Operating Instructions for the unit and the control.
•Ordered accessories (steam manifold, steam hose,
condensate hose, etc.).
•Maintenance o-ring set for steam cylinder.
Shipping Companies After Receipt of Goods
Carriers no later than 4 days
Parcel Service immediately
Please note
Please note

Page 12
4. Functional description and device compo-
sition
4.1 Mode of Operation
Electrodes through which electrical current flows heat conduc-
tive water in a cylinder to create unpressurized, hygienic steam.
Electrode steam humidifiers are suitable for use with normal tap
water, as this is normally conductive.
The steam produced has a temperature of about 100°C/212°F
with minimal excess pressure ("pressureless steam"). It is
largely free of minerals and germ-free.
4.2 Structure and operation of the device
By pressing the control switch („Pos. I”) the humidifier is turned
on. When the controller specifies an increase in humidity, the
main contactor is switched on and the electrodes ((48) number
in paranthesis refers to exploded view fig.) are supplied with
power. The water inlet solenoid valve (25) feeds water into the
steam cylinder (16+19).
As soon as the electrodes are immersed, the current begins to
flow. The water is now heated. When the pre-selected output is
reached, the control turns off the solenoid valve and interrupts
the water supply.
After a short heating up period, the water between the elec-
trodes begins to boil and vaporize. The vaporization lowers the
water level in the steam cylinder, reducing the output provided.
The inlet solenoid valve, equipped with a fine mesh filter, inter-
mittently admits fresh water.
Humidifier power usage is continuously monitored. With a cold
start-up, the nominal current increases to 125% in order to
achieve quick-start output parameters.
The concentration of dissolved salts increases over time, which
can lead to a rise in the conductivity of the water. For this rea-
son, regular, periodic blow-downs of some of the concentrated
water are very important.
Water blow-down is performed by a blow-down pump (32).
With normal water quality, the blow-down loss rate is between
7% and 15% of the amount of steam produced. The steam cylin-
der requires complete drainage every 3-8 days, regardless of
the water quality.
During blow-downs, water flows from the pump into the drainage
system.
A sensor electrode (10) monitors the maximum
water capacity
of the cylinder. When the water level reaches the sensor elec-
trode, the water supply is interrupted.

Page 13
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 14
• 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 15
5.1.1 Fitting measures
Clearances
When choosing the site for the steam humidifier, consider the
location of existing water installations (feed and drain lines).
Mounting Fixtures (for HY45 to HY116)
The unit should be mounted on a stable wall.
To achieve a uniform immersed surface area for the electrodes,
the humidifier must be installed plumb and level.
> 300mm/
> 500mm/
> 200mm/
> 50mm/
Please note
Please note

Page 16
to Install Units Type HY05- HY30:
» Place the steam humidifier in its intended location, use
a level to adjust position, and secure. See chapter "Unit
Dimensions".
» Attach the unit to the lower mounting fixtures.
to Install Units HY45- HY116:
» Fix bracket at the intended location. See chapter "Unit
Dimensions".
» Mount the unit, adjust position using a level, and screw
tightly into the mounting fixtures.
» Attach the unit to the lower mounting fixtures.
If no suitable wall is present, we recommend construction of a
free-standing console anchored to the floor.

Page 17
5.1.2 Unit Dimensions HY05-HY45
Water inlet
Waste water connection
Cable entries
Steam outlet (1x/2x)
View from below
Rear view
View from top

Page 18
Type /
Dimensions
[mm]/
[inch]
a b c d e f g h i j k1 k2 mn1 n2
HY05-HY08 480/
18.9
449/
17.7
251/
9.9
415/
16.3
438/
17.2
43/
1.7
35/
1.4
35/
1.4
120/
4.7
120/
4.7
103/
4.1
- 147/
5.8
65/
2.6
-
HY13-HY23 650/
25.6
522/
20.6
301/
11.9
486/
19.1
619/
24.4
63/
2.5
35/
1.4
38/
1.5
210/
8.3
152/
6.0
136/
5.4
- 184/
7.2
96/
3.8
-
HY30 708/
27.9
561/
22.1
344/
13.5
515/
22.3
665/
26.2
58/
2.3
50/
2.0
38/
1.5
250/
9.8
172/
6.8
156/
6.1
- 197/
7.8
106/
4.2
-
HY45 788/
31.0
654/
25.7
405/
16.0
588/
23.2
742/
29.2
68/
2.7
50/
2.0
48/
1.9
300/
11.8
209/
8.2
200/
7.9
330/
13.0
227/
9.0
153/
6.0
283/
11.1

Page 19
5.1.3 Unit Dimensions HY60-HY116
c
g1
i1
g2
i2
h
f
d4 d2 d1 d3
b
j
m
n1
k1
n2
k2
n3
k3
n4
k4
e
a
Water inlet (2x)
Waste water connection
(2x)
Cable entries
Steam outlet (2x/4x)

Page 20
Type / Dims.
[mm]/
[inch] a b c d1 d2 d3 d4 e f g1 g2 hi1 i2 j
HY60 709/
27.9
927/
36.5
333/
13.1
327/
12.9
371/
14.6
95/
3.7
133/
5.2
680/
26.8
67/
2.6
46/
1.8
368/
14.5
50/
2.0
195/
7.7
525/
20.7
186/
7.3.
HY90-HY116 788/
31.0
1061
41.8
403/
15.9
398/
15.7
398/
15.7
132/
5.2
132/
5.2
758/
29.8
67/
2.6
35/
1.4
432/
17.0
50/
2.0
238/
9.4
635/
25.0
220/
8.7
Type / Dims.
[mm]/
[inch] k1 k2 k3 k4 mn1 n2 n3 n4
HY60 157/
6.2
488/
19.2
- - 204/
8.0
110/
4.3
441/
17.4
--
HY90-HY116 199/
7.8
329/
13.0
597/
23.5
727/
28.6
324/
12.8
183/
7.2
216/
8.5
580/
22.8
613/
24.1
* HY60 only one steam outlet per zylinder