HydroMatik LPS, LPS45, LPS72, LPS110 Operating Manual

LPS

Humidifies and Cools

ÁLPS.Ä4-&3Ö.ENhÈ

LPS.20130619.EN

Operating manual

Page 2

Caution: Voltage: All work must be carried out by specialists. All electrical installa­tion work and work on the device's electrical components must be carried out by
authorised electricians. Switch off devices and disconnect them from the ma ins sup­ply first!

Certain computer programs contained in this product [or device] were developed by HygroMatik
GmbH ("the Work(s)").

Copyright © HygroMatik GmbH [2013.06.19]
LPS
All Rights reserved.

HygroMatik GmbH grants the legal user of this product [or device] the right to use the Work(s)
solely within the scope of the legitimate operation of the product [or device]. No other right is
granted under this licence. In particular and without prejudice to the generality of the foregoing,
the Work(s) may not be used, sold, licensed, transferred, copied or reproduced in whole or in part
or in any manner or form other than as expressly granted here without the prior written consent of
HygroMatik GmbH.

Information in this manual is subject to change or alteration without prior notice.

Page 3

1. Introduction ....................................................................................................................... 5

1.1 Typographic markings .......................................................................................................5

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

1.3 Intended use .....................................................................................................................6

2. Safety instructions ............................................................................................................8

2.1 General information ...........................................................................................................8

2.2 Operational safety instructions .......................................................................................... 8

2.3 Disposal upon disassembly ...............................................................................................9

3. Transport ............................................................................................................................ 10

3.1 General information ...........................................................................................................10

3.2 Packaging ..........................................................................................................................10

3.3 Temporary storage ............................................................................................................ 10

3.4 Inspecting for correctness and completeness ................................................................... 10

3.5 Scope of delivery ...............................................................................................................10

4. Function and design .........................................................................................................11

4.1 Functioning ........................................................................................................................11

4.2 Design and process ........................................................................................................... 11

4.2.1 Pump group ....................................................................................................................12

4.2.2 Dimension drawing of HygroMatik LPS nozzle system .................................................. 12

4.2.3 Vortex modules .............................................................................................................. 13

4.2.4 Atomising nozzles .......................................................................................................... 14

4.2.5 Droplet separators (optional) .......................................................................................... 15

4.2.6 Humidification section ....................................................................................................15

4.3 Partial and Full-Load .........................................................................................................16

5. Connnections .................................................................................................................... 17

5.1 Water .................................................................................................................................17

5.2 Waste water ......................................................................................................................17

5.3 Pressure water .................................................................................................................. 17

5.4 Electrical ............................................................................................................................18

6. Interfaces to the HygroMatik nozzle system LPS ........................................................... 19

6.1 Air ......................................................................................................................................19

6.2 Humidification chamber .....................................................................................................19

7. Mechanical assembly ........................................................................................................ 21

7.1 Overview of the humidification chamber ...........................................................................21

7.2 Vortex wall module assembly ............................................................................................ 22

7.3 Assembling the vortex module wall ................................................................................... 22

7.3.1 Guide rails for the vortex module wall: ...........................................................................22

7.3.2 Examplary design of guide rails for a vortex module wall .............................................. 23

7.3.3 Side rails for the vortex module wall: ..............................................................................23

7.3.4 Assembling of the side rails for the vortex module wall ..................................................23

7.4 Installation of the nozzles, distributor pipe and tubing .......................................................24

7.4.1 Nozzle Installation: ......................................................................................................... 25

7.4.2 Assembling the distributor pipe ......................................................................................26

Page 4

7.4.3 Piping ............................................................................................................................. 27

7.5 Assembling the droplet separators .................................................................................... 32

7.5.1 Examplary design of guide rails for the droplet separators ............................................32

7.6 Pump station wall mounting ..............................................................................................35

7.7 Checking the installation ...................................................................................................36

8. Dimensions - Pump Station ..............................................................................................37

9. Water connection ..............................................................................................................38

9.1 Overview Water connection ..............................................................................................38

9.2 Water supply .....................................................................................................................39

9.3 Drainage ............................................................................................................................40

9.3.1 Water drain for the humidification chamber ....................................................................40

9.4 Water Quality ..................................................................................................................... 41

9.5 Inspection the water supply ...............................................................................................41

10. Hygiene ............................................................................................................................42

10.1 Ensuring hygiene (VDI 6022) ..........................................................................................42

10.2 Automatic flushing ...........................................................................................................42

11. Electrical connection ......................................................................................................43

11.1 Connection data .............................................................................................................. 44

11.2 System enabling / Safety chain .......................................................................................44

11.3 Circuit diagram ................................................................................................................ 45

11.4 Inspecting the electrical installation ................................................................................. 47

12. Commissioning ............................................................................................................... 48

13. Maintenance ..................................................................................................................... 49

13.1 Maintenance activities .....................................................................................................49

13.1.1 Inspection / replacement of the net-based water filter ..................................................50

13.1.2 Cleaning the atomizer nozzle ....................................................................................... 51

13.1.3 Cleaning the droplet separators ...................................................................................52

13.1.4 Cleaning the vortex module wall ..................................................................................52

13.1.5 Cleaning the humidification chamber ...........................................................................53

14. Control System ................................................................................................................54

14.1 Control and speed regulation ..........................................................................................54

14.1.1 Full load and part load ..................................................................................................55

14.1.2 Summer / winter mode .................................................................................................55

14.2 Description of the programmable controller (PLC) .......................................................... 56

14.2.1 General description ......................................................................................................56

14.2.2 Menu ............................................................................................................................ 58

14.2.3 Overview of error reports ..............................................................................................61

15. EC declaration of conformity ......................................................................................... 63

16. Spare parts ....................................................................................................................... 64

17. Fax Form - Order for spare parts ................................................................................... 66

18. Technical Specifications ................................................................................................ 67

19. Plant scheme ................................................................................................................... 68

Page 5

1. Introduction

Dear Customer,

Thank you for purchasing a LPS nozzle system.
The HygroMatik LPS nozzle system corresponds to the current

state of the art. It features exceptional operational reliability,
ease of use and cost-effectiveness.

To ensure the proper, safe and economical operation of your
HygroMatik LPS nozzle system, please read this operating man­ual.

Only use the HygroMatik LPS nozzle system if it is in perfect
condition and only for its intended purpose, considering all
safety and risk aspects as well as all instructions in this manual.

If you have further questions please contact us:

Tel.: [phone] (Switchboard)
Tel.: [phone] (Technical Hotline)
Fax: [phone]
Email: [e-mail]

Please have your device data ready for queries or spare part
orders!

1.1 Typographic markings

• lists with items beginning with bullets: general lists
» lists with items beginning with arrows: work or operating

steps which should or must be carried out in the speci-

fied order
 installation steps which must be checked
italics figure and plan names

1.2 Documentation

Storage

Please keep this operating manual in a safe place where it is
accessible at all times. If you sell the product, be sure to include
this manual. Please contact HygroMatik if the documentation is
lost.

Language versions

This operating manual is available in different languages. Please
contact your HygroMatik dealer or HygroMatik for details.

Page 6

1.3 Intended use

The HygroMatik LPS nozzle system is used for air humidification
and cooling with desalinated water having a conductivity of 5-20
µS/cm. The feed water should have a temperature of 5-15°C.

Caution: Proper use includes fulfilment of the assembly, disas­sembly, reassembly, start-up, operating and maintenance condi­tions specified by us as well as disposal measures.

Only appointed qualified staff may work on or with the system.
Persons transporting or working on or with the system must
have read and understood the relevant parts of this operating
manual, particularly the 'Safety instructions' section. Staff must
also be informed of possible hazards by the operating company.
Please keep a copy of the operating manual at the location
where the device is being used.

The HygroMatik LPS nozzle system is not frost-proofed and not
suitable for outdoor installation.

The room temperature should be between 5 and 40°C.
At an altitude of over 1000 meters please contact your Hyg roMa-

tik dealer or HygroMatik for details.

Applications:

The HygroMatik LPS nozzle system has a wide range of applica­tions. These systems are used wherever low-energy adiabatic
humidification or cooling or systems with high-precision control
are needed. They can be found in such places as offices, store­rooms, production halls, clean rooms, hospitals and concert
halls.

Note: Components installed in ventilation and air-conditioning
systems must be suitable for the intended use; i.e. they must be
corrosion-resistant, easy to clean, accessible and hygienic. Fur­thermore, they must not facilitate growth of micro-organisms.

Improper use:

Hardware and software may not be modified.

Page 7

Exemptions of usage:
The HygroMatik nozzle system LPS is not frost resistant and is

unsuitable for outdoor installation.
The HygroMatik nozzle system LPS PLC control may not be

deviate from the preset programmed On-/Off Control (or only
after consultation with HygroMatik).

The default constant pressure level of the HygroMatik LPS noz­zle system may not be changed (or only after consultation with
HygroMatik).

The HygroMatik LPS nozzle system may only be used for the
purpose of cold-water cooling after consultation with HygroMa­tik.

The HygroMatik LPS nozzle system or may not be used in a ver­tical flow (or only after consultation with HygroMatik).

Page 8

2. Safety instructions

2.1 General information

The safety instructions are prescribed by law. They are intended
to ensure health and safety at work and accident prevention.

Warnings and safety symbols

The following safety symbols are used in this manual to indicate
hazard and risk warnings. Please familiarise yourself with these
symbols.

Caution: Failure to heed this warning may result in injury or dan­ger to life and limb and/or damage to the device.

Caution: Voltage: Dangerous electrical voltage! Failure to heed
this warning may result in injury or danger to life and limb.

Note: indicates materials and consumables which must be han­dled and/or disposed of in accordance with statutory require­ments.

Note: precedes explanations for or cross-references to other
places in the text.

2.2 Operational safety instructions

General information

Observe all safety instructions and warnings found on the sys­tem.

If malfunctions occur switch the system off immediately and
secure it to prevent it from being switched on. Eliminate the mal­functions immediately.

After maintenance work has been carried out, expert staff must
ensure that the system is safe to operate.

Only use original spare parts.
National regulations beyond the scope of this manual apply with-

out restriction for operation of this device.
During operation of the HygroMatik LPS nozzle system it is not

allowed to stay in the humidification chamber.
The desalinated water used for feeding the HygroMatik LPS

nozzle systemis unsuitable for drinking.
Work on the high pressure components of the nozzle system is

only allowed if the unit is disconnected from the power supply.
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.

Page 9

Supervise children in order to ensure that they will not play with
the unit.

Accident prevention regulations
Caution: Heed the HSW (Health and Safety at Work) regulations

for electrical installations and equipment (VBG4/BGVA3).
By doing so you protect yourself and others from harm.

Operating the HygroMatik LPS nozzle system

Refrain from all work practices which compromise the safety of
the system.

Check all protection and warning devices at regular intervals to
ensure they are in perfect working order.

Do not remove or deactivate safety devices.

Assembling, disassembling, servicing and maintaining the
device

Disconnect system parts from the mains supply before servicing
or repairing them.

Mounting or insertion of additional devices is only permitted
with the written consent of the manufacturer.

The HygroMatik LPS nozzle system is protected to IP20. Ensure
that the devices are protected from dripping water and dust at
the installation location.

If a HygroMatik LPS nozzle system is to be set up in an area
without water drainage, safety measures which eliminate the
possibility of water entering the system due to leaks must be
taken.

Electrical equipment
Caution: Only a qualified electrician is permitted to work on the

electrical system and the control cabinet.
Disconnect system parts from the mains supply before working

on them. Switch off the system immediately if faults in the electri­cal energy supply occur. Only use original fuses with the speci­fied amperage. Inspect the system's electrical equipment at
regular intervals. Promptly eliminate deficiencies, such as loose
connections or melted cables. After carrying out the correspond­ing electrical assembly or maintenance work, test all protective
measures used (e.g. earth resistance).

2.3 Disposal upon disassembly

Note: The operating company is responsible for disposal of the

system parts in accordance with statutory requirements.

Page 10

3. Transport

3.1 General information

Note: Take care when transporting the HygroMatik LPS nozzle

system to prevent the device and packaging from being damaged
by impact or accidental loading or unloading.

3.2 Packaging

Note: The HygroMatik LPS nozzle system is delivered on a pal-

let.

3.3 Temporary storage

Store the material in a clean dry place. The storage temperature
should be 0-40°C.

Note: Only clean components may be installed in a ventilation
duct.

3.4 Inspecting for correctness and complete-

ness

When you receive the goods, ensure that:

• the equipment is complete and all parts are in perfect

condition.
Note: Any transport damages and/or missing parts must be re-

ported immediately to the shipper or supplier.
The periods in which notification of the transport company must
occur for the purposes of identifying the damage are as follows*:

* Periods are subject to change without notice.

3.5 Scope of delivery

The following items are included in the delivery:

• vortex modules

• droplet separators (optional; Hygiene compliance

checks applies only to systems with droplet separators)

• pump station

• operating instructions for the system

• bushing/s for duct

Note: Hoses and nozzles are delivered at the time of start-up.

Transport company Time after receipt of

goods

Post no later than 24 hours

Rail 7 days at the latest

Rail and road transport

companies

4 days at the latest

Parcel services immediately

Page 11

4. Function and design

4.1 Functioning

The HygroMatik LPS nozzle system is based on atomisation of
water.

Desalinated water is fed into a vane pump. With an operating
pressure of up to 16 bar, the water then goes to the nozzles.
These nozzles generate a very fine spray mist which is taken up
by the air in the device chamber. The ambient air is cooled adia­batically in the process.

4.2 Design and process

1: Pump group
2: Water feed
3: Vortex module wall
4: Viewing window (necessary according to VDI 6022)
5: 2-stage droplet separator
6: Humidification chamber or duct with service doors and water

tray
7: Water drain, siphoned
8: SPS-control

Page 12

4.2.1 Pump group

The vane pump generates a pressure of up to 16 bar. The main­tenance-free asynchronous motor with variable frequency ena­bles continuous operation up to 50 Hz.

4.2.2 Dimension drawing of HygroMatik LPS nozzle

system

Pump group Capacity [l/h] Max. speed

[rpm]
LPS 45 45 1350
LPS 72 72 1350

LPS 110 110 1350

H T B Weight

LPS 45-110 700 230 600 30 Kg

T

B

H

Page 13

4.2.3 Vortex modules

The vortex modules provide for effective mixing of the air and
the water mist.

Due to their special design, they generate turbulence and shear
zones which lead to a homogeneous distribution of moisture
along the humidification section (0.9 m).
The vortex modules (dimensions: 150 x 150 mm) are delivered
individually and can be assembled to form a wall. For optimal
moisture absorption, the air velocity is 1.0-2.5 m/s. The vortex
module wall exhibits a low pressure drop of 10Pa at an air veloc­ity of 2.0 m/s.

Page 14

4.2.4 Atomising nozzles

Desalinated water at a pressure of up to 16 bar reaches the noz­zles where the water is atomised to form ultra-fine mist-like aero­sols. The aerosols enter the area of the vortexed air stream
downstream of the vortex modules. The air and aerosols are
mixed intensively here.

The atomising nozzle generates a spray cone with a wide open­ing angle.

1: Nozzle opening
2: Nozzle body

Functioning:
The nozzle sets the flowing water in rotation and thereby it can

leave at high speed. This enables a very fine water spray. The
higher the operating pressure, the finer the droplets.

Material of the nozzle: corrosion-free stainless steel

2

1

Page 15

4.2.5 Droplet separators (optional)

There are no more atomised water droplets in the air stream
behind the HygroMatik LPS nozzle system (if the environmental
parameter specifications are complied with). The two wire-mesh
droplet separators arranged in series ensure this. The trap pads
exhibit a low pressure drop (75 Pa at air velocity of 2.0 m/s and
average air density of 1.2 kg/m³).

The air velocity should be between 0.9 m/s and 2.8 m/s. If it is
outside this range it can cause moisture breakthrough down­stream of the droplet separators - in such cases please first con­tact HygroMatik.

The droplet separators are inserted into the humidification
chamber via guide rails and are hence easy to remove for serv­icing.

The traps are standardly delivered with corrosion-resistant metal
frames.

Note: Hygiene compliance checks applies only to systems with
droplet separators.

4.2.6 Humidification section

The section between the vortex module wall and the droplet sep­arators is called the 'humidification section' in this system. It is
unobstructed and hence easy to monitor and clean.

For a total standard installation length of 1.5 m for the HygroMa­tik LPS nozzle system the humidification section should have a
length of at least 0.9 m. The exact dimensions are described in
the schematic in the section entitled 'Overview of the humidifica­tion chamber'.

droplet separators

Page 16

4.3 Partial and Full-Load

For optimal humidification control under various input conditions
the HygroMatik nozzle system LPS can be equipped with a „Par­tial and Full-Load” control function.

At Full-load all nozzles are fed with water. At Partial-load a sole­noid valve switches off the water supply for approximately half
of the nozzles.

Construction:
The vane pump has to exits for water - one is the water supply

for the nozzles for Partial load and the othe one is the water sup­ply for the nozzles for Full load.

If the external control signal decreases below a special switching
point, the HygroMatik nozzle system LPS switches off the water
supply for half of the nozzles.

Page 17

5. Connnections

5.1 Water

Connection: 3/4”-external thread (within the

system)

Conductivity: 5-20 µS/cm
Pressure: 0.15-0.5 MPa (1.5-5 bar)
Temperature: max. 15°C
pH value: 7 +/- 1

Note: The supply water for the HygroMatik high-pressure nozzle

system must comply with VDI 6022; i.e. from a microbiological
point of view it must be of drinking water quality.

5.2 Waste water

Connection: Connecting piece DN 12 for

plastic hose (resistant to low
conductive water)
Fitting: with constant fall and free outlet
and siphon

5.3 Pressure water

Connection „Full-Load”: plug-in connection for 6/4

pressure hose

Connection „Cooling”: plug-in connection for 6/4

pressure hose

Connection „Partial-Load”: plug-in connection for 6/4

pressure hose

Page 18

5.4 Electrical

Power supply: LNE 230 V AC, 50 Hz (a fixed

socket (16 A) at the installation

site is necessary)

External control signal: 0-10 V DC

4-20 mA DC

System enabling: via ext. potential-free contact
Collective fault signal: potential-free contact (change

over contact)

Operating status signal: potential-free contact (NO)

Page 19

6. Interfaces to the HygroMatik nozzle system
LPS

6.1 Air

Air purity: A Class F7 pre-filter is to be

placed upstream of the HygroMatik nozzle system LPS.
Air velocity: 0.9-2.8* m/s
If the air velocity is outside this range please contact HygroMa-

tik.
(*: under ideal conditions)

Pressure drop: Approx. 80 Pa (at an air velocity
of 2.0 m/s and with use of a vortex module wall and two dry
droplet separators).

Air volume flow (for 'partial-load / full-load switching'
option):

If the HygroMatik nozzle system LPS is operated in systems with
modifiable air volume flows (reduced air volume of less than
70% of the maximum air volume), the full-load solenoid valve is
switched off and the partial-load mode is activated. This also
applies for systems with multi-stage ventilators.

Note: For humidification of rooms the humidified air must exhibit
a purity in terms of bacterial count in accordance with VDI 6022.

6.2 Humidification chamber

The humidification component should be designed with a floor
tray that has an inclination of at least 1.5° towards the trap and
to be waterproof.

The water drain must be at the end of the humidification section.
The ideal humificiation section length (distance between vortex

module wall and droplet separators) is 0.9 m. This corresponds
to a total installation length of 1.5 m (see schematic in section
entitled 'Overview of the humidification chamber'). Should this
installation length not be available please contact HygroMatik.

The humidification chamber should be aerosol-tight and it
should be able to withstand desalinated water.

Note: The guide rails for the vortex module wall and droplet sep­arators are supplied by the manufacturer. The guide rails must
already be installed for the system to be started. The vortex
module wall and droplet separators must also already be
installed.

Page 20

Note: The guide rails must be designed such that

- the vortex module wall and droplet separators can be removed

(for servicing)

- there cannot be any stagnant water.

Note: When starting the system check again that the humidifica­tion chamber has been thoroughly cleaned. In particular the
humidification chamber and the ventilation duct upstream of it
must be free from metal swarfs to prevent corrosion.

Page 21

7. Mechanical assembly

Caution: The device may only be assembled by qualified staff.

HygroMatik accept no liability for damages resulting from incor­rect assembly.

Observe all safety instructions and warnings found on the
device. The device must be de-energised during assembly.
Mounting or insertion of additional devices is only permitted with
the written consent of the manufacturer. Otherwise the guaran­tee and warranty will become void.

7.1 Overview of the humidification chamber

1: Vortex module wall with spray system
2: Droplet separators
3: Upper guide rails for droplet separators
4: Lower guide rails for droplet separators
5: Collection tray
6: Drain with trap

7. Guide rails for vortex module wall

8. Humidification section, >/= 0.9 m

9. Two supplied bushings for the duct (for partial-load / full-load

switching) for connecting high-pressure hoses * Only one bush­ing is needed for the standard model.

10. Distribution pipe

Note: In front of the vortex module wall and from the droplet
separators a minimum distance of 0.3 m to other installed com­ponents must be maintained (see above schematic). In case of
an upstream installation of a fan in front of the vortex module
wall, the minimum distance shall be 1 m or appropriate action
has to be taken in order to ensure a laminar flow of the vortex
module wall. Temperatures higher than 60°C may destroy the
vortex modules.

Page 22

7.2 Vortex wall module assembly

The vortex module wall provides firstly the air turbulence and
secondly it holds the atomiser nozzles and water distributor.

The vortex module wall is supplied as specified (please note the
number of vortex modules in width and height), assembled in the
accompanying nozzle assembly data sheet:

» The Vortex modules are slotted together piece by

piece, starting at the bottom right

The bottom right vortex module must be so positioned that the
right hand and lower side is flat surface up while the other two
sides show the guide bars (1).

7.3 Assembling the vortex module wall

Two guide rails are required for assembly of the vortex module
wall.

We recommend to have an air gap sideways between the vortex
module wall and the housing wall as it generates a laminar air
flow and prevents moisture build-up on the walls.

7.3.1 Guide rails for the vortex module wall:

In order to position the vortex module wall in the humidification
chamber guide rails are required. The guide rails are fixed to the
ceiling and the floor of the humidification chamber.

The guide rails must be installed in a way that makes it possible
to either pull out of or lift up the vortex module wall and stagnant
water is prevented.

Ensure that after installation the floor of the h umidification cham­ber is leackage-free.

1

Page 23

7.3.2 Examplary design of guide rails for a vortex

module wall

Pos. 1: upper guide rail
Pos. 2: vortex module wall
Pos. 3: spacer or direct connection floor of chamber
Pos. 4: lower guide rail
Pos. 5: humidification chamber

Inner dimension of guide rail: 62 mm
Hight: please see above sketch
Material: 1.4301 stainless steel sheet, thickness: 1 mm

7.3.3 Side rails for the vortex module wall:

If the wall consists of 11 or more vortex module rows side rails
are required in order to avoid bending of the vortex module wall.

Having more than 16 vortex modules in horizontal position the
the vortex module wall has to be vertically separated into two
halfs, that are separately fixed by side rails

Guide rail (cross section)

Page 24

7.3.4 Assembling of the side rails for the vortex

module wall

Vortex module walls consisting of 11 or more vortex module
rows are automatically equipped with side rails and self-tapping
screws.

The side rails have to be adapted to the right lenght by the
installer. The required lenght is the distance between the middle
of the lowest and the middle of the top vortex module.

The side rail is an u-section and made of stainless steel. It is

1.5mm thick. For the assembling the open side of the u-section

has to be attached to the latteral edge of the vortex module wall
(pos. 3). The lower end of the side rail is positioned in the middle
of the lowest vortex module. The lowest drilling (pos. 2) of the
side rail is used to screw in a self-tapping screw (M3.9X20). A
second self-tapping screw is used for the upper end of the side
rail.

The side rail for the other side of the vortex module wall has to
be assembled in the same way.

1

2

3

Page 25

7.4 Installation of the nozzles, distributor pipe

and tubing

7.4.1 Nozzle Installation:

» In accordance with the supplied nozzle assembly data

sheet locate the vortex module to be equipped with a
nozzle.

» Then plug the nozzle body (1), as shown in the picture,

on the upstream side of the vortex module, so that it
protrudes about 1 cm on the other side

» Screw the nozzle (2) and copper washer (3) firmly into

the nozzle body.

1

2

3

Page 26

7.4.2 Assembling the distributor pipe

The high-pressure water coming from pump station first enters a
manifold and is routed from there to the nozzle.

The manifold is mounted according to the nozzle assembly
sheet (project specific) produced by HygroMatik on the vortex
wall.

Each nozzle in the vortex wall is connected to the manifold with
a hose. Each nozzle must be higher than the corresponding port
on the manifold - the water hose must have a constant slope

Installation:

» A manifold is mounted on the inlet side to at least two

vortex modules.

» Determine distributor pipe position (1) on vortex wall in

accordance with nozzle data sheet.

» Place retaining clips (3) on the appropriate position on

Vortex Modules.
» Put screw (2) through by retaining clip Vortex Module.
» Tighten nut (4) with washer (5) on the rear of the Vortex

Module where the screw stands proud.
» Repeat this process for all the holding clamps.
» Press manifold (1) into the holding clamps (see figure

C) and check for tightness.

1

C

4

5

2

B

2

2

3

A

Page 27

7.4.3 Piping

Manifold - Nozzles

» The supplied 4 / 2 Hose pipe is firmly fitted into one of

the snap-connections on the manifold pipe.
» Check connection by gently pulling on the hose.
» Estimate the hose length (noting nozzle assembly plan)

to the nozzle by observation. Minimum bending radius

no less than 25mm.

» Cut the hose at right angles with a hose cutter.

» Insert hose into the nozzle snap-connector.
» Check connection by gently pulling the hose.

Page 28

The completed finished hose connection should look like this:

Manifold - Pump Station

In the standard version a 6/4 hose leads from the pump station
to a manifold. However, if the LPS nozzle system is equipped
with a partial/full load switch, then there is a 6/4 hose line lead­ing to two manifolds.

Since the 6/4 hose line goes through the air conditioning duct a
duct wall grommet is provided (or two in the case of a partial/full
load switch).

Page 29

Assembly of the hose guide

» Drill a hole with a diameter of 15mm. through the wall of

the air conditioning duct,
» Assemble snap connector (4), nut (3) and washer (2) to

hose opening (1) and insert through the duct wall from

the outside (see picture below).

» From the inside of the duct, assemble washer (5),

mother (6) and necessary snap-connectors (7) and

screw tight.

1
2

3
4

5

6

7

Page 30

Hoses:

For standard version:

The pump station has a hose leading to a manifold at the vortex
wall. From the manifold, it goes to all the nozzles of the LPS noz­zle system.

Additionally:
» All hose assemblies are to be laid with a constant inc-

line.
» Put a 6/4 hose line in the pump station outlet (I).
» Check by gently pulling the tube.
» Estimate the hose length to the ducting snap-connector

(external duct wall). Maximum bend radius 40mm.
» Cut the hose at right angles with a hose cutter.
» Put the 6/4 hose line into the ducting angled snap-con-

nector (external duct wall).
» Check by gently pulling the tube.
» Put a further 6/4 hose line into the straight snap-con-

nector (internal duct wall).

Connection I: Water supply for
nozzles (for standard and partial
load operation)

Connection II, Optional: Water
supply for nozzles (only at full
load operation)

Page 31

» Check by gently pulling the tube.
» Estimate the hose length from the snap-connector to

the duct opening (external duct wall) to the manifold.

Maximum bending radius 40mm.
» Cut the hose at right angles with a hose cutter.
» Put the 6/4 hose line into the angled snap-connector on

the duct opening (external duct wall).
» Check by gently pulling the tube.

Partial / full load switching:

The tubing for partial/full load switching is initially in the same as
described above for the standard version.

In addition, though, there is a further pump station hose for
optional output II (for full load operation) to a second manifold on
the vortex wall

Page 32

7.5 Assembling the droplet separators

The guide rails must be installed in a way that makes it possible
to either pull out or lift up the vortex module wall.

Detail B

Detail A

7.5.1 Examplary design of guide rails for the droplet

separators

Detail A:

Dimensions given in mm

A1: Trap guide rail: U-section with perforated 1.4301 stainless
steel sheet

A2: Trap guide rail holder: U-section made from 1.4301 stain-
less steel

A3: Several holes (at least 4 per metre) 8-10 mm in diameter
distributed over the length of the trap holder

A4: Collection tray for humidification chamber
A5: Fixation of guide rail with the floor of the humidification

chamber (ensure that condensate can freely run to the drain)

Page 33

Dimensions of guide rails for droplet separators

Material used for upper guide rail: 1.4301 stainless steel sheet,
thickness: 1 mm

Detail B:

Hight is variabel:

pushed in droplet
separators: 55
lifted in droplet
separatosr: 30
The upper guide rail is directly attache to the ceiling of the

humidification chamber (using screws, rivets or similar)

Assembling two droplet separators in a stack

For installation heights of above 1.5 m, two droplet separators
must be mounted in a stack.

The waste water from the upper droplet separator is drained via
an additional collector. For this the waste water from the upper
trap is drained via a flexible hose either directly or into the collec­tion tray. This additional collector is to be provided for both the
preliminary and the final droplet separator.

1. Upper guide rail

2. Detail C (please see next
page)

3. Lower guide rail

Page 34

Detail C (side view):

B1: Preliminary droplet separator
B2: Final droplet separator
B3: Angle bracket
B4: Hose connection for drainage of waste water from upper

droplet separator
Perforated sheet metal (material: 1.4301) should be used for the

lower guide rails for the droplet separators. Alternatively, sheet
metal with several holes (at least 4 per metre) 8-10 mm in diam­eter can be used.The assembly must be made with 1.5% incline.

Page 35

7.6 Pump station wall mounting

The installation of this unit must be carried out only by qualified
personnel. We can assume no liability for damages caused by
incorrect installation.

Please observe all the safety instructions and warnings on the
equipment.

On the rear wall of the unit housing there are 4 mounting brack­ets (see also: Dimensions, pump station). There is a mounting
kit supplied in which four screws, and rawlplugs are included for
hanging the unit housing.

Firstly, holes are to be
drilled according to the
pump station dimensions
(see pump station dimen­sions). Press rawlplugs
into the drilled holes if
dealing with stone or con­crete walls. Then screw
the top two fittings to the
wall (allowing a 12mm
distance from the screw
head to the wall) and
hang up the pump station.
Then attach and tighten
the bottom two screws.

Note: If installing the system is done by a single person there is
a danger that the unit can be dropped. Therefore we recom­mend that two qualified persons do the installation.

Hanging tab

Page 36

7.7 Checking the installation

Assembling the vortex module wall

 Have all electrical cable and plug connections been

properly tightened?Is the vortex module wall in accor-

dance with the nozzle arrangement data sheet? (please

note the number of modules in width and height)?

Vortex module wall assembly

 Have all electrical cable and plug connections been

properly tightened?Are the guide rails built so that the

vortex wall module can be lifted or slid from the guide

rails?
 Is it ensured after assembly that the floor pan is sho-

wing no leaks?
 Have all electrical cable and plug connections been

properly tightened?With a wall height of 11 modules is

the Vortex-Vortex-module supported by two side rails.

With16 Vortex modules is it vertically split and sup-

ported individually by side rails?

Droplet separator assembly

 Are the guide rails built so that separator can be lifted or

slid from the guide rails?
 Is it ensured after assembly that the floor pan is sho-

wing no leaks? Are all electrical plug connections

secure?

Mounting of the distributor pipe / tubing

 Has the seating of the individual hoses on their connec-

tors been checked by pulling gently on them? Are all

electrical plug connections secure?
 Is the arrangement of the nozzles and tubing in accor-

dance with to the supplied nozzle arrangement data

sheet?

Pump station installation

 Is the pump station fixed horizontally on a suitable wall?

Does the mains voltage match the voltage on the name

plate/delivery note?

Page 37

8. Dimensions - Pump Station

View from
below

Side view

Rear view

Page 38

9. Water connection

9.1 Overview Water connection

1: Water supply
2: Water drainage
3: 12mm plastic tube (1.5 meter ): included
4: plastic hose DN12: on site
5: Water filter (input side: 3/4 external thread
output side: 12mm snap-connector)
6: Mounting Bracket
7: Pump Station
8: External drain, siphoned (free entry must be assured)
9: Manometer, 0-10 bar

7

1

2

5

4

3

6

8

9

Page 39

Note: There must be a stopcock and a sampling valve in the
immediate vicinity of the HygroMatik LPS nozzle system pro­vided.

9.2 Water supply

Attention: Please observe during installation:

• All work must only be performed by qualified personnel.

• System must be switched off and voltage free.

• Please observe local waterworks and utilities regulations

When using de-mineralized water we recommend the use of
stainless steel or plastic pipes.

Water supply:

» Locate water Filter (position 5 in the graph above) near

the pump station (7).
» Transfer mounting bracket hole pattern (6) to a suit a ble

location on wall.
» Then drill using rawplugs and mounting brackets inclu-

ding water filters.
» An 8mm plastic tube is supplied (length 1.5 m, shorten

if necessary). Connect this to the snap-connector on

the output side of the water filter. Gently pull on the

hose to check for tight fit.
» Attach other end of the 8mm plastic tube into the snap-

connector to the pump station water supply. Gently pull

on the hose to check for tight fit.
» Connect the external feed water line to the input side of

the water filter (3/4 "external thread).

Page 40

9.3 Drainage

At the bottom of the housing, a DN12 spout is sticking out. This
is a drain and is used to:

• empty and relieve the pressure lines to the vortex wall

after removal of the module enable signal

• drain the flush water after flushing

Water drainage

» A DN12 water hose (position 4 on the graph above) is

attached to the DN12spout on the bottom and made

fast with a clamp.
» The tube is then siphoned off and installed on the slope

to the drain (8).

9.3.1 Water drain for the humidification chamber

Note: The water drain in the collection tray must be at the lowest

point in the humidification chamber.
It is recommendable to have the water drain positioned behind

the droplet separators with respect to the direction of air flow.
Only in this way can the waste water drain completely.

Page 41

9.4 Water Quality

Conductivity: 5-20 µS/cm
Pressure: 0,15-0,5 MPa (1,5-5 bar)
Flow rate greater than max output of the

nozzle sytem
Temperature: 5-15°C
PH value: 7 +/-1

9.5 Inspection the water supply

Water supply

 Is the supplied water filter installed to the water inlet for

the pump station?

 Is the feed water quality within the specified range?
 Is the hose that lies between the water filter and pump

station waterproofed?

Drainage

 Is the drain hose siphoned and installed wit h a constant

incline to the drain?

 Can the flushing water drain off freely?

Humidification chamber

 Is the humidification chamber provided with a drain at

the lowest point?

Page 42

10. Hygiene

10.1 Ensuring hygiene (VDI 6022)

The regulations require that only inert materials must be used
and biocides should only be used as a last option.

Prior to humidification the supply air is to be purified using a
Class F7 filter.

A metal filter made of mesh wire is used as a droplet separator.
The droplet separators can, as far as is necessary, be easily

cleaned and reused. Addition of a biocide is not required.
All components must be easily accessible to perform a cleaning

in accordance with VDI6022.
In order to carry out a visual inspection according to VDI 6022

sufficiently large windows / removable panels have to be pro­vided in the area of the droplet separators and the vortex mod­ules.

10.2 Automatic flushing

If the HygroMatik nozzle system LPS is in „stand by mode” and
there is no demand for work for 24 hours the system will periodi­cally run (every 24h) flush cycles.

Hereby the growth of bacteria in standing water is obviated.
During flushing the inlet water solenoid valve and the flushing

valve are simultaneously open. Thus the water in the pump sta­tion is being exchanged and directly led into the drain without
reaching the humidification chamber.

Page 43

11. Electrical connection

Caution: Voltage! All electrical installation work must be carried

out by qualified specialist staff (electricians or skilled workers
with equivalent training) only. It is the customer's responsibility to
monitor qualifications.

Caution: Voltage! All installation work must be completed
before the HygroMatik nozzle system LPS is connected to the
mains supply.

Please observe all local regulations for electrical installation
work.

Caution: The electronic components of the HygroMatik nozzle
system LPS control system are sensitive to electrostatic dis­charge. To protect these components from damage by electro­static discharge, special measures must be taken during all
installation work.

Caution: During installation please perform the following steps:

• Disconnect the system from the mains supply and secure

it to prevent it from being switched on again.

• Ensure that the system is de-energised.

• Installation and removal of the control system may only be

performed if the device is switched off.

• Lay electrical cables properly.

• Make the electrical connections according to the circuit

diagrams.

• Ensure that all terminals are tight.

• Connect the system via socket to the supply network. The

back-up fuses specified in the technical data must be
used.

• The mains plug of the nozzle system HygroMatik LPS is

the network point of separation according to VDE and is
therefore absolutely necessary.

Page 44

11.1 Connection data

Power supply: LNE 230 V AC, 50 Hz
External control signal: 0-10 V DC

4-20 mA DC

System enabling: via ext. potential-free contact
Group fault signal: potential-free contact (change

over contact)

Operating status signal: potential-free contact (NO)

Note: If a residual current device should be installed up stream of

the system a universal-current-sensitive circuit-breaker should
be selected.

Note: When sizing the connection lines, observe that the supply
impendance must be low! If a short circuit occurs the circuit­breaker must switch off automatically within 0.4 s. The magnetic
short circuit trigger for the circuit-breaker (type B) acts immedi­ately when the flowing short circuit current is more than five
times the rated current.

11.2 System enabling / Safety chain

Note: Interlock contacts, such as max. hygrostat, air flow relay,

duct pressure switch, ventilator interlock etc., are placed in
series between series terminals X2.1 and X2.2 (= safety chain).

Caution: If the ventilation system fails or the supply air face
velocity is too low (less than 0.9 m/s) the built-in control must
switch off the humidifier via the safety chain. Otherwise unde­sired condensate build-up behind the droplet separator may
occur.

Caution: Integration of a max. hygrostat into the safety chain is
state-of-the-art. The max. hygrostat serves as a safety element
in case of malfunction of the humidity sensor and protects
against over-humidification.

Caution: The contacts which are placed on terminals X2.1 and
X2.2 must be potential-free and suitable for switching 24 V DC /
100 mA. After the HygroMatik nozzle system LPS has been
started, a standard voltage of 24 V DC is applied to terminal
X2.1.

Pump group Rated power [kW] Rated current [A] Fuse [A]

LPS 45 0.15 1.9 1 x 16
LPS 72 0.16 2.1 1 x 16

LPS 110 0.18 2.7 1 x 16

Page 45

11.3 Circuit diagram

S-103801

S-103801B.001

HYGROMATIK

Lise-Meitner-Str. 3

D-24558 Henstedt-Ulzburg

Germany

Telefax

+49-(0)4193 / 895 - 33

Phone

+49-(0)4193 / 895 - 0

15.09.2011

Schl

3
2

V

W

U

N
L

3x 0,75 qmm

1.5 qmm

Motor

230V/3ph

L

24

25

6

8

K1

13

14

A01

F1

S1

F3

GND

1,6AF

SMP5500/C

N

N

PE

N PE

PE

N

PE

PE

X4

PE

PE

PE

L

L'

5AF

N

PE

N

PE

16

1718

1011

1213

14

15

0,75 qmm

Supply

Supply

GND

LAN

DI2

DI3

DI5

AI3AI4

DI4

12687

354

5GND

3

G

4

A03

DO6

12V

DO1

DO2

DO3

DO4

AO

Supply

Supply

LAN

10

798

A04

DO1 DO2

DO3

A02

0V

+12V

L

N

L'

N'

C1

F2

5AF

N

PE

50°C

B1

DI6

DI1

1

2

K1

K1

K2

20

A1

A1

A2

A2

19

21

SE632

origin Ers.dErs.f

page 1

of 1 p.

(drawing Nr.)(description)

(file)

modification date name

edit

Norm

date

LPS + Options

Supply

230VAC

control signal

HP-sensor

0...20mA

water

supply

pressure

switch

interlock

potential

free

input

winter-/

summer

Mode

operation

message

collective

fault

Fan 230V

MV 230V

water inlet

valve

MV 230V

full load

winter

MV 230V

flushing

MV 230V

part load

winter

OPTION

winter-/ summer

Mode

winding

motor

MV 230V

full load

summer

power

supply

+12VAC

OPTION

Full-/ Partload

OPTION

controler

Frequency

converter

Extension module

A

15.09.2011

Schl

release

+24V

X1

X3

PE

PE

7 6 5

PE

4

2

1

21

PE

X2

5

6

K2

K1

22

30

2829

4

3

(+)

(-)

+24V

(-)

PE9 8PEPE

A

B

05.01.2012

Schl

ATTENTION:

Plug in position

without black

marker.

If ELCB was

activated, set the

plug to <3.5mA!

Page 46

S-103802

S-103802B.001

HYGROMATIK

Lise-Meitner-Str. 3

D-24558 Henstedt-Ulzburg

Germany

Telefax

+49-(0)4193 / 895 - 33

Phone

+49-(0)4193 / 895 - 0

25.10.2011

Schl

A

25.10.2011

Schl

origin Ers.dErs.f

page 1

of 1 p.

(drawing Nr.)(description)

(file)

modification date name

edit

Norm

date

LPS 3-Step control

release

3
2

V

W

U

N
L

3x 0,75 qmm

1.5 qmm

Motor

230V/3ph

L

24

25

6

8

K1

13

14

A01

F1

S1

F3

GND

1,6AF

SMP5500/C

N

N

PE

N PE

PE

N

PE

PE

X4

PE

PE

PE

L

L'

5AF

N

PE

16

1718

1011

1213

14

15

0,75 qmm

Supply

Supply

GND

LAN

DI2

DI3

DI5

AI3AI4

DI4

12687

354

5GND

3

G

4

A03

DO6

12V

DO1

DO2

DO3

DO4

AO

Supply

Supply

LAN

10

798

A04

DO1 DO2

DO3

A02

0V

+12V

L

N

L'

N'

C1

F2

5AF

N

PE

50°C

B1

DI6

DI1

1

2

K1

K1

K2

20

A1

A1

A2

A2

19

SE632

Supply

230VAC

control signal

HP-sensor

0...20mA

water

supply

pressure

switch

interlock

potential

free

input

winter-/

summer

Mode

operation

message

collective

fault

Fan 230V

MV 230V

water inlet

valve

MV 230V

3rd Step

MV 230V

flushing

MV 230V

2nd Step

winding

motor

power

supply

+12VAC

controler

Frequency

converter

Extension module

+24V

X1

X3

PE

PE

7 6 5

PE

4

2

1

21

PE

X2

5

6

K2

K1

22

30

2829

4

3

(+)

(-)

+24V

(-)

PE9 8PEPE

ATTENTION:

Plug in position

without black

marker.

If ELCB was

activated, set the

plug to <3.5mA!

B

20.03.2012

Schl

Page 47

11.4 Inspecting the electrical installation

The electrical installation must be checked by an electrician in
accordance with customer requirements and the regulations set
out by the public electricity supply company:

 Does the mains voltage match the voltage specified on

the nameplate / delivery note?

 Have all electrical connections been carried out accord-

ing to the connection diagrams?

 Have all electrical screw and plug cable connectors

been attached properly?

 Are the switch-off conditions for protection in case of

faults complied with?

 Has the system been earthed?

The system can then be switched on.

Page 48

12. Commissioning

Note: The LPS nozzle system may only be operated by qualified

personnel.

Turning the LPS nozzle system off
Note: Before the LPS nozzle system is put into operation, it

must be clear how to switch the system off.
» Switch off Nozzle system using control switch (Pos.0).

» Shut off water supply shut-off valve.

Check all cable connections

» Check all cable connections for tightness.

Activating the LPS nozzle system

» Operate main switch.
» Set manometer to „open“
» Open up water shut-off valve
» Switch on unit using control switch (Pos.I).
» Set commissioning control to permanent demand

steam production.

The following functions begin:
A self-test.
When humidity is demanded, the pump vane is operated and

directs the water at a pressure of up to 16 bar to the nozzle.
The water is atomized at the nozzle. All nozzles should not drip

and show an even spray pattern.

Further tests:

 All electrically-powered functions must function.

» Observe LPS nozzle system and let it run for 15-30

minutes. The air conditioning duct fan should be in ope­ration so that the moisture produced can be blown
away. Should any leakages be evident then turn the
LPS nozzle system off.

» Eliminate the leaks:
Attention, voltage! Please observe all safety instructions while

working on live components.

Page 49

13. Maintenance

The HygroMatik nozzle system LPS is maintenance-friendly.
However, operational faults which can be traced back to inade­quate or improper maintenance may occur.

Regular maintenance of the HygroMatik nozzle system LPS is
indispensable for ensuring long service life.

Caution: For maintenance work please bear in mind that:

• the system must be serviced by qualified appointed staff

only;

• safety instructions must be followed;

• the system must be taken out of operation and secured to

prevent it from being switched (take the plug out of the
socket) on before maintenance work is performed;

• after maintenance work has been completed the device

must be inspected by qualified staff to determine whether it
is safe to operate.

13.1 Maintenance activities

For the system to operate without any problems the following
checks and maintenance tasks must be carried out regularly:

1 x per month:

» Check housing for contamination and clean if neces-

sary.

» Carry out a visual inspection of droplet separators and

clean if necessary.

» Check the water filter cartridge upstream of the pump

for contamination and replace if necessary; flush the
mains water system if necessary.

» Check the resulting spray cone of the nozzles and

clean or change nozzles if necessary.

1 x per year (or after 2500 h)

» Nozzles should be checked as part of annual mainte-

nance and cleaned if necessary (see "Cleaning nozzle).

If required, the nozzles to be replaced.
» Water filter cartridge change
» Visual inspection of the vortex module wall, if necessary

clean.
» Check shutdown function, such as a "Max-Hygrostat".

Page 50

13.1.1 Inspection / replacement of the net-based

water filter

Water filter check

Water filter must be checked for cont amination 1 x monthly and if
necessary replaced. If the white water filter cartridge changes its
colour this means it is polluted.

Pollution causes a higher flow resistance. This reduces the
water pressure at the pump. Too little pressure can cause the
nozzle system to switch off (dry-run protection).

Replacing the water filter:

1

2

3

1. Filter housing holder

2. Filter cartridge (inside­ lying

3. Filter housing

4. Mounting plate

4

Page 51

1. Set the main switch on the control panel of the HygroMatik
nozzle system LPS to '0'.

2. Close the (external) stopcock.

3. Relieve the line pressure.

4. Open the filter housing by hand. The threads may be dam­aged if pliers are used.

5. Clean the filter housing.

6. Replace the filter cartridge (if necessary).

7. Screw the filter housing into the seat by hand.
Note: Do not pinch the sealing ring.

8. Open the external stopcock.

9. Set the main switch to 'I'.

13.1.2 Cleaning the atomizer nozzle

1. Switch the HygroMatik LPS Nozzle System power supply to 0

2. Unscrew the nozzle from nozzle holder. Take care not to touch
the impact pin.

3. Unscrew the nozzle by screwing the inside part out.

4. Clean the nozzle components in an ultrasonic bath for about
10 minutes, if necessary use a lime remover in low concentra­tion (less than 10%).

5. Put nozzle components back together.

6. Screw nozzle in the nozzle holder.

7. Switch power switch back to I

8. Finally check spray pattern

Caution: Make sure that the pressure reduces by, for instance,
activating the wash cycle.

Caution: Wear eye protection when cleaning the nozzle.

Caution: Use only an appropriate tool to remove the nozzles.

Page 52

13.1.3 Cleaning the droplet separators

The droplet separators should be checked every 4 weeks for
possible contamination and cleaned if necessary. The droplet
separators should be thoroughly cleaned at least once a year.

13.1.4 Cleaning the vortex module wall

The vortex module wall should be checked for contamination and
damage as part of annual maintenance. Any contaminants must
be removed with a cleaning agent.

Cleaning the droplet separators:

1. Pull or lift the droplet separators out of the guide rails.

2. Clean the droplet separators with a cleaning agent and then
rinse and dry them.

3. Carry out a visual inspection of the droplet separators, repeat
the cleaning step if necessary and replace the droplet separa­tors if damaged.

4. Place the droplet separators back on the guide rails. While
doing so ensure that the trap frame drain holes are facing down­wards to guarantee free drainage.

Page 53

13.1.5 Cleaning the humidification chamber

Clean the humidifier housing and the base tray as required with
a cleaning agent, then rinse and dry them.

For cleaning and disinfection we recommend INCIDUR pro­duced by Ecolab.

When using other cleaning and disinfection agents please check
material compatibility with all plastic materials used in the humid­ification chamber.

Caution: Do not aim the water jet at the droplet separators. Any
upstream or downstream heating or cooling units must not
become wet during cleaning.

Page 54

14. Control System

14.1 Control and speed regulation

The electrical components and terminals are located in the
system cabinet under the removable cover. A programmable
logic controller PLC (Item 1 in the illustration below) is
responsible for the control function.

Important operating data are depicted in the control system
display. A frequency inverter (Item 2) supplies different
frequencies and voltages for the asynchronous motor of the
pumping station located in the lower part of the system cabinet.

Depending on the speed of the pump, it is possible to vary the
water pressure and thereby the quantity of water atomized. The
water pressure may range between 5 and 16 bars.

The main switch (Item 3), which is located at the top left-hand
side, is for switching off the HygroMatik low-pressure nozzle
system LPS.

HygroMatik low-pressure nozzle system LPS

2

3

1

Page 55

14.1.1 Full load and part load

The HygroMatik low-pressure nozzle system LPS is controlled
by a 0-10V control signal.

In the 5-10V range, all the nozzles are charged with pressurized
water. If the control signal falls below a value of 5 volts, the
system switches to part load operation. In this case, approx.
50% of the nozzles are no longer supplied with water. The rotary
vane pump then works with a higher pressure, whereby an
improved spray pattern is produced.

14.1.2 Summer / winter mode

The HygroMatik low pressure nozzle system can be operated in
summer or winter mode.

In winter mode, the HygroMatik low pressure nozzle system is
used to regulate air humidity, whereas summer mode is used for
exhaust air cooling.

Changeover between summer and winter modes is made by
potential-free contact between connecting terminals 6 and 7:

Contact open = Winter mode
Contact closed = Summer mode
In summer mode, regulation of the HygroMatik low pressure

nozzle system LPS is made solely by means of the safety chain
(Terminals 1 and 2) in single-stage switching mode; as long as
the safety chain is closed, the system operates at 100%
humidification performance.

Page 56

14.2 Description of the programmable

controller (PLC)

14.2.1 General description

The HygroMatik low pressure nozzle system LPS controller
regulates the complete atomizing operation. The user interface
for operating and regulating the function of the appliance is on
the face of the PLC controller.

Functions of keys:

(F1): - increase value

- to the next identifier

(F3): - decrease value

- to previous identifier

(F2): - exit without saving the setting

- return to previous level

(F4): - confirm value / exit and setting save

- to the next level (select menu,
submenu, parameter, value)

- select reading level

Page 57

Functional description of the display and LED:

The display consists of 14 icons in 3 categories:

1. Operating modes

2. Values and dimensional units

3. Switching states

Icon Description Color

Error red
(Error codes F1...F8 are displayed;

detailed description see below)

Summer mode green
(cooling)

Winter mode green
(humidify)
No demand green

(the safety chain is closed,
the demand is however
below the activation threshold)

Pressure [bars] red

Relative humidity [%] red

Control signal error red

(control signal wrong or missing ­humidification is interrupted)

Page 58

Description of switching states:

Condition Description LED color

1 Mode (nozzle system operating) orange
2 Maintenance/fault orange
3 Magnetic valve drain enabled orange
4 Magnetic valve full load enabled orange
5 Magnetic valve water inlet enabled orange
6 Magnetic valve winter mode part load

enabled orange

7 Magnetic valve summer mode full load

enabled orange

14.2.2 Menu

System start

After switching on the Hygromatik low pressure nozzle system
LPS at the main switch, an initial flushing operation is carried out
(default setting 10 sec.).

The system is then in the main menu, i.e. the actual pressure is
displayed.

From here one can navigate to the reading level and read off
current reading parameters (L1 ... L15) or to the programming
level, where parameters can be set or changed.

A detailed description of the programming steps can be found in
the following subsection "Menu structure and parameter setting”.

Page 59

14.2.2.1 Reading level:

The following reading parameters can be selected in the reading
level:

L01 Actual value of pressure [bars]
L03 Actual value of the control signal
L04 Setpoint control signal
L05 Set value of performance limiter [%]
L06 Set value for the target humidity (only valid

with PI control [%]

L07 Actual value of current humidity (only valid

with PI control [%]
L11 Total running time of pump [h]
L13 Total running hours [h]
L14 Remaining running time before next service

reminder [h]
L15 Remaining time until standby-draining [hh:mm]

14.2.2.2 Programming level:

The following parameters can be changed in the programming
level:

Parameter Designation Option Factory setting
U6 Controls 0 = external controller 0

1 = single-stage/ On-Off
2= PI control

L06 Setpoint rel. humidity 10-100% 50%

(only activ if U6=2)
L05 Output limitation 25-100% 100%
r_S Reset „Service” message ON/OFF OFF
C12 Integral part, 50-500 100

with PI humidity controller
C11 Proportional part, 50-200 100

with PI humidity controller
E03 External control signal 4 = 0-10V DC 4

3 = 4-20mA DC

Page 60

14.2.2.3 Operation

If the HygroMatik low pressure nozzle system LPS is enabled,
(i.e. the safety chain is closed) and a control signal greater than
the activation threshold is put in, the system atomizes water.

The LED 1 for status "Operating" is illuminated.
At the same time the current working pressure in bars is shown

on the display.
In addition, the topmost line of the display shows whether the

HygroMatik low pressure nozzle system LPS is operating in
summer or winter mode.

14.2.2.4 Function of the safety chain

It is possible to read off from the main display window whether
the system is enabled for operation. It is essential that a
potential-free normally closed contact for enabling (= closing the
safety chain between terminals X2.1 and X2.2) is provided on
site. Here, several safety contacts (NO / NC) can be connected
in series.

No demand:

Should the PLC controller show the safety chain is closed,
however the requirement is below the activation threshold.

There is no demand for humidification.

Ready for use:

If is not displayed and if the display indicates 0.0 bars the
safety chain is open (terminals X2.1 and X2.2 are not bridged).

The HygroMatik low pressure nozzle system LPS is ready for
use.

14.2.2.5 Accumulated malfunction

If a fault is detected in the HygroMatik low pressure nozzle
system LPS by the controls, the dedicated changeover relay is
de-energized (terminals X2.28-30 NC, terminals X2.29-30 NO).
Simultaneously a specific error report (F1 ... F8) is shown in the

display and the icon is illuminated red. The HygroMatik
low pressure nozzle system LPS is deactivated.
If no fault exists, the changeover relay is energized.
You will find a detailed description of the errors and their

possible elimination in the following table.

Page 61

14.2.3 Overview of error reports

Fault
No.

Malfunction
report

Description Possible cause Remedial action

F1 Water inlet

Pressure
< 1bar

Water supply
inadequate. Inlet
pressure must be
between 1 to 5 bars.

Water supply not
connected.

Connect water
supply with
adequate pressure.

F2 Temperature

in control
cabinet

The temperature sensor
in the control cabinet is
recording a temperature
in excess of 50°C +/­10%

The ventilator in the
control cabinet failed

Air inlets blocked

Check ventilator
and replace if
necessary

Clean out air inlets

F3 FU

defective

Frequency inverter
reports a malfunction.
This is shown in the
frequency inverter
display.

Overload of motor
Motor cable short

circuited
Fault in electronics

frequency inverter
Earthing fault of output

terminals

For remedial action
please observe the
instructions in the
documentation for
the frequency
inverter.

F4 Motor

winding

Temperature control of
the motor winding
activated due to excess
temperature.

Failure of external
ventilator

Air inlets of the external
ventilator blocked.

Check external
ventilator and
replace if
necessary.

Remove blockage

F5 Low

pressure

No pressure can be built
up after activating the
rotary vane pump for
30 seconds

Pressure pipe leaking
Water deficiency
Signal cable pressure

sensor not connected

Check pressurized
water pipe and
replace

if necessary

Check cable
connection and
correct

F6 Excess

pressure

The supply of
pressurized water
exceeds a pressure of
16 bars for 30 seconds

Nozzles blocked
Pressure-relief valve

not set correctly

Clean nozzles or
replace

Please contact
HygroMatik

F7 Sensor fault

pressure

The value of the
pressure sensor is
outside the normal
range

Pressure sensor
defective

Burst pipe

Replace pressure
sensor

Renew pipe

F8 Sensor fault

humidity

The value of the
humidity sensor fitted
(optional) is outside the
normal range

Humidity sensor
defective

Burst pipe

Replace humidity
sensor

Renew pipe

Page 62

14.2.3.1 Menu structure and parameter setting

4

3

Page 63

15. EC declaration of conformity

Page 64

16. Spare parts

Article no. pump station

E-7800100 Motor LPS s

y

stems, 230V, 0,37kW

E-7800202 Rotar

y

vane pumpe LPS-100; LPS110

E-7800204 Rotar

y

vane pumpe LPS72

E-7800206 Rotar

y

vane pumpe LPS45

E-3720010 fan, axial, 230VAC

E-7702200 protection grill, cabinet fan HDS, incl. filter inlay 120 x 120 mm
B-7800400 Solenoid valve water inlet, incl.

p

ressu re switch 1b a

r

E-7800300 3/2 Solenoid valve, incl. coil 230V/50-60Hz
E-7800310 Plu

g

for solenoid valve

E-7800610 High pressure sensor LPS

E-7800436 pipe fitting G3/8, 12mm hose
E-7800438

pip

e fitting G3/8, 90°, turnable, 12mm hose

E-7800416

pip

e fitting G1/8, 6mm hose

E-7800444 female pipe fitting G1/8, 6mm hose

E-7621028

Filter element 10" filter quality 10 µm for water-prefilter HP­pumpstation

E-7705200

Water filter housing, 10" bothside connection 3/4" iD blue sump,

p

ressure release button

B-2504021

A

uxiliary relay 230V AC 2 switching contact

E-2505206 Safety fuse 1,6A 5x20mm
E-2504039 Safety fuse 1,6A 5x20mm

E-7704870

Thermal circuit breaker ; NC with automatic reset, switching point at

50°C ± 5

K

E-7800544 Transformer 230V/12V 11V

A

E-7800500 Frequenzy converter 0,37kW

E-7800540 Display CPU unit

E-2501005 main contactor 16A(AC1)coil 230V AC

Page 65

Artikel -Nr . Article no.Vortex-wall

E-770 1000 E-770 1000 Vortex module
E-780 0400 E-780 0400 LPS wa ter distributi on tub e
E-7601630 E-7601630 T-

p

iece female 1/8"

E-760 1586 E-760 1586 Double ni

pp

le G1/8" - G1/8"

E-780 0410 E-780 0410 Sealing plug M5
E-780 0412 E-780 0412 Sealing plug male 1/8"

E-7800414 E-7800414 Pipe fitting M5, 4mm hose
E-7800416 E-7800416 Pi

p

e fitting G1/8, 6mm Hose

E-7800472 E-7800472 Fixin

g

cli

p

E-7800452 E-7800452 Mountin bracket for nozzle

E-7621020 E-7621020 O -ring for nozzle mounting bracket
E-7800450 E-7800450 Nozzle HY 0,27/120°

E-7800454 E-7800454 Nozzle HY 0,27/60°
E-7601572 E-7601572 O-Rin

g

, 10 x 1.5, 70° Shore

E-7800424 E-7800424 Pipe fitting male 1/8", 90°, turnable, 4mm hose
E-7800428 E-7800428 Hose PA, 6mm

E-7800426 E-7800426 Hose PA, 4mm
B-780 0301 B-780 0301 LPS duct inlet fittin

g

Page 66

17. Fax Form - Order for spare parts

Lise-Meitner-Str. 3

24558 Henstedt-Ulzburg

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. +49(0)4193/895-33

company stamp (delivery adress)

date/signature

Page 67

18. Technical Specifications

LPS 45 LPS 72 LSP 110

Effective humidification capacity [l/h] 45 72 110

Nominal power rating [kW] 0,15 0,16 0,18

Amps [A] 1,9 2,1 2,7
Volts [V/Ph/Hz] 230/1/50
Control signals 0-10V / 4-20mA

(other control signal levels on request)

Nozzle number 15 22 32

Humidification path, ideal [m] 0,9

Installation lenght, ideal [m] 1,5

Flow velocity [m/s] 0,9 - 2,8

Pressure drop in duct [Pa] 80 at 2.0m/s air speed

Dimensions H, D, W [mm] 700, 230, 600

Weight [kg] 30

D

W

H

Page 68

19. Plant scheme

Lise-Meitner-Str. 3
24558 Henstedt-Ulzburg
Tel.: [phone]

Fax: [phone]

)UHLPDWROHUDQ]

JHP',1

'DWXP 1DPH

%HDUE
*HSU
1RUP

=HLFKQXQJVQXPPHU

%H]HLFKQXQJ

%ODWW

YRQ

0DVWDE

*HZLFKW

5HY QGHUXQJ 'DWXP 1DPH

+<*520$7,.

0DWHULDO

7

 0DU





$QODJHQVFKHPD/36

PLWWHO

FU: Frequenzumrichter
frequency converter

SPS: Speicherprogrammierbare Steuerung
programmable logic controller

PID: Drucksensor
pressure sensor

3ODQWVFKHPH/36

FU

SPS

PID

5 - 16 bar

VE-Wasser
Deionised water

1 - 5 bar
5 - 20μs/cm

Pumpe
pump

Wassereinlassfilter

water filter

MV

Wassereinlass-

Magnetventil

water solenoid

valve

PID

MV

MV

Spülmagnetventil

flushing solenoid valve

Volllast-Magnetventil

full load valve

Teillast

partial load

Option:
Teil-/ Volllast
part-/ full load

MV

MV

Spülmagnetventil

flushing solenoid valve

Winter
Teillast-Magnetventil
winter part load valve

Option:
Sommer-/ Winterschaltung
summer-/ winter contr ol

MV

Winter
Volllast-Magnetventil
winter full load valve

MV

Sommer Magnetventil

summer valve

A Blatt 2 eingefügt Mar

22.10.12

Lise-Meitner-Str. 3
24558 Henstedt-Ulzburg
Tel.: [phone]

Fax: [phone]

)UHLPDWROHUDQ]

JHP',1

'DWXP 1DPH

%HDUE
*HSU
1RUP

=HLFKQXQJVQXPPHU

%H]HLFKQXQJ

%ODWW

YRQ

0DVWDE

*HZLFKW

5HY QGHUXQJ 'DWXP 1DPH

+<*520$7,.

0DWHULDO

7

 0DU





$QODJHQVFKHPD/36

PLWWHO

FU: Frequenzumrichter
frequency converter

SPS: Speicherprogrammierbare Steuerung
programmable logic controller

PID: Drucksensor
pressure sensor

FU

SPS

PID

5 - 16 bar

VE-Wasser
Deionised water

1 - 5 bar
5 - 20μs/cm

Pumpe
pump

Wassereinlassfilter

water filter

MV

Wassereinlass-

Magnetventil

water solenoid

valve

PID

MV

Spülmagnetventil

flushing solenoid valve

Option:
Zuluftbefe uchtung 3-stufig
humidification 3-step control

MV

MV

3ODQWVFKHPH/36

1. Stufe

1st step

2. Stufe

2nd step

3. Stufe

3rd step

A Blatt 2 eingefügt Mar

22.10.12

Page 69

4

3

12/2004

Lise-Meitner-Str.3 • D-24558 Henstedt-Ulzburg
Phone [phone] • Fax -33
eMail [e-mail] • www.hygromatik.com
A member of the Group