HygroMatik SteamKit H User manual

FlexLine
Heater Steam Humidifier Kit
Manual
ÁKITH.EN:È
KITH.EN
E-8881178
SteamKit H

Page 2
Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").
Copyright © HygroMatik GmbH [12.01.2022]
SteamKit H
KIT H02/03/06/09/15/ 25/ 30/ 40/ 50
All Rights reserved.
Current version of this manual to be found on: www.hygromatik.com
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.
Ensure that the system/machine in which the HygroMatik installation kit will be installed fully
complies with the regulations of the directives (2006/42/EC) and the EMC directive 2014/30/EU
and that all safety-relevant functions have been implemented in the control system.
Risk of electrical shock!
Hazardous electrical voltage!
All electrical work to be performed by certified expert staff (electricians or expert personnel with
equivalent training) only.
Risk of scalding!
Steam with a temperature of up to 100 °C is produced.
Do not inhalate steam directly!

Page 3
1. Introduction ....................................................................................................................... 5
1.1 Typographic Distinctions ...................................................................................................5
1.2 Documentation .................................................................................................................. 5
1.3 Symbols in Use ................................................................................................................. 5
1.3.1 Specific Symbols related to Safety Instructions ............................................................. 5
1.3.2 General Symbols ............................................................................................................ 5
1.4 Intended Use ..................................................................................................................... 6
1.5 Possibility of certification ................................................................................................... 6
2. Safety Instructions ............................................................................................................ 7
2.1 Guidelines for Safe Operation ........................................................................................... 7
2.1.1 Scope ............................................................................................................................. 7
2.1.2 Unit control ..................................................................................................................... 7
2.1.3 Unit Operation ................................................................................................................ 7
2.1.4 Mounting, dismantling, maintenance and repair of the unit ............................................ 8
2.1.5 Electrical ......................................................................................................................... 8
3. Transport ............................................................................................................................ 9
3.1 Overview ........................................................................................................................... 9
3.2 Packing .............................................................................................................................. 9
3.3 Interim Storage .................................................................................................................. 9
3.4 Check for complete and correct delivery of goods ............................................................ 9
4. Functional Description and Device Composition .......................................................... 10
4.1 Mode of Action .................................................................................................................. 10
4.2 Mechanical Construction ................................................................................................... 10
4.3 Operational Sequence .......................................................................................................11
4.4 Internal Output Setting ...................................................................................................... 11
5. Mechanical installation .....................................................................................................12
5.1 Environment parameters to be met ................................................................................... 12
5.2 Mounting recommendations .............................................................................................. 12
5.3 Dimensions of the unit ....................................................................................................... 13
5.4 Dimensions of the board ................................................................................................... 14
5.5 Unit Installation Check ....................................................................................................... 14
5.6 Absorption Distance BN .................................................................................................... 15
5.6.1 Determining the Absorption Distance ............................................................................. 15
5.6.2 Absorption Distance Nomogram .................................................................................... 16
5.7 Steam line and condensate hose layout ........................................................................... 17
5.7.1 Guide lines for steam line design .................................................................................. 17
5.7.2 Condensate hose layout ................................................................................................. 17
5.7.3 Steam line and condensate hose installation types ....................................................... 18
5.8 Steam Manifold ................................................................................................................. 19
5.8.1 General installation guidelines ....................................................................................... 19
5.8.2 Recommendations for dimensioning .............................................................................. 19
6. Water connection .............................................................................................................. 22
6.1 Water supply ..................................................................................................................... 22

Page 4
6.2 Water discharge ................................................................................................................ 23
6.3 Water connections final check ........................................................................................... 23
7. Electrical connection ........................................................................................................ 24
7.1 Electrical installation approach .......................................................................................... 24
7.2 Safety interlock .................................................................................................................. 25
7.3 Internal electrical connection .............................................................................................25
7.3.1 Overview ........................................................................................................................ 25
7.3.2 Internal electrical eonnection w/o HygroMatik control .................................................... 26
7.3.3 Internal Electrical Connection when the kit is delivered with a HygroMatik control ........ 26
7.4 Connection diagrams ........................................................................................................26
8. Commissioning ................................................................................................................. 27
9. Maintenance ....................................................................................................................... 28
9.1 General .............................................................................................................................. 28
9.1.1 Safety instructions for maintenance ............................................................................... 28
9.2 Maintenance frame work when unit is operated with fully demin. water and condensate . 29
9.3 Maintenance when unit is operated with tap water or partially softened water ................ 29
9.4 Maintenance steps ............................................................................................................ 30
9.4.1 Removal of the steam cylinder ....................................................................................... 30
9.4.2 Cylinder cleaning / O-ring replacement .......................................................................... 30
9.4.3 Cleaning the connecting hoses, base connections, fine filter and drain pump ............... 32
9.4.4 Level control device cleaning ......................................................................................... 32
9.4.5 Cleaning the vent hole on the pipe elbow ...................................................................... 33
9.4.6 Reinstallation of the steam cylinder ................................................................................ 33
9.5 Removal and installation of unit components .................................................................... 34
9.6 Blow-down pump (removal, cleaning, reinstallation) ......................................................... 34
9.6.1 Solenoid valve (removal, reinstallation) .......................................................................... 35
9.7 Leak test ............................................................................................................................ 35
9.8 Functional check ............................................................................................................... 35
10. Dismantling ...................................................................................................................... 36
11. Spare parts ....................................................................................................................... 37
12. Exploded view ................................................................................................................. 39
13. Technical specifications ................................................................................................. 43

Page 5
1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam
humidifier kit (referred to as „kit“ in the
descriptions following hereafter).
HygroMatik kits represent the latest in humi-
dification technology.
In order to operate your kit safely, properly
and efficiently, please read these operating
instructions.
Employ your kit only in sound condition and
as directed. Consider potential hazards and
safety issues and follow all the recommenda-
tions in these instructions.
If you have additional questions, please con-
tact your expert dealer.
For all technical questions or spare parts
orders, please be prepared to provide unit
type and serial number (see name plate on
the unit).
1.1 Typographic Distinctions
•preceded by a bullet: general speci-
fications
» 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 documentation
over to the new operator. If the documenta-
tion is lost, please contact HygroMatik.
Versions in Other Languages
These operating instructions are available in
several languages. If interested, please con-
tact HygroMatik or your HygroMatik dealer.
Co-applicability
If the kit is ordered and delivered with a
HygroMatik control, the manual of that con-
trol must be regarded as an applicable docu-
ment.
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 attention beyond the scope
of safety instructions.

Page 6
1.4 Intended Use
HygroMatik electric heater steam humidifiers
serve for steam production based on tap
water, partially softened water or fully desali-
nated water/cleaned condensate.
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 Maintenance 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 opera-
tional location (or near the unit).
By construction, the kit is not qualified for
exterior application.
Risk of scalding!
Steam with a temperature of up to 100 °C is
produced.
Do not inhalate steam directly!
1.5 Possibility of certification
HygroMatik humidifiers are certified accord-
ing to the household appliance standard DIN
EN 60335-1 in accordance with the special
requirements for humidifiers DIN EN 60335-
2-98 and comply with the requirements of the
EC Low Voltage Directive 2014/35/EU con-
tained therein.
It has been shown by the legislator through a
risk analysis in accordance with the Machin-
ery Directive that the risks are mainly of elec-
trical origin and that all essential safety
requirements of the Machinery Directive
together with the main objectives of the Low
Voltage Directive are covered by the EN
60335-2-98 standard.
HygroMatik humidifier installation kits corre-
spond in their construction to the certified
humidifiers. Due to the lack of enclosure, wir-
ing and only optional control, they are incom-
plete in the broader sense, but not an
incomplete machine in accordance with the
Machinery Directive 2006/42 / EC.

Page 7
2. Safety Instructions
These safety instructions are required by law.
They promote workplace safety and accident
prevention.
2.1 Guidelines for Safe Opera-
tion
2.1.1 Scope
Comply with the accident prevention regula-
tion „DGUV Regulation 3“ to prevent injury to
yourself and others. Beyond that, national
regulations apply without restrictions. This
way you can protect yourself and others from
harm.
2.1.2 Unit control
Do not perform any work which compromises
the safety of the unit. Obey all safety instruc-
tions and warnings present on the unit.
In case of a malfunction or electrical power
disruption, switch off the unit immediately and
prevent a restart. Repair malfunctions
promptly.
Restricted use.
IEC 60335-1 stipulates as follows:
This device may be used by children of eight
years of age and above as well as by persons
with reduced physical, sensory or mental ca-
pabilities or lack of experience and knowledge
so long as they are supervised or have been
instructed regarding the safe use of the de-
vice and understand the hazards that may re-
sult from it. Cleaning and user maintenance of
the unit must not be undertaken by children
without supervision.
The following applies to the HygroMatik
installation kits:
Ensure that the system/machine in which the
HygroMatik installation kit will be installed fully
complies with the provisions of the directives
(2006/42/EC) and the EMC directive 2014/30/
EU and that all safety-relevant functions have
been implemented in the control system.
2.1.3 Unit Operation
Risk of scalding!
Uncontrolled hot steam escape in case of
leaking or defective components possible.
Switch off unit immediately.
For Ministeam devices applies:
Risk of scalding!
No persons may be under the cloud of steam
blowing out (at a distance of approx. 1 m/40
inch in the direction of blowing out and 0.5 m/
20 inch on both sides of the device).
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 transports
the steam (not valid for MiniSteam
units).
• Regularly check that all safety and
monito-ring devices are functioning
normally. Do not remove or disable
safety devices.
• Steam operation is only allowed when
the unit cover is closed.
Water leaks caused by defective connec-
tions or malfunctions are possible.
Water is constantly and automatically filled
and drained in the humidifier. Connections
and water-carrying components must be
checked regularly for correct operation.
WARNING
!
WARNING
!
WARNING
!
NOTICE
NOTICE

Page 8
2.1.4 Mounting, dismantling, mainte-
nance and repair of the unit
The HygroMatik steam humidifier is IP20 pro-
tected. Make sure that the unit is not object to
dripping water in the mounting location.
Installing a humidifier in a room without water
discharge requires safety devices to protect
against water leakages.
• 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
Do not install HygroMatik steam generators
above electrical equipment such as fuse
boxes, electrical appliances, etc. In the case
of a leakage, leaking water can damage the
underlying electrical equipment
2.1.5 Electrical
Risk of electrical shock!
Hazardous electrical voltage!
Any work on the electrical system to be per-
formed by certified expert staff (electricians
or expert personnel with comparable training)
only.
Steam operation may only be started when
the unit cover is closed.
During maintenance or installation work, the
device must be disconnected from the power
supply and secured against being switched
on again. The absence of voltage must be
ensured by a measurement.
Leaks can cause leakage currents. Observe
safety regulations on working with voltage
parts (applies to electrode steam humidifi
es).
After electrical installation or repair work, test
all safety mechanisms (such as grounding
resistance).
Use only original fuses with the appropriate
amperage rating.
Regularly check the unit‘s electrical equip-
ment. Promptly repair any damage such as
loose connections or burned wiring.
Responsibility for intrinsically safe installation
of the HygroMatik steam humidifiers is
incumbent on the installing specialist com-
pany.
NOTICE
NOTICE
WARNING
!
NOTICE

Page 9
3. Transport
3.1 Overview
Proceed carefully when transporting the kit in
order to prevent damage due to stress or
careless loading and unloading.
3.2 Packing
Pay attention to the icons affixed to the pack-
ing box.
3.3 Interim Storage
Store the unit in a dry place and protect from
frost and strong sunlight.
3.4 Check for complete and cor-
rect 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 do-
cuments.
Scope of delivery
Pls., check whether the equipment is com-
plete and all parts are in perfect condition.
A main contactor is not included and must be
supplied on-site. For selection, pls. keep
max. current draw of the kit in mind as speci-
fied in the electrical connection section (sec-
tion 10).
Claim
In case of damage from shipment and/or
missing parts, immediately notify the carrier
or supplier in writing.
Time limits for filing freight claims with ship-
ping companies are*:
* Time limits for some services subject to
change.
Qty. Item
1 Console with steam cylinder/
cylinder base, solenoid valve,
blow-down pump, internal
tubing with elbow
1 SteamKit manual
1 Steamhose adaptor
1 O-Ring for cylinder base and
steamhose adaptor
1 Clamp 20 - 32 mm for steam
hose DN25
1 Cylinder connection coupling
and plug 4 mm2
Please note
Please note
4 Blade receptacle for
connection of solenoid valve
and blow-down pump
4 Insulating sleeve
1 Ring cable lug for grounding
1 Water level detection / control
cylinder
1
1
1
1
Control (optional)
„Control“ manual
Display
Solid State Relais
Shipping company After receipt of
goods
Carriers no later than 4 days
Parcel service immediately
Qty. Item
Please note

Page 10
4. Functional Description and
Device Composition
4.1 Mode of Action
The immersion heater principle
Depending on the output rating, one or three
heater elements are arranged within a closed
cylinder. The cylinder is filled with either tap
water of varying quality, fully desalinated
water or partially softened water. The heat
introduced by the heater element(s) heats up
the cylinderwater to approx. 100 °C, trans-
forming the water into steam with a tempera-
ture of approx. 100 °C and very little positive
pressure (so called pressureless steam).
This steam is virtually mineral-free and germ-
free. When fully desalinated water is used,
the cylinder water is almost totally clear of
minerals. This situation guarantees a long
lifetime of the cylinder and the heater ele-
ment(s), since virtually no hardeners will fall-
out and no mineral deposits will occur.
Such, the number of inspections and/or
maintenance operations required will be
reduced to a minimum.
When tap water is used for operation, some
of the minerals dissolved in the water are
likely to settle in the cylinder in form of solids
of various compositions. However, most of
the solids are flushed out by cyclic blow-
down with the help of a heavy-duty blow-
down pump.
4.2 Mechanical Construction
The kits are designed for wall mounting or
standing on a horizontal, level surface.
The composition of a kit with 1 heater ele-
ment is shown in the fig. following hereafter.
For maintenance purposes, the steam cylin-
der is separable in the middle.
Steam cylinder
Solenoid valve
Blow-down pump
Steam hose
Wastewater
M4 thread for
grounding screw
Elbow
Cylinder base
Draining hose
Console
Capillary tube
Thermoswitch
Heater element
adaptor
Control cylinder
connection
Supply water
connection

Page 11
4.3 Operational Sequence
The operational sequence depends on the
electrical interconnection and control of the
the kit. Following hereafter, the typical opera-
tional sequence is described for a setting of
the kit with the HygroMatik control „Stan-
dard“:
The steam humidifier is switched on by
pressing the control switch on the front panel
to the „I“ position. When the controller gener-
ates a demand for humidification, the inlet
solenoid valve (25)*opens and water is fed
into the steam cylinder.
Filling level in the cylinder is controlled by a
level control device (27)*) . In a plastic cylin-
der, connected to the steam cylinder via
hoses in the way communicating tubes are
connected, a sensor for continous propor-
tional water level survey is located.
The cylinder water is periodically blown
down. For usage of the unit with fully desain-
ated water, the blow-down function may be
blocked.
Water blow-down is achieved by means of
the blow-down pump (32)*) that is continously
monitored during unit operation. In case of
pump disruption, the kit is shut off.
With normal water quality, blow-down loss is
in the range of 7 to 15 % of the steam amount
produced. Depending on water quality, a full
steam cylinder blow-down is run every 3 to 8
days.
Mineral deposits settle in the open area
below the heater element(s) 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.
On blow-down, water flows from the pump
into the drain hose system.
For maintainence purposes, the cylinder
water may be pumped out by pressing and
holding the control switch in the „II“ position.
*) numbers indicated correspond with those in
the exploded view in the „Exploded view“
chapter.
4.4 Internal Output Setting
The description following hereafter relates to
the usage of the steam humidifier kit with the
HygroMatik controls „Basic“ and „Standard“.
Continuous control is achieved by propor-
tional driving (pulse width modulation) of the
heater element(s). In this way the steam
humidifier kit can be proportionally operated
across the entire output range of 10 % - 100
% of the nominal capacity.

Page 12
5. Mechanical installation
Risk of foot injuries!
Prevent unit from dropping during installation!
Helping hand of a second person is advis-
able.
Risk of electrical shock!
Hazardous electrical voltage.
During installation, the unit must be discon-
nected from power supply and secured
against being switched on again. The
absence of voltage must be ensured by a
measurement.
5.1 Environment parameters to
be met
• By design, the kits are not qualified for
outdoor installation since electrical/
electro-mechanical/electronical compo-
nents (depending on configuration vari-
ant) and water-bearing parts may be
damaged
• Ambient temperature must lie between
+5 and +40 °C (+41 and +104 °F) ; frost
may damage the steam cylinder, the
solenoid valve and pump, as well as
make hoses burst
• Relative humidity must not exceed
80 % r.h., since values beyond may
lead to electronic malfunction or dam-
age
• Installation in a closed room requires
aeration and, eventually, temperature
conditioning in order to meet the a.m.
environmental conditions
5.2 Mounting recommendations
When selecting the installation site for the
steam humidifier, take the following into
account:
• The kit should be installed as close as
possible to the steam manifold. Opti-
mum 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; sagging and kink-
ing prevention is a must
• Mount the unit on a stable, preferably
solid wall offering the bearing capacity
required (s. unit technical specifica-
tions) or standing on a horizontal, level
surface. If such a wall is not at hand,
the unit may be attached to a stand
bracket firmly bolted to the floor.
• The steam humidifier console heats up
during operation. Take care that the
construction on which the unit is to be
mounted is not made of temperature-
sensitive material.
• The elbow is to be attached to a suit-
able vertical surface ba means of a
screw
When selecting the mounting material to be
supplied by the customer, attention must be
payed to adequate strength. For the correct
functioning of the steam humidifier it is
required that the device is mounted level and
plumb.
After mounting the kit make sure that it sits
firmly.
To fulfil all safety requirements, ensure suffi-
cient ventilation of the installation kit in the
housing.
WARNING
!
WARNING
!

Page 13
5.3 Dimensions of the unit
Table of dimensions
Model A
[mm]
B
[mm]
C
[mm]
E1
[mm]
E2
[mm]
H1
[mm]
H2
[mm]
H3
[mm]
H4
[mm]
L1
[mm]
L2
[mm]
KIT E02 / KIT H02 300 220 400 157,5 125 30 25 42 226 15 185
KIT E06 300 220 530 157,5 125 30 25 42 226 15 185
KIT E10 / KIT H03/06/09 300 220 550 157,5 125 30 25 42 226 15 185
KIT E15 /20/30/ KIT H15/25 350 285 700 270 270 35 25 80 160 15 250
KIT E45/65 / KIT H30/40/50 420 400 785 280 280 35 25 100 200 15 365
%
/
/
&
$
+
+
/(
+ +
(

Page 14
5.4 Dimensions of the board
FlexLine / StandardLine
5.5 Unit Installation Check
Before start-up, pls. check proper unit instal-
lation following the list below:
Kit perpendicularly aligned in both
the vertical and horizontal axis ?
Steam hose installed with a 5 - 10 %
minimum incline/decline (see chap-
ter "Steam line“) ?
Condensate hose features a loop
functioning as a steam barrier (see
chapter „Condensate hose“) ?
Steam manifold(s) properly posi-
tioned?
All bolts and clamps properly tight-
ened?
Steam manifold(s) horizontally
mounted and suspended on the free
end, if required ?
All seals (o-rings) in place?
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



Page 15
5.6 Absorption Distance BN
The "absorption distance" (BN)is defined as
the distance from the steam feed to where
the steam is completely absorbed in the
treated air. Within the absorption distance,
steam is visible as mist in the air stream.
Condensation may occur on anything
installed within the absorption distance.
Although steam outside the absorption dis-
tance (BN) is completely absorbed, it is not
yet evenly diffused in the duct. If you plan to
install any parts or devices inside the absorp-
tion distance, such as sensors or elbows, we
recommend increasing the absorption dis-
tance using the formulae below. The absorp-
tion distances required for certain installed
fittings are distinguished by separate sym-
bols and calculated as a multiplier of the
absorption distance BN.
The absorption distance has no fixed value,
but depends on many factors. These are
depicted in the absorption distance nomo-
gram below.
5.6.1 Determining the Absorption
Distance
To determine the absorption distance, the fol-
lowing parameters are required:
•Air humidity before humidification x1
in g/kg
•Air temperature after humidification
t2in °C (with steam humidifiers the
change in air temperature due to
humidification may be disregarded
t1or t2)
•Specific increase in humidity x in
g/kg (can be determined in the h,x
diagram)
•quantity of steam introduced in
kg/h.
•air speed wLin m/s in air duct
•Total length lD of the steam manifold
installed in the air duct
Length IDof the usable steam manifold
depends on the dimensions of the air duct.
The length of the absorption distance can be
reduced by using multiple steam manifolds
(also see section on the steam manifold).
Method:
Graphically determine absorption distance
BNusing the absorption distance nomogram
(also see Section „Absorption Distance
Nomogramm“). Enter the value of the param-
eters enumerated above into the respective
quadrants. The resulting point of intersection
indicates the value of the desired absorption
distance BN.
Notes:
Air humidity before humidification x1:....[g/kg]
Air temperature after humidification t2:.....[°C]
Specific increase in humidity x:...........[g/kg]
Quantity of steam introduced :.........[kg/h]
Air speed WL:..........................................[m/s]
Total length of steam manifold lD:...........[mm]
o
D
m
o
D
m
Absorption Distance
BNfor normal obstructions
such as sensors, ventila-
tors, outlets
Bc= (1.5...2) x BNfor fine fiters, heat regis-
ters
Bs= (2.5...3) x BNfor particle filters
Bd= (3...5) x BNfor humidity sensors,
duct humidistats

Page 16
5.6.2 Absorption Distance Nomogram
Source: Henne, Erich: Luftbefeuchtung (Air Humidification), 3rd Edition 1984 (Page 101), Olden-
bourg Industrieverlag, Munich

Page 17
5.7 Steam line and condensate
hose layout
Because of the high requirements on hose
material under the operating conditions
given, it is recommended to use genuine
HygroMatik hoses only.
5.7.1 Guide lines for steam line
design
• Steam hose nominal diameter must not
be smaller than the steam outlet of the
HygroMatik steam humidifier (do not
restrict the cross-section, otherwise
back pressure will increase)
• Steam hoses must be laid without sags
and kinks and with a continuous slope
of 5-10% (otherwise sags may result).
• Steam hoses must be supported every
500 mm (20 inches) by clamp brackets
• Steam hoses should be kept as short
as possible. Implement lengths be-
yond 5 m (16 ft.) as insulated fixed pip-
ing to keep energy loss and conden-
sate generation to a minimum. Beyond
10 m (32 ft.) insulated installation is a
must. Fixed piping is generally recom-
mended for straight steam line seg-
ments
• When 2 steam manifolds are in use
(other than with a standard implemen-
tation), place steam Y piece as close as
possible to the steam manifolds. Such,
for the main part of the piping just one
steam hose is required and condensate
loss is minimized
• Allow easy access to the steam pipe/
steam hose installation
• Pressure conditions within the duct are
influenced by device steam output, steam
line layout and the duct composition itself.
In some rare situations it may become
necessary to optimize steam line layout
for achieving the results intended
• Respect minimum bending radii:
DN 25 Steam hose: Rmin = 200 mm/8“
DN 40 Steam hose: Rmin = 400 mm/16“
5.7.2 Condensate hose layout
(only for electrode steam humidifiers)
The condensate hose may be run from the
steam manifold back to the steam cylinder,
as depicted in the schematic drawing below
with concern to installation type 1. Alterna-
tively, the condensate hose may be fed
directly in a wastewater pipe or a drain (s.
installation type 2).
Should condensate return into the steam cyl-
inder be intended, the connection stub on the
cylinder upper part must be drilled out first
with a ANSI drill size „O“ drill. To do so, the
steam cylinder must be removed from the
housing (s. maintenance chapter, section
„Steam cylinder removal and reinstallation“).
In case of a console instead of a housing, the
cylinder is to be lifted off the cylinder base for
drilling the stub or may even remain in place.
For heater element humidifiers:
If condensate return is necessary, please
contact the HygroMatik hotline.
Please note
Please note
with an 8 mm (ANSI drill size „O“) drill,
Drill out condensate hose connection stub
Steam cylinder top view
if required

Page 18
5.7.3 Steam line and condensate
hose installation types
Installation type 1
Steam manifold is positioned more than
500 mm above device upper edge:
» Run steam hose to a height of 400
mm/16 inch minimum above the
steam humidifier and then to the
steam manifold with a continuos
incline of 5 to 10 %.
» Feed condensate hose from steam
manifold with a decline into waste-
water pipe or drain.
» As a steam barrier, lay out a 200
mm/8 inch min. loop (s. schematic
representation below). Minimum dis-
tance from steam manifold to loop
must be 500 mm/20 inch. Fill loop
with water prior to steam humidifier
commissioning.
Installation type 2
Steam manifold is positioned less than
500 mm above or below device upper
edge:
In this arrangement the condensate hose
cannot be fed back to the steam humidifier.
» Run steam hose to a height of 400
mm/16 mm minimum above the
steam humidifier and then to the
steam manifold with a continuos
decline of 5 to 10 %.
» Feed condensate hose to a waste-
water pipe/drain with a 200 mm/8
inch diameter loop as a steam bar-
rier. Minimum distance from steam
manifold to loop must be 500 mm/20
inch. Fill loop with water.
Steam cylinder
Steam manifold
Steam
hose
Condensate
hose
Installation type 1,
Device
upper edge
schematic representation
500 mm
20 inch
min.
400 mm
16 inch
200mm/8‘‘min
Rmin
DN25: 200 mm/8 inch
DN40: 400 mm/16 inch
Steam cylinder
Steam
hose
Device
upper
Condensate
hose
Drain
Detail „x“
wrong!
Installation type 2,
schematic representation
edge
Detail „x“
Rmin
DN25: 200 mm/8 inch
DN40: 400 mm/16 inch
400 mm
16 inch
200 mm
8 inch
Please note

Page 19
5.8 Steam Manifold
5.8.1 General installation guidelines
When installing steam manifolds, pls. follow
these guidelines:
Positioning within duct
• Install the steam manifold as close as
possible to the steam humidifier in
order to minimize steam loss through
condensation
• Steam manifold placement on the sup-
ply side of the air duct is preferable
• Install steam manifold strictly horizontal
in order to ensure proper condensate
drain
• Shown installation and positioning
dimensions are based on empiric
values. Special environmental conditi-
ons may require adjustments. Pay
special attention to avoid condensate
generation in air duct
Allowable pressures
• Max. allowable pressure in air duct is
1500 Pa/.218 PSI (exemption: SLE02,
SLH02, KIT E02 and KIT H02 only
allow for 1200 Pa/.174 PSI)
• On suction side, max. -500 Pa (.07
PSI) is tolerable
• With high-pressure air conditioning
systems, modifications of the unit‘s
drain hose system may possibly be
required depending on the overall pres-
sure situation. These modifications
must be coordinated with your
expert dealer.
Water drain
• We point out that according to the Ger-
man Association of engineers (VDI)
guideline VDI 6022, a water drain must
be provided within the absorption
distance inside the air duct
When increased airflow speed is encoun-
tered
• Air flow rates beyond 3m/s (9.84 ft/s)
may lead to condensate drainage prob-
lems at the steam manifolds due to
vacuum built-up. A possible remedy is
twisting the steam manifold in its hori-
zontal axis by few angular degrees. In
case of problems, pls. consult your
expert dealer.
5.8.2 Recommendations for dimen-
sioning
The recommendations given below are
based on homogenous air flow in the duct.
Horizontal installation of steam manifold
Standard steam manifold arrangement:
An even distribution of steam manifolds ensu-
res a uniform steam distribution.
Please use the
total hight of the
duct!
L1=L2=L3
Air flow
direction
Steam manifold
(Side view)
Air duct
*) s. table of manifold lengths Horizontal assembly position in duct
l*) (depends on duct dimension)
4.7 inch 3.5 inch 2.8 inch
120 mm 90 mm 70 mm
1.5 mm
.06 inch

Page 20
Minimum distance for condensation
avoidance:
Lmin = 210mm/8.3 inch: „Steam manifold -
Next steam manifold“ distance
L4min = 120mm/4.7 inch: „Lowest steam
manifold - Duct bottom plane“ distance
L5min = 120mm/4.7 inch: „Highest steam
manifold - Duct ceiling plane“ distance
Steam manifold arrangement for special air
duct shapings
Air flow
direction
flat steam manifold laterally staggered (with
respect to air flow direction) in case of
Lmin (s. above) not to be met
very flat by tilting the steam manifold 30 - 45°
towards the air flow direction, the mini-
mum upper clearance can be reduced
to 70 mm/2.8 inch.
Min[mm/inch] H1 H2
30° 45°
DN25/1“ 182/7.2 168/6.6 225/8.6
DN40/1 1/2“ 193/7.6 179/7.2 230/9.1
narrow, high identical lenghts one on top of the other,
staggered laterally if possible
square identical lengths, staggered vertically
and laterally
low, very
wide
facing each other
Air flow
direction
Air flow
direction
Air flow
direction
narrow channel