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Electrode Steam Humidifier
MiniSteam
Manual
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A Word about Water Quality
The mode of operation of all electrode steam humidifiers is based on the fact that water contains
minerals and is therefore conductive.
• "normal" tap water is ideal.
• but what is "normal" tap water exactly?
Users of HygroMatik units in the most diverse areas consider their tap water "normal."
HygroMatik typically defines "normal" as feed water with a conductivity between 200 and 500 µS/
cm (microSiemens per centimeter) at 15° C.
Some areas, however, are supp lied with tap water whose quality is outside the parameters specified by HygroMatik. If the HygroMatik steam humidifier's control is not adjusted correctly in these
areas, the unit cannot perform optimally. For example, the electrodes could wear out particularly
quickly or the steam production could be too low.
The operational parameters set by HygroMatik in the factory are intended for normal tap water.
However, they can very easily be reprogrammed to fit the special requirements of a particular
area. In addition, it is possible to install a plastic star in the cylinder in order to increase the life
span of the electrodes or to provide a flushing mechanism to extend maintenance intervals.
Because of this you should monitor your new unit during initial operation. Make sure that it has
been properly installed and is operating to your satisfaction.
Consult your HygroMatik specialists. We will test the quality of your water and advise you on
installation and initial operation. Your HygroMatik steam humidifier will be carefully adapted to
your particular application.
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; MiniSteam, July 2012
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
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1. Introduction ....................................................................................................................... 5
1.1 Directions for Use ..............................................................................................................5
1.2 Typographic Distinctions ...................................................................................................6
1.3 Documentation .................................................................................................................. 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 Overview ........................................................................................................................... 9
3.2 Carton outer Size and Weight ...........................................................................................9
3.3 Packing ..............................................................................................................................10
3.4 Interim Storage ..................................................................................................................10
3.5 Check for Complete and Correct Delivery of Goods .........................................................10
3.6 Included in the Delivery .....................................................................................................10
4. Operation and Installation ................................................................................................ 11
4.1 Mode of Operation .............................................................................................................11
4.2 Installation and Operation .................................................................................................11
5. Installation ......................................................................................................................... 15
5.1 Steam Humidifier Operating Environment ......................................................................... 15
5.1.1 Fitting measures .............................................................................................................16
5.2 Unit Installation Check ....................................................................................................... 17
5.3 Unit Dimensions ................................................................................................................ 18
6. Water Installation ..............................................................................................................19
6.1 Operation with Softened Water .........................................................................................19
6.2 Water Supply .....................................................................................................................20
6.3 Water discharge ................................................................................................................ 21
6.4 Water Installation Check ...................................................................................................22
7. Electrical Connection ........................................................................................................ 23
7.1 Electrical Installation .......................................................................................................... 23
7.2 Cable Connections ............................................................................................................ 25
7.3 Safety Interlock .................................................................................................................. 26
7.4 Wiring Diagram .................................................................................................................. 26
7.5 Electrical Installation Checklist ..........................................................................................26
8. Maintenance ....................................................................................................................... 27
8.1 Maintenance Work ............................................................................................................28
8.2 Access Electrical Enclosure .............................................................................................. 28
8.3 Removing and Cleaning the Steam Cylinder .................................................................... 30
8.4 Electrode wear ..................................................................................................................33
8.4.1 Original Electrode Lengths .............................................................................................33
8.4.2 Uneven Electrode Lengths .............................................................................................34
8.5 Replacing Electrodes ........................................................................................................34
8.6 Cleaning the Blow- Down Pump ........................................................................................36
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8.7 Cleaning the Water Inlet Solenoid Valve ........................................................................... 36
8.8 Chekking Cable Connections and Electrode Cables .........................................................37
8.9 Checking Operation ........................................................................................................... 37
8.10 Dismantling ......................................................................................................................37
9. Commissioning ................................................................................................................. 38
10. EC-Declaration of Conformity ........................................................................................ 39
11. Spare Parts ...................................................................................................................... 40
12. Fax Form - Order for spare parts ................................................................................... 42
13. Technical Data ................................................................................................................. 43
14. Exploded View ................................................................................................................. 44
15. View of housing ............................................................................................................... 45
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1. Introduction
Dear Customer,
Thank you for choosing a HygroMatik steam humidifier.
HygroMatik steam humidifiers represent the latest in humidifica-
tion technology.
They will impress you with their safety, ease of use and econom-
ical operation.
In order to operate your HygroMatik steam humidifier safely,
properly and efficiently, please read these operating instructions.
Employ your steam humidifier only in sound condition and as
directed. Consider potential hazards and safety issues and follow all the recommendations in these instructions.
If you have additional questions, please contact us:
Tel.: +49-(0)4193 / 895-0 (Main Number)
Tel.: +49-(0)4193 / 895-293 (Technical Support Hotline)
Fax: +49-(0)4193 / 895-33
e-mail: hot1@HygroMatik.de
For all technical questions or spare parts orders, please be prepared to provide unit type and serial number (see name plate on
the unit).
1.1 Directions for Use
The HygroMatik steam humidifier is intended for steam production.
Proper usage also entails following HygroMatik's instructions for
installation, dismantling, reassembly, initial operation and operation and maintenance, as well as disposal procedures.
Only qualified, authorized personnel may operate or service the
unit. Workers who transport or service the unit must have read
and understood the relevant sections of the operating instructions, especially the section "Safety Notes." In addition, staff
must receive safety training about potential hazards from the
operator. Place a copy of the operating instructions at the location where the unit is operated.
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Use feed water with a conductivity between 125 and 1250 µS/
cm only
D1: Lower threshold
C1: Range of reduced conductivity
A: Normal tap water
B: Range of heightened conductivity
C2: Range of heigh conductivity
D2: Upper threshold
Warning: HygroMatik steam humidifiers emit steam with a tem-
perature of 100° C. The steam may not be inhaled directly.
The HygroMatik Steam Humidifier is not designed for out door fit-
ting.
1.2 Typographic Distinctions
preceded by a bullet: general specifications.
» preceded by an arrow: Procedures for servicing or
maintenance which should or must be performed in the
indicated order.
Installation step which must be checked off.
italics Terms used with graphics or drawings.
1.3 Documentation
Retention
Please retain these operating instructions in a secure, always
accessible location. If the product is resold, turn the documentation over to the new operator . If the document ation 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.
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2. Safety Notes
2.1 Overview
These safety notes are required by law. They promote workplace safety and accident prevention.
Warnings and Safety Symbols
The safety symbols below identify sections containing warnings
about hazards or potential dangers. Please familiarize yourself
with these symbols.
Warning: Failure to observe this warning may result in serious
injury or death and/or damage to the unit.
Danger, Hazardous Voltage: Hazardous electrical current!
Failure to observe this warning may result in injury or even seri-
ous injury or death.
Warning: Failure to follow these instructions may result in dam-
age to the unit due to electrostatic discharge. The electronic
components of the humidifier control are very sensitive to electrostatic discharges. In order 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: Appears before explanations or cross-references 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
restart. Repair malfunctions promptly. After any repair work,
have qualified personnel check the 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
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safely leads the steam.
HygroMatik steam humidifiers are 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 Prevention Regulation Electrical Systems and Equipment to prevent injury to yourself and others.
Operation of the Unit:
Do not perform any work which compromises the safety of the
unit. Regularly check that all safety and monitoring devices are
functioning normally. Do not remove or disable safety devices.
Installation, Dismantling, Maintenance and Repair 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 electrical system must be performed by qualified
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 electrical equipment. Promptly repair any damage, such as loose connections,
burned wiring or defective electrical insulation. After proper electrical installation 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.
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3. Transport
3.1 Overview
Note: Proceed carefully when transporting the steam humidifier
in order to prevent damage due to stress or careless loading and
unloading.
3.2 Carton outer Size and Weight
HyLine:
CompactLine:
MiniSteam:
* Dimensions and weights may vary slightly.
Type* Height
[cm]
Width
[cm]
Depth
[cm]
Weight
[kg]
HY05- 08 58 56 32 16
HY13- 17 75 63 37 24
HY23 75 63 37 25
HY30 81 67 41 33
HY45 88 76 48 46
HY60 80 104 41 54
HY90- 116 90 117 48 77
Type* Height [cm] Width [cm] Depth [cm] Weight [kg]
C01 46 45 26 11
C02 48 44 31 12
C06 52 50 28 13
C10 58 51 31 14
C17 75 54 37 22
C22 75 54 37 22
C30 75 58 37 23
C45 81 63 41 25
C58 90 72 48 36
Type**Height [cm] Width [cm] Depth [cm] Weight[kg]
MS 5 59 48 28 13
MS 10 68 51 31 15
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3.3 Packing
Note: Notice the symbols affixed to the packing box.
3.4 Interim Storage
Store the unit in a dry place and protect from frost.
3.5 Check for Complete and Correct Delivery of
Goods
Upon receipt of the unit, confirm that:
the type and serial number on the name plate match
those specified in the order and delivery documents
and
the equipment is complete and all parts are in perfect
condition
Note: In case of damage during shipment or missing parts,
immediately notify the carrier or supplier in writing.
Time limits for filing freight claims with shipping companies are*:
* Time limits for some services subject to change.
3.6 Included in the Delivery
The delivery includes:
Unit of the selected humidifier type including selected
control.
Water installation hose 0,6m, 3/4".
Mounting set with anchors and screws. For HyLine
types HY45 to HY116, extra mounting bar.
Operating Instructions for the unit and the control.
Ordered accessories (steam manifold, steam hose,
condensate hose, etc.).
Maintenance o-ring set for steam cylinder.
Shipping Companies After Receipt of Goods
Mail no later than 24 hours
Rail no later than 7 days
Truck and Rail Carriers no later than 4 days
Parcel Service immediately
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4. Operation and Installation
4.1 Mode of Operation
The HygroMatik steam humidifier utilizes the conductivity normally present in tap water for steam production. Electrodes
inside an enclosed steam cylinder are immersed directly into the
tap water. They are connected to the alternating current.
The conductivity of the water generates an electric current
between the electrodes. In this way, the electric power supplied
is converted directly into heat without energy loss.
The amperage is a function of the available voltage, the
immersed electrode surface area, the average distance between
the electrodes and the water conductivity. The steam output of
the humidifier is determined by electric power usage, which is
regulated by increasing or decreasing the immersed surface
area of the electrodes.
Concurrently, a self-regulating control keeps conductivity within
a specified range.
The steam produced has a temperature of about 100°C with
minimal excess pressure ("pressureless steam"). It is largely
free of minerals and germ-free. Mineral deposits typically remain
behind in the cylinder.
4.2 Installation and Operation
When the controller specifies an increase in humidity, the main
contactor is switched on and the electrodes (48) are supplied
with power. The water inlet solenoid valve (25) feeds water into
the steam cylinder (16+19).
As soon as the electrodes are immersed, the current begins to
flow. The water is now heated. When the pre-selected output is
reached, the control turns off the solenoid valve and interrupts
the water supply.
After a short heating up period, the water between the electrodes begins to boil and vaporize. The vaporization lowers the
water level (W) in the steam cylinder, reducing the output provided. The inlet solenoid valve, equipped with a fine mesh filter,
intermittently admits fresh water.
Humidifier power usage is continuously monitored. With a cold
start-up, the nominal current increases to 125% in order to
achieve quick-start output parameters. This activates the electronic overflow limiter which causes a partial draining of the cylinder. This reduces the immersed surface area of the electrodes,
lowering power usage.
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Please also see Section „Exploded View“.
Location Designation
1 steam nozzle
6 vent pipe
10 max. water level sensor electrode
14 water drain, discharge
16 top part of steam cylinder
17 o-ring cylinder flange
18 cylinder flange and o-ring
19 lower part of cylinder
25 solenoid valve water inlet
32 blow-down pump
35 o-ring
37 cylinder base
48 electrodes
32
42
20
12
25
15
26
21
24
39
11
37
6
18
43
44
49
1
8
17
4
58
22
22
22
22
22
2
10
14
16
19
48
35
31
30
38
22
22
22
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The concentration of dissolved salts increases over time, which
can lead to a rise in the conductivity of the water. If this continues, conductivity may increase until a short circuit occurs. This
could damage the unit, but in any case would significantly
reduce the life span of the electrodes.
For this reason, regular, periodic blow-downs of some of the
concentrated water are very important. Following this procedure
as recommended provides stable cylinder water conductivity as
well as minimal water loss for the expected service life of the cylinder.
Water blow-down is performed by a blow-down pump (32). The
functioning of the blow-down pump is continuously monitored
during operation. If the pump is damaged, the steam humidifier
shuts down.
With normal water quality, the blow-down loss rate is between
7% and 15% of the amount of steam produced. The steam cylinder requires complete drainage every 3-8 days, regardless of
the water quality.
Mineral deposits settle in the open area below the electrodes
and are removed through periodic maintenance. The blow-down
pump itself has wide openings and can flush out smaller pieces
of mineral deposit. This extends the service life of the unit and
reduces the required maintenance interval.
During blow-downs, water flows from the pump into the drainage
system.
A sensor electrode (10) monitors the maximum
water capacity
of the cylinder. When the water level reaches the sensor electrode, the water supply is interrupted. This can occur when the
water has low conductivity or when the electrodes are worn out.
In the case of low water conductivity, however, this state usually
lasts only a short time. The built-in control and the large area
electrodes combine to produce a rapid rise in conductivity by
increasing the concentration of the water.
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The steam cylinder consists of a top (16) and lower (19) part
joined with a cylinder flange. The seal between the cylinder and
cylinder base (37), as well as between the top and lower part of
the cylinder, is maintained using an o-ring (35).
Warning:
During operation and also soon afterwards the steam
nozzle is hot! If touched this can cause burns to the
skin.
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.
Due to pollution or incorrect installation hot water could
discharge from the nozzle.
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5. Installation
Warning: Installation of this unit to be attempted only by quali-
fied personnel. We accept no liability for damage due to faulty
installation.
Obey all safety notes and warnings present on the unit.
During installation the unit must be disconnected from its power
supply.
Attaching or installing additional components is permitted only
with the written consent of the manufacturer, or else the warranty is void.
5.1 Steam Humidifier Operating Environment
Note: When selecting the installation site for the steam humidi-
fier, note that:
Ambient temperature must be between 5° and 40° C.
Relative humidity must not exceed 80% RH.
The minimum clearances indicated in the diagram
below must be observed; these are necessary to
ensure adequate ventilation for the housing.
The rear panel of the steam humidifier heats up during
operation (to a maximum of 60°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.
Make sure that there are no people and bearing materi-
als below the steam cloud (approx. 3 meters in exhaust
direction).
The steam humidifier is not qualified for exterior appli-
cations.
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5.1.1 Fitting measures
Wall Distances [mm]
> 150
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Wall Mounting
Note: The steam humidifier must be installed vertically in order
to function properly.
Note: The steam humidifier should be positioned such that
draught effects are avoided. The minimum height is 0.15 m
above floor level but we propose a height of 2m in order to avoid
scalding.
Warning: If the installation of this unit is attempted by only one
person there is a risk that the unit drops down. We propose to
carry out the installation by two persons.
» Position the steam humidifier in the planned location,
adjust with spirit level and mark position of hanging
bolts. See also "Equipment Dimensions".
» Hang the unit onto bolts screwed into the marked posi-
tion.
5.2 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
Is the unit installed in such a way that draught effects
are avoided?
Are all bolts and clamps tightened?
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5.3 Unit Dimensions
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6. Water Installation
Warning: When installing the water installation, note the follow-
ing:
Have all work performed by a professional.
Disconnect power supply before installation.
Obey local public utility
regulations
Verify that necessary safety measures have been taken
– in compliance with either German Technical and Scientific Association for Gas and Water (DVGW) guidelines (DIN EN1717) or local regulations – to eliminate
backflow of polluted water into drinking water treatment
facilities. This can mean installing a backflow preventer .
Within the humidifier, a double check valve (58) is
located in the water supply line. It prevents - in accordance with DIN EN 61770 - the backflow of water.
Use feed water without chemical additives and with a
conductivity between 200 and 800 µS/cm only. Above
conductivity levels of 800µS/cm to a maximum of
1250µS/cm and below conductivity levels of 200µS/cm
to a minimum of
125µS/cm, special adjustments are
required. In this case please contact HygroMatik.
The water supply temperature may not
exceed 40° C.
Water installation pressure: 1 - 10 bar (100 x 10
3
to 100
x 10
4
pascal).
Blow-down water must be able to drain.
For water installation please use the water connecting
hose that is delivered with the unit.
6.1 Operation with Softened Water
Warning: Unless special measures are taken, feeding softened
water into the HygroMatik steam humidifier is dangerous. It can
cause
unacceptably high conductivity
the formation of salt bridges between the electrodes
and the electrode leads on the inner surface of the top
part of the steam cylinder
foaming in the steam cylinder
Salt bridges cause electrical arcs. These are indicated by the
presence of black grooves in the top part of the cylinder. The top
part must be replaced to prevent further damage to the cylinder
material, as well as short circuits which trip main circuit breakers.
Foam comes into contact with the maximum water level sensor
electrode and triggers a signal indicating the cylinder is filled to
capacity, even though this is false and the nominal current has
not yet been reached.
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Note: Please contact HygroMatik if you wish to operate the unit
with softened water.
If using a water softening system, we recommend diluting the
softened water with normal tap water to produce an overall hardness between 4-8°dH. This value can be set lower if the water
does not foam.
When blending softened water with deionized water (conductivity = 5-20 µS / cm) it is to ensure that the mixture neither foams
nor is too low in conductivity.
When feed water contains softened water, the level of conductivity is typically higher at operating temperature. Install a HygroMatik "cylinder star" to extend the service life of the electrodes.
6.2 Water Supply
» Install a shut-off valve (SV) in the supply line.
» Install a water filter (WF) if water quality requires it.
Note: Shut-off valve (SV) and water 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 the cap nut with its inner seal ring
around the water supply screw connection that pro-
trudes from the base.
Note: Tightening too much will destroy the fitting. The valve
strainer must be placed inside the solenoid valve.
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» Use a cap nut (internal thread ¾“) with inner seal for a
customer-provided water installation.
6.3 Water discharge
Warning: During blow down hot water with a temperature of
about 95°C is being drained. If touched this can cause burns to
the skin.
Warning: Pay attention for free and non-pressure drainage of
the water! During blow down up to 0,3 L/sec are being drained.
For water discharge, we recommend installation of a flexible
water drain hose. Humidifier and wastewater discharge must be
on the same pressure level.
Please note:
Do not bend the drain hose.
Install discharge line and drain pipe made from temper-
ature resistant material (to 95° C).
Install water discharge as follows
Loosely insert a length of 1 1/4 " drain hose, approx.
250 - 1000 mm, into a drain pipe with a minimum inner
diameter of 40 mm and seal with a rubber gasket.
Fit water drain hose over the pump drain hose and fas-
ten to the housing drain connection.
A grounding clip is fixed on the inner surface of the housing
drain connection. The end of the pump drain hose is pushed into
this clip. During blow-down, the grounding clip is in direct contact
with the water and shunts potential residual electric currents
away from the housing.
min.: 250mm
max.: 1000mm
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There is a 3mm-wide crack between the pump drain hose jacket
and the inner surface of the housing drain connection. If water
collects in the base plate, it will flow through this crack into the
drainage system.
6.4 Water Installation Check
Go down the following water installation checklist:
Are all screws and clamps properly tightened?
Is the water supply pipe flushed?
Was the water installation correctly installed?
Can the blow-down water drain freely?
Was the water discharge correctly installed?
Is there no leakage from the water supply pipe and
water discharge?
Warning: Flush the water supply pipe before connecting to the
solenoid valve, especially a newly installed pipe. This prevents
premature damage.
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7. Electrical Connection
Danger, Haza rdous Voltage: All work related to electrical inst al-
lation to be performed by authorized personnel only (electricians
or professionals with equivalent training). The customer is
responsible for checking qualifications.
Danger, Hazardous Voltage: Do not plug the steam humidifier
into the power grid until after all installation work has been completed.
Warning: The electronic components of the humidifier control
are very sensitive to electrostatic discharges. In order to protect
these components during any type of installation, steps must be
taken to guard against damage from electrostatic discharge
(ESD protection).
Warning: For electrical installation, note the following:
Disconnect power supply before installation and protect
against restart.
Verify the absence of electric current.
Make sure the unit is switched off before installing or
removing the display plate or basic PCB.
Professionally lay electrical connector cable.
Install the electrical connections according to the wiring
diagram.
For units with rated power over 33 kW, only a perma-
nent connection to a permanent wire is allowable (Ger-
man Association for Electrical, Electronic & Information
Technologies [VDE] Standard 0700 Section 98).
Verify that all terminals have been tightened.
7.1 Electrical Installation
» Fuses must have a contact gap of at least 3mm per
pole.
» Install a separate main connection for each steam cylin-
der, complete with main contactor, main switch, etc.
» Connect potential equalization to the outer ground bolt.
» Observe the German Association for Electrical, Elec-
tronic & Information Technologies [VDE] Standard 0100
when selecting a connection cross section.
» Install main power supplies as follows:
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Other voltages are available on request.
We recommend employing medium blow main fuses (applicable
only to the grid voltages above). See table below indica ting maximum power usage for each circuit protection:
When using fault current circuit breakers please use a separate
one for the humidifier.
HyLine:
CompactLine:
Type Standard Main Power Supply
HY05 - HY45 1 x 400V/3Phase/N
HY60 - HY116 2 x 400V/3Phase/N
C01, C02 1 x 230/1Phase/N
C06 - C58 1 x 400V/3Phase/N
MS5, MS10 1 x 400V/3Phase/N
MS5 1 x 230/1Phase/N
DBE 2 1 x 230V/1Phase
DBE 6-45 1 x 400V/3Phase/N
Type Power Usage Circuit Protection
HY05 5,4 A 3 x 6A
HY08 8,7 A 3 x 10A
HY13 14,1 A 3 x 16 A
HY17 18,4 A 3 x 20 A
HY23 24,9 A 3 x 35 A
HY30 32,5 A 3 x 35 A
HY45 48,8 A 3 x 63 A
HY60 2 x 32,5 A 6 x 35 A
HY90 2 x 48,8 A 6 x 63 A
HY116 2 x 62,8 A 6 x 63 A
Type Power Usage Circuit Protection
C01 3,3A 1 x 6A
C02 6,5A 1 x 10A
C06 6,5 A 3 x 10 A
C10 10,8 A 3 x 16 A
C17 18,4 A 3 x 20 A
C22 23,8 3 x 35 A
C30 32,5 A 3 x 35 A
C45 48,8 A 3 x 63 A
C58 62,8 A 3 x 63 A
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MiniSteam:
DBE:
7.2 Cable Connections
The table below shows the cable connections provided in electrode steam humidifiers:
Characteristics of metric cable connections:
Type Power Usage Circuit Protection
MS5, 230V/1/N 15,7 A 1 x 16 A
MS5, 400V/3/N 5,4 A 3 x 6 A
MS10, 400V/3/N 10,8 A 3 x 16 A
Type Power Usage Circuit Protection
DBE1 3,3 A 1 x 6 A
DBE2 6,5 A 1 x 10 A
DBE6 6,5 A 3 x 10 A
DBE10 10,8 A 3 x 16 A
DBE17 18,4 A 3 x 25 A
DBE30 32,5 A 3 x 35 A
DBE45 48,8 A 3 x 63 A
Unit Connection
M16
Connection
M25
Connection
M32
HY05, HY08 4 3 HY13, HY17,
HY23, HY30,
Hy45
421
HY60, HY90,
HY116
-42
C01, C02 4 1 C06 3 2 C10 3 3 C17, C30 4 3 C45, C58 4 2 1
MS5, MS10 - 2 -
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
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Page 26
7.3 Safety Interlock
Note: Install contact interlocks, i.e. max. hygrostat, vane relay,
pressure controller, air interlock, in series between terminals 1
and 2.
Warning: A max-hygrostat shou ld be installed in the safety interlock. The max-hygrostat acts as a safety device in case the
humidity sensor malfunctions.
Warning: Contacts laid between terminals 1 and 2 must be
potential free and rated for 230V switches.
7.4 Wiring Diagram
Please remove the wiring diagram from the technical manual
supplied with the control used with your humidifier. Every steam
humidifier comes with one technical manual for the unit and one
for the control.
7.5 Electrical Installation Checklist
Perform electrical installation checks in compliance with customer site requirements and public power utility regulations:
Is the power grid voltage compatible with the voltage on
the name plate?
Have all electrical connections been made according to
the terminal connection diagram?
Have all electrical cable and plug connections been
properly tightened?
Are all electrical socket connections secure?
Is the unit grounded?
After this check the unit can be switched on.
Warning: The unit must be closed and locked. This guarantees
that the cover is grounded. (only humidifier type HyLine and
MiniSteam)
Note: For initial operation, control, service, malfunctions, and
circuit diagrams, consult the operation instructions for the HygroMatik-controls.
Page 27
Page 27
8. Maintenance
The HygroMatik steam humidifier is easy to maintain. However,
inadequate or improper maintenance can lead to operational
malfunctions. Perform regular maintenance to give your unit a
long life span.
Warning: When performing maintenance work, please note:
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.
Leakages within the humidifier could lead to leakage
currents.
The unit is only to be serviced by qualified, authorized
personnel.
Observe safety notes.
Switch off the unit before maintenance and protect
against restart.
After maintenance work, have qualified personnel
check that the unit is operating safely.
The steam humidifier's performance and maintenance intervals
primarily depend on the water quality (carbonate hardness, conductivity) and the quantity of steam produced since the last
maintenance. Abnormal water quality can shorten or lengthen
maintenance intervals. Ongoing maintenance intervals can be
estimated based on the amount and type of residue found in the
steam cylinder.
Indications that cylinder maintenance is required immediately
include:
* Also see corresponding control operation instruction, Section
"Malfunctions".
Control Indicator
Basic maintenance message: red LED is blinking:
Unit has switched itself off automatically.
Comfort
Comfort
Plus
Maintenance message on the display (red LED is
blinking). Unit has switched itself off automatically*.
The maintenance message can also be sent by
one of the open programmable potentialfree contacts See EMP-Control Operation, Section "Parameter Settings with Codes"
Page 28
Page 28
8.1 Maintenance Work
Mineral deposits precipitate and crystallize very differently in different types of water, even when two types have the same conductivity and hardness levels (the various constituents in the
water interact differently).
Instructions on maintenance and cleaning intervals, or on electrode service life, are based entirely on empirical data
In most cases, the conductivity levels given in Section "Directions for Use" of these instructions can be considered normal.
Individual parameter setting of the control may be necessary.
In extreme cases, water pretreatment may be necessary (softening by dilution to approx. 4 - 8 °dH; decarbonization/partial
desalination to achieve target reductions in carbonate hardness).
HygroMatik would be pleased to refer you to companies specializing in water treatment systems.
8.2 Access Electrical Enclosure
» Remove cover from humidifier (B) and lift display plate
(A) of guiding.
» Turn display plate (please see sketch) and hang up dis-
play plate by using the „front guiding“.
Cycle Maintenance Work
4 Weeks after
initial operation
(with normal
water quality)
Visual inspection of electrical and
mechanical connections
Remove mineral deposits from steam cylinder, water drain hose and blow-down
pump
Check electrodes for erosion
Semiannually
(with normal
water quality and
"normal" opera-
tion = 8h/Day)
Visual inspection of electrical and
mechanical connections
Remove mineral deposits from steam cylinder, water drain hose and blow-down
pump
und ggf. erneuern.Check electrodes for
erosion
Page 29
Page 29
» The basic PCB (C) is now accessable.
Danger, Hazardous Voltage: Make sure the unit is switched off
before installing or removing the display plate.
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Page 30
8.3 Removing and Cleaning the Steam Cylinder
Warning: Please follow the det ailed instructio ns in these operat-
ing instructions! The unit is only to be serviced by qualified,
authorized personnel. Note the warnings and safety notes in the
operating instructions. Failure to observe warnings and safety
notes may result in injury, serious injury or death, and/or damage to the unit. The steam cylinder may still be hot when you
begin maintenance work. Handle carefully!
Warning: Bot h the clamp s that fix the steam cylin der halves and
the electrodes have sharp edges and angles that possibly could
lead to cut injuries.
Disassembly
» Switch on the unit by the main switch. The humidifier
runs the pump for a few seconds. The purpose of this is
to check that the system is operating properly.
» Drain residual water in the cylinder.
» Units with Basic, Comfort or Comfort Plus control elec-
tronics:
» Press the on/off control swith in position „II“.
» Units with Comfort or Comfort Plus control electronics:
» Press the Softwarekeys and simultane-
ously longer than 5 seconds.
» Open and remove cover.
» Disconnect the steam generator from the power supply.
Control switch OFF and remove safety fuse F1.
» Check that unit is without power.
» Unscrew and remove the steam nozzle (1).
» Unplug the electrodes (4).
» Unplug the sensor electrode (10).
» Remove adapter (2) between steam cylinder and steam
nozzle (1).
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Page 31
» then:
Cleaning
Warning: Check the inside of the top part of steam cylinder for
crust build-up and possible salt bridges (black grooves between
the electrode leads). If present, wash away completely .
Note: If electrical arcs have burned deep grooves in the material, the top part of the cylinder must be replaced.
Warning: Clean the sensor electrode until it is bright.
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Page 32
Reassembly
» Connect plug (10) to level sensor.
» Connect plugs (4) to electrodes.
»
Warning: The plug must be pressed down onto the electrode as
far as it will go.
Note: Connect plugs to the correct electrodes. Note the color of
the knurled nut.
Note: Condensate connection must be showing in the front on
the left.
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Page 33
» Push in safety fuses.
Switch on the unit and check for leaks after 15-30 minutes of
operation.
If leakage occurs, switch off power supply and follow safety
instructions for work on live components.
8.4 Electrode wear
Electrode wear depends on:
feed water composition and conductivity.
the quantity of steam produced.
Warning: At the latest, electrodes must be replaced if a maintenance message is displayed. The maintenance message
appears after one hour of operation at maximum water level.
The humidifier switches itself off. Also see Section "Maintenance." When the electrodes are less than 1/3 to 1/2 of their
original length, replace them.
8.4.1 Original Electrode Lengths
Original lengths of HygroMatik large area stainless-steel electrodes are:
HyLine:
CompactLine:
MiniSteam:
Type HY05-HY08 HY13-HY60 HY90-HY116
Length
[mm]
155 235 300
Type C6 C10 C17-45 C58
Length [mm] 125 155 235 300
Type MS5 MS10
Length [mm] 125 155
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Page 34
8.4.2 Uneven Electrode Lengths
In most case, the longer electrode(s) will not be supplied with
electricity for a time. Therefore they will not wear. The cause of
the problem, such as a tripped circuit breaker, can be repaired.
However, since the shorter electrode(s) have a greater specific
load, the electrodes continue to wear unevenly.
Note: Replace electrodes with significantly uneven wear. Check
the power supply (breaker, voltage drop). Also see electronic
operation, Section "Malfunctions."
8.5 Replacing Electrodes
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Page 35
» Remove cylinder, as described in Chapter 8.3 "Remov-
ing and Cleaning Steam Cylinder."
» Loosen knurled nuts (5) and remove electrodes (48).
» Install new electrodes and hand tighten the nuts.
» Use solvent-free, HygroMatik-quality o-rings (for flange,
cylinder base and steam hose adapter).
» assemble steam cylinder and place it into housing.
» Connect plugs (4) directly to the electrodes (48) (with
gray, red and black knurled nuts). It is not necessary to
detach the knurled nuts!
Warning: The plug must be pressed down onto the electrode as
far as it will go.
Note: Connect plugs to the correct electrodes. Pay attention to
the color of the knurled nut.
» Attach plug (8) to the sensor electrode.
<
(Knurled nut
(9) - gray)
» Switch breaker back on.
» Switch on the unit and check for leaks after 15-30 min-
utes of operation.
If leakage occurs, switch off power supply and follow safety
instructions for work on live components.
Note:
In the following cases:
the electrodes must be frequently replaced,
black slime collects inside the cylinder, or
there is "lightning" in the cylinder,
the conductivity of the water is too high or it isn't decanted often
enough. In this case please contact HygroMatik.
Page 36
Page 36
8.6 Cleaning the Blow- Down Pump
» Remove cylinder, as described in Section: "Removing
and Cleaning the Steam Cylinder”
» Detach e-cable from the pump.
» Detach adapter (30) from the pump.
» Loosen screws (44) and remove the pump from the
base.
» Open the pump (bayonet lock).
» Remove residues from the drain hoses and pump
(potentially replace o-ring (33) or
housing (34) if these
components are no longer in excellent condition).
» Reassemble the pump.
» Moisten o-ring (31) and insert in the side connection of
the base.
» Push pump into the base and mount tightly with screws
(44).
» Moisten o-ring (31) and insert in adapter (30).
» Fit adapter (30) over the side connection of the pump.
» Connect e-cable to the pump.
» Install cylinder,
» Switch on the unit and check for leaks during operation.
If leakage occurs, switch off power supply and follow safety
instructions for work on live components.
8.7 Cleaning the Water Inlet Solenoid Valve
Removal
» Shut off water supply.
» Remove cylinder, as described in Section: "Removing
and Cleaning the Steam Cylinder” .
» Loosen water installation hose connection.
» Loosen connecting hose (21) from the base.
» Detach e-cable from the solenoid valve.
» Loosen solenoid valve mounting screws (28).
» Remove solenoid valve from the borehole.
» Remove fine mesh filter (29) from the solenoid valve,
clean and replace if needed.
Installation
» Insert fine mesh filter (29).
Page 37
Page 37
» Place solenoid valve with seal in the borehole of the
unit housing.
» Attach solenoid valve tightly with screws (28).
» Screw on water installation hose.
» Connect e-cable to the solenoid valve.
» Attach connecting hose (21) to the base.
» Install cylinder, as described in Section: "Removing
and Cleaning the Steam Cylinder”
» Turn on the tap.
» Switch on the unit and check for leaks during operation.
If leakage occurs, switch off power supply and follow safety
instructions for work on live components.
8.8 Chekking Cable Connections and Electrode
Cables
» Make sure that no cable and plug connections are
loose.
Warning: Plugs must be pressed down onto electrodes as far as
they will go.
Loose cable connections cause excessive contact resistance
and overheating of contact surfaces.
» Check electrode plug isolation, replace plugs as
needed.
Warning: Replace electrode plugs after removing and reinstall-
ing them several times.
8.9 Checking Operation
Start up the unit and operate for a few minutes at maximum output if possible.
» Check safety devices.
» Check hose connections for possible leaks.
8.10 Dismantling
After you stop using the steam humidifier, dismantle (demolish
or scrap) it by following the installation procedures in reverse
order.
Warning: Dismantling of the unit is only to be attempted by qualified personnel. Electrical dismantling is only to be attempted by
trained professionals.
Note the information provided in Section 2 "Safety Notes," especially the guidelines for disposal.
Page 38
Page 38
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 how
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.
• When there is a demand for humidity, the water inlet
solenoid valve opens and feeds water into the steam
cylinder.
• Initiation of steam production can take up to 20 min-
utes.
Let all electrically-driven operations run to completion.
As soon as the solenoid valve begins replenishing the water
periodically, the steam humidifier 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 Voltage! Follow safety instructions for
work on live components.
Page 39
Page 39
10. EC-Declaration of Conformity
Page 40
Page 40
11. Spare Parts
*
MS5 MS10 Article no . Description
E-2124010 Keys for safe ty, set =2pc.
E-2124012
Safety lock incl. 2 keys
St ea m ge nera ti o n
1 B-3216067
Steam cylinder CY4 transp. compl. with electrodes and Hand nuts **
1 B-3204031
Steam cylinder CY8 transp. compl. with electrodes and Hand nuts **
16 1 E-3216043
Top part of steam cylinder CY4 empty
16 1 E-3226005 Top part of steam cylinder CY8 empty
19 1 B-3216044
Lower part of steam cyli nder compl. with st raine r **
19 1 B-3216007 Lower part of steam cyli nder compl. with strai ner **
17 1 E-3216046
O-ring seal for cylinder flange, trans parent cylinder
17 1 E-3216010 O-ring seal for cylinder fl ange, trans p arent cylinder
35 1 1 E-3216011
O-ring seal for cylinder base
12 1 E-3216020 Condensat e pl ug DN 9
12 1 E-2204035
Conden sat e pl ug DN 12
11 1 1 E-2304014
Hose clamp 10-16mm Torro
48 1 B-3216061
Electr odes compl. with hand nuts , set=3 pc.
48 1 B-3204019
Electr odes compl. with hand nuts , set=3 pc.
10 1 B-3204037
Sensor electrode com pl . with hand nut , max. limit ation
10 1 B-3204027
Sensor electrode com pl . with hand nut , max. limit ation
4 1 1 E-3216024
Plug-in contact with insulating hose for electrodes
10 3 3 E-3216025
Plug-in contact with insulating hose for sensorelectrode
18 12 12 E-3216022
Clamp for flange of transparent cylinder
37 1 1 E-3220000
Cylinder base DN 20/2 5/15/ 12
1 B -3117015 Fan 60x120 mm
1 E-3117012
Fan 60x180 mm
1 1 E-3126048 Steam nozzle
1 1 E-3126130
Steam nozzle
2 1 E-3126054 Adapter between steam cylinder and steam nozzle
2 1 E-3720008
Adapter between steam cylinder and steam nozzle
38 0,41m 0,84m E-2604002 Condensate hose steam no zzle - cylinder base DN12, per m
1 B-3216077
maintena nce ki t for cyl inde r CY 4
1 B- 32160 79 mai ntenance kit for cyl in der CY 8
(1) B-2304063
Super Flus h -upgrade kit-
Water feed
25 1 B-2304081
Solenoid valve, servo controlled, straight type, 0,2-10 bar, 1,2l/min
25 1 B-2304083
Solenoid valve, servo controlled, straight type, 0,2-10 bar, 2,5l/min
1 B-2304021
Solenoid valve, long-life, servo controlled,straight, 0,2-10bar,2,5l/min
56 1 1 B-2304031
Hose for water connection , 3/4 " cap nuts on both sides
49 1 1 E-3616010
angle piece 90°, reduci ng DN14/ 12
20 1 1 E-23040 80 eart hi ng bush
21 0,71m 0,90m E -2604002
Connecting hose, solenoid valve - reduction, per m
26 0,05m 0,05m E -2604004 Connecting hose, reduction - cylinder base, per m
22 7 7
E-2304015 Hose clamp 10-16mm
39 2 2
E-8501064 Hose clamp 12-20mm
24 0,06m 0,06m
E-2604002 Connecting hose solenoid valve - bush for earthing
20 1 1
E-2304080 Bush for ear thing
58 1 1
E-2604094 double ch eck valve
Water fee d wit h fi llin g cup (optio n)
1 1 B-3320406
Filling cup compl. with cover
1 1 E-2325054
Earth plat e for fill i ng cup
0,32m 0,41m E -2604002
Connecting hose, solenoid valve - filling cup, per m
0,37m 0,47m E -2604004
Connecting hose, filli ng cup - cylind er base, per m
1 1 E-3616010
angle piece 90°, reduci ng DN14/ 12
Page 41
Page 41
*
MS5 MS10 Article no . Description
Water drain
15 0,3m 0,4m E-2604002
Connecting hose pump-elbow
30 1 1 E-3425002
Adapter pump - drain hose. connections DN25/13
31 1 1 E-3220005
O-ring seal for adapter - p ump
31 1 1 E-3220005
O-ring seal for cylinder base - pump
32 1 1 B-2404027
Drain pump without mou nti ng set
14 0,36m 0,45m E-2604004
Connecting hose elbow-drain
57 1 1 E-2420423
Drain hos e, 1 1/4", per m
1 B-3401015
Drain hos e system (pos. 6, 14, 15, 30, 31)
1 B-3401017
Drain hos e system (pos. 6, 14, 15, 30, 31)
6 1 1 E-2425004
Elbow with vent pi pe
B-2424014 Mounting set for drain pump (pos. 42-44)
Control
universa
l
1 1 E-2501005
Main contac tor 16 A, 230 V
1 1 E-2505206 Control fus e 1,6 A, 5x20 mm
4 1 1 B-3526019
Connecting cables for electrodes with plug-in contact, set=3pc
8 1 1 B- 25 25051 Conne ct ing cable for sensor electr ode with pl ug-i n cont act, 630 mm
x x E-0611001
Room hygros tat HG-Mini
Basi c Control
51 1 1 B-2526201
Basic mai nbo ard
1 1 E-2502412
control switch, 2 po le
52 1 1 B-2120901
Mountinig plate (Basic)
Comfort Control
51 1 1 B-25262 01 Basi c mai nboard
1 1 E-2502412
control switch, 2 po le
52 1 1 B-21209 03 Mounting pl ate (Comfort)
1 1 B-2526401
Display (Comfort)
If you order any spare parts, please sp ecify type and serial number of the unit.
* Exploded view
** If the Super Flush System is insta lled, consi der to order also a new nozzle (B-2304079), please.
*** Maint enance set consist s of: electrod es (without hand nuts), o-ring for steam hose adapte r, o-r in g for
cyli nder flange, o-r i ng for cylinder base
Page 42
Page 42
12. Fax Form - Order for spare parts
HygroMatik
Lise-Meitner-Str. 3
24558 Henstedt-Ulzburg
Tel. +4904193/895-0
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)4193/895-31
company stamp (delivery adress)
date/signature
Page 43
Page 43
13. Technical Data
Technical Data Steam Humidifiers MiniSteam
Type MS5 MS5 MS10
Steam Output [kg/h] 4,8 5 10
Electrical Supply 230V/1/N/50-60Hz 400V/3/N/50-60Hz
Electrical Power [kW] 3,6 3,8 7,5
Current [A] 15,7 5,4 10,8
Fuse [A] 1 x 16 * 3 x 6 * 3x 16 *
Control Type Basic, Comfort
Control Voltage 230V/50-60Hz
Empty Weight [kg] 11 11 13
Operation Weight [kg] 14 14 19
Dimensions Height [mm] 471 561
Width [mm] 373 407
Depth [mm] 178 208
Water Supply
100 x 10
3
to 100 x 104 Pa (1 to 10 bar) incl. connection ¾"
Water Drain into funnel
Air Circulation [m³/h] 66 165
Sound Level (1m distance to the
source of noise) [dB(A)]**
48 48 52
* Times 1.3 power input after Full Blow Down. If explusion fuses are use d close to their specific limit
we recommend to chosse explusion fuses with a higher range.
** During sporadic Blow Downs higher values.
Page 44
Page 44
14. Exploded View
32
42
20
12
25
15
26
21
24
39
11
37
6
18
43
44
49
1
8
17
4
58
22
22
22
22
22
2
10
14
16
19
48
35
31
30
38
22
22
22
Page 45
Page 45
15. View of housing
Page 46
12/2004
Lise-Meitner-Str.3 D-24558 Henstedt-Ulzburg
Phone +49(0)4193/ 895-0 Fax -33
eMail hy@hygromatik.de www.hygromatik.com
A member of the Group
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