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Page 21

Vertical steam manifold installation

Horizontal installation of the steam mani-
folds is preferable. However, vertical
installation into the air duct from below is
also possible.

Standard manifold dimensions [mm]/
[inch]***:

*** Special lengths on demand.

**** will be replaced in 2019 by 1500 mm / 59,1 inch long
steam distributors

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

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Summary of Contents for FlexLine Plus Series

Page 1: ...FlexLine Plus Electric Heater Steam Humidifiers ÁFLP ENcÈ FLP EN E 8881170 Manual ...

Page 2: ...l 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 in...

Page 3: ...nd Device Composition 10 4 1 Mode of Action 10 4 2 Operational sequence 11 4 3 Internal Output Setting 11 4 4 Mechanical Construction 11 4 4 1 FlexLine Plus 11 4 4 2 FlexLine Process 11 4 5 Thermal fuses 12 5 Mechanical installation 13 5 1 Environment Parameters to be met and Mounting Recommendations 13 5 1 1 Dimensions and Mounting Directions 14 5 2 Unit Installation Check 17 5 3 Absorption Dista...

Page 4: ...r and heater element cleaning 37 9 7 Cleaning Connection Hoses Cylinder Base Connections Steam Hose Adapter Nozzle 38 9 8 Level control device cleaning 39 9 9 Heater element replacement 40 9 10 Releasing the thermical safety devices 40 9 10 1 Variety of thermal protection devices in use 40 9 10 2 Unlocking of a thermo switch on the cylinder cover 41 9 10 3 Unlocking of the Klixon thermo switch 41 ...

Page 5: ...anual the appropriate FlexLine Control documentation is mandatory for the operation of the unit Retention Please retain these operating instructions in a secure always accessible location If the product is resold turn the documentation over to the new operator If the documenta tion is lost please contact HygroMatik Versions in Other Languages These operating instructions are available in several l...

Page 6: ...nnel may operate the unit Persons transporting or working on the unit must have read and understood the cor responding parts of the Operation and Main tenance Instructions and especially the chapter 2 Safety Notes Additionally operating personnel must be informed of any possible dangers by the pro vider A copy of this manual is to be placed at the unit s operational location By construction HygroM...

Page 7: ...e and above as well as by persons with reduced physical sensory or mental ca pabilities or lack of experience and knowledge so long as they are supervised or have been instructed regarding the safe use of the de vice and understand the hazards that may re sult from it Cleaning and user maintenance of the unit must not be undertaken by children without supervision 2 1 3 Unit Operation Risk of scald...

Page 8: ...us electrical voltage Any work on the electrical system to be per formed by certified expert staff electricians or expert personnel with comparable training only Disconnect unit components from electrical power supply prior to work After electrical installation or repair work test all safety mechanisms such as grounding resistance Use only original fuses with the appropriate amperage rating Regula...

Page 9: ...ry of Goods Upon receipt of the unit confirm that model and serial number on the name plate match those specified in the order and delivery 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...

Page 10: ...lly desalinated water is used the cy linder water is almost totally clear of minerals This situation guarantees a long lifetime of the cylinder s and the heater element s since virtually no hardeners will fall out and no min eral deposits will occur Such the number of inspections and or maintenance operations required will be reduced to a minimum When tap water is used for operation some of the mi...

Page 11: ... pressing and holding the control switch in the II position numbers indicated correspond with those in the exploded view in the Exploded view chapter 4 3 Internal Output Setting Continuous control is achieved by propor tional driving pulse width modulation of the heater elements via one or both solid state relays In this way the humidifier can be pro portionally operated across the entire output r...

Page 12: ...tect against overheating of the steam cylin der the switch has a pin for manual reset after cooling down 1 or 2 for devices with six radiators thermal sensors with capillary tube for direct thermal monitoring of the radia tors One capillary tube each is con nected to 1 to 3 radiators depending on the device type After a thermal sensor has been triggered it must be reset manually see maintenance de...

Page 13: ...d 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 to the steam manifold Optimum perfor mance is on...

Page 14: ...ns and Mounting Directions PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK PP LQFK View from below View from top Front view 3D model under https www hygromatik com en downloads ...

Page 15: ...s for the upper sus pension brackets screws drill holes and dowel screw in the supplied mounting screws let the screws protrude approx 12 mm 5 inch from wall ensure firm fixation and load carry ing capacity of 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 l...

Page 16: ...Page 16 Device connections Cable entries 1 Waste water connection Water inlet DN25 DN40 Steam outlet ...

Page 17: ... 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 18: ...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 19: ...Page 18 5 3 2 Absorption Distance Nomogram Source Henne Erich Luftbefeuchtung Air Humidification 3rd Edition 1984 Page 101 Olden bourg Industrieverlag Munich ...

Page 20: ...on the overall pres sure situation These modifications must be coordinated with your expert dealer Water drain We point out that according to the Ger man Association of engineers VDI guideline VDI 6022 a water drain must be provided within the absorption distance inside the air duct When increased airflow speed is encoun tered Air flow rates beyond 3m s 9 84 ft s may lead to condensate drainage pr...

Page 21: ...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 22: ...ions mm inch Special lengths on demand will be replaced in 2019 by 1500 mm 59 1 inch long steam distributors 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 d...

Page 23: ...uch for the main part of the piping just one steam hose is required and condensate loss is minimized Allow easy access to the steam pipe steam hose installation Pressure conditions within the duct are influenced by device steam output steam line layout and the duct compo sition itself In some rare situations it may become necessary to optimize steam line layout for achieving the results intended R...

Page 24: ...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 humidfier and then to the steam manifold with a continous 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 loo...

Page 25: ...ation of a system separator of the CA type minimum measure allowable only when free discharge into the drai nage system is given 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 Supply water must not exceed 40 C Allowable range of water pressure 1 to 10 bar 100 x 103 to 100 x 104 Pa For connection to...

Page 26: ...used Make connection as follows Attach cap nut with inner seal ring to inlet screw joint on the humidifier housing and tighten Do not overtighten the cap nut Excessive tightening will destroy the fitting Strainer must be placed inside the solenoid valve Screw the other hose end cap nut with its inner seal on a customer provided water tap cap nut internal thread is 3OHDVH QRWH 127 127 3OHDVH QRWH ...

Page 27: ...to one of the grounding clips s fig below Slide overflow hose of the HyFlow system separator if present onto the other grounding clip Grounding clip functioning The two grounding clips attached to the inner surface of the housing drain stub are in direct contact with water and shunt potential resid ual electric currents away from the housing during blow down and in case of a cylinder water overflo...

Page 28: ...installation checklist All screws and clamps properly tigh tened Water supply line flushed before making connections Water connection properly installed Water discharge properly installed Does blow down water drain freely Water supply line and water discharge leakage free ...

Page 29: ...e struction through electrostatical dischar ge Prior to 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 ...

Page 30: ...racteristics of metric cable connec tions Multiple seal insert Model Current draw A Fusing A FLP05 9 0 9 9 3 x 16 FLP08 15 0 16 3 3 x 20 FLP15 15 6 17 1 3 x 20 FLP25 25 9 28 3 3 x 32 35 FLP30 31 2 34 1 3 x 35 FLP40 41 5 45 4 3 x 50 FLP50 51 8 56 6 3 x 63 Model M25 PG M25 with MSI M40 PG Ø 25 filler plug FLP05 FLP08 1 1 0 3 FLP15 25 1 1 0 3 FLP30 40 FLP50 0 1 1 3 Thread Wrench size mm Cable diamete...

Page 31: ...r h sensor malfunction 7 4 Connection diagrams Pls find full wiring diagrams in the FlexLine Control Climate manual shipped with the unit The current version of all manuals can be found on www hygromatik com 7 5 Electrical installation check list Check electrical installation with respect to customer site requirements and local power supply regulations Safety interlock properly wired across termin...

Page 32: ...st and then commences normal operation During self test the On Off button icon flashes for a couple of seconds On completion of the test the software version is displayed for a short moment Consequently normal opera tion is commenced However steam is not produced without a demand pen ding Step 4 Trigger steam demand Set control for commissioning check for permanent steam demand and close safety in...

Page 33: ...ntrols manuals Following hereafter pls find 2 service messages denoted as examples Steam_amount_counter is output when the pre set produced steam amount is reached Maintenance of the device is necessary 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 th...

Page 34: ...enance 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 Wear proper PPE Personal Protection Equip ment Take care of ESD protection The electronic components of the humidifier control...

Page 35: ...clic blow down by means of a powerful blow down pump followed by fresh water refills remove parts of this solid built up Water quality When tap water is used it must be taken into account that cleaning intervals shorten as the carbonate hardness level increases As a gen eral rule it is preferable to operate the unit with fully demineralized water since ope ration will not be affected by mineral de...

Page 36: ...Risk of material damage When lifting the cylinder out of the housing or reassembling be aware not to damage the heating element cable Reinstallation Remove cylinder base o ring 13 and check o ring seating in cylinder base for deposits In case of deposits present clean seating as described in the Clea ning of cylinder base and strainer section Check o ring for damage and replace if required replace...

Page 37: ...ase o ring 13 Lift strainer insert 12 out of the base using the two access holes on the side Remove all deposits from the coarse strainer Keep coarse strainer clean with mechanical utilities Check base for deposits and remove if necessary Especially the passes of the hose connections should be checked Insert coarse strainer and position correctly by clicking the cut out into place in the clip Thor...

Page 38: ...rs are not in the closing range 9 7 Cleaning Connection Hoses Cylinder Base Connections Steam Hose Adapter Nozzle Within the regular maintenance frame all connection hoses should be checked for freedom of deposits and good overall condi tion Also all of the cylinder base 11 con nections should be checked for free passage and cleaned if necessary When operating with partially softened water or tap ...

Page 39: ...ut any deposits if present Inspect both level control connection hoses and clean if required Insert new o ring Re attach enclosure cap Align metallic plate with level control device enclosure mounting holes and insert screws in upper left and lower right position Reintroduce level control device into humidifier housing and loosely affix to unit rear wall with the 2 screws Insert the 2 screws remai...

Page 40: ... protection the steam humidifier is equipped with one or two thermo switches depending on the power output rating They are mounted on the steam cylinder cover The thermo switch es is are coupled to the heater element s by means of a capillary tube Each of thermo switch controls 1 to 3 heater elements Thus with 6 heater element units each one of the thermo switches is assigned to a group of 3 heate...

Page 41: ...when overheat is encountered the thermo switch es trigger Unlocking is accomplished by pressing the unlocking pin located between the electrical connection contacts of the Klixon switch see fig in section 9 11 9 11 Thermo switch replace ment for heater element A Thermo switch B Unlocking button for thermo switch C M4 Mounting nut 2x D Lock washer 2x E Washer 2x F Seal G Flat seal 2x H M4x10 Flange...

Page 42: ... elements the capil lary tube is attached to all of the heating elements max 3 Insert thermo switch wires into the terminals of the wiring connector fol lowing the markings made when dis sembling Reassemble steam cylinder and reinstall in humidifier housing as described in the Removing and cleaning the steam cylinder section 9 12 Inspection of wiring con nections and heater ele ment wiring Risk of...

Page 43: ...ws D save washers Remove twin solenoid valve from housing bore Fine filter cleaning Remove fine filter from twin solenoid valve tap water connection side and clean under running water Reinsert fine filter into twin solenoid valve Reinstallation Reinsert twin solenoid valve with seal F in unit housing bore Bolt down twin solenoid valve using screws D and washers Reconnect electrical cables to twin ...

Page 44: ...uple solenoid valve A after marking connection position Remove quadruple solenoid valve from housing bore Fine filter cleaning Remove fine filter from quaduple solenoid valve tap water connection side and clean under running water Reinsert fine filter into quadruple solenoid valve Reinstallation Reinsert solenoid valve in unit housing bore Reattach connecting hoses D regard the connection position...

Page 45: ...ng removal Moisten O ring 31 and insert into adapter 30 Slide adapter onto pump stub Refit electrical cable to pump con nector no polarisation Open water supply Perform leakage check according to section 9 4 1 numbers refer to the exploded view in the section of the same name 9 16 Inspection of hoses Since steam and condensate hoses are prone to wear as well those hoses should undergo regular chec...

Page 46: ...lowing the installation procedures in reverse order Warning Dismantling of the unit may only be performed by qualified personnel Electrical dismantling may only be performed by trained electricians Obey the safety guidelines in section Safety Instructions especially the guidelines for disposal 51 1 3OHDVH QRWH ...

Page 47: ...Page 47 11 Declaration of Conformity ...

Page 48: ...8 01082 Steam cylinder FLP30 complete incl O ring set 1 SP 08 01092 Steam cylinder top FLP30 complete incl O ring set 1 SP 08 01102 Steam cylinder FLP40 complete incl O ring set 1 SP 08 01112 Steam cylinder top FLP40 complete incl O ring set 1 SP 08 01122 Steam cylinder FLP50 complete incl O ring set 1 SP 08 01132 Steam cylinder top FLP50 complete incl O ring set 8 1 3 6 3 SP 07 01102 Heating elem...

Page 49: ...tactor 50A K1 1 FLP40 1 E 2507060 Main contactor 35A K1 2 FLP40 1 E 2507080 Main contactor 65A K1 1 FLP50 1 E 2507060 Main contactor 35A K1 2 FLP50 Main contactor 440 690 V 1 1 E 2507040 Main contactor 20A K1 1 FLP05 FLP08 1 1 E 2507060 Main contactor 35A K1 1 FLP15 FLP25 1 E 2507060 Main contactor 35A K1 1 FLP30 1 E 2507040 Main contactor 20A K1 2 FLP30 1 1 E 2507070 Main contactor 50A K1 1 FLP40...

Page 50: ... x 40 5 Empty weight kg Max filling volume l Operation weight kg Width 6 mm Height 6 mm Depth 6 mm Drain water connection 1 Other voltages upon request 4 Internal control voltage upon request 5 Inclusive Y piece DN40 Water connection FlexLinePlus Professional Fully demineralized water cleaned condensate 1 to 10bar with 3 4 connection for external thread Connection Ø 1 1 4 Technical specifications ...

Page 51: ...g Max filling volume l Operation weight kg Width 6 mm Height 6 mm Depth 6 mm Water connection Drain water connection 1 Other voltages upon request 4 Internal control voltage upon request 5 Inclusive Y piece DN40 6 Outer dimensions of widthand depth Hight incl drain connection 380 Fully demineralized water cleaned condensate partially softened Water tap water different qualities 1 to 10bar with 3 4...

Page 52: ...on The number of heater elements vary with respect to the complete FLP series The index numbers in the figure corre spond to the spare parts list 30 31 32 33 35 1 2 3 4 5 6 7 12 13 14 15 11 10 9 27 25 8 21 22 36 28 37 38 23 24 29 34 16 FLP Water supply version FLPxx TPRO 71 72 ...

Page 53: ...Page 53 15 View of housing 70 56 57 2 steam exits only with FLP30 40 50 70 ...

Page 54: ...100 A Member of the group ...

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