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FlexLine

Electrode Steam Humidifiers

ÁFLE.ENBÈ

FLE.EN
E-8881162

Manual

Summary of Contents for FlexLine FLE05

Page 1: ...FlexLine Electrode Steam Humidifiers ÁFLE ENBÈ FLE EN E 8881162 Manual ...

Page 2: ...nual can be found at www hygromatik co uk 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...

Page 3: ...g sequence 11 5 Mechanical installation 12 5 1 Environment Parameters to be met and Mounting Recommendations 12 5 1 1 Dimensions and Mounting Directions 13 5 2 Unit Installation Check 15 5 3 Absorption Distance BN 16 5 3 1 Determining the Absorption Distance 16 5 3 2 Absorption Distance Nomogram 17 5 4 Steam Manifold 18 5 4 1 General installation guidelines 18 5 4 2 Recommendations for dimensionin...

Page 4: ...34 9 3 2 Cylinder cleaning O ring replacement 35 9 3 3 Cleaning the connecting hoses base connections fine filter and drain pump 37 9 3 4 Cleaning the vent hole on the pipe elbow 37 9 3 5 Reinstallation of the steam cylinder 38 9 4 Removal and installation of unit components 39 9 4 1 Blow down pump removal cleaning reinstallation 39 9 4 2 Solenoid valve removal reinstallation 40 9 4 3 Electrode re...

Page 5: ... documentation is manda tory for the operation of the unit This is not applicable to StandardLine devices here the documentation of the controller is included in the operation manual Retention Please retain these operating instructions in a secure always accessible location If the product is resold turn the documentation over to the new operator If the documenta tion is lost please contact HygroMa...

Page 6: ...ers 2 1 and 2 2 in the section Detailed parameter descriptions in this manual Proper usage also comprises the adherence to the conditions specified by HygroMatik for installation dismantling reassembly commissioning operation maintenance disposal Only qualified and authorised personnel may operate the unit Persons transporting or working on the unit must have read and understood the corresponding ...

Page 7: ...sult from it Cleaning and user maintenance of the unit must not be undertaken by children without supervision 2 1 3 Unit Operation Risk of scalding Uncontrolled hot steam escape in case of leaking or defective components possible Switch off unit immediately For Ministeam devices applies Risk of scalding No persons may be under the cloud of steam blowing out at a distance of approx 1 m 40 inch in t...

Page 8: ...s electrical voltage Any work on the electrical system to be per formed by certified expert staff electricians or expert personnel with comparable training only Steam operation may only be started when the unit cover is closed During maintenance or installation work the device must be disconnected from the power supply and secured against being switched on again The absence of voltage must be ensu...

Page 9: ...oods Upon receipt of the unit confirm that model and serial number on the name plate match those specified in the order and delivery documents the equipment is complete and all parts are in perfect condition In case of damage from shipment and or missing parts immediately notify the carrier or supplier in writing Time limits for filing freight claims with ship ping companies are Time limits for so...

Page 10: ...cal Construction The FlexLine humidifiers are designed for wall mounting For maintainance purposes the steam cylinders are separable in the mid dle Starting with the manufacturing date of 11 2018 the steam humidifiers FLE50 65 100 130 make use of a modified steam cylinder that are separable in the upper part of the wall When replacing the steam cylinder the new cylinders with the designation CY45 ...

Page 11: ...some of the concentrated water are very important Following this procedure as rec ommended 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 W...

Page 12: ...frost may damage the steam cylinder the solenoid valve and pump as well as make hoses burst Relative humidity must not exceed 80 r h since values beyond may lead to electronic malfunction or dam age Installation in a closed room requires aeration and eventually temperature conditioning in order to meet the a m environmental conditions The steam humidifier should be installed as close as possible t...

Page 13: ...3 1 750 29 5 420 16 5 870 34 4 620 24 4 FLE100 FLE130 1170 46 785 30 9 420 16 5 1000 39 4 660 25 6 Detailed measurements under https www hygromatik com files pdf hygromatik flexline dimensionsv13 pdf 3D models under https www hygromatik com en downloads Units with production date January 2022 and earlier X 540 A 390 Wall clearances When mounting the steam humidifier the wall clearanc es shown in t...

Page 14: ... the mounted screws hook in the unit and ensure safe suspension mark the holes for the lower suspen sion brackets screws remove the unit drill holes and dowel hook in the unit and mount the lower screws firmly To function properly the steam humidi fier must hang level and plumb When choosing the installation loca tion consider the necessary distance between the unit and existing desig nated paths ...

Page 15: ... Steam hose installed with a 5 10 minimum incline decline see chap ter Steam line Condensate hose features a loop functioning as a steam barrier see chapter Condensate hose Steam manifold s properly positio ned All bolts and clamps properly tighte ned Steam manifold s horizontally mon ted and suspended on the free end if required All seals o rings in place All ventilation slots on housing top unob...

Page 16: ...humidification t2 in C with steam humidifiers the change in air temperature due to humidification may be disregarded t1 or t2 Specific increase in humidity x in g kg can be determined in the h x diagram quantity of steam introduced in kg h air speed wL in m s in air duct Total length lD of the steam manifold installed in the air duct Length ID of the usable steam manifold depends on the dimensions...

Page 17: ...Page 17 5 3 2 Absorption Distance Nomogram Source Henne Erich Luftbefeuchtung Air Humidification 3rd Edition 1984 Page 101 Olden bourg Industrieverlag Munich ...

Page 18: ...d depending on the overall pres sure situation These modifications must be coordinated with your expert dealer Water drain We point out that according to the Ger man Association of engineers VDI guideline VDI 6022 a water drain must be provided within the absorption distance inside the air duct When increased airflow speed is encoun tered Air flow rates beyond 3m s 9 84 ft s may lead to condensate...

Page 19: ...y staggered with respect to air flow direction in case of Lmin s above not to be met very flat by tilting the steam manifold 30 45 towards the air flow direction the mini mum upper clearance can be reduced to 70 mm 2 8 inch Min mm inch H1 H2 30 45 DN25 1 182 7 2 168 6 6 225 8 6 DN40 1 1 2 193 7 6 179 7 2 230 9 1 narrow high identical lenghts one on top of the other staggered laterally if possible ...

Page 20: ...o possible Standard manifold dimensions mm inch Special lengths on demand Number and size of the steam manifolds available as well as the nominal diameter of the repective steam and condensate hoses may be taken from the tables shown in chapter Technical Data 220 8 7 400 15 7 600 23 6 900 35 4 1200 47 2 1450 57 1 Steam manifold arrangement Steam supply Air flow direction ...

Page 21: ...m hose installation Pressure conditions within the duct are influenced by device steam output steam line layout and the duct composition itself In some rare situations it may become necessary to optimize steam line layout for achieving the results intended Respect minimum bending radii DN 25 Steam hose Rmin 200 mm 8 DN 40 Steam hose Rmin 400 mm 16 5 5 2 Condensate hose layout only for electrode st...

Page 22: ...r below device upper edge In this arrangement the condensate hose cannot be fed back to the steam humidifier Run steam hose to a height of 400 mm 16 mm minimum above the steam humidifier and then to the steam manifold with a continuos decline of 5 to 10 Feed condensate hose to a waste water pipe drain with a 200 mm 8 inch diameter loop as a steam bar rier Minimum distance from steam manifold to lo...

Page 23: ...is located in the water supply line It prevents in accordance with DIN EN 61770 the backflow of water Supply water must not exceed 40 C 104 F Allowable range of water pressure 1 to 10 bar 14 5 to 145 psi 100 x 103 to 100 x 104 Pa For connection to the water supply pipe make use of a water hose Blow down water must drain freely The following applies to electrode steam humidifiers Use feed water wit...

Page 24: ...th softened water at operating tempera ture conductivity level usually is higher than is the case with tap 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 gH This value can be set lower if the water does not foam 6 2 Water supply Foreign material in water supply pipe may cause premature wear of the so...

Page 25: ... be on the same pressure level In case of a drain connection on posi tive pressure pls consult your expert dealer Guidelines for water discharge composi tion Use flexible water hose Do not buckle drain hose Discharge line and drain pipe material must be temperature resistant up to 95 C 203 F How to proceed Run a 1 1 4 drain hose of 250 to 1000 mm 10 to 40 inch length into a pressure free outlet ac...

Page 26: ...ter cooling system HyCool not available for FLP XX TPRO units HygroMatik offers an option for limi ting the steam humidifier wastewater temper ature in order to protect thermosensitive wastewater pipe lines By blending with tap water during blow down wastewater temper ature is below 60 C 140 F as long as inlet water temperature does not exceed 30 C 86 F 6 4 Water connections final check Go down th...

Page 27: ...o commencing electrical installation work steps must be taken to guard the sen sitive electronical components of the unit con trol against damage from electrostatical discharge 7 1 Electrical installation approach Provide fuses with a contact gap of at least 3mm per pole Install a separate main connection for each steam cylinder including main circuit breaker main switch etc Make main connection a...

Page 28: ...ays pressure controllers air interlock devices etc in series across ter minal 1 and 2 Contacts across terminals 1 and 2 must be potential free and properly rated Rating must comply with the control voltage in use Best practice implies the integration of a max hygrostat in the safety interlock wiring to pro tect against over humidification due to a r h sensor malfunction Model M25 M25 with MSI M32 ...

Page 29: ... across terminals 1 and 2 Supply voltage in accordance with name plate voltage rating All ectrical connections made accor ding to the wiring diagram Is the sensor temperature sensor or r h sensor depending on the appli cation scenario properly connected to the main p c b make sure that the input selected is adequate for the type of sensor installed with respect to the signal type and range specifi...

Page 30: ...s for a couple of seconds After the self test of the controller the display shows the setup view for the basic device settings language date time and control settings Refer to the chapter Commissioning in the opera ting instructions for the control system Consequently normal operation is commenced However steam is not produced without a demand pending Step 4 Trigger steam demand Set control to 1 s...

Page 31: ...s Steam_amount_counter is output when the pre set produced steam amount is reached Cycles_main_contactor x is indicated when the number of cycles pre set for main contactor x x 1 5 is reached The main contactor should then be replaced and the counter reset s Service submenu in the FlexLine controls manuals After a Steam_amount_counter message maintenance work mainly encompasses checking and cleani...

Page 32: ...maintenance work is commenced After that wait approx 10 mins before starting maintenance work Check steam cylinder temperature by cau tious approximation with hand do not touch Risk of scalding Water pumped or drained from the steam cylinder may have a temperature of up to 95 C 203 F Wear proper PPE Personal Protection Equipment Take care of ESD protection The electronic components of the humidifi...

Page 33: ...r expert dealer If the water quality differs this could result in a more frequent need for maintenance Cycle time Maintenance work 4 weeks after commissioning also after installa tion of a new steam cylinder 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 burn o...

Page 34: ...an cool down Check the temperature by carefully approaching it with your hand do not touch the cylinder if the rest heat should be too strong Remove Super Flush solenoid hose from cylinder bottom if applicable Remove the steam hose from the steam hose adapter If the steam hose is not to be disconnected the steam hose adapter with the steam hose still attached may be detached from the steam cylinde...

Page 35: ... of eye injuries The clips that fix the steam cylinder halves have sharp edges and can jump off during dismantling Eye injuries are possible Wear proper PPE Personal Protection Equip ment Remove the cylinder flange clamps Separate cylinder halves Remove the used O rings between the cylinder halves in the base and in the steam hose adapter Clean the cylinder inside CAUTION ...

Page 36: ...e the O rings of the elec trodes Install new electrodes 48 Make sure that the electrodes are posi tioned correctly see exploded view The deposits in the upper part of the cylinder can be conductive and lead to unwanted cur rents between the electrode connections and the sensor electrode and thus to the mes sage cylinder full If electrical bridges have penetrated deep into the material the steam cy...

Page 37: ...id valve and clean it under running water Clean the drain pump as described in the section of the same name When operating with partially softened water or tap water scale may be discharged with the steam flow and may settle in the nozzle positioned in steam hose adapter Therefore this nozzle should be inspected regularly as part of the general maintenance review and cleaned if necessary 9 3 4 Cle...

Page 38: ...st sit on their respective contacts as far as they will go Check electrode plugs for corro sion Replace if stained Risk of functional disruption Risk of material damage Loose cable connections may result in increased transition resistance and contact area overheating Reattach Super Flush solenoid hose if applicable to steam cylinder bot tom stub Attach steam hose adapter to cylin der Affix the ste...

Page 39: ...er base 37 Open the pump bayonet lock Remove residues from pump and drain hoses Remove the used o Ring 33 Reinstallation Moisten the new O ring 33 and insert into cylinder base 37 hori zontal stub Push pump back into cylinder base and bolt to bottom plate encorporat ing the vibration buffer 42 and washers saved during removal Moisten O ring 31 and insert into adapter Slide adapter 30 onto pump stu...

Page 40: ...r and open it see also chapter Removal of the steam cylinder When mounting the electrodes make sure that the hand nut colours corresponding with the wiring colours remain in the same posi tion as before in order to omit any unwanted shift of electrical potential Hence the hand nut positions must be recorded before they are removed During reassembly particular care must be taken to ensure that no g...

Page 41: ...th of 300 mm Electrode wear Eelctrode wear depends on composition and conductivity of the supply water the amount of steam produced In case of the electrodes being burned off to less than one third to half of their genuine length electrode replacement should be made When cylinder water maximum level is detected for a period of 60 mins an error message s FlexLine control manual Faults and warnings ...

Page 42: ... O rings seals after 15 30 minutes of operation In case of leakage turn off power supply and secure against being switched on again Find leakage and eliminate Check again Follow the instructions in the section funktional check 9 6 Functional check Run the system with maximum out put for a couple of minutes Check hose connections and seals for leakage 9 7 Finishing maintenance Reattach unit housing...

Page 43: ...e humidifier is made up of metal parts and plastic parts In reference to European Union directive 2012 19 EU issued on 4 July 2012 and the related national legislation please note that The components of the electrical and elec tronic devices must not be disposed of as municipal waste and therefore the method of waste separation must be applied The public or private waste collection systems defined...

Page 44: ...Page 44 11 Declaration of Conformity ...

Page 45: ...33 34 35 36 38 1 AC 04 00100 O ring set Pos 3 17 31 33 34 35 36 38 1 1 2 AC 05 00000 O ring set Pos 3 17 31 33 34 35 36 38 1 1 2 2 AC 06 00000 O ring set Pos 3 17 31 33 34 35 36 38 for cylinders until 10 2018 1 1 2 2 AC 06 00002 O ring set Pos 3 17 31 33 34 35 36 38 for cylinder CY45 2 from 11 2018 Steam generation special voltage 208V to 240V 1 SP 03 00000 Steam CYlinder CY08 compl 1 SP 04 00000 ...

Page 46: ...es and sensor electrode with plugs Pos 4 5 1 1 WR 04 00001 Connecting cables for electrodes and sensor electrode with plugs Pos 4 5 1 WR 04 00101 Connecting cables for electrodes and sensor electrode with plugs Pos 4 5 1 1 1 WR 05 00001 Connecting cables for electrodes and sensor electrode with plugs Pos 4 5 1 WR 05 00002 Connecting cables for electrodes and sensor electrode with plugs right cylin...

Page 47: ...40 per m 57 x x x x x x x x x x x E 2420423 Drain hose 1 1 4 per m x x x x x x x x x x x E 2604002 Condensate hose DN12 per m x x E 2404004 Steam hose clamp DN25 x x x x x x x x x x x E 2604016 Steam hose clamp DN40 x x x x x x x x x x x E 2404010 Clamp for drain hose 1 1 4 x x x x x x x x x x x E 8501064 Condensate hose clamp x E 2604042 Connectors for steam distribution T piece DN25 stainless st...

Page 48: ...4 1 23 3 35 7 71 4 1 2 FlexLine mainboard with capacitive 3 5 touch colour display 220 240V 2 5A 2 x 40 4 x 40 640 1170 785 785 75 0 146 9 7 Maximum water consumption at 100 demand plus blowdown losses The water consumption depends on the water quality and installed options 2 13 28 above nominal power consumption after full blowdown Observe actuation characteristics of automatic circuit breakers 4...

Page 49: ...nsumption after full blowdown Observe actuation characteristics of automatic circuit breakers If necessary select the next highest circuit breaker level 785 785 420 tap water of varying qualities 1 to 10bar 1 to 10 bar for 3 4 external thread Connection Ø 1 1 4 2x Connection Ø 1 1 4 35 7 71 4 75 0 146 9 640 1170 FlexLine mainboard with capacitive 3 5 touch colour display 220 240V 2 5A 2 x 40 4 x 4...

Page 50: ...Page 50 14 Exploded view 2 1 3 35 19 18 17 16 4 5 49 48 36 38 30 31 32 33 42 6 14 15 34 37 25 58 20 28 29 8 ...

Page 51: ...Page 51 15 View of housing FLE05 FLE30 FLE80 FLE40 FLE100 FLE130 FLE50 FLE65 70 56 57 70 56 57 70 56 57 56 57 70 56 57 56 57 70 56 57 ...

Page 52: ...Ein Unternehmen der Gruppe 100 Lise Meitner Str 3 D 24558 Henstedt Ulzburg Phone 49 0 4193 895 0 Fax 33 eMail hy hygromatik de www hygromatik com member of CAREL Group ...

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