HydroMatik HeaterCompact User Manual

Electric Heater Steam Humidifier

HeaterCompact

Installation yellow

Plumbing blue

Electrics red

Maintenance green

General Information white

ÁHC.EN0È

HC.EN

Manual

Page 2

Warning, 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; HeaterCompact 08.09.2015

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 Typographic Distinctions ...................................................................................................5

1.2 Documentation .................................................................................................................. 5

1.3 Directions for Use .............................................................................................................. 6

2. Safety Notes ....................................................................................................................... 7

2.1 Overview ........................................................................................................................... 7

2.2 Guidelines for Safe Operation ........................................................................................... 7

2.3 Disposal after Dismantling .................................................................................................8

3. Transport ............................................................................................................................ 9

3.1 Overwiew ........................................................................................................................... 9

3.2 Transport Size and Weigth ................................................................................................ 9

3.3 Packing .............................................................................................................................. 9

3.4 Interim Storage .................................................................................................................. 9

3.5 Check for Complete and Correct Delivery of Goods ......................................................... 9

3.6 Included in the Delivery ..................................................................................................... 10

4. Operation and Device Construction ................................................................................ 11

4.1 Mode of Action .................................................................................................................. 11

4.2 Installation and Method of Operation ................................................................................ 12

4.3 Internal Output Setting ...................................................................................................... 14

5. Mechanical Installation .....................................................................................................15

5.1 Steam Humidifier - environmental conditions .................................................................... 15

5.1.1 Equipment Dimensions HC ............................................................................................ 16

5.1.2 Fitting Measures ............................................................................................................. 18

5.2 Absorption Distance BN .................................................................................................... 19

5.2.1 Determining the Absorption Distance ............................................................................. 19

5.3 Fan Unit (option) ................................................................................................................ 21

5.3.1 Fan Unit Type VG ........................................................................................................... 21

5.3.2 Absorption Distance Nomogram .................................................................................... 23

5.4 Steam Manifold ................................................................................................................. 24

5.4.1 Notes on Installation ....................................................................................................... 24

5.5 Steam Line ........................................................................................................................ 28

5.6 Cover Plate ........................................................................................................................ 29

5.7 Drill Pattern ........................................................................................................................ 30

5.8 Condensate Hose .............................................................................................................. 32

5.9 Types of Installation .......................................................................................................... 32

5.10 Steam Solenoid Valves ................................................................................................... 34

5.11 Unit Installation Check ..................................................................................................... 34

6. Water Installation .............................................................................................................. 35

6.1 Water Quality ..................................................................................................................... 35

6.2 Water Supply (For Operation with Demineralized Water or Purified Condensate) ........... 36

6.3 Water Supply (For Operation with Tap Water or Partially/Fully Softened Water) ............. 37

6.3.1 Feed from Holding Tank ................................................................................................. 38

Page 4

6.4 Water Treatment ............................................................................................................... 38

6.5 Water Discharge ............................................................................................................... 39

6.6 Checklist ............................................................................................................................ 40

7. Electrical Installation ........................................................................................................ 41

7.1 Electrical Installation .......................................................................................................... 41

7.2 Safety Interlock .................................................................................................................. 42

7.3 Control Connection ............................................................................................................ 43

7.4 Control Connection - Steam Bath Application ................................................................... 43

7.4.1 Temperature Sensor Connection ................................................................................... 43

7.5 Control Connection - Air Conditioning Application ............................................................ 43

7.5.1 1-step control .................................................................................................................. 44

7.5.2 Proportional Control with an external control signal ....................................................... 44

7.5.3 Proportional Control with Built-In PI-Controller .............................................................. 46

7.6 Cable Connections ............................................................................................................ 47

7.7 Fan Unit ............................................................................................................................. 47

7.8 Wiring Diagram .................................................................................................................. 48

7.9 Electrical Installation Checklist ..........................................................................................48

8. Maintenance ....................................................................................................................... 49

8.1 Maintenance for Operation with Demineralized Water / Condensate ............................... 50

8.2 Maintenance for Operation with Tap Water or Partially Softened Water ........................... 51

8.3 Access to Control Unit ....................................................................................................... 52

8.4 Removing and Cleaning the Steam Cylinder .................................................................... 53

8.5 Maintenance of the Control Cylinder ................................................................................. 58

8.5.1 Cleaning the nozzle in the steam hose adapter ............................................................. 58

8.6 Replacing Heater Elements ............................................................................................... 58

8.7 Replacing Thermo Sensor (for Heater Element) ............................................................... 59

8.8 Unlocking of a Released Thermo Sensor (for heater element) ......................................... 60

8.9 Unlocking of a Released Thermo Sensor (for Solid State Relay) ..................................... 60

8.10 Removing Inlet Solenoid Valve and Cleaning Fine Mesh Filter ...................................... 61

8.11 Cleaning Blow-Down Pump ............................................................................................. 62

8.12 Cleaning connection hoses and cylinder base ................................................................ 63

8.13 Checking Cable Screw Connections, Heater Element Wires .......................................... 64

8.14 Operational Check ........................................................................................................... 64

8.15 Dismantling ...................................................................................................................... 64

9. Commissioning ................................................................................................................. 65

10. EC-Declaration of Conformity ........................................................................................ 66

11. Spare Parts ...................................................................................................................... 67

12. Fax Form - Order for spare parts ................................................................................... 71

13. Index ................................................................................................................................. 72

14. Technical Specifications ................................................................................................ 74

15. Exploded View ................................................................................................................. 76

16. View of Cabinet ................................................................................................................ 77

Page 5

1. Introduction

Dear Customer,

Thank you for choosing a HygroMatik steam humidifier.

HygroMatik steam humidifiers represent the latest in humidifica­tion technology.

They will impress you with their safety, ease of use and econo­mical operation.

In order to operate your HygroMatik steam 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 fol­low all the recommendations in these instructions.

If you have additional questions, please contact us:

Tel.: [phone] (Main Number)

Tel.: [phone] (T

echnical Support Hotline)

Fax: [phone]

e-mail: [e-mail]

For all technical questio

ns 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 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 ret ain th ese o perating instruction s in a secure, alwa ys
accessible location. If the product is resold, turn the documenta­tion 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 dea­ler.

Page 6

1.3 Directions for Use

The proven principle of heating wa ter by the use of electric
immersion heate rs is exploited to generate steam. Usin g diffe­rent t ap water q ualities or p artial softened water (all hu midifier
types) or fully demineralized wate r / condensate water (only for
humidifier type HeaterLine, HeaterCompact/Kit and HeaterSlim).

Warning: HygroMatik steam humidifiers emit steam with a tem­perature o f 10 0°C. Th e steam may no t b e inhaled directly.
Proper usage also entails following HygroMatik's instructions for
installation, dismantling, reassembly, initial operation and opera­tion and maintenance, as well as disposal procedures.

Only qu alified a nd authorised personnel may opera te the unit.
Persons transporting or working on the unit , must have read
and unde rstood the corre sponding p arts of the Operation and
Maintenance Instruct ion and especially the chapter 2. „Sa fety
Notes“. Additionally, op erating personne l must be informed of
any possible dangers. You should place a copy of the Operation
and Maintenance Instruction at the unit‘s operational location (or
near the unit).

The steam humidifier is not qualified for exterior application.

Page 7

2. Safety Notes

2.1 Overview

These sa fety notes are required b y law . The y p romote work­place safety and accident prevention.

Warnings and Safety Symbols

The safety symbols be low identify sections containing warnings
about hazards or pot ential da ngers. Please fa miliarize yourself
with these symbols.

Warning: Failure to o bserve this warning ma y result in serious
injury or death and/or damage to the unit.

Danger, Hazardous Voltage: Hazardous electrical current!

Fai-

lure to observe this warning may result in injury or even serious
injury or death.

Warning: Failure to follow these instructions may resu lt in
damage to the unit due to electrostatic discharge. The electronic
components of the humidifier control a re very sensitive t o elec­trostatic discha rges. In orde r to safeguard these components
during installation and servicing, steps must be taken to protect
against ESD.

Reminder: Materials and consumables must be handled and/or
disposed of as required by law.

Note: App ears before explanations o r cross-refere nces which
refer to other sections of the operating instructions.

2.2 Guidelines for Safe Operation

Overview

Obey all safety notes and warnings present on the unit.

In case of a malfunction, switch off the unit immediately and pre­vent a re start. Rep air malfun ctions promptly. Af ter any rep air
work, h ave qualified personnel check t he safe operation of the
unit.

Use original spare parts only. Additional national safety regulati­ons also fully apply to the operation of this unit.

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 trai­ned by a person, who is responsible for their safety.
Supervise children in order to ensure that they will not play with
the unit.

The unit is only allowed to work with connected steam hose that
safely leads the steam.

Caution

steam

Page 8

Accident Prevention Regulations

Attention: In t he e vent of leaky or faulty components un con-

trolled hot steam may flow.

HygroMatik steam humid ifiers a re IP20 -protected. 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.

Accident Prevention Regulations

Comply with the Accident Pr evention Regulatio n Electrical
Systems and Equipment to prevent injury to yourself and others.

Operation of the Unit:

Do not pe rform any work which co mpromises the safety of the
unit. Regularly check that all sa fety and monitoring devices are
functioning normally. Do not remove or disable safety devices.

Installation, Di smantling, Maintenance and Re pair of the
Unit:

Disconnect unit components from power supply prior to mainte­nance or repair work.

Attaching or installing additional components is permitted only
with the written consent of the manufacturer.

Electrical

Work on the e lectrical system must be p erformed by q ualified
personnel.

Disconnect unit components from power supply prior to work.

It is not allowed to connect the unit to DC voltage supply.

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 e quip­ment. Promptly repair any damage, such as loose connections,
burned wiring or defective electrical insulation. After proper elec­trical inst allation or repair, test all safety mechanisms (such as
grounding resistance).

2.3 Disposal after Dismantling

Note: The operator is responsible for the disposal of unit compo-

nents as required by law.

Page 9

3. Transport

3.1 Overwiew

Note:Proceed carefully when transporting the steam humidifier in

order to prevent damage from rough or careless loading and un­loading.
If the transport of this unit is attempted by only one person there
is a risk that the unit will drop down. We propose to transport the
unit by two persons.

3.2 Transport Size and Weigth

* Dimensions and weigths can vary insignificantly

3.3 Packing

Note: Observe the symbols affixed to the box.

3.4 Interim Storage

Keep the unit dry and protect from frost.

3.5 Check for Complete and Correct Delivery of

Goods

Upon receipt of the unit, make sure that:

• type and serial number on the name plate match what

is in the purchasing and delivery documents,

• equipment is complete and in perfect condition.

Note: In case of damage during shipment and/or missing parts,
immediately file a written claim with your carrier or supplier.

Type* depth

[cm]

higth

[cm]

width

[cm]

weigth

[kg]

HC02 33 47 46 14
HC03 36 65 51 16
HC06 36 65 51 16

HC09 36 65 51 16
HC06P 41 78 59 25
HC09P 41 78 59 25

HC12 41 78 59 26

HC18 41 78 59 26

HC27 41 78 59 27

Page 10

Time limits for filing freight claims with shipping companies are*:

* Subject to change without prior notice.

3.6 Included in the Delivery

The delivery includes:

• Unit of the selected humidifier type including selected con­trol.

• Water installation hose.

• Manuals for the steam humidifier and the control.

• Ordered accessories (steam manifold, steam hose, con­densate hose, etc.).

• Maintenance o-ring set for steam cylinder.

Transport Company After Receipt of Goods

Mail 24 hours at the latest
Rail 7 days at the latest

Truck and railway compa-

nies

4 days at the latest

Parcel Service immediatly

Page 11

4. Operation and Device Construction

4.1 Mode of Action

The Imersion Heater Principle

One to three heater eleme nts (Pos. 8 in the explo ded view,
please see co ver foldout) a re pla ced in a close d cylin der and
connected to a lternating current. The cylin der is filled with t ap
water, fully demineralized water or partially softened water. Heat
generated by the heater element increases water temperature to
approx. 100°C.

When fully demineralized water is used, the feed water is practi­cally free of minerals. This ensures long life for the cylinder and
heater elements since virtually no mineral deposits can settle or
build up. Fully demineralized water minimizes the number of ser­vice / maintenance checks.

When tap water is used, some of the minerals dissolved in the
water will settle in the cylinder as solids of various compositions.
Most of these scale deposits are removed by periodic flushing or
use of a h eavy-duty blow-down pump. See section "Se rvicing
During Operation with Tap Water".

The gen erated steam has a temperatu re of abo ut 100°C and
minimal po sitive pressure ("pressure less” steam). It is virtually
demineralized and germ-free.

Page 12

4.2 Installation and Method of Operation

By pressing the control switch („Pos. I”) the humidifier is turned
on. Wh en th e hygrost at or controller signals a demand for
humidification, the inlet solenoid valve (14) opens. The solenoid

valve is designed for pressures from 100 x 10

3

to 100 x 104 Pas-

cals (1 to 10 bar).

Water is fed into the cylinder.

The water level in the cylinder must be maintained within a spec­ified range. If the water level is to o high, the ellbow act s as a
safety overflow for water drainage. If the water level is too low, it
could cause the heat er elemen t (8) to overhea t. Th erefore,
power supply to the heater element is shut off when water levels
are too low.

The cylinder water level is controlled by a level control (27). The
level control consists of a stainless steel cylinder with two float
switches and three reed contacts. The float switches indicate the
water level in the steam cylinde r: "Dry Run", "Humidification "
and "Max. Level". The control capsule is pressure-equalized.

At the standard setting, the inlet solenoid valve (14) opens when
the water level remains below “humidif ication” level for 10 sec­onds. The water level then rises again to “humidification” level.

The steam cylinde r consist s of a to p (16) an d lower (9) p art
joined with a cylinder flange. The seal between the cylinder and
cylinder base (11), as well as between the top and lower part of
the cylinder, is maintained using an o-ring.

Page 13

General survey

The heater elements are equipped with a mechanical high tem­perature sa fety. Th is mechanism provides a re dundant safety
system in the event of excessively low water levels (“Dry Run”).

The cylinder water is periodically flushed out with a hea vy-duty
blow-down pump (10).

Steam is fed into air-condition ing duct s through special steam
hoses a nd steam ma nifolds. Under normal condition s, t his
steam has virtually no heating effect on the air to be humidified.
Accumulated condensate can be returned to the steam cylinder
via a condensate hose.

Direct room humidification (without ducts) is performed using fan
units (with blower and n ozzle). T he st eam g enerator is con­nected to the fan unit with steam and condensate hoses.

Page 14

Steam lines in steam ba th cabin s employ special steam hoses
and piping (if required). Accumu lated condensate is n ormally
routed into the steam cabin. At a relative humidity of 100%, the
supplied steam is used to heat the steam bath.

Warning: Leakage of the steam cylinder can cause a serious
hazard, such as giving an electric shock.

Warning: During blow down hot wat er wit h a temperature of
about 95°C is being drained. This can cause burns to the skin at
direct contact.

4.3 Internal Output Setting

Continuous control of the HeaterCompact Type steam humidifier
is achieved by proportional control of the heater elements. In this
way th e hu midifier ca n be prop ortionally op erated across the
entire output range of 5% - 100% nominal capacity.

Page 15

5. Mechanical Installation

Warning: Installation of this unit should be performed by quali-

fied personnel only . HygroMatik accept no liability for d amage
due to faulty installation.

Obey all safe ty instructions and wa rnings on the unit. Durin g
installation the unit must be disconnected from its power supply.

Accessory equipment may not be installed on or in the unit with­out prior written co nsent from Hygro Matik. Otherwise the war­ranty is void.

Warning: If the installation of this unit is a ttempted by only one
person there is a risk that the unit will drop down. We propose to
carry out the installation by two persons.

5.1 Steam Humidifier - environmental con diti­ons

Note: When selecting the location for steam hu midifier installa-

tion, be aware of the following:

• Ambient temperature must be between +5 and +40 °C.

• Relative humidity may not exceed 80% RH.

• Observe clearances specified in the diagrams below to

ensure adequate ventilation.

• An Installation in a closed room requires aeration and if

neccessary temperature conditioning in order to reach
the above mentioned environmental conditions.

• HygroMatik humidifiers are not suitable for direct out-

door installation.

• Install the steam humidifier as close as possible to the

steam manifold. Use only short lengths of steam and
condensate hose to ensure optimal performance.

• Hoses must be laid at a constant 5-10% grade to uni-

formly prevent sags and kinks.

• The back surface of the steam humidifier heats up dur-

ing operation (to max. 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 mainte­nance.

• The unit’s protection class is IP20.

Page 16

5.1.1 Equipment Dimensions HC

c

a

e

l

j

m

k

o

n

d

b

h

f

i

g

View from below

Rear view

View from top

Water inlet

Waste water connection

Steam outlet

Condensate inlet

Cable entries

Page 17

HC02 HC03-09 HC06P-09P

HC12-HC27

a 390 562 707
b 394 427 490
c 260 257 306
d 320 382 445
e 351 513 657

f33 30 30
g 170 190 250
h48 35 50

i80 44 50

j 158 145 162
k 110 109 138

l 178 100 81

m 167 50 86

n43 56 56
o18 18 18

all dimensions in mm

General Survey

Page 18

5.1.2 Fitting Measures

Wall Distance

Note: It is often advantageous to use existing water connections

(feed and drain) when selecting the steam humidifier.

Wall Mounting

Note: To function properly the steam humidifier must be installed

vertically.

Measures for drills for wall mounting please see table (measures
d and e) in chapter „Equipment Dimensions”.If there is no suit­able wall, it is recommended that th e equipment is inst alled on
brackets which can be embedded in the floor.

(all dimensions in mm)

B

B

Page 19

5.2 Absorption Distance BN

The "ab sorption d istance" (BN) is defined as the dist ance from
the steam feed to where the steam is completely absorbed in the

treated air. W ithin the ab sorption d istance, steam is visible as
mist in the air stream.

Condensation ma y occur o n anythin g inst alled within the
absorption distance.

Although st eam outside th e absorptio n dist ance (B

N

) is com-

pletely absorbed, it is not yet evenly diffused in the duct. If you
plan to inst all a ny p arts or device s in side the a bsorption dis­tance, such a s sensors or elbows, we recommend increasing
the absorption distance using the formulae below. The absorp­tion dist ances required for certain in stalled fittings are distin­guished by separate symbols a nd calcula ted a s a multiplier of
the absorption distance B

N

.

The absorptio n dist ance has no fixe d value, but depe nds on
many factors. T hese are dep icted in th e absorptio n dist ance
nomogram below.

5.2.1 Determining the Absorption Distance

To determine the absorption distance, the following parameters
are required:

• Air humidity before humidification x

1

in g/kg.

• Air temperature after humidification t

2

in °C (with steam

humidifiers the change in air temperature due to humid­ification may be disregarded t

1

or 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 w

L

in m/s in air duct

• Total length l

D

of the steam manifold installed in the air

duct

Absorption Distance

B

N

for normal obstructions, such as se n­sors, ventilators, outlets

B

c

= (1,5...2) x BNfor fine filters, heat registers

B

s

= (2,5...3) x BNfor particle filters

B

d

= (2,5...3) x BNfor humidity sensors, duct humidistats

o

D

m

Page 20

Length ID of the usable steam manifold depends on the dimen­sions of the air duct. Th e length of the absorption distance can

be reduced by using multiple st eam manifolds (also see section
on the steam manifold).

Method:

Graphically determine absorption distance B

N

using the absorp-

tion distance nomogram (also see Section „Absorption Distance
Nomogramm“). Enter the va lue of the p arameters enumerated
above into the respective quadrants. The resulting point of inter­section ind icates the value of the desired absorption dist ance
B

N

.

Notes:

x

1

: _______________________________[g/kg]

t

2

: _______________________________[°C]

x:_______________________________[g/kg]

:_______________________________[kg/h]

w

L

: _______________________________[m/s]

l

D

: _______________________________[mm]

Air humidity before humidification

Air temperature after humidification

Specific increase in humidity

quantity of steam introduced

air speed t

Total length of the steam manifold

o

D

m

Page 21

5.3 Fan Unit (option)

Note: The fan unit shou ld be positioned to avoid drafts. A mini-

mum height of 2 m is generally sufficient.

• Install the fan unit directly on a wall.

Warning:

• During operation and some time afterwards the steam
nozzle is hot! This can cause burns to the skin at direct
contact.

• During operation the cross-flow fan rotates. Do not
touch the fan during operation.

• During operation hot steam discharges from the nozzle.
In the field of the visible steam cloud contact can cause
burns to the skin.

• During operation the cross-flow fan rotates. Do not
touch the fan during operation.

5.3.1 Fan Unit Type VG

• The fan unit is installed above the steam humidifier.

• When using multiple fan units, do not exceed a maxi-

mum distance of 5 m from the steam humidifier.

• Observe the clearances specified in the diagrams
below.

Type Fan Unit

HC02,HC03
HC06(P)

VG 08

HC09(P),
HC12

VG 17

HC18 - 27 VG 30

(all dimensions in mm)

Page 22

Fan unit, wall installation

Side view, wall-mounted fan unit

Technical Specifications Fan Unit VG
Fan Unit VG08 VG17 VG30

Quantity of Steam [kg/h] 8 17 30
Steam Inlet [mmφ]25 25 40
Condensate Outlet [mmφ]12 12 12
Airflow Capacity [cbm/h] 150 185 350
Nominal Output [W] 26 35 67
Nominal voltage [V] 230 230 230

Dimensions W [mm] 441 507 550

H [mm] 171 171 171
D [mm] 180 237 277

Weight [kg] 3.6 6 7
Sound Level (1m dis-

tance to th e sou rce of
noise)

[dB(A)] 52 54 57

Page 23

5.3.2 Absorption Distance Nomogram

Source: Henne, Erich: Luftbefeuchtung (Air Humidification), 3rd Edition 1984 (Page 101), Olden­bourg Industrieverlag, Munich

Page 24

5.4 Steam Manifold

5.4.1 Notes on Installation

These notes are based on a homogeneous

Standard steam manifold installation:

An even distribution of steam manifolds ensures a uniform steam
distribution.
Please use the total hight of the duct!

Minimum distances in order to avoid condensation:

L

min = 210mm: distance „ steam manifold - next ste am mani-

fold“

L4

min = 120mm: distance „lowest steam manifold - duct bot-

tom“:L5

min = 120mm: distance „highest steam manifold - duct

ceiling“Installations depending on special designs of air ducts:

Horizontal installation of
steam manifold

Steam Manifold

L1=L2=L3

Duct

Steam Manifold

Air flow

Air flow
direction

Page 25

Steam manifold

placement:

Horizontal installation of the steam manifolds is preferred. Howe­ver, installation from below into the air duct is possible.

Air duct Positioning of steam manifolds Sample

flat Staggered vertically and laterally

Air flow

very flat By tilting t he steam manifo ld 30 - 45°

towards the air flow directio n, the mini­mum upper clearan ce ca n be reduced
to 70mm.

min. distances: H1[mm] H2[mm]

30° 45°

DN25 182 168 225

DN40 193 179 230

very flat duct

narrow, high Identical lenghts one on top of the other.

Staggered laterally if possible.

square Identical leng hts, st aggered vertically

and laterally

low, very
wide

facing each other

Vertical installation of
steam manifold

Page 26

Note:

• Install the steam manifold horizontal with it ensure a clean

steam out.

• Maximum allowable pressure in the air duct is 1200 Pa.

• On the return side, th e ma ximum allowable nega tive air

pressure is 500 Pa. Placeme nt of the steam manifold on
the supply side of the air duct is preferred.

• With high-pressu re air-cond itioning systems, the un it's

drain ho se system must be modified depending on the
over p ressure. W hen this is the ca se please consult
HygroMatik.

• Install t he steam m anifold as c lose as p ossible t o t he

steam humidifier in orde r to minimize steam loss t hrough
condensation.

• Depending on the design of the air duct, additional moun-

ting of the steam man ifold may be required. Shown instal­lation and position dimensions are based on experimental
values. S pecial environment al con ditions could re quire
adjustments.

• We note that th e German Association of Engineers (VDI)

Guideline 6022 specifies a water drain within the absorp­tion distance inside the air duct.

• For steam ba th ap plications: Install the ste am manifold

safe from contact with people in order to prevent injuries or
burns. Do n ot install the steam manifold near a tempera-

ture sensor or inaccurate readings may result.

• Air flow rates o ver 3m/s can possibly lead to conden sate

drainage problems at the steam ma nifolds which may
require adaptation measures.

Length of steam manifold [mm]*:

* special lenght on request

Note: At len gths of 600 mm or mo re, st eam manifolds are
shipped with an extra alternative mounting fixture (Nut, M8) on
the closed end.

l 220 400 600 900 1200 1450

DN25xxxx x x

DN40xxxx x x

Page 27

The nu mber and size of appropriate steam manif olds, as well
the no minal wid th of the ir respective ste am a nd conden sate
hoses, are found in the tables below.

HyLine:

CompactLine:

HeaterCompact/Kit:

CompactLine Kit:

HeaterLine:

* For units HL 6 - 12 and HC3-12 HygroMatik delivers one adapter DN40 / 25 (but not for
SPA applications)..

** For units HL 36 - 45 HygroMatik delivers one t-connector for separating the steam on
two steam manifolds.

Type Steam Manifold Stea m Hose Condensate hose

HY05-HY17 1xDN25 DN25 DN12

HY05DS - HY17DS (for
SPA)

1xDN40 DN40 DN12

HY23-HY30 1xDN40 DN40 DN12

HY45-HY60 2xDN40 2xDN40 2xDN12

HY90-HY116 4xDN40 4xDN40 4xDN12

Type Steam Manifold Steam Hose Condensate Hose

C01-C17 1xDN25 DN25 DN12

C10-DS, C17DS
(for SPA)

1xDN40 DN40 DN12

C22, C30 1xDN40 DN40 DN12

C45** 2xDN40 DN40 DN12

C58 2xDN40 2xDN40 2xDN12

Type Steam Manifold Steam Hose Condensate Hose

HC02/Kit 1 xDN25 DN25 DN12

HC03-12* 1xDN25 DN25 DN12

HC03-12/Kit 1xDN40 DN40 DN12

HC16-27/Kit 1xDN40 DN40 DN12

HC3-27 (for SPA) 1xDN40 DN40 DN12

Type Steam Manifold Steam Hose Condensate Hose

C01 Kit - C06 Kit 1x25 DN25 DN9

C10 Kit - C17 Kit 1x25 DN25 DN12

C22 Kit / C30 Kit 1x40 DN40 DN12

C45 Kit 2x40 DN40 DN12

Type Steam Manifold Steam Hose Condensate Hose

HL 6-12 * 1xDN25 DN25 DN12

HL 6-12
(for SPA)

1xDN40 DN40 DN12

HL 18-30 1xDN40 DN40 DN12

HL 36-45 ** 2xDN40 1xDN40 1xDN12

Page 28

5.5 Steam Line

Note: Whe n inst alling the steam hose, please pay att ention to

the following:

• The steam hose diameter may n ot b e smaller than the

steam ou tlet of th e HygroMatik steam humidifier (do not
restrict the cross-section , otherwise back pressu re will
increase).

• The steam hose must be without sags and kin ks and be

laid with a continuous slope of 5-10% (otherwise sags will
be formed).

• The steam hose should be as short as possible. In case of

lengths of over 5 m the hose should be insulated to avoid
excess condensation.

• In the case that steam o utput is distributed on two steam

manifolds the Y-pieces for the steam and condensate hose
should be installed near the manifolds. If the installation is
carried out in this way only one st eam hose is necessary
for the main part, loss of condensate will be decrease d. If
the inst allation is carrie d out in th is way only o ne steam
hose is necessary for the main part, loss of condensate
will be d ecreased. In deviation of this the y-piece tha t is
delivered ex works with a humidifier type C45, HL36, HL45
should be installed near the humidifier.

• Depending on how the hose is laid, hose clips should be

set at intervals of approx. 500 mm.

• Allow access to the steam hose, so th at it ca n be inspec-

ted later.

• In case of straight lengths of several me ters, it is recom-

mended to pla ce the steam hose in temperature resistant
plastic pipe (40 mm dia for hose DN25; 60 mm dia for hose
DN40) or to use copper pipe.

• Device outp ut, steam line inst allation, a nd th e duct influ-

ence pressure condition in the duct. In an exeptional case
this could mean to optimize ths steam line installation.

• Only genuine HygroMatik hoses are capable of withstan-

ding the operating conditions.
Allow for minimum bending radii:
Steam hose DN 25: Rmin = 200 mm
Steam hose DN 40: Rmin = 400 mm

Page 29

5.6 Cover Plate

HygroMatik flange plates may be used to neatly complete instal­lation of the steam humidifier in the air duct.

Two-piece flange plates are ava ilable for the DN2 5 and DN40
steam manifolds.

flange plate DN25 E-2604260

flange plate DN40 E-2604410

Page 30

5.7 Drill Pattern

Drill Pattern DN25 (not to scale)

Note: Due to variable print med ia the dimension s are not to

scale.

Page 31

Drill Pattern DN40 (not to scale)

Note: Due to variable print med ia the dimension s are not to

scale.

Page 32

5.8 Condensate Hose

Note: When inst alling the conden sate hose, please pay atten-

tion to the following:

Warning: To ke ep cond ensate from accumula ting in the duct,
make sure condensate can drain freely.

If the s team m anifold i s positio ned hig her than 5 00 mm
above the steam humidifier:

» Remove the condensate plug (12) from the connection

fitting on the cylinde.

» Lay the condensate hose at an approximate incline of

5-10% to the steam cylinder connection fitting, to allow
the condensate to drain freely.

Note: It is recommended to form a loop of 200 mm diameter as
a vapour trap provided there is enough space. Possible operat­ing n oises can be re duced in t his manner. The loop should be
filled with water before commissioning.

If the ste am ma nifold is position ed lower than 5 00 mm
above the steam humidifier:

» The condensate must be drained separately.

» To prevent steam loss, lay a loop at least 200 mm in di-

ameter. The loop should be filled with water before
commissioning.

» To ensure condensate drainage, place the loop (vapor

trap) as far away as possible below the steam manifold
connection.

» The condensate connection on the steam cylinder must

be closed with a sealing cap.

» Place hose clamps at intervals of at least 500 mm, de-

pending on how the hose is laid.

5.9 Types of Installation

If the s team m anifold i s positio ned hig her than 5 00 mm
above the steam humidifier:

» Lay the steam hose at a height of at least 400 mm

above unit and then connect to the steam manifold with
a constant rise or fall.

» Lay condensate hose with a slope to the steam cylin-

der.

Page 33

» If enough space is available, lay a loop as a vapor trap.

The steam manifold must be at least 500 mm from the
loop.

If the ste am ma nifold is position ed lower than 5 00 mm
above the steam humidifier:

» Lay steam hose at a height of at least 400 mm above

unit and then connect to the steam manifold with a con­stant fall.

» Lay condensate hose with a loop of 200 mm diameter

(vapour trap) to the drain. The distance between vapour
trap and steam manifold should have at least 500mm.

» Lay the loop of condensate hose 200 mm directly

above the drain. Detail x

Page 34

5.10 Steam Solenoid Valves

When humidifying a number of loads, which are to be controlled
separately, using a sin gle steam hu midifier, steam solenoid
valves can be included in the steam hoses. Valve control has to
provided by the customer.

• Install the vertical risers with flow from bottom to top.

• The best position is just above the steam humidifier.

Installation of Steam Solenoid Valve

5.11 Unit Installation Check

Attention: This unit may only be operated by qualified and prop-

erly trained personnel.

Please check the installation using the following list:

 Does unit hang vertically?

 Are wall distances to the unit within the range

 Does steam hose have a slope of 5-10%?

 Is condensate hose installed with a loop of min. 200

mm?

 Is steam manifold positioned correctly? Are all bolts and

clamps tightened?

Page 35

6. Water Installation

Warning: For installation, note the following:

• Have all work performed by a professional.

• Disconnect power supply prior to installation.

• Obey regulations of local public utilities. Verify that neces-

sary saf ety me asures have been t aken - in compliance
with either German Technical and Scientific Association for
Gas and Water (DVGW) guidelines (DIN EN1717) or local
regulations - to eliminate backflow of pollute d wa ter into
drinking water treatment facilities. This can mean installing
a system sep arator an d a fre e discharge in the drainage
system. W ithin the h umidifier, two do uble check valves
(58) are located in the water supply lines. They prevent - in
accordance with DIN EN 61770 - the backflow of water.

• The water supply temperature may not exceed 40 °C.

• Flushed-out water must be able to drain freely.

• The water supply line must have a minimum diamet er of

DN 12 (3/8").

• If (chemical) ad ditives are pre sent in th e humidification

water, health risks and/or imp aired unit opera tion cannot
be ruled out. Use of additives is not advised unless specifi­cally recommended by the unit manufacturer.

• When employing demineralized water or purified conden-

sate, do not use copp er or brass in the supp ly or drain
lines of the HeaterCompact u nit. These materials ca n be
corroded by demineralized wate r or pu rified condensate.
Instead, use st ainless stee l or temp erature-resistant pla­stic pipes.

• Water in stallation pre ssure: 1 to 10 ba r (10 0x10³ to

100x10

4

Pa)

• For water inst allation ple ase use the water connecting

hose that is delivered with the unit.

6.1 Water Quality

The HeaterCompact Type steam humidifier is designed for use
with:

• tap water of different qualities up to 15°gH total hardness

• demineralized water (min. conductivity 3µS/cm)

• fully cleaned condensate (min.conductivity 3µS/cm)

• partially or fully softened water

Boiling n ormal t ap water a lways pro duces lime. Lime deposits
on the surface of the heater elements may reduce their lifetime.
We recommend to use a water treatment device in order to pre­vent scaling.

In case of any questio ns regard ing water trea tment devices
please contact HygroMatik.

Page 36

6.2 Water Supply (For Operation with Demineral-

ized Water or Purified Condensate)

» Install a shut-off valve (AV) in the supply hose

» Install a water filter (WF) if the water quality requires it

» Make sure that a backflow preventer is installed in the

water supply line.

Note: Shut-o ff valve ( AV), wate r filter (W F) and backflow pre­venter are not provided by HygroMatik.

Install as follows:

» Check whether the valve strainer has been inserted in

the solenoid valve.

» Screw cap nut (Q) onto the supply connection. Tighten

by hand.

The supply connection protrudes from the intermediate tray.

Note: Excessive tightening will damage the threads.

» Slide 13mm inner diameter hose (SCH) over the pres-

sure clip (R) and secure with a hose clamp.

Page 37

6.3 Water Supply (For Operation with Tap Water

or Partially/Fully Softened Water)

» Install a shut-off valve (SV) in the supply line.

» Install a water filter (WF) if water quality requires it.
» Make sure that a backflow preventer is installed in the

water supply line.

Note: Shut-off valve (SV) and wate r filter (WF) are not supplied
with the unit

» HygroMatik provides a water hose (56) with a cap nut at

both ends which can be used for water installation.

Install as follows:

» Screw and tighten th e cap n ut with it s inner seal ring

around the water su pply screw con nection t hat pro­trudes from the base.

Note: T ightening to o much will destroy the fitting . The va lve
strainer must be placed inside the solenoid valve.

» Use a cap nut (interna l thread ¾“) with inner se al for a

customer-provided water installation.

Page 38

6.3.1 Feed from Holding Tank

If a holding tank will be used to supply water, the „option sole­noid valve 0-1 0bar” must be ord ered. Make sure that th e feed
height is at least 0.5 meter. If the height is less than 0.5 m, insert
a feed pump or install the humidifier lower if possible.

6.4 Water Treatment

For water treatment system specifications, use the following

table. The figures below assume that the humidifier has
been running for 24 hours at 100% output.

HeaterCompact Max. Water Consump-

tion in over24 h [l]

255
383
6 166

9 248
12 331
18 497
27 745

HeaterSlim Max. Water Consump-

tion in over24 h [l]

383

6 166
10 277

option: solenoid
valve 0-10 bar

Page 39

6.5 Water Discharge

Warning: Please pay attention to free a nd non-pressure drain-

age of the wate r! During blo w down up to 0,3 L/s is b eing
drained. For wa ter discharg e, we recommend installation of a
flexible water drain hose. Humidifier and waste water discharge
must be on the same pressure level.

Please note:

• Do not bend, shorten or lengthen the drain hose.

• For the discharge line and drain pipe, select materials

temperature-resistant up to 95°C.

Install the water drain system as follows:

• Install a drain hose 1 1/4 ", 250 -. 1000 mm long, into a
pressure-free outlet according t o DIN EN 171 7. Please
ensure that ascending vapor does n ot conde nsate on
the humidifier`s housing.

• Slide the drain hose over the pump discharge hose and
secure to the cabinet drain connection.

A grounding clip is fixed on the inner surface of the cabinet drain
connection.Slide the end of th e pump d rain hose onto this clip.
During blow-down, the grou nding clip will be in direct cont act
with the water and will conduct any residual currents which may
appear away from the cabinet.

There is a 3mm-wide gap between the pump drain hose jacket
and th e inn er surface of the cabinet dra in connection. If water
collects on the base pla te, it will flow thro ugh this gap into the
drainage system.

Type Drain Hose

HC 2-27

HS 3-10

1 x 1 1/4"

Page 40

6.6 Checklist

Verify correct system installation using the checklist below:

 Can flushed-out water drain freely?

 Have all screws and clamps been properly tightened?

 Is the water supply line properly flushed out?

 Has the water installation been performed correctly?

Is the drainage system correctly installed?

Are the water supply and drain lines free of leaks?

Warning: Flush out the water supply line before connecting to
the so lenoid va lve, espe cially wh en installing a ne w line. T his
prevents dirt particles from damaging the solenoid valve.

Page 41

7. Electrical Installation

Warning, Haza rdous V oltage! All work re lated to ele ctrical

installation may b e perfo rmed b y au thorized pe rsonnel o nly
(electricians or professionals with equivalent training). The cus­tomer is resp onsible for checking qualifications.Warning, Haz-
ardous V oltage! Do not connect the steam humidifier to the
power grid un til after all inst allation work has bee n completed.
Please obey all local re gulations concerning electrical inst alla­tion.

Warning: The electronic comp onents of the humidifier co ntrol
are very sensitive to ele ctrostatic disch arges. In order to safe­guard these components during installation and servicing, steps
must be taken to protect against ESD.

Warning: For installation, note the following:

• Disconnect power supply prior to installation and secure

against restart.

• Verify the absence of electric current.

• Installation or removal of the display and control unit may

only be performed when the unit is switched off. See also
section "Access to Control.”

• Electrical connector cables must be wired by qualified per-

sonnel.

• Install electrical connections as specified in the wiring

diagrams.

• For units with power ratings over 33 kW, only a permanent

connection to a permanent installation is permitted
(observe European Directives shown in chapter „EC Dec­laration of Conformity“).

• Ensure that all terminals have been tightened.

• We recommend to install a fault current circuit breaker.

7.1 Electrical Installation

» Breakers must have a contact gap of at least 3 mm per

pole.

» Each steam cylinder requires a separate main power

supply including main fuses, main breaker, etc.

» Connect potential equalization inside the unit to the

external ground bolt (located on the underside of the
cabinet beside the cable connections).

Observe European Directives shown in chapter „EC Declaration
of Conformity.

Page 42

We recommend using a main f use with medium blow r ating
(applies only to the mains voltages above.) See table below indi­cating maximum power consumption corresponding to each type
of circuit protection:

The steam generator should be operated with a residual current
circuit breaker (RCCB).

7.2 Safety Interlock

Between terminal 1 and 2 of the humidifier the so called safety
interlock is located. If the safe ty interlock is not closed the
humidifier is not allowed to work.

Any additional safety de vices (see be low) h ave to be installed
between those terminals. The safety interlock is also used for an
On/Off control mode (remote switch).

There is no jumper between terminal 1 and 2 ex works.

If neither a Remote Switch nor any safety devices are wired to
terminal 1 and 2 an electrical bridge has to be set.

Note: Inst all co ntact interlo cks, i.e. max. hygrostat, vane relay,
pressure controller, air interlock etc. in series between Terminals
1 and 2.

Warning: It is st andard practice for air-condition ing to in stall a
max. hygro stat in the safety interlock (not valid for stea m bath
applications). The ma x. hygrostat acts as a safety device in the
event of a humidit y senso r malfunction and p rotects against
overhumidification.

Warning: Contacts laid between Terminals 1 and 2 must be
potential free and rated for 230V switches. Terminal 1 is supplied
with 230V AC after switching on the humidifier.

Type Power Supply Power Con-

sumption

Fuses

HC02 230V/1Phases/N 6,5A 1x10A
HC03 230V/1Phases/N 9,8A 1x10A
HC06 230V/1Phases/N 19,6A 1x20A
HC06(P) 400V/3Phases/N 11,3A 3x20A
HC09(P) 400V/3Phases/N 16,9A 3x20A
HC12 400V/3Phases/N 19,5A 3x25A
HC18 400V/3Phases/N 29,3A 3x35A
HC27 400V/3Phases/N 29,3A 3x35A

Terminals Humidifier

230V int.

Page 43

7.3 Control Connection

Within the scope of this manual there is only a short descrip­tion of the „Adjustment of th e Control to th e Control Signal” at
this point. More detailed information please find in the technical

manual for the co ntrol that is also delive red with the Heater
Compact.

The Heater Compact is used in both applications for steam bath
and air conditioning. As the Heater Compact is controlled via the
temperature in steam bath applications and via the air humiditiy
in air conditioning ap plications different typ es of controls are
used. Therefore the descriptions of the Control Connections are
also different:

7.4 Control Connection - S team Ba th Applic a-

tion

Valid for Controls: Basic-DS (B-DS), Comfort-DS (C-DS) und
ComfortPlus-DS (CP-DS).

7.4.1 Temperature Sensor Connection

Connect the temperature sensor cable to the designate d termi­nals 6 and 7 on the HygroMatik steam generator.

The factory settin g for the value for the set point of steam bath
temperature is 45°C. After switching the main switch to I (=ON)
the humidifier starts to produce steam if the cabin temperature is
a) below setpoint of temperature and b) if the safety interlock is
closed (please see also chapter „Safety Interlock).

Connection for other steam bad components is described in the
technical manual for the DS-Control.

7.5 Control Connecti on - Air Conditioning

Application

Valid for Controls: Basic (B), Comfort (C) und ComfortPlus (CP).

Note: The factory setting for the controls is to an „External con­trol signal, 0-10 VDC“ if no other setting is described in the deliv­ery note of th e humidifier .Within th e scope of this technical
manual there is only a short description of „Adjustment of Con­trol to the Control Signa l”. For more d etailed information please
see the also delivered technical manual „Controls”.

Warning: Se t the cont rol to prevent ove rly freq uent activation
and de activation o f the steam humidifier . Main cont actors are
wearing p arts and are guaranteed by the manu facturer for
150,000 cycles. Operation which minimizes activation cycles will
extend the life of the main contactors.

Page 44

7.5.1 1-step control

With 1-S tep Controls, the external control hyg rostat or co ntrol
switch is wired in series with the contacts of the safety interlock.

Warning: Cont acts laid between terminals 1 and 2 mu st be
potentialfree and rated for 230V switches

By the use of a

Basic control: For 1 -step controls the jumpers

must be set as indicated below:

By the use of a

Comfort/Comfort-Plus control: For 1-step con­trols, Parame ter U6 must be set to “1-step,” a lso see Section
„Parameter Se tting with Codes (P0=10) / Advan ced Customer
Level“ in the technical manual for the Control.

7.5.2 Proportional Control wi th an external control

signal

The control can be adjusted to the following external control sig­nals:

0(2) - 5 V DC

0(2) - 10 V DC

0(4) - 20 V DC

0(4) - 10 mA DC

0(4) - 20 mA DC

0 - 140 Ohm

230V int.

Basic Control

A

B

C

JP1

Comfort Control

Page 45

The factory setting is a control signal of 0-10V.

Controller

Humidifier Terminals

By the use of a

Basic control:

For a Proportional Control with an e xternal control signal the
jumpers must be set as indicated below:

By th e use o f a

Comfort/Comfort-Plus contro l: F or a propor­tional control connected to an external control signal, Software­Parameters U6 and E3 must be set as indicated below.

Setting for External Control

Signall

Parameter

U6 E3

0(2) - 10V DC external control-

ler

0 - 10 V

0(4) -20 mA external control-

ler

0 - 20 mA

0 - 140 Ohm external control-

ler

0 - 140 Ohm

Basic Control

A

B

C

JP1

Setting fo r External Control
Signal:

0(2) - 10 V DC

A

B

C

JP1

Setting for External Control
Signal:

0(4)-20 mA

Setting for External Control
Signal:

0-140 Ohm

A

B

C

JP1

Comfort Control

Page 46

7.5.3 Proportional Control with Built-In PI-Controller

Upon reque st, Hygro Matik will provide an active sen sor with a
control signal of 0 -10 V DC. Sensors with othe r control signals
can also be used; the control (only available at Comfort or Com­fort-Plus Control) need only be set to them.

Humidifier Terminals

If other types of active sensors are used Paramter E3 has to be
adjusted:

Humidifier Terminals

Note: The desired relative humidity value is set at Parameter P8
(factory setting: P8=50%).

Setting for Sensor Signall Parameter

U6 E3

0(2) - 10V DC PI-Control 0 - 10 V

0(4) -20 mA PI-Control 0 - 20 mA

0 - 140 Ohm PI-Control 0 - 140 Ohm

Connection: Active Se nsor,
one-cylinder and double- cyl­inder humidifier; vo ltage out­put

active sensor

terminal block

Connection: active sensor;
current out put, sin gle-cylin­der and double cylinder un its,
two-wire system

Page 47

7.6 Cable Connections

The t able belo w shows t he ca ble connectio ns pro vided in
HeaterLine steam humidifiers:

Characteristics of metric cable connections:

7.7 Fan Unit

» Connect fan unit as specified in the wiring diagram.

The fan unit is activated/deactivated in parallel with humidif ica­tion.

Note:Terminals 37 und 38 are supplied with the unit only when
the fan unit a nd humidifier a re purchased simult aneously. In
other cases (i.e. re trofitting) the fan unit motor p hase can be
connected to Terminal 2 guided via the a uxiliary contact of the
main contactor.

Only cables with same diameter are alllowed to be connected to
one common clamp.

Unit Connection

M16

Connection

M25

Connection

M32

HC02 - 09 4 2 0
HC06P-HC09P

HC12 - HC27

421

Thread

across-flats

dimensions [mm]

for cable diameter

[mm]

M16x1,5 19 4,5 - 10

M25x1,5 30 9 - 17

M32x1,5 36 11 - 21

Page 48

7.8 Wiring Diagram

Please refer to th e wiring diagram in the technical manual sup­plied with th e con trol used wit h you r humidifier . Eve ry steam
humidifier comes with a u nit-specific technical manual an d a
manual fo r the control. I n add ition, you will find d ownloadable
wiring diagrams and technical manuals at www.hygromatik.de.

7.9 Electrical Installation Checklist

Perform e lectrical inst allation checks in compliance with cus­tomer site requirements and public power utility regulations:

 Does the mains voltage match the voltage on the name

plate?

 Have all electrical connections been made according to

the terminal diagram?

 Have all electrical cable and plug connections been

properly tightened?

 Are all electrical plug connections secure?

 Is the unit grounded?

After this check the unit can be switched on.

Warning: The unit must be closed and locked (only for humidifer
type HeaterLine). This guarantees that the cover is grounded.

Note: For initial o peration, control, service, malf unctions, and
circuit diagrams, consult the operation instructions for the Hygro­Matik-controls or at www.hygromatik.de.

Page 49

8. Maintenance

The HygroMatik steam humidifier is easy to maintain. Neverthe­less, ina dequate or imp roper ma intenance can le ad to opera­tional ma lfunctions. Perfo rm reg ular main tenance to g ive your
unit a long life span.

Since steam and co ndensate hoses are also subject to wear
they have to be checked regularly. Seals are wearing parts and
must there fore b e examined in the periodic mainte nance and
replaced if required.

For maintenance the screw t erminals must be checked and
retightened if necessary.

Warning: When performing maintena nce work, ple ase follow
these instructions:

• During operation and also for a while after switching off

the unit the steam cylinder is hot. Before touching the
cylinder, check its temperature.

• Drained cylinder water could have a temperature up to

95°C.

• Before removing the steam cylinder make sure that it is

completely drained and that it does not contain any hot
water.

• During disassembling a steam hose hot steam could

leave the steam hose if several humidifiers are working
on the same air duct, although the currently maintained
unit is switched off.

• Have the unit serviced only by qualified, authorized per-

sonnel.

• Obey safety regulations.

• Switch off the unit prior to maintenance and secure

against restart.

• After maintenance work, have qualified personnel

check that the unit is operating safely.

• If a defective cable is detected through a visual check

switch off the unit, secure it against restart and replace
the cable.

• The clamps that fix the steam cylinder halves have par-

tially sharp edges and could spring out uncontrolled
during removement. Prevent springing out clamps by
covering the clamps with one hand during removement.

During operation the fan for cooling the solid state relay is run­ning.

The steam humidifier’s performance and maintenance intervals
depend primarily on the existing water quality and the quantity of
steam generated. Variable water quality can lengthen or shorten
the maintenance interval. Ongoing maintenance intervals can be
estimated based on the amount and type of residue found in the
steam cylinder.

Page 50

Immediate cylinder maintenance is indicated by:

a green, blinking LED on the display and operating panel.

the

display reads Service (only with co ntrols of T ype Comfort and
Comfort Plus).

8.1 Maintenance for Operation with Demineralized

Water / Condensate

Instructions f or maintena nce and clean ing intervals are b ased
exclusively on typical, empirically determined values.

Cycle Maintenance Task

4 W eeks af ter
Initial Operation

Visual check o f electrical and me chanical
connections.

Visual check of water level control.

Visual check of steam cylinder interior.

Annually Visual check of electrical and mechanical

connections.

Visual check of water level control.

Visual check of heater elements / thermo sen­sor.

Visual inspection of interior of steam cylinder.

If needed, cleaning of steam cylinder, heater
elements and thermo sensor.

Page 51

8.2 Maintenance for Operation with Tap Water or Par-

tially Softened Water

No precise ma intenance intervals can be specified because
these always de pend on water q uality an d quan tity of steam
generated. It is advisable to adjust the frequency of maintenance
to the specific operational application.

HYGROMATIK recommends to op en and check the steam cyl­inder two weeks af ter commissioning. Ongoing maintenance
intervals can be estimated based on the amount and type of res­idue found in the steam cylinder.

Blow-Down Cycles

The vaporization process causes mineral (calcium) deposits of
different compositions to settle in the steam cylinder. Part of this
solid build-up is removed through periodic blow-downs and fresh
tap water refills.

Water quality

When using t ap wa ter, not e that clean ing intervals short en as

the carbonate hardness level in the water increases. As a gen-

eral rule, it is prefera ble to operate the unit with fully demineral­ized water. Op eration will no t be affected by mineral depo sits
and flushing losses will be minimized.

Note: If desired , maintena nce intervals can b e len gthened by
moderately incre asing blow-down rate s. Please consult Hygro­Matik.

Page 52

8.3 Access to Control Unit

» Remove cover (or electric compartment cover) and lift

display panel (A) out of its guide.

» Turn display panel (see drawing) and hang display

panel on the humidifier cabinet (B) by placing the two
guide pins in the two front guides.

» The PCB (C) is now accessible.

Danger, Hazardous Voltage: Switch off unit before installing or
removing the display plate.

Page 53

8.4 Removing and Cleaning the Steam Cylinder

Warning: Please follow the detailed instructions in these operat-

ing in structions! The unit is only to be se rviced by qualified,
authorized personnel. Note the warnings and safety notes in the
operating instru ctions. F ailure to ob serve warnings a nd safety
notes may result in injury, serious injury o r death, and/or dam­age to the unit. The stea m cylind er may still be hot wh en you
begin maintenance work. Handle carefully!

Note: After a longer period of operation the steam cylinder could
shrink a little. This doesn‘t matter but could lead to tightness dis­crepancies when o nly one h alf of the cylinder is b eing
exchanged. The refore we recommend not to change only one
half of the cylinder but a complete cylinder.

Removal:

on/off switch in position II

after cylinder draining switch off unit

open unit

disconnect unit from voltage supply
and secure it against restarting

Page 54

disconnect unit from water
supply

check for voltage disconnection

check cylinder temperature

remove steam hose from
adapter

lift steam cylinder out of base

push clip on adapter
outside cabinet

Page 55

Cleaning of Steam Cylinder and Cylinder base

When using minera l deposit removers or cleaners to clea n the
cylinder and h eater e lements, ma ke sure you th oroughly rinse
the unit before return ing reasse mbling it. Use mineral depo sit
removers only for cylinder and heater elements.

Note: Overly strong mechanical cleaning can damage the cylin­der / heater elements.

detach connecting cable for
heater element(s)

remove flange clamps

open cylinder

remove used O-ring

clean cylinder inside

clean the two strainers

Page 56

» Remove all deposits. However, small amounts of scale

deposits on the heater elements (8) are harmless.

» Cylinder base (11) and the connections have also to be

checked for deposits and cleaned if necessary.

Cleaning of the Control Cylinder

The control cylinder (27, 28, 29) monitors the water level. When
cleaning the steam cylinder the control cylinder should also be
cleaned. Therefore:

» Loosen the four top screws that interconnect floating

switch (27) and control cylinder housing (29).

» Pull out floating switch and clean it carefully.

» Take off sealing (28) and clean it.

Note: The rod assembly may not be lubricated.

» Clean the sealing surface it the control cylinder housing

(28).

» For installation mount the a.m. components in reverse

order.

Assembly

connect upper and lower
part with clamps

insert new O-ring

remove used O-ring

insert new O-ring

Page 57

Note: When putting the cylinder back toge ther, the jo ints and
reinforcements of both sections must fit together snugly.

Switch on t he un it and check for leaks af ter 15-30 minutes of
operation.

install connecting cable for
heater element(s)

remove old O-ring
insert new O-ring

place cylinder vertically
into cylinder base

reconnect to power supply

fix adapter with clip

push adapter onto
steam outlet

Page 58

8.5 Maintenance of the Control Cylinder

When clea ning the steam cylinder th e co ntrol cylinder sh ould
also be cleaned.

As the access to the control cylinder is only possible if the steam
cylinder is remo ved o ne can fi nd the sub chapte r „Cleaning of
the Control Cylinder” in chapter „Cleaning the Steam Cylinder”.

8.5.1 Cleaning the nozzle in the steam hose adapter

From the top of the control cylinder a hose is laid to the connec­tor at the steam ho se adapter. Within this connector there is an
integrated nozzle that has to be cleaned regularly as it could be
blocked by lime.

8.6 Replacing Heater Elements

Removal

» Remove and open the steam cylinder as described

above in section “Removing and Cleaning the Steam
Cylinder.”

» Detach connecting cable for the heater element in

question. Mark these two terminals.

» If necessary, remove the capillary tube from the thermo

sensor by detaching the retainer clips.

» Detach the heater element from the cover by removing

the nut and adjusting washer.

» If present detach cable lug for grounding.

» Pull heater element downward out of the steam cylin-

der.

» Clean the sealing surface on the underside of the cover

around the area where the new heater element will be
installed.

Installation

» Install new heater element (with sealing), replacing the

parts in the correct sequence, and screw nut.

» Insert the heater element’s connecting cable into the

two marked terminals and tighten. Polarity of (heater
element) connecting cable is not important.

» If necessary: Install capillary tube on the thermo sensor

using retainer clips.

» To proceed further, follow the steps described above in

section “Removing and Cleaning the Steam Cylinder”.

Page 59

8.7 Replacing Thermo Se nsor (for Heater Ele-

ment)

Removal

» Remove and open the steam cylinder as described

above in section “Removing and Cleaning the Steam
Cylinder.”

» Loosen clips of capillary tube (T).

» Disconnect capillary (T) tube from the heater elements

(8).

» Remove the etwo screws (S) of thermo sensor (O).

» Remove thermo sensor.

O: Thermo Sensor
P: Unlocking Button for Thermo Sensor
Q: Seal
R: Steam Cylinder
S: Screw
T: Capillary tube

Warning: Do not bend the capillary tube of the thermo sensor!
Installation

» Install thermo sensor with new sealing. Do not fix the

screws too tightly!

» Neatly connect the capillary tube to the heater element.

Having humidifiers with two or more heating elements
the capillary tube is connected to two heating elements.

» To proceed further, follow the steps described above in

section “Cleaning Coarse Strainer in Cylinder Base ­Assembly” .

O

P

Q

R

S

T

Page 60

8.8 Unlocking of a Re leased Ther mo S ensor

(for heater element)

If a thermo sensor (for heater element) has released due to a too
high temperature the red release button (P) is some millimetres
above the level of the top of it s holder . Additiona l the co ntrol
reports a failure „thermo sensor activated“. After the system has
cooled down the release button (P) can be unlocked by pressing
it down a few millimetres.

8.9 Unlocking of a Re leased Ther mo S ensor

(for Solid State Relay)

If a th ermo sensor (for solid state relay) has release d due to a
too high temperature (>100°C +/- 5°K) the con trol reports a fail­ure „thermo sensor activated“. After the system has cooled down
the release pin (that lays between the bot h pla in connectors)
can be released by pressing it carefully down until there is a klick
sound.

Release
button

Page 61

8.10 Removing Inlet Sole noid Valve and Clean-

ing Fine Mesh Filter

Removal

» Remove and open the steam cylinder as described

above in section “Removing and Cleaning the Steam
Cylinder - Removal.”

» Seal off water supply and remove screw joint from fresh

water connection.

» Detach connector hose from base.

» Remove electrical connectors from solenoid.

» Remove solenoid valve mounting screws.

» Take the solenoid valve out of hole.

Cleaning

» Remove fine mesh filter from the solenoid valve and

clean.

Installation

» Place solenoid valve with seal in the hole in the unit

cabinet.

» Secure solenoid valve tightly with screws .

» Attach fresh water connection.

» Connect elecrical cable to the solenoid valve.

» Attach connector hose to the base by using clamps .

» Install cylinder as described above in section “Cleaning

Steam Cylinder - Assembly”.

» Open water supply.

» Switch on unit and check for leakage after 15-30 min-

utes of operation.

If leakage occurs, switch off power supply and repair the leaks,
following safety instructions for work on live components!

Page 62

8.11 Cleaning Blow-Down Pump

Removal

» Remove and open the steam cylinder as described

above in section “Removing and Cleaning the Steam
Cylinder - Removal.”

» Detach electrical connector from the pump (10).

» Detach union adapter (E) from the pump.

» Remove screws (G) and take the pump out of the base

(11).

» Open pump (bayonet lock).

» Remove all residue from the drain hoses and pump

(possibly replace o-ring (A)).

» Assemble pump.

» Moisten o-ring (C) and place in the side connection of

the base.

» Push pump into the base and secure tightly with screws

(G).

» Moisten o-ring (D) and place on the side connection of

the pump.

» Slide union adapter (E) over the side connection of the

pump.

» Connect electrical connector to the pump (polarity not

specified).

» Open water supply.

» Switch on unit and check for leaks after 15-30 minutes

of operation.

If leakage occurs, switch off power supply and repair the leaks,
following safety instructions for work on live components!

Page 63

8.12 Cleaning c onnection hose s a nd c ylinder

base

All connection hoses should be free of deposits and under good
conditions.

As well check all conne ctions of the cylinder base (11) and the
steam hose adapter (2) for deposits and remove if neccessary.

G

Page 64

8.13 Checking Cable Screw Connections,

Heater Element Wires

» Check that all cable screw connections are securely

tightened

» Ensure that heating element cable is not dammaged.

Warning: Lo ose cable connection s cause excessive cont act
resistance and overheating of contact surfaces.

8.14 Operational Check

» Start up the unit and operate for a few minutes, ideally

at maximum output..

» Check safety devices.

» Check hose connections for possible leaks.

8.15 Dismantling

Once the steam humidifier will no long er be used, dismantle
(demolish or scrap) it b y following the installation procedures in
reverse order.

Warning: Dismantling of th e unit may on ly be performed by
qualified pe rsonnel. Electrical d ismantling may only be per­formed by trained electricians.

Obey the safety guidelines in section “Safety Instructions,” espe­cially the guidelines for disposal.

Page 65

9. Commissioning

Warning: This unit is only to be started by qualified personnel.

Switching off steam humidifier

Warning: Before starting up the unit, make sure you know h ow

to switch it off.

» Switch off unit by setting control switch to “0”

» Close water supply stopcock valve.

Check of electrical wire connections

»
» Check that all electrical wire connections, including

heater element wire connections, are tight and secure.

» Check cylinder seating, and if necessary steam and

condensate hose clamps.

Switching on Steam Humidifier

» Switch on main breaker.

» Open water supply stopcock valve. Operating pressure

100 x 10

3

to 100 x 104 Pa (1 to 10 bar overpressure).

» Switch on unit by setting control switch to “I”.

» Set control of initial operation check to humidity

demand.

The following functions are operating:

• The unit performs a self-test. If the control includes a

display, the message “self-test“ is displayed.

• If the safety interlock (see also chapter „Safety inter-

lock”) is closed, the water inlet solenoid valve opens
and feeds water into the steam cylinder.

• If there is a demand for humidity, the main contactor is

switched and a few minutes later steam production
starts.Initiation of steam production can take up to 20
minutes.

Further checks:

 Let all electrically-driven operations run to completion.

As so on as the solen oid valve be gins replenishing the water
periodically, th e ste am hu midifier operates at steady nominal
output and the cold start sequence is complete.

» Monitor the unit and let it operate for 15 to 30 minutes.

If leaks appear, switch off the unit.

» Repair leaks, and in doing so:

Attention, Hazardous V oltage! Follow safe ty instructio ns for
work on live components.

Page 66

10. EC-Declaration of Conformity

Page 67

11. Spare Parts

*

HC02

HC 0 3

HC06

HC09

HC06P

HC 09P

HC 1 2

HC18

HC27

Arti c le No. D esc ri pt ion

Cabinet HC

Stea m Gen era ti on

1

B-2 205 493 C ylin de r c ompl ., wit h 1 h ea ter e lem ent 1 ,5k W, 1 ther mal se nsor and

termina l, 2 30V

1

B-2 205 483 C ylin de r c ompl ., wit h 1 h ea ter e lem ent 2 ,25kW , 1 t herm al sen sor

an d t erminal , 23 0V

1

B-2 205 455 C ylin de r c ompl . Inc l 1 h ea ter e lemen t 4. 5 kW , 1 th ermal senso r an d

termina l

1

B-2 20545 9

Cylinder compl. Incl 1 heater element 6.75kW, 1 thermal sensor and

termina l

1

B-2 205 463 C ylin de r c ompl . Inc l 1 h ea ter e lemen t 4. 5 kW , 1 th ermal senso r an d

termina l

1

B-2 20546 7

Cylinder compl. Incl 1 heater element 6.75kW, 1 thermal sensor and

termina l

1

B-2 205 471 C ylin de r c ompl . Inc l 2 h ea ter e lemen ts 4.5kW, 1 th ermal s enso r an d

termina l

1

B-2 205 47 5 Cylin de r c om pl . Inc l 2 hea ter e lem en ts 6.7 5kW , 1 the rma l sen sor

an d t erminal

1

B-2 205 47 9 Cylin de r c om pl . Inc l 3 hea ter e lem en ts 6.7 5kW , 1 the rma l sen sor

an d t erminal

16 1

B-3216046 top part of cylinder Cy2, empty

16 1 1 1

B-3 216 050 to p par t of c yli nder, empt y fo r 1 h ea ter e lemen t and 1 th . Sen sor,

including strainer

16 1 1

B-2 206 051 to p par t of c yli nder, empt y fo r 1 h ea ter e lemen ts and 1 th . Sen sor,

including strainer

16 1 1

B-2 206 059 to p par t of c yli nder, empt y fo r 2 h ea ter e lemen ts and 1 th . Sen sor,

including strainer

16 1

B-2 206 061 to p par t of c yli nder, empt y fo r 3 h ea ter e lemen ts and 1 th . Sen sor,

including strainer

191111

B-3 216 052 l ower p art o f cyl ind er Cy08 , in clud ing straine r

19 11111

B-2 206 053 l ower p art o f cyl ind er Cy17 , in clud ing straine r

1

B-2 209 031 he ater ele me nt 230V / 1, 5k W with se aling and moun ting se t, big

diameter

81

B-2 209 029 he ater ele me nt 230V / 2, 25 kW wi th sealin g a nd mou nt ing set, big

diameter

81

B-2 20902 5

he ate r ele ment

23 0V

/ 4.5kW with sealing and mounting set, big

diameter

81

B-2 209 021 he ater ele me nt

40 0V

/ 4,5kW with sealing and mounting set, big

diameter

81

B-2 209 023 he ater ele me nt 400V / 6. 75 kW wi th sealin g a nd mou nt ing set, big

diameter

812

B-2 209 001 he ater ele me nt 400V / 4. 5k W with se aling and moun ting se t

8123

B-2 209 003 he ater ele me nt 400V / 6. 75 kW wi th sealin g a nd mou nt ing set

262222

E-2 205 138 Ga sket for h ea ter e lemen t

252222

E-2205140 Mounting nut for heater

26 22446

E-2 204 006 Ga sket for h ea ter e lemen t

25 11223

E-2204007 Mounting nut for heater

151111

E-3 216 010 O- rin g se al f or cy l ind er fl a ng e

15 11111

E-2 206 050 O- rin g se al f or cy l ind er fl a ng e

1

B-3 216 015 O- rin g se t f ür HC 02

111

B-3 216 095 O- rin g se t f or HC 06-0 9

11111

B-3 216 097 O- rin g se t f or HC 06P- 27

59 1

B-2 209 035 pr otec ti ve tube incl m e lt ing fu se

5111111111

B-2 205 03 1 The rma l s ensor 1po le

6666668810

E-2 205 012 C lam p for ther mal se nsor 1p ole

6111111111

E-2 205 010 ga sket for the rma l sen sor 1 po le

21

E-2 209 000 ad apter for ste am h ose D N25

1

E-2 209 014 ad apter for ste am o utle t D N40/DN25

24 1

E-3 221 004 C lip for stea m ho se adap ter D N25

1

E-2 204 022 O- rin g f or cy lind er ba se an d st eam ho se adapt er

2 11111111

B-2 205 025 ad apter for ste am h ose D N40

24 11111111

E-2 209 002 C lip for stea m ho se adap ter D N40

4 11111111

E-2 204 022 O- rin g f or ste am h ose ada pter DN 4 0

1 22222222

E-2205088 star knob screw, fixation for steam hose adapter

12 11111111

E-2 204 03 5 conde nsa te pl ug

Page 68

*

HC02

HC 0 3

HC06

HC09

HC06P

HC 09P

HC 1 2

HC18

HC27

Arti c le No. D esc ri pt ion

Water feed

14 1

B-2 304 059 do uble so leno i d va lve, 0. 2-10 ba r, 2 00-2 40V AC, 1.2 l /m in

14 1 1 1

B-2 304 061 do uble so leno i d va lve, 0. 2-10 ba r, 2 00-2 40V AC, 2.5 l /m in

14 11111

B-2 304 069 do uble so leno i d va lve, 0. 2-10 ba r, 2 00-2 40V AC, 3.5 l /m in

111111111

E-2304024 fine filter in solenoid valve inlet

111111111

E-2 304 103 c ap ti ve c ou pling rin g f or so leno id va lve 3 /4"

111111111

E-2 30410 7 ga sket for in let screwed fittin g, sole noid

111111111

E-8 501 034 ho se col lar f o r inlet screw ed fi ttin g, 3/ 4" so len oid

56111111111

B-2 304 031 ho se for w at er co nnec ti o n, 0,6 m 3/ 4" ca p nut s o n b ot h sid es, sea l

inc lud ed

32111111111

E-2 304 036 ru bber se al so len oid valv e - c abin et

111111111

B-2 304 040 m ounti ng se t f or so leno id va lve

31 0,9 1, 2 1 ,2 1,2 1,4 1,4 1,4 1 ,4 1, 4

E-2 604 00 2 hose s ol en oi d valv e - c yl in de r

33 0,9 0, 7 0 ,7 0,7 0,7 0,7 0,7 0 ,7 0, 7

E-2 604 00 2 hose s ol en oi d valv e - s up er flu sh

211111111

E-2 604 044 bu ckl in g pr ot ectio n f or ho se

1111

B-2504121 water level control, compl with flow switch, consisting of pos. 27, 28,

29 , va lid s i nce 06/2 014

11111

B-2504141 water level control, compl with flow switch, for HC06P/09P, HC12-27

291111

E-2 504 142 wa ter lev el co ntrol , wi tho ut fl ow sw itch , va lid sinc e 0 6/2 014

29 11111

E-2 504 174 wa ter lev el co ntrol , wi tho ut fl ow sw itch , f or HC0 6P/0 9P/ 12 -2 7,

before 06 /2014 for: HC03 -09

27 11111

B-2 50416 7 fl ow sw itch incl. Seal ing s, b efore 06/201 4 for : HC03- 27, sin ce

06 /20 14 fo r: H C06P/0 9P/12 -27

1111

B-2 504 171 fl ow sw itch incl . sea lin gs, si nce 06/ 2 01 4 f or: H C03 -0 9

28111111111

E-2 304 038 ru bber se al f or w ate r level control

30 0,2 0, 3 0 ,3 0,3 0,4 0,4 0,4 0 ,4 0, 4

E-2 604 004 ho se, cylin der ba se - c ontrol c yl ind er

3 0 ,3 0, 5 0,5 0,5 0,6 0 ,6 0,6 0 ,6 0, 6

E-2 604 002 ho se, wate r level co ntro l- stea m ho se ad apt er

1111111

E-2604021 T-piece condensate manif old, type TS12, DN12
E-2 604 029 ho se nozz le DN 2 5 - R 3 /4"

58222222222

E-2 604 094 D ouble c hec k v alv es

34 1 0 10 1 0 1 0 10 1 0 10 1 0 10

E-2 304 01 5 hose c la m p DN12

39222222222

E-8 501 06 4 hose c la m p DN14 ,2

Water Drain

11111111111

E-2 206 086 c yl inde r ba se for C , Hy, HC, DN40

13111111111

E-2 204 022 O- Ring f or cyli nder b ase DN40

10111111111

B-2 404 027 D rain p ump 230V / 50- 60Hz with ou t mo unt ing set

111111111

B-2 424 014 Mo unti ng se t fo r dr ain pu m p

111111111

E-2 404 026 D rain p ump housing

18111111111

E-3 220 005 O- rin g cy lind er b ase - dra in p ump

211111

E-3 425 002 ad apter , pum p - dra in h ous e, ang led DN25/ 13

11111

E-2 425 002 ad apter , pum p - dra in h ous e, str aigh t, DN2 5/ 13

17111111111

E-3 220 005 O- rin g f or dr a in p um p

7111111111

E-2 425 004 El bow wit h ve nt pip e

22 0,3 0, 5 0 ,5 0,5 0,6 0,6 0,6 0 ,6 0, 6

E-2 604 002 ho se, drain pum p-elbo w

23 0,4 0, 6 0 ,6 0,6 0,6 0,6 0,6 0 ,6 0, 6

E-2 604 004 dr ain ho se, elb ow - ou tlet

57111111111

B-2 304 03 1 hose wa ter co nn ec t io n 3/4 "

1

B-3401053 drain hose system for HC02, consisting of pos. 7 , 17, 21, 22, 23

111

B-3401035 drain hose system for HC03-09, consisting of pos. 7, 17, 21, 22, 23

11111

B-3401037 drain hose syste m for HC06(P)-27, consi sting of pos. 7,17,22,23,

ad ap er st raig ht

Page 69

*

HC02

HC 0 3

HC06

HC09

HC06P

HC 09P

HC 1 2

HC18

HC27

Arti c le No. D esc ri pt ion

Control

1

E-2 501 005 m ain con tact or 1 6A, ( ABB) , co il v ol ta ge.23 0VAC

111111

B-2 507 041 m ain con tact or 2 0A, D ILM7 , c o il volt a ge .230V AC

11

B-2 507 061 m ain con tact or 3 5A, D ILM1 7, coil vo ltag e 2 30VAC

51111111111

E-2 502 412 c on tr ol b utt on 2 pole B asi c, L3/ DS, middle 0

1

E-2 205 110 s olid sta te re lais 2 5 A , wit ho ut co oler

11111

B-2 602 001 s olid sta te re lay 2 5 A, 1 ph., cooli n g d evi ce 15 0 x 50 mm, th erm al

circuit breaker

11

B-2 602 103 s olid sta te re lay 5 0 A, 2 ph., cooli n g d evi ce 15 0 x 50 mm, th erm al

ci rcu it b re ak er (not at Sl a ve- unit s

1

B-2 602 009 s olid sta te re lay 7 5 A, 1 ph., cooli n g d evi ce 15 0 x 80 mm, th erm al

ci rcu it b re ak er (not at Sl a ve- unit s)

111 1

B-2 602 107 s olid sta te re lay 2 5 A, 1 ph.

11

B-2 602 109 s olid sta te re lay 5 0 A, 2 ph.
B-2 602 111 s olid sta te re lay 7 5 A, 1 ph.

11

E-2 205 102 Pr otec ti o n c ap ag ainst co ntact w ith cut out

1111111

E-2 205 116 c oo l ing de vi ce 1 50 x 50 m m

1

E-2 205 118 c oo l ing de vi ce 1 50 x 80 m m

111111111

E-2205108 Thermal circuit breaker with manual reset, 100°C ± 5K

11111

E-3 720 010 F an , 2 30VA C

Basic

111111111

B-2 526 203 El ekt ro nic pcb typ e B asic
B-2 526 203 El ekt ro nic pcb typ e B asic f or S lav e-un its

(1) (1) (1) (1) (1) (1) (1) (1) (1)

B-2 526 213 El ekt ro nic pcb typ e B asic f or H C ste am b ath

1

B-2120915 Mounting plate with foil for Basic (without display), small

11111111

B-2120901 Mounting plate with foil for Basic (without display)

(1)

B-2120919 Mounting plate with foil for Basic DS

(without display), sma ll

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2120909 Mounting plate with foil for Basic DS

(without display)

(1) (1) (1) (1) (1) (1) (1) (1) (1)

B-2 526 301 R elais p cb for B asi s pcb

Comfort

111111111

B-2 526 203 El ekt ro nic pcb typ e B asic

B-2 526 203 El ekt ro nic pcb typ e B asic f or S lav e-un its

(1) (1) (1) (1) (1) (1) (1) (1) (1)

B-2 526 213 El ekt ro nic pcb typ e B asic f or H C ste am b ath

1

B-2 526 489 C omfo rt disp la y C 01/0 2 HC02 , sm all

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 526 401 C omfo rt disp la y i ncl. mou ntin g p late with foil

1

B-2 526 487 C omfo rt Dis play DS C01 /02 HC 02

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 526 445 C omfo rt disp la y i ncl. mou ntin g p late with foil st eam bath

1

B-2 120 917 m ounti ng p late wit h foi l fo r Comf o rt un i t ( wit hout displa y), sm all

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 120 903 m ounti ng p late wit h foi l fo r Comf o rt un i t ( wit hout displa y)

1

B-2 120 919 m ounti ng p late wit h foi l fo r Comf o rt un i t fo r ste am b ath DS (wi thout

display), small

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 120 911 m ounti ng p late wit h foi l fo r Comf o rt un i t fo r ste am b ath DS (wi thout

display)

Comfort Plus

11111111

B-2 526 203 El ekt ro nic pcb typ e B asic

B-2 526 203 El ekt ro nic pcb typ e B asic f or S lav e-un its

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 526 213 El ekt ro nic pcb typ e B asic f or H C ste am b ath

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 526 403 C omfo rt Pl u s Dis play in cl . Mou ntin g plat e

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 120 905 m ounti ng p late wit h foi l fo r Comf o rt Pl u s un it ( wit ho ut displ ay)

(1 ) ( 1) (1 ) ( 1) ( 1) ( 1 ) ( 1) (1 )

B-2 526 447 C omfo rt plu s di spl ay in cl. mou ntin g pl ate w i th foil st eam bath

Page 70

*

HC02

HC 03

HC06

HC09

HC06P

HC 09P

HC 12

HC18

HC27

Arti c le No. D esc ri pt ion

Accessories

E-2 604 034 R educi ng pi e ce DN4 0/D N 25 fo r ste am h ose
E-2 604 012 Ste am hos e DN25 , p er m
E-2 604 013 Ste am hos e DN40 , p er m
E-2 604 002 C onden sate h ose DN 12 , p er m
E-2 404 004 Ste am hos e cla mp D N25
E-2 604 016 Ste am hos e cla mp D N40
E-2 304 015 C onden sate h ose clam p D N 12

57 E-2 420 423 D rain h ose 1 1/4"

E-2 604 042 Ste am mani fol d p i ece DN25, sta inl ess ste el
E-2 604 023 Ste am mani fol d p i ece DN40, sta inl ess ste el
E-2 604 021 C onden sate c onnect or T- piece DN12
B-2 604 025 s te am so leno id va lve 0-0, 4 b ar, c ompl . for st eam ho se DN 2 5

B-2 604 040 s te am so leno id va lve 0-0, 4 b ar, c ompl . for st eam ho se DN 4 0

If you order any spar e part s , sp eci fy ty pe a nd se ria l num be r of the u nit, plea se.

* see exploded view

Page 71

12. Fax Form - Order for spare parts

Badgermeter Swiss AG

Mittelholzerstrasse 8

3006 Bern

Tel. [phone]

Order of spare parts

unit type *______________ serial no.* ___________________

commission: ______________ order no.: __________________

date of delivery ____________forwarder _____________ shipment by ___________

delivery address (if different
from invoice address)

__________________________
__________________________
__________________________
__________________________

* Order can only be processed if unit type and unit serial no. are filled in.

quantity article article no.

Fax Form

Please copy, fill in and fax to

Fax.No. [phone]

company stamp (delivery adress)

date/signature

Page 72

13. Index

A

Absorption Distance

................................................................. 19

Determining the Absorption Distance ................................ 19

C

Commissioning

......................................................................... 65

Condensate Hose Installation .................................................. 32

E

EC-Declaration

......................................................................... 66

Electrical Installation ................................................................ 41

Environmental Conditions ........................................................ 15

Exploded View.......................................................................... 76

F

Fan Unit

.................................................................................... 21

I

Installation

Equipment Dimensions HC

................................................ 16

Fitting Measures................................................................. 18

Installation of a HeaterCompact............................................... 15

Internal Output Setting ............................................................. 14

M

Maintenance

............................................................................. 49

Blow Down Pump............................................................... 62

Control Cylinder.................................................................. 56

Heater Elements................................................................. 58

Steam Cylinder................................................................... 53

Thermo Sensor................................................................... 59

Method of Operation ................................................................ 12

Mode of Action ......................................................................... 11

S

Safety Interlock

......................................................................... 42

Setting for Control Signal ......................................................... 43

Spare Parts............................................................................... 67

Steam Line ............................................................................... 28

Steam Manifold ........................................................................ 24

Notes on Installation........................................................... 24

Page 73

T

Technical Specification

............................................................ 74

U

Unlocking Thermo Sensor (for heater element)

...................... 60

Unlocking Thermo Sensor (for Solid State Relais).................. 60

V

View of Cabinet

........................................................................ 77

W

Water Installation

...................................................................... 35

Water Supply............................................................................ 36

Page 74

14. Technical Specifications

HeaterCompact HC

Type HC02 HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27

Steam Output [kg/h] 2 3 6 6 9 6 9 12 18 27
Electrical Supply* 230V/1/N 400V/3/N 50-60Hz
Power Rating [kW] 1,5 2,25 4,5 4,5 6,8 4,5 6,8 9,0 13,5 20,3
Power Consumption
[A]**

6,5 9,8 19,6 11,3 16,9 11,3 16,9 19,5 29,3 29,3

Circuit Protection [A] 1 x 10 1x10 1x20 3x16 3x20 3x16 3x20 3x25 3x35 3x35
Control Type Basic, Comfort and Comfort Plus
Number of Steam
Cylinder

1

Number of Heater
Elements

111111122 3

Steam Hose Con­nection

1x25mm*** 1x40mm

Condensate Hose
Connection

1x12mm

Net Weight [kg] 12 16 16 16 16 22 22 23 23 24
Operating Weight
[kg]

15 20 20 20 20 36 36 37 37 38

Height [mm]**** 390 562 704
Width [mm]**** 394 427 490
Depth [mm]**** 260 260 309
Water Supply Fully Demineralized Water / Cleaned Condensate: 1 to 10 bar, 13mm Hose

Partially Softened Water / Tap Water (different qualities): 1 to 10 bar, for 3/4” exter-

nal thread
Fan Unit, Wall­Mounted

VG08 VG08 VG08 VG08 VG17 VG08 VG17 VG17 VG30 VG30

Airflow Capacity of
Fan Unit [m

3

/h]

150 150 150 150 185 160 185 185 350 350

* Other voltages upon request.
** Current load of phases is not uniform. See table below.
*** incl. reducing piece DN40/DN25
**** Outer dimensions of width and depth.

Max. current load [A] according to phase:

Phase HC06(P) HC09(P) HC12 HC18 HC27
Electrical Supply* 400V/3/N 50-60Hz
L1 11,3 16,9 11,3 16,9 29,3
L2 11,3 16,9 19,5 29,1 29,3
L3 0,2 0,2 11,3 16,9 29,3

Page 75

HeaterCompact HC for SPA

HC03..-DS - HC27..-DS

Type HC03 HC06 HC06 HC09 HC06P HC09P HC12 HC18 HC27

Steam Output [kg/h] 3 6 6 9 6 9 12 18 27
Electrical Supply* 230V/1/N 400V/3/N 50-60Hz
Power Rating [kW] 2,25 4,5 4,5 6,8 4,5 6,8 9,0 13,5 20,3
Power Consumption
[A]**

9,8 19,6 11,3 16,9 11,3 16,9 19,5 29,3 29,3

Circuit Protection [A] 1x10 1x20 3x16 3x20 3x16 3x20 3x25 3x35 3x35
Control Type Basic-DS, Comfort-DS and ComfortPlus-DS
Number of Steam
Cylinder

1

Number of Heater
Elements

1 1111122 3

Steam Hose Con­nection

1x40mm

Condensate Hose
Connection

1x12mm

Net Weight [kg] 16 16 16 16 25 25 26 26 27
Operating Weight
[kg]

18 18 18 18 43 43 44 44 45

Height [mm]*** 562 707
Width [mm]*** 427 490
Depth [mm]*** 257 306
Water Supply Fully Demineralized Water / Cleaned Condensate: 1 to 10 bar, 13mm

Hose

Partially Softened Water / Tap Water (different qualities): 1 to 10 bar, for 3/

4” external thread

* Other voltages upon request.
** Current load of phases is not uniform. See table below.
*** Outer dimensions of width and depth. Hight incl. drain connection.

Max. current load [A] according to phase:

Phase HC06(P) HC09(P) HC12 HC18 HC27
Electrical Supply* 400V/3/N 50-60Hz
L1 11,3 16,9 11,3 16,9 29,3
L2 11,3 16,9 19,5 29,1 29,3
L3 0,2 0,2 11,3 16,9 29,3

Page 76

15. Exploded View

















































































Page 77

16. View of Cabinet

56

57

51

12/2004