HygroMatik HyLine User manual

Electrode Steam HumidifierElectrode Steam Humidifier
ÁHYL.ENsÈ
HYL.EN
E-8881100
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.
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 reprogrammed to fit the special requirements of a particular
area. In addition, it is possible to install a plastic star in the cylinder in order 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 new 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 water and advise you on
installation and initial operation. Your HygroMatik steam humidifier will be carefully adapted to
your particular application.
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").
©Copyright HygroMatik GmbH
HyLine [03.07.2017]
Current version of this manual can be found at: www.hygromatik.co.uk
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.

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, dismantling, maintenance and repair of the unit ............................................ 9
2.2 Electrical ............................................................................................................................ 10
2.2.1 Disposal after dismantling ..............................................................................................10
3. Transport ............................................................................................................................ 11
3.1 Overview ........................................................................................................................... 11
3.2 Packing .............................................................................................................................. 11
3.3 Interim Storage .................................................................................................................. 11
3.4 Check for Complete and Correct Delivery of Goods ......................................................... 11
4. Operation and Installation ................................................................................................ 12
4.1 Mode of Operation ............................................................................................................. 12
4.2 Installation and Operation .................................................................................................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 ....................................................................................... 20
5.2 Fan Unit (optional) ............................................................................................................. 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 Notes on Installation ....................................................................................................... 26
5.5 Steam Line ........................................................................................................................ 30
5.6 Cover Plate ........................................................................................................................ 31
5.7 Condensate Hose .............................................................................................................. 32
5.8 Types of Installation .......................................................................................................... 32
5.9 Steam Solenoid Valves .....................................................................................................34
5.10 Unit Installation Check ..................................................................................................... 34

Page 4
6. Water Installation .............................................................................................................. 35
6.1 Operation with Softened Water ......................................................................................... 36
6.2 Water Supply ..................................................................................................................... 37
6.3 Water discharge ................................................................................................................ 38
6.4 HyFlow Provision (Special Model) ..................................................................................... 40
6.5 Water Installation Check ...................................................................................................41
7. Electrical Connection ........................................................................................................ 42
7.1 Electrical Installation .......................................................................................................... 42
7.2 Cable Connections ............................................................................................................ 45
7.3 Fan Unit ............................................................................................................................. 46
7.4 Safety Interlock .................................................................................................................. 47
7.5 Wiring Diagram .................................................................................................................. 47
7.6 Electrical Installation Checklist ..........................................................................................47
8. Commissioning ................................................................................................................. 48
9. Maintenance ....................................................................................................................... 50
9.1 Maintenance Work ............................................................................................................ 51
9.2 Access to Electrical Enclosure ..........................................................................................52
9.3 Removing and Cleaning the Steam Cylinder ....................................................................52
9.4 Electrode wear .................................................................................................................. 59
9.4.1 Original Electrode Lengths ............................................................................................. 59
9.4.2 Uneven Electrode Wear .................................................................................................60
9.5 Replacing Electrodes ........................................................................................................ 60
9.6 Cleaning the Blow- down pump ......................................................................................... 61
9.7 Cleaning the Water Inlet Solenoid Valve ........................................................................... 63
9.8 Cleaning the Water Inlet Solenoid Valve and HyFlow System Separator (special models only)
................................................................................................................................................. 64
9.9 Checking Cable Connections and Electrode Cables ......................................................... 65
9.10 Checking Hoses .............................................................................................................. 65
9.11 Checking Operation ......................................................................................................... 65
9.12 Dismantling ...................................................................................................................... 65
10. EC-Declaration of Conformity ........................................................................................ 66
11. Spare Parts ...................................................................................................................... 67
12. Fax Form - Order for spare parts ................................................................................... 72
13. Technical Specification .................................................................................................. 74
14. Exploded View ................................................................................................................. 76
15. View of housing ............................................................................................................... 77

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.
1.3.2 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 HeaterLine, 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
to1250 µS/cm.
Please note

Page 7
D1: Lower threshold
C1: Rangeofreducedconductivity(adjustmentsrecommended)
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 100 °C 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 ans 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 power grid disruption, switch off the
unit immediately and prevent a 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.
In case of malfunction or electrical power disruption, switch off
the unit immediately and prevent from restart.

Page 9
Risk of material damage!The unit may be damaged if switched
on repeatedly following a malfunction without prior repair.Rectify
defects immediately!
The unit must not be operated on a DC power supply.
The unit may only be used connected to a steam pipe that safely trans-
ports the steam (not valid device type MiniSteam).
Regularly check that all safety and monitoring devices are functioning
normally. Do not remove or disable safety devices.
2.1.4 Mounting, dismantling, maintenance and repair
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 permitted
only with the written consent of the manufacturer.

Page 10
2.2 Electrical
Risk of electrical shock!Hazardous electrical high voltage.Any
work on the electrical system may only be performed by quali-
fied personnel.Disconnect unit components from electrical
power supply prior to work.After electrical installation or repair
work, test all safety mechanisms (such as grounding resi-
stance).
Use only original fuses with the appropriate amperage
rating.Regularly check the unit‘s electrical equipment. Promptly
repair any damage such as loose connections or burned
wiring.Responsibility for intrinsically safe installation of the
HygroMatik steam humififiers (steam generators) is incumbent
on the installing specialist company.
2.2.1 Disposal after dismantling
The operator is responsible for the disposal of unit components
as required by law.

Page 11
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 Packing
Pay attention to the icons affixed to the packing box.
3.3 Interim Storage
Store the unit in a dry place and protect from frost.
3.4 Check for Complete and Correct Delivery of
Goods
Upon receipt of the unit, confirm that:
•model 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.
Shipping company After receipt of goods
Carriers no later than 4 days
Parcel service immediately
Please note
Please note
Please note

Page 12
4. Operation and Installation
4.1 Mode of Operation
The HygroMatik steam humidifier utilizes the conductivity nor-
mally present in tap water for steam production. Electrodes
inside an enclosed steam cylinder are immersed directly into the
tap water. They are connected to the alternating current.
The conductivity of the water generates an electric current
between the electrodes. In this way, the electric power supplied
is converted directly into heat without energy loss.
The amperage is a function of the available voltage, the
immersed electrode surface area, the average distance between
the electrodes and the water conductivity. The steam output of
the humidifier is determined by electric power usage, which is
regulated by increasing or decreasing the immersed surface
area of the electrodes.
Concurrently, a self-regulating control keeps conductivity within
a specified range.
The steam produced has a temperature of about 100°C with
minimal excess pressure ("pressureless steam"). It is largely
free of minerals and germ-free. Mineral deposits typically remain
behind in the cylinder.
4.2 Installation and Operation
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) are 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, 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. This activates the elec-
tronic overflow limiter which causes 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 steam cylinder
17 o-ring cylinder flange
18 cylinder flange and o-ring
25 solenoid valve water inlet
32 blow-down pump
35 o-ring
37 cylinder base
48 electrodes
48

Page 14
The concentration of dissolved salts increases over time, which
can lead to a rise in the conductivity of the water. If this contin-
ues, conductivity may increase until a short circuit occurs. This
could damage the unit, but in any case would significantly
reduce the life span of the electrodes.
For this reason, regular, periodic blow-downs of some of the
concentrated water are very important. Following this procedure
as recommended provides stable cylinder water conductivity 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 continuously monitored
during operation. If the pump is damaged, the steam humidifier
shuts down.
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.
Mineral deposits settle in the open area below the electrodes
and are removed through periodic maintenance. The blow-down
pump itself has wide openings and can flush out smaller pieces
of mineral deposit. This extends 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 maximum water capacity
of the cylinder. When the water level reaches the sensor elec-
trode, the water supply is interrupted. This can occur when 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 short time. The built-in control and the large area
electrodes combine to produce a rapid rise in conductivity by
increasing the concentration of the water.
The steam cylinder consists of a top (16) and lower (19) part
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 o-rings (35+17).
For maintenance the cylinder can be drained by pressing the
control switch „Pos.II”.

Page 15
5. Installation
Installation of this unit to be accomplished only by qualified
personnel (persons with completed training in the plumbing
field and in the field of electrical installation work, respec-
tively) !
Obey all safety notes and warnings present on the unit.
Risk of electrical shockHazardous electrical voltage! During
installation the unit must be disconnected from power supply.
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.
Risk of foot injuries!
Unit may drop during mounting involving a single person.
Helping hand of a second person is required.
5.1 Steam Humidifier Operating Environment
When selecting the installation site for the steam humidifier, take
the following in account:
•Place the steam humidifier so that the unit is easily
accessible with sufficient space to perform mainte-
nance
•Ambient temperature must lie between +5 and +40 °C
•Relative humidity must not exceed 80% RH
•Installation in a closed room requires aeration and,
eventually, temperature conditioning in order to meet
the a.m. environmental conditions
•The minimum clearances indicated in the diagram
below must be observed; these are necessary to
ensure adequate ventilation for the housing
Please note

Page 16
•HygroMatik humidifiers are not suitable for direct out-
door installation
•The steam humidifier should be installed as close as
possible to the steam manifold. Optimal performance is
guaranteed only with short lengths of steam and con-
densate hose
•Hoses must be laid at a consistent 5 - 10% incline to
prevent sagging and kinking
•The rear panel of the steam humidifier heats up during
operation (to a maximum of 70 °C). Take care that the
construction on which the unit is mounted is not made
of temperature-sensitive material
•Place the steam humidifier so that the unit is easily
accessible with sufficient space to perform mainte-
nance
•Protection class IP 20

Page 17
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.
Note: To achieve a uniform immersed surface area for the elec-
trodes, the humidifier must be installed plumb and level.
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.
Mount the unit on a stable and thermoresitive, preferably solid
wall offering the bearing capacity required (s. unit technical spe-
cifications). If no adequate wall the is available, we recommend
the 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)
Type /
Dimensions a b c d e f g h i j k1 k2 mn1 n2
HY05-HY08 480 449 251 409 436 65 40 40 174 156 133 - 195 85 -
HY13-HY23 651 522 301 481 608 65 50 40 220 170 136 - 228 62 -
HY30 708 561 344 519 665 65 50 45 250 190 160 - 245 60 -
HY45 788 654 403 608 742 65 50 45 300 208 200 330 316 182 218
Specifications in (mm)
View from below
Rear view
View from top

Page 20
5.1.3 Unit Dimensions HY60-HY116
Type /
Dims. a b c d1 d2 d3 d4 e f g1 g2 hi1 i2 j
HY60 709 927 334 342 342 120 120 678 66 46 376 47 248 579 183
HY90-HY116 788 1061 403 390 390 139 139 756 66 41 432 48 300 705 218
Type / Dims k1 k2 k3 k4 mn1 n2 n3 n4
HY60 157 -* 488 -* 245 61 - 392 -
HY90-HY116 199 329 597 727 324 183 216 580 613
Specifications in (mm); * HY60 only one steam outlet per zylinder
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)