HygroMatik HyLine User manual

Electrode Steam HumidifierElectrode Steam Humidifier
ÁHYL.CSA9È
HYL.CSA
IMPORTANT: READ AND SAVE
THESE INSTRUCTIONS
Manual

Page 2
A Word about Water Quality
The mode of operation of all electrode steam humidifiers is based on the fact that water contains
minerals and is therefore conductive.
• "normal" tap water is ideal.
• but what is "normal" tap water exactly?
Users of HygroMatik units in the most diverse areas consider their tap water "normal."
HygroMatik typically defines "normal" as feed water with a conductivity between 200 and 500 µS/
cm (microSiemens per centimeter) at 15°C/59°F.
Some areas, however, are supplied with tap water whose quality is outside the parameters spec-
ified by HygroMatik. If the HygroMatik steam humidifier's control is not adjusted correctly in these
areas, the unit cannot perform optimally. For example, the electrodes could wear out particularly
quickly or the steam production could be too low.
The operational parameters set by HygroMatik in the factory are intended for normal tap water.
However, they can very easily be repro grammed to fit the sp ecial requirements of a p articular
area. In addition, it is possible to install a plastic star in the cylinder in o rder to increase the life
span of the electrodes or to provide a flushing mechanism to extend maintenance intervals.
Because of this you should monitor your n ew unit during initial operation. Make sure that it has
been properly installed and is operating to your satisfaction.
Consult your HygroMatik specialists. We will test the quality of your wat er and advise yo u on
installation and initial operation. Your HygroMatik steam humidifier will be carefully ad apted to
your particular application.
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 HyLine, 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 Directions for Use .............................................................................................................. 5
1.2 Typographic Distinctions ...................................................................................................6
1.3 Documentation .................................................................................................................. 7
2. Safety Instructions ............................................................................................................ 8
2.1 Overview ........................................................................................................................... 8
2.2 Guidelines for Safe Operation ........................................................................................... 8
2.3 Disposal after Dismantling .................................................................................................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 ......................................................................................................................... 15
5.1 Steam Humidifier Operating Environment ......................................................................... 15
5.1.1 Fitting measures ............................................................................................................. 17
5.1.2 Unit Dimensions HY05-HY45 ......................................................................................... 19
5.1.3 Unit Dimensions HY60-HY116 ....................................................................................... 21
5.2 Fan Units (Options) ........................................................................................................... 23
5.2.1 Fan Unit Type VG ........................................................................................................... 23
5.2.2 Fan Unit Cover ............................................................................................................... 24
5.3 Absorption Distance BN .................................................................................................... 25
5.3.1 Determining the Absorption Distance ............................................................................. 25
5.3.2 Absorption Distance Nomogram .................................................................................... 27
5.4 Steam Manifold ................................................................................................................. 28
5.4.1 Notes on Installation ....................................................................................................... 28
5.5 Steam Line ........................................................................................................................ 32
5.6 Cover Plate ........................................................................................................................ 33
5.7 Drill Pattern ........................................................................................................................ 35
5.8 Condensate Hose .............................................................................................................. 37
5.9 Types of Installation .......................................................................................................... 37
5.10 Steam Solenoid Valves ................................................................................................... 39
5.11 Unit Installation Check ..................................................................................................... 39
6. Water Installation .............................................................................................................. 40
6.1 Operation with Softened Water ......................................................................................... 40
6.2 Water Supply ..................................................................................................................... 42

Page 4
6.3 Water discharge ................................................................................................................ 43
6.4 Water Installation Check ...................................................................................................44
7. Electrical Connection ........................................................................................................ 45
7.1 Electrical Installation .......................................................................................................... 45
7.2 Cable Connections ............................................................................................................ 47
7.3 Safety Interlock .................................................................................................................. 48
7.4 Wiring Diagram .................................................................................................................. 48
7.5 Electrical Installation Checklist ..........................................................................................48
8. Commissioning ................................................................................................................. 50
9. Maintenance ....................................................................................................................... 52
9.1 Maintenance Work ............................................................................................................ 53
9.2 Access Electrical Enclosure .............................................................................................. 54
9.3 Removing and Cleaning the Steam Cylinder .................................................................... 54
9.4 Electrode wear .................................................................................................................. 60
9.4.1 Original Electrode Lengths ............................................................................................. 61
9.4.2 Uneven Electrode Lengths ............................................................................................. 61
9.5 Replacing Electrodes ........................................................................................................ 62
9.6 Cleaning the Blow- down pump ......................................................................................... 63
9.7 Cleaning the Water Inlet Solenoid Valve ........................................................................... 64
9.8 Checking Cable Connections and Electrode Cables ......................................................... 64
9.9 Checking Hoses ................................................................................................................ 65
9.10 Checking Operation ......................................................................................................... 65
9.11 Dismantling ...................................................................................................................... 65
10. CSA Certificate of Compliance ...................................................................................... 66
11. Spare Parts ...................................................................................................................... 69
12. Fax Form - Order for spare parts ................................................................................... 78
13. Exploded View ................................................................................................................. 79
14. View of housing ............................................................................................................... 80
15. Technical Specification .................................................................................................. 81

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
They will impress you with their safety, ease of use and econom-
ical operation.
In order to op erate your HygroMatik stea m humidifier safely ,
properly 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 Directions for Use
The HygroMatik steam humidif ier is int ended for ste am produc-
tion.
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, authorized personnel may operate or service the
unit. Workers who transport or service the unit must have read
and unde rstood the relevant section s of the operating instruc-
tions, especially the section "Safety Notes." In addition, staff
must receive sa fety training about poten tial hazards from the
operator. Place a copy of the operating instructions at the loca-
tion where the unit is operated.

Page 6
Use feed water with a conductivity between 125 and 1250 µS/
cm only
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
Hot Steam!
Do not inhalate!
HygroMatik steam humidifiers emit steam with a temperature of
100°C/212°F. The steam may not be inhaled directly.
The Hygro Matik Steam Humidifier is not design ed for out door
installation.
1.2 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..

Page 7
1.3 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 inte rested, plea se cont act HygroMa tik o r your HygroMa tik
dealer.

Page 8
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 not 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 9
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 proper electrical installation
or repair, test all safety mechanisms (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 resp onsible for the disposal of unit co mponents
as required by law.

Page 10
3. Transport
3.1 Overview
Proceed ca refully when tra nsporting the steam hu midifier in
order to prevent d amage 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 dama ge during shipmen t or missing p arts, 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
The Hygro Matik steam humidifier utilizes th e con ductivity nor-
mally pre sent in t ap water for steam production . Electr odes
inside an enclosed steam cylinder are immersed directly into the
tap water. They are connected to the alternating current.
The conductivity of th e water generates a n electric current
between the electrodes. In this way, the electric power supplied
is converted directly into heat without energy loss.
The ampera ge is a function of the ava ilable volt age, the
immersed electrode surface area, the average distance between
the electrodes and the water conductivity. The steam output of
the humidifier is dete rmined by electric power usage, which is
regulated by in creasing or dec reasing the immer sed su rface
area of the electrodes.
Concurrently, a se lf-regulating control keeps conductivity within
a specified range.
The steam produced has a temperature of about 100°C/212 °F
with min imal excess pressure ("pressureless st eam"). It is
largely free of minerals and germ-free. Mineral deposits typically
remain behind in the cylinder.
4.2 Structure and operation of the device
By pressing the control switch („Pos. I”) the humidifier is turned
on. When the co ntroller specifies an increase in humidity, the
main contactor is switched on and th e electrodes (48) a re sup-
plied with power. The water inlet solenoid valve (25) feeds water
into the steam cylinder (16+19).
As soon as the electrodes are immersed, t he current b egins to
flow. The water is now h eated. When the pre-selected output is
reached, the control turns off the solen oid valve and interrupts
the water supply.
After a sho rt heating up period, the water betwee n the elec-
trodes begins to b oil and vaporize. The vaporization lo wers the
water level in the steam cylinder, reducing the outp ut 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 nomina l cu rrent increa ses to 125 % in order to
achieve qu ick-start output parameters. This activates th e e lec-
tronic overflow limiter which ca uses a partial draining of the cyl-
inder. This reduces the immersed surface area of the electrodes,
lowering power usage.

Page 13
Please also see Section „Exploded View“.
Location Designation
1 adapter
6 vent pipe
10 max. water level sensor electrode
14 water drain, discharge
16 top part of steam cylinder
17 o-ring cylinder flange
18 cylinder flange and o-ring
19 lower part of cylinder
25 solenoid valve water inlet
32 blow-down pump
35 o-ring
37 cylinder base
48 electrodes

Page 14
The concentration of dissolved sa lts increases over time, which
can lead to a rise in the co nductivity of th e water. If this co ntin-
ues, conductivity may increase until a short circuit occurs. This
could dama ge the unit, but in any case wo uld significan tly
reduce the life span of the electrodes.
For this reason, re gular, perio dic blow-do wns of some of the
concentrated water are very important. Following this procedure
as recommended provides stable cylinder water condu ctivity as
well as minimal water loss for the expected service life of the cyl-
inder.
Water blow-down is performed by a blow-down pump (32). The
functioning of the blow-down pump is contin uously monitored
during operation. If the p ump is damaged, the steam humidifier
shuts down.
With normal water quality, th e blow-down loss r ate is between
7% and 15% of the amount of steam produced. The steam cylin-
der requires co mplete drainage ev ery 3-8 da ys, regardless of
the water quality.
Mineral dep osits settle in the open area belo w the electrodes
and are removed through periodic maintenance. The blow-down
pump itself has wide op enings and can flush out smaller pieces
of mineral deposit. This exte nds the service life of the unit and
reduces the required maintenance interval.
During blow-downs, water flows from the pump into the drainage
system.
A sensor electrode (10) monitors the ma ximum water capacity
of the cylinder. Whe n the wate r level re aches the sensor elec-
trode, the water supply is interrupted. This can occur whe n the
water has low conductivity or when the electrodes are worn out.
In the case of low water conductivity, however, this state usually
lasts only a sh ort time. The built-in control and the large area
electrodes combine to produce a rapid rise in con ductivity by
increasing the concentration of the water.
The steam cylinder consist s of a top ( 16) an d lo wer (19) p art
joined with a cylinder flange. The seal between the cylinder and
cylinder base (37), as well as between the top and lower part of
the cylinder, is maintained using an o-ring (35+17).
For maintena nce th e cylind er can be draine d by pre ssing the
control switch „Pos.II”.

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 are
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
Clearances
When choosing the site f or the st eam 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 18
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 suit able wall is p resent, we recommend construction of a
free-standing console anchored to the floor.

Page 19
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 20
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