Steam Injection Humidifiers DDS

FlexLine
for existing steam systems

MANUAL ÁDDS.ENZÈ
DDS.EN
E-8881128
Copyright © HygroMatik GmbH [25.01.2022]
Steam Injection Humidifiers / DDS EN
Information in this manual is subject to change or alteration without prior notice.

! WARNING
Risk of electrical shock!
Hazardous electrical high voltage!
All electrical work to be performed by certified expert staff (electricians or expert personnel with
eqivalent training) only.

Page 2
1. Introduction ....................................................................................................................... 5
1.1 Typographic Distinctions ................................................................................................... 5
1.2 Documentation .................................................................................................................. 5
1.3 Symbols in Use ................................................................................................................. 5
1.3.1 Specific Symbols related to Safety Instructions ............................................................. 5
1.3.2 General Symbols ............................................................................................................ 5
1.4 Intended Use ..................................................................................................................... 6
2. Safety Instructions ............................................................................................................ 7
2.1 Guidelines for Safe Operation ........................................................................................... 7
2.1.1 Scope ............................................................................................................................. 7
2.1.2 Unit control ..................................................................................................................... 7
2.1.3 Mounting, dismantling, maintenance and repair of the unit ............................................ 8
2.1.4 Electrical ......................................................................................................................... 8
2.2 Disposal after dismantling ................................................................................................ 9
3. Transport ............................................................................................................................ 10
3.1 Overview ........................................................................................................................... 10
3.2 Packing .............................................................................................................................. 10
3.3 Interim Storage .................................................................................................................. 10
3.4 Check for Complete and Correct Delivery of Goods ......................................................... 10
4. Function and Assembly .................................................................................................... 11
4.1 Areas of application ........................................................................................................... 11
4.2 Function ............................................................................................................................. 11
4.3 Components ...................................................................................................................... 13
4.3.1 Separator ........................................................................................................................ 13
4.3.2 Strainer ........................................................................................................................... 14
4.3.3 Control Valve and Actuator ............................................................................................ 14
4.3.4 Start-up safety switch ..................................................................................................... 16
4.3.5 Steam Lances ................................................................................................................ 17
4.3.6 Pressure Gauge Station ................................................................................................. 18
4.3.7 Ball Float Steam Trap ..................................................................................................... 19
4.3.8 Thermostatic Capsule Steam ......................................................................................... 20
5. Humidification Output ....................................................................................................... 21
5.1 Output Graphs ................................................................................................................... 21
5.2 Determining the control valve Kvs-Value .......................................................................... 21
5.3 Separator Type 20 with one steam lance ........................................................................ 22
5.4 Separator Type 20 with multiple steam lances .................................................................. 23
5.5 Separator Type 40 with one steam lance .......................................................................... 24
5.6 Separator Type 40 with multiple steam lances .................................................................. 25
6. Graph for Determing Absorption Distance ..................................................................... 26
7. Mechanical installation ..................................................................................................... 27
7.1 Allowable environmental parameters ................................................................................ 27
7.2 Attaching steam pipes ....................................................................................................... 27
7.3 Installing the steam pipes .................................................................................................. 28

Page 3
7.3.1 Water hammer prevention .............................................................................................. 28
7.4 Separator ........................................................................................................................... 29
7.5 Control Valve and Actuator ............................................................................................... 29
7.6 Pneumatic Start-up safety feature ..................................................................................... 30
7.7 Steam Lances ................................................................................................................... 30
7.7.1 Duct mounting set for steam lance ................................................................................. 31
7.7.2 Installation Examples ..................................................................................................... 32
7.8 Steam Lance Heating System ........................................................................................... 35
7.9 Check List .......................................................................................................................... 36
8. Electrical connection ........................................................................................................ 37
9. Commissioning ................................................................................................................. 39
10. Maintenance ..................................................................................................................... 41
10.1 Strainer ............................................................................................................................ 41
10.2 Ball float condensate drain .............................................................................................. 42
10.3 Thermostatic Capsule Steam trap Type MST21 ............................................................. 42
11. Malfunctions .................................................................................................................... 43
12. Dimensions and Installation Schematic ........................................................................ 45
13. Spare Parts ...................................................................................................................... 47
14. Technical Data ................................................................................................................. 50

Page 4
1. Introduction
Versions in Other Languages
Dear Customer,
These operating instructions are available in
Thank you for choosing a HygroMatik steam
several languages. If interested, please con-
injection humidifier.
tact HygroMatik or your HygroMatik dealer.
HygroMatik steam humidifiers represent the
latest in humidification technology.
In order to operate your HygroMatik steam 1.3 Symbols in Use
injection humidifier safely, properly and effi-
1.3.1 Specific Symbols related to
ciently, please read these operating instruc-
Safety Instructions
tions.
Employ your steam injection humidifier only
in sound condition and as directed. Consider According to ANSI Z535.6 the following
potential hazards and safety issues and fol- signal words are used within this document:
low all the recommendations in these instruc-
tions.
! DANGER
If you have additional questions, please con-
tact your expert dealer. DANGER indicates a hazardous situation
which, if not avoided, will result in death or
For all technical questions or spare parts serious injury.
orders, please be prepared to provide unit
type and serial number (see name plate on
the unit).
! WARNING
WARNING indicates a hazardous situation
which, if not avoided, could result in death or
1.1 Typographic Distinctions
serious injury.
 Preceded by a bullet: general speci-
fications ! CAUTION
» Preceded by an arrow: procedures CAUTION indicates a hazardous situation
for servicing or maintenance which which, if not avoided, could result in minor or
should or must be performed in the moderate injury.
indicated order
NOTICE
 Installation step which must be
checked off. NOTICE is used to address practices not
related to physical injury.
italics Terms used with graphics or 
drawings 1.3.2 General Symbols

1.2 Documentation Please note

Retention This symbol is used whenever a situation
requires special attention beyond the scope
Please retain these operating instructions in
of safety instructions.
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.

Page 5
1.4 Intended Use
NOTICE
Areas of application: By construction, HygroMatik steam injection
humidifiers are not qualified for exterior appli-
The HygroMatik steam injection humidifier
cation.
(SIH) uses existing pressurized steam for air
humidification. The SIH humidifies with con- The room temperature during operation of
densate-free saturated steam and offers the the system should be between 5 and 40 °C.
shortest possible humidification distances.
They are used e.g. in clean rooms and hospi-
tals.
Improper use:
Proper usage also comprises the adherence
to the conditions specified by HygroMatik for: Any other use not compatible with the
intended use outlined above is not allowable.
• installation Improper use as well as changes in hardware
• dismantling or software that are not authorized by Hygro-
• reassembly Matik will lead to the total loss of guarantee
• commissioning and warranty claims.
• operation
• maintenance
• disposal

Only qualified and personnel may work on or

with the system (a supplementary qualifica-
tion according to VDI 6022 Part B or an
equivalent qualification is recommended).
Persons transporting or working on or with
the system must have read and understood
the relevant parts of this operating manual,
particularly the 'Safety instructions' section.
Staff must also be informed of possible haz-
ards by the operating company. Please keep
a copy of the operating manual at the loca-
tion where the device is being used.

NOTICE
Components installed in ventilation and air-
conditioning systems must be suitable for the
intended use; i.e., according to VDI 6022 or
equivalent, they must be corrosion-resistant,
easy to clean, accessible and hygienic. Fur-
thermore, they must not facilitate growth of
micro-organisms.

Page 6
2. Safety Instructions
These safety instructions are required by law. NOTICE
They promote workplace safety and accident Risk of material damage!
prevention. The unit may be damaged if switched on
repeatedly following a malfunction without
2.1 Guidelines for Safe Opera- prior repair.
tion
Rectify defects immediately!
2.1.1 Scope Use only original spare parts.
Comply with the accident prevention regula-
tion „DGUV Regulation 3“ to prevent injury to ! WARNING
yourself and others. Beyond that, national
regulations apply without restrictions. Restricted use.
According to IEC 60335-2-98 the following
applies: Very young children must not use the
2.1.2 Unit control device. Children are not allowed to play with
the device, this must be ensured by a super-
Do not perform any work which compromises
visor. Children are not allowed to do cleaning
the safety of the unit. Obey all safety instruc-
and user maintenance without a supervision.
tions and warnings present on the unit.
In case of a malfunction or electrical power
disruption, switch off the unit immediately and
prevent a restart. Repair malfunctions
promptly. Close the steam supply line and
secure it against unauthorized reopening.
After repair work, ensure the operational
safety of the steam injection humidifier by
qualified personnel. Regularly check that all
safety and monitoring devices are functioning
normally. Do not remove or disable safety
devices.

Page 7
2.1.3 Mounting, dismantling, mainte-
nance and repair of the unit NOTICE
Water leaks caused by defective connec-
! CAUTION tions or malfunctions are possible.
• Use only steam with a minimum pres- Water is constantly and automatically filled
sure of 0,5 barg and a maximum pres- and drained in the humidifier. Connections
sure of 4,5 barg at the entry point of the and water-carrying components must be
steam injection humidifier. checked regularly for correct operation.
• Steam pipes are hot and care must be
taken accordingly. Do not install HygroMatik steam generators
above electrical equipment such as fuse
• Use only steam without chemical addi-
boxes, electrical appliances, etc. In the case
tives.
of a leakage, leaking water can damage the
• Steam supply must be dimensioned so underlying electrical equipment.
that the steam velocity does not exceed
25 m/s.
• The control valves are not stop valves.
They have been optimised to control 2.1.4 Electrical
the necessary steam supply. They are
metal to metal sealed according to IEC
534-4 Class IV and can, therefore, ! WARNING
show a leakage of 0.01 % when sup-
Risk of electrical shock!
plied. We recommend the use of a stop
Hazardous electrical voltage!
valve in order to ensure that the steam
supply is completely shut off. • Any work on the electrical system to be
performed by certified expert staff
• There may be impurities in the steam
(electricians or expert personnel with
supply. In order to prevent valve dam-
comparable training) only.
age there must be a filter installed with
a pore diameter of <0.16 mm. • During maintenance or installation
work, the device must be disconnected
• During maintenance or installation from the power supply and secured
work, the device must be disconnected against being switched on again. The
from the power supply and secured absence of voltage must be ensured by
against being switched on again. The a measurement.
absence of voltage must be ensured by
• After electrical installation or repair
a measurement.
work, test all safety mechanisms (such
• To enable constant and steady humidi- as grounding resistance).
fication, the humidity sensors should
not be mounted in the supply air duct.
• Use genuine spare parts only.
• After electrical installation or repair
work, test all safety mechanisms (such
as grounding resistance) and ensure
operational safety through competent
and qualified staff.
• Attaching or installing of additional
components is permitted only with the
written consent of the manufacturer.

Page 8
 NOTICE

• Use only original fuses with the appro-

priate amperage rating.
• Regularly check the unit‘s electrical
equipment. Promptly repair any dam-
age such as loose connections or
burned wiring.
• Responsibility for intrinsically safe
installation of the HygroMatik steam
humidifiers is incumbent on the install-
ing specialist company.

2.2 Disposal after dismantling

The 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 electronic
devices must not be disposed of as municipal
waste, and therefore the method of waste sepa-
ration must be applied. The public or private
waste collection systems defined by local legis-
lation must be used.

NOTICE
The operator is responsible for the disposal
of unit components as required by law.

Page 9
3. Transport 3.4 Check for Complete and Cor-
rect Delivery of Goods
3.1 Overview
Upon receipt of the unit, confirm that:
Please note  model and serial number on the
name plate match those specified in
Proceed carefully when transporting the
the order and delivery documents
steam injection humidifier in order to prevent
damage due to stress or careless loading
 the equipment is complete and all
and unloading.
parts are in perfect condition

3.2 Packing Please note

The type of packaging depends on the series In case of damage from shipment and/or
and type of the delivered device. missing parts, immediately notify the carrier
or supplier in writing.
Accessories (e.g. steam traps) are packed
separately.
If the control valve is included in the scope of
delivery, it is delivered mounted with the actu-
ator and connected to the steam dryer. Addi-
Time limits for filing freight claims with ship-
tional fittings are packed separately.
ping companies are*:
The steam lances are delivered in special
protective coatings. After receipt of
Shipping company
goods

Carriers no later than 4 days

Parcel service immediately
3.3 Interim Storage
Store the unit in a dry place and protect from * Time limits for some services subject to
frost and strong sunlight. change.

Please note
Only clean components are permitted to be
installed in a ventilation duct.

Page 10
4. Function and Assembly 4.2 Function
Steam flows through a dirt particle trap (1)
4.1 Areas of application over the Separator interface (2) into the
The typical use of the HygroMatik DDS pres- Separator (3). The separator separates con-
surized steam humidifier is for supply air densation from the steam.
humidification. The system is connected to Condensation is drained using the float con-
an existing steam network and humidifies trolled condensation drainage (4). The
with condensate-free saturated steam. It thus Start-up safety feature (5) measures the
offers the shortest possible humidification temperature at the condensation return.
distances. Operation switch (11) is activated when the
The HygroMatik DDS offers four components switch temperature has reached approx.
in one unit: Separator, strainer condensation 80°C.
drain and start-up safety switch. Now the main portion of the steam flows
through the control valve (7). The amount of
steam is regulated over the operation switch
(11).
Steam lance (s) (8) are flanged or screwed
onto the valve exit side.
Dried steam is blown out through the spe-
cially formed nozzles (9) that take the dried
SIH Version C steam from the pipe centre. The nozzles are
(MaterialMix) press-fitted into the steam lances.
The steam lance heating system is fed over
connection (6) on the separator. Alterna-
tively there is the possibility to seal the sep-
arator connection and operate the steam
lance heating system from a separate steam
reservoir. A thermic Capsule Condensation
Drain (10) ensures that condensation in the
steam lance heating system is drained off.

 











 

Page 11
SIH Version C (Material Mix)

SIH Version C (MaterialMix)







 


 



1 - dirt particle trap 7- control valve

2 - Separator interface 8 - Steam lance (s)
3 - Separator 9 - Nozzles
4 - Float controlled Condensation Drain 10 - Thermic Capsule Condensation Drain
5 - Start-up safety feature 11 - Operation switch
6 - connection 12 - steam lance heating system













 


 

SIH Version A (stainless steel)

Page 12
4.3 Components Function
The HygroMatik pressure steam humidifier Steam flows through the pipe union (1) into
consists of 4 basic elements: the separator.
• Seperator Steam and condensate are separated by the
• Control valve with or without actuator joint action of the inlet pipe (2) and the spi-
• Steam Plants ral-shaped flow system.
• Accessories The aerosole droplets present in the steam
are thrown against the outer wall by centrifu-
gal force which separates them from the
The system is available completely in stain- steam phase. The droplets are conveyed
less steel (A) or as a material-mix version (C). through the drain (3) into the condensate
return. This prevents droplets from being
transported by the steam.
4.3.1 Separator
The stainless steel separator is the essential Steam is conveyed into the upper part of the
component for moisture separation. The sep- separator chamber via a supply pipe (4) or
arator is available in versions 20 and 40. The directly to the valve.
separator size is dependent upon the desired
A certain amount of steam flows through the
steam output and available steam pressure.
connector (5) and feeds the steam lance
heating system.
Separator Version C The bulk of the steam exits the separator
through the outlet connection (6) and flows
through the control valve.

Separator Version A


 

Separator Version A 

Page 13
4.3.2 Strainer Control valve
There should be a strainer installed in the The control valve regulates the steam quan-
steam supply line directly in front of every tity by means of the valve lift. When the valve
separator. Only if this is done there is guaran- is closed the valve cone rests against the
tee that no foreign particles enter the humidi- valve face. When the valve rods lift the cone
fier unit. there is a resultant gap through which the
desired quantity of steam flows. The gap can
Valve cone and valve face in both the control be widened or narrowed as required.
valve and steam trap are sensitive to fouling.
Dirt particles between the face and the cone As a general rule the customer is free to use
prevent normal closure and have a corrosive any typical control valve which is approved
effect. for steam control.
Standard are the Spirax-Sarco Valves from
HygroMatik. Alternative suppliers can be
listed on application.
Control valves ARI type BR440

SIH Type A Principle description

SIH Type C

Function

Steam flows through the inlet in the cylindri-

cal version (type C) or the conical strainer
(type A) and through the holes to the exit.
Foreign matter is retained by the strainer.

4.3.3 Control Valve and Actuator

The desired steam quantity is set over a con-
trol valve, which is located between separator
and steam lance. The control valve itself is Flanged A B Kvs‐Value [m³/h]
controlled by an electrical or pneumatic actu-
ator.
DN15 130 118 0.25, 0.4, 0.63, 1.0, 1.6, 4.0
DN20 150 118 6.3
If control valve and actuator are included in
DN25 160 126 10.0
the delivery the relevant operating and instal-
lation instructions will be enclosed. DN32 180 126 16.0
DN40 200 133 25.0
If control units from other manufacturers are
used the customer must check whether these
are compatible with the steam injection
humidifier.

Page 14
Actuator Electrical Actuator
The actuator controls the valve cone posi- The spindle and valve cone are set in motion
tioning against the valve face. Through con- by the electrical actuator by means of a
tinuous actuation a specific control signal can motor.
be assigned to every position of the valve
Electrical Actuators typically require a 24V
cone.
AC/DC supply voltage and a control signal of
To prevent air-duct over-saturation all actua- 0-10 V.
tors, even pneumatically operated ones,
Actuators with a 3 position control for modu-
should be equipped with a fail-safe. This fail-
lated control voltages are also available.
safe closes the control valve immediately in
the case of power failure or pressure loss. In order to comply with DIN 32 730 an electri-
cal actuator must have a fail-safe function so
that in the case of a power failure the control
Mögliche Regelsignale für Stellventil valve is reset into a safe position (fully
pneumatical 0,2 - 1,0 bar closed)
3-Position 24V AC
electrical
(230V on request)
0 (2) - 10 V, continuous
electrical
Supply voltage 24V AC
0 (4) - 20 mA, continuous
Supply voltage 24V AC
The 500 Ohm (or 2x1K
electrical Ohm parallel) resistor is
connected to over connec-
tors 1 and 3. The resistor is
attached under the cover.

Typ Hygromatik B-4520005

Typ Spirax Sarco PN9000

Pneumatic Actuator
Pneumatic Actuators are controlled using
compressed air (e.g. 0,2-1barg).

Compressed air is supplied over a com-

pressed air supply (3) to a diaphragm (2).
As soon as the supply pressure exceeds the
spring (1) strength the diaphram is pushed
upwards. This pulls the two actuator spin-
dles (4) and control valve (5) upwards and
the actuator opens.
If control pressure drops the spring lowers
the spindle again. In the case of a total pres-
sure loss the spring immediately causes the
control valve to close.

Page 15
4.3.4 Start-up safety switch
The start-up safety switch ensures that no
condensate from the steam network has
entered the air conditioning duct over the relief valve
steam lances.

capillary
tube

screw 1/2”

temperature
sensor

electrical Start-up safety switch E-4111952

Electrical Start-up safety switch

Please note
With an electrical actuator the supply voltage
is looped through the start-up safety switch. The wiring diagram for the electrical connec-
The start-up safety switch is set to allow the tion of the actuator and start-up safety switch
supply voltage through only when a specified can be found in the chapter Electrical con-
temperature (in this case 80°C) is reached. nection.

If the temperature remains below this level

the fail-safe function is triggered.

Pneumatic Start-up safety switch

The pneumatic start-up safety switch keeps
an exhaust valve open for compressed air as
long as the specified temperature has not
been reached.

This prevents control air from entering the

actuator.

NOTICE
If no start-up safety switch is available it is
advisable to let the unit run a few minutes
before switching the control on. This allows
time for the steam lance heating system to
heat the lances.

Page 16
4.3.5 Steam Lances Number of steam lances
The steam lance system may comprise multi-
In the steam lances dry steam is blown out of
ple steam lances.
specially formed nozzles. They are designed
for low noise steam emission. The nozzles With a duct height of more than 1000 mm
take steam from the driest area in the steam multiple lances should be positioned horizon-
lance centre. tally one on top of the other. This ensures an
even steam distribution. See table for number
In order to prevent accumulated condensate
of steam lances recommended for various
or aerosol droplets from being transported
duct heights.
with the steam, the steam lances are pro-
vided with a steam lance heating system.
Due to this system such droplets either evap-
orate or cannot form in the first place.
The steam lance heating system can be fed
by the separator or from a separate steam
reservoir.

NOTICE
Steam pressures of 1 barg or higher have an
optimum heating effect on the steam lances.
With less pressure the pre-heating and re-
evaporation times may be lengthened.
Re-evaporation
In some cases condensate remains in the
steam lances immediately following control
valve closure. This condensate is evaporated
by the steam lance heating system and exits
the steam lances as pressureless steam. Re-
evaporation of residual condensate can take
up to 20 minutes. The higher the steam pres- Duct height Number of lances
sure the better is the performance of the up to 1000 mm 1
steam lance heating system and the shorter
the evaporation time.
1000 ‐ 1700 mm 2
1700 ‐ 2200 mm 3
2200 ‐ 2600 mm 4
over 2600 mm 5

Page 17
 4.3.6 Pressure Gauge Station
NOTICE
Check number of steam lances when the
following factors apply:
• duct air speed exceeds 5 m/s.
• Duct air temperature under 21°C.
• Last fine mesh filter located less than 3
m behind steam lance.
• Air flow branching occurs less than 1 m
behind steam lance.
Installation of a pressure gauge on the steam
Depending upon additional parameters such injection unit ensures immediate detection of
as pre-defined steam output, existing or pressure drops or fluctuations.
desired absorbtion distance or rise in humid-
ity the installation of additional lances may The HygroMatik Pressure gauge station con-
improve efficiency. sists of a tubular spring pressure gauge (0-6
bar), a T-junction and a dual nipple.
The pressure gauge is temperature resistant
up to 200° C.
Steam lance piping for multiple steam
lances. Pressure gauge shut-off valves and siphons
are available on request.
HygroMatik standard supply is for lengths of
300 mm and 450 mm. Distances are
approximate and can vary from installa-
tion to installation. Piping should be NOTICE
installed for even lance distribution along the
duct height. Distance between duct floor and The pressure gauge station is to be installed
ceiling should not exceed 250 mm. upstream of the steam injection unit.

Page 18
4.3.7 Ball Float Steam Trap
After separation from the steam inside the
separator condensate is drained out through
a ball float steam trap.
Function
The discharge valve is controlled by the ball
float dependent upon the density of the
incoming medium.

Please note
During installation, it is important to ensure
that the marking "TOP" is in the correct instal-
lation direction. The sideway arrow shows
the flow direction.

NOTICE
Water hammers can severely damage the
ball float, condensate loads in outdoor instal-
lations increase the risk of freezing.
95

sectional view Ball Float Steam Trap

Page 19
4.3.8 Thermostatic Capsule Steam
Condensate that has collected in the steam
lance heating system is discharged through a NOTICE
thermostatic capsule steam trap.

Function Do not insulate the thermic capsule steam

trap.
The discharge valve is controlled dependent The minimum connection pipe length of
upon the capsule volume and the tempera- 1.0 m (L3) between the lance connection and
ture and pressure of the incoming medium. the drain is absolutely mandatory.
The capsule contains a liquid whose satura-
tion curve parallels that of steam. However,
the liquid boiling point is always somewhat
less than that of water.

Please note
During installation, it is important to ensure
that the marking showing the correct installa-
tion direction is taken care of. The sideway
arrow shows the flow direction.
-

Page 20
5. Humidification Output
Kv flow figure [m³/h]
The maximum humidification output [kg/h] of
one steam injection unit depends upon the Kvs Valve coefficient [m³/h]
available steam pressure in barg. Example:
Maximum humidification output can be more Desired humidification output: 110 kg/h
than 770 kg/h (Type A) or 730 kg/h (Type C).
Maximum operating pressure is pmax = 4,5 Operating pressure, p = 2 barg
barg. The length and number of steam lances is
determined by the duct dimensions. See
Section 9 "Steam Lances".
5.1 Output Graphs
Result:
The following graphs serve as an aid to
determining the necessary Kvs-Values for Follow the operating pressure line until the
the control valve, a given steam pressure and desired humidification output in kg/h is
a desired humidification output. reached.
The graphs help to determine whether a Run a vertical line upwards from this point
Type 20 or Type 40 should be selected. until it intersects the plotted curve. The first
intersected curve indicates the steam lance
Type 20 up to approx. 270 kg/h. code and its minimum length.
Type 40 up to approx. 770 kg/h.
Now run a horizontal line to the left and read
off the minimum Kv-Wert of the installation
5.2 Determining the control on the vertical axis. The minimum Kvs-Value
valve Kvs-Value for selcting the control valve is Kv=5,2 m³/h +
10% = Kvs=5,7 m³/h. If this value is not pres-
ent in table 6.4 then it is recommended to
Control Valve Kvs- Value: take the next higher value..
The Kv-Value corresponds to a water flow
rate (in m³/h) through a valve at a pressure
difference of 1 barg and a water temperature If the customer has not specified something
of 5 - 30 °C. else, then it is always calculated whether the
desired output can be achieved with the Type
A Kv-Value is valid only for the corresponding 20. In this case a Type 20 separator and a
valve lift of a valve. The Kv-Value of a valve steam lance of at least code 3 is necessary.
at nominal lift (100% open) is described as Always check whether this result is consis-
the Kvs-Wert. Using the Kvs-Value one can tent with the results from Section 9 "Steam
determine the maximum possible flow. Lances."
Separator Typ 20 for only one lance Lance Code

Kv-value
from valve

Pressure
In bar g

110kg/h Steam output kg/h

Page 21
 5.3 Separator Type 20 with one
Please note steam lance
The following 4 graphs show Kvs -Values
determination.

steam output [kg/h]

Lance code

KVS-Value [m³/h] Pressure [barg]

Page 22
5.4 Separator Type 20 with multiple
steam lances

[kg/h]
Lance code

output [kg/h]
Dampfleistung
steam

KVS-Value [m³/h] Pressure [barg]

Page 23
5.5 Separator Type 40 with one
steam lance

Dampfleistung [kg/h]
Lance code

steam output [kg/h]

KVS-Value [m³/h] Pressure [barg]

Page 24
5.6 Separator Type 40 with multiple
steam lances
Lance code

Dampfleistung [kg/h]

steam output [kg/h]

KVS-Value [m³/h] Pressure [barg]

Page 25
 Absorption Distance: distance from the steam outlet until the end of the visible trail
rel. humidity in [%] air temperature, duct
Outlet Example:
given parameters:
rel. humidity, inlet: 40%
rel. humidity, outlet: 55%
air temperature, duct: 23°C
air speed: 2,8m/s
nr. of steam lances: 1
duct height: 1,0m

75
C
result:

%
°C

65 %
35°C
30°
25
°C absorption distance (ad)=1,25m
6.

%
20 °C

55
15
%
45
%
35 normal absorption distance [m]
0.5 1.0 1.5 2.0 2.5 3.0 3.5

80 70 60 50 40 30 20 10

rel. humidity in [%]

Inlet

factors affecting
downstream obstructions:
fine mesh filter: Ad x 1,5
particle filter: Ad x 2,5 1.0
4.

2.
3.
1.

0
0
0
0.8

5.0

6.0
0.9

7.0
0

0.6
0.4

8.0
0.3
0.5
0.7

humidity sensor: Ad x 5,0

air speed [m/s] duct height quotient [m]
Graph for Determing Absorption Distance

Page 26
by number of steam lances
7. Mechanical installation
NOTICE
Steam lance fittments are not suitable to sup-
! WARNING
port the entire humidification unit.
Risk of foot injuries!
Supports are to be done on-site.
Prevent unit from dropping during installation!
Helping hand of a second person is advisa-
ble.

! WARNING 7.1 Allowable environmental parameters

Risk of electrical shock! NOTICE

Hazardous electrical voltage. When selecting the installation site for the
During installation, the unit must be discon-
steam humidifier, take the following into
nected from power supply and secured
account:
against being switched on again. The
absence of voltage must be ensured by a • By design, HygroMatik steam humidifi-
measurement. ers are not qualified for outdoor instal-
lation (electronical components and
NOTICE water-bearing parts may be damaged)
• Ambient temperature must lie between
• This steam injection humidifier may
+5 and +40 °C (+41 and +104 °F)
only be installed by qualified personnel.
HygroMatik can accept no responsibil- • Relative humidity must not exceed
ity for any damage caused by incorrect 80 % r.h.
installation. Installation in a closed room requires aera-
• Please observe all safety and hazard tion and, eventually, temperature conditioning
instructions supplied with the steam in order to meet the a.m. environmental con-
injection humidifier. ditions

• Installation of any additional units is

only permitted following written permis-
sion by the manufacturer, otherwise all
guarantees are null and void. 7.2 Attaching steam pipes
• Individual packing should be opened at
the installation site. This can prevent ! WARNING
damage to individual items.
When installing please observe the following:
NOTICE • all work is to be done by qualified per-
HygroMatik steam injection humidifiers are sonnel only.
delivered largely pre-assembled. If individual • Use only steam with no chemical addi-
components are in the delivery then all instal- tives.
lation instructions concerning those items are
to be followed. • Use only dry saturated steam.

Normally the steam supply supports are suffi-

cient to support the steam injection system.
Should this not be the case then extra sup-
ports must be provided (for instance using a
fixed and supported U profile arrangement).

Page 27
 NOTICE NOTICE
• follow local regulations. Ensure sufficient steam line drainage before
• Use only steam with a minimum pres- and after the installed DDS.
sure of 0,5 barg and a maximum pres-
sure of 4,5 barg.
• Dimension the on-site steam connec-
tions (insulated) so that a steam veloc- 7.3.1 Water hammer prevention
ity of 25 m/s is not exceeded.
! WARNING
NOTICE Water hammers are dangerous and can
cause bodily harm.
HygroMatik recommends the installation of a
shut-off valve in front of the steam injection It is necessary to drain off any low angles in
system in order to facilitate any necessary order to ensure that condensate is not drawn
maintenance work. along and to avoid water hammers. Very long
steam piping systems must also be drained
regularly.
7.3 Installing the steam pipes Water Hammers: Condensate accumulates in
Steam piping must be installed inclined (at depressions. During start-up, steam flows
least 2% in flow direction). They must be fit- over the condensate causing it to vibrate. This
ted using a suitable pitch and suitable materi- can continue until a certain amount of conden-
als. The piping holders must allow for lateral sate is carried off. At the next flow bifurcation
movement. In more lengthy installations this condensate hits the first available object
expansion fittments must be used to avoid at a velocity of up to 27 yd 1 ft/s (25 m/s). This
expansion stresses. impact is known as a water hammer.
Condensate load: Accumulated conden-
sate which cannot drain due to a depression.

NOTICE
Steam piping must be installed using state-of-
the-art methods.
Steam connections must be fitted to the pip- Ensure professional installation and drainage
ing upper surface in order that condensate is of the steam lines by a certified specialist
not drawn into the piping system. company.
This includes, among other things, the instal-
lation of condensate traps in accordance with
valid guidelines.
Trap sets should be installed:
• before high points
The steam outlet for the DDS must be in the • at low points
direct neighbourhood (1-2m) of the steam • before shut-off fittings
connection.
• before control valves
The HygroMatik steam injection system must • in long pipelines every 30 - 50 m
have a filter installed in front of the system.
This is delivered with the system or is already
installed on-site. Also install shut-off valves at the condensate
traps for maintenance purposes.

Page 28
7.4 Separator 7.5 Control Valve and Actuator
If the valve is part of the on-site installation,
NOTICE the necessary connection fittings between
• Before installation, check out the steam control valve and the separator come
supply piping. It must be established attached to the separator. All other parts are
that the steam humidifier is supplied delivered separately (e.g. connection bolts
with as dry a steam as possible (steam and flange seals).
with as little condensate as possible). Only control valves suitable and certified for
• Steam pressure at the separator entry steam regulation may be used.
point must not exceed 4,5 barg.
Actuators must have a fail-safe function in
• Steam humidifier operating pressure order to prevent an uncontrolled over-humidi-
must be kept at a constant level. It is fication in the case of a power failure.
possible that in order to generate con-
stant pressure, pressure reduction sta- Dirt between the valve face and cone prevent
tions may be required. proper closing. Therefore install a filter
directly in front of the separator.
• It must be guaranteed the steam sup-
plying the steam humidifier is as dry as
possible. Check that the steam supply NOTICE
lines are equipped with the necessary • Control air for pneumatic actuators
condensate drains. must be free from oil and humidity.
• The supply line for the steam humidifier • If control valves and actuators are part
must be taken from the highest point in of the delivery then operating and
the main supply line. installation instructions are present.
• Install a filter in the steam supply line • Customer is responsible for checking
directly in front of every humidifier. This steam injection humidifier compatibilty
is the only way to ensure that no for- if control units from other manufactur-
eign objects can find their way into the ers are used.
humidification unit.
• Keep the piping connections as short Actuator and valve installation positioning:
as possible. In this way the energy
losses are reduced, the system can
heat up quicker, condensates are mini-
mised and the system overall efficiency
is increased.

Page 29
7.6 Pneumatic Start-up safety feature 7.7 Steam Lances

NOTICE With single lance systems the lance is fitted

Pneumatic start-up safety is set at 96°C. This directly onto the valve exit using the delivered
value can be altered only by the manufac- fittments.
turer. If multiple lances are necessary to distribute
» First install a T-piece with a 1/2" exit steam in the ducting, then a there is a com-
in the condensate piping in front of plete assembled steam lance piping in the
the condensate drain. delivery. Angle pieces for installation of
humidifier/valve unit parallel to ducting walls
» A T-piece with a 1/8" exit is also
are available from HygroMatik.
installed in the control air piping.
» A temperature sensor is screwed In order to reduce the absorbtion distance
into the T-piece in the condensate the steam from the lance should be
piping. directed opposed to the air direction in
the ducting.
» The 1/8" drain valve is installed in
the air control piping in the T-piece. All piping seals should be done with tempera-
ture resistent (>150°C) sealing tape.
» Take great care not to damage the
capillary by bending. If only one lance is required for even steam
distribution install this at duct half-height.
With a multiple lance system position the
lances so that there is an even steam distri-
bution over the duct cross section and ensur-
ing that the necessary duct wall distance is
guaranteed.
HygroMatik can supply stainless steel stand-
ard modules for lance pitches of 300 and 450
mm
The distance between lance and duct ceil-
ing or floor should be a minimum of 200
mm.
Before the lance is installed in the duct check
that the correct lance is present. The steam
lance should be utilized over the entire duct
width (Please observe the lance codes).
Steam lances are pressed into the appropri-
ate holes.
Steam lance nozzles should be position
opposed to the air flow.

Page 30
In order to prevent steam condensing on the 7.7.1 Duct mounting set for steam lance
duct inner walls the lances should be
After the lance is positioned, an angle is posi-
installed according to the following dimen-
tioned on the opposite duct wall side at the
sions:
same height. The screws are self tapping.
Then the necessary threaded bar length „y“
is measured.
/ /
y = z + 20mm

NOTICE

<
• A gap x“ between bar end and duct
inner wall must be present in order to
&

accomodate a lance lateral expansion.

• Steam lances from code 2 on must be
<

supported at the end.

%
$

/ '

DDS20 A DDS40 A DDS20 C DDS40 C

[mm] [mm] [mm] [mm]
L1 310…330 440...500 420…440 660…700
L2
170 200 170 200
one lance system
L2 multiple lance
250 300 250 300
system
L3
70 100 70 100
one lance system
L3 multiple lance
150 200 150 200
system
A 310 330 260 350
B / / 43 70
Number Description
C 310 330 330 360 1 Duct wall
Y* 300 / 450 2 Screw M6x35
D see technical data lance 3 Nut M10
Distance lance/duct wall: 100 mm (L2‐L3)
* other distances possible on demand 4 Steam Lance

Threaded bar M10 & M8 x

5
NOTICE 250
6 Angle
• At 0.5 barg to 2.0 barg steam pressure 7 anti-vibration collar
there is a minimum distance of 200 to
300 mm to existing elements which The diameter of the hole in the duct wall is:
must be kept to. Higher pressures and/ SIH 20: 38 mm /SIH 40: 54 mm
or sensitive elements need 500 mm.
• A duct wall thickness of 30mm is
assumed. If „m“ is larger than 30mm,
then the distance „q“, is to be reduced
by the difference m-30mm.

Page 31
Lance guide is installed in the following After the lance has been installed the gap
manner: between duct outer wall and lance is closed
using the two cover plates as supplied with
» feed bar through hole in angle
the steam lances. The cover plates are
» screw M10 bar end in the steam
attached using two self tapping panel screws.
lance
The sealing between cover and duct wall
» use nut to lock to lance
should be done with silicone or a rubber seal-
ant.
Alternatively, the lance can be installed from
the duct ceiling with a threaded bar or held in
a U pipe. The necessary parts thereto are to
be supplied on site.

7.7.2 Installation Examples

NOTICE
If lances are positioned vertically then the
steam supply piping should have an addi-
tional float controlled condensate drain.

Page 32
Position lances in the duct centre if possible.

If the humidifier blows into a compact multi-

zone unit then it should be installed directly in
the air flow and as close as possible to the fan.

The bifurcated pipe should never be installed

less than one meter in front of the fan suction
side. In this case the correct installation is be-
hind the fan.

Never install the lances pointing vertically

downwards. This would cause condensate to
collect in the steam lance heating system. On
the other hand a vertical installation pointing
upwards is possible.

Page 33
When selecting the lance choose a size suffi-
cient for the entire duct width or height.

If the ducting is taller than it is wide, install the

steam lance vertically. If this is not possible
then a second lance must be installed in order
to ensure an even steam distribution.

Lances should have a minimum distance of

5x the absorbtion distance to the duct humid-
ity controller.

Page 34
7.8 Steam Lance Heating System Installation of the steam lance heating sys-
tem follows the installation of the steam injec-
tion system including steam lances. In
! WARNING accordance with the dimensions of the
humidifier unit a pipe with an external dimen-
The line to the heating system must be able to sion of 8mm is bent to shape and installed
tolerate pressures of up to maximum 8 barg. with the help of the supplied pipe fittings (1/4“
Cutting ring screw connection).

NOTICE Pipe length „L4“ must be at least 1 meter to

ensure effective functioning of the capsule
• The pipe is easy to bend with a suitable condensate drain. There are various installa-
tool. The customer must adjust the pipe tion possibilities, also where there is little
in accordance the conditions on site. room. Important here is to ensure the opti-
Take care not to kink the pipe when mum vertical positioning of the capsule con-
bending. densate drain. Pressure in the condensate
• Observe minimum bend radius of 1,5 x piping must not exceed half the pressure in
diameter (here:1,5 x 8mm= 12mm) the heating piping.
• Alternatively it is possible to close off Piping must always be installed properly
the connection to the separator and inclined.
feed the steam lance heating system
from another separate steam reservoir
with a maximum pressure of 4,5 barg.
Higher steam lance heating tempera-
tures result from higher pressure and
cause an even better heating heating
effect.

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Page 35
7.9 Check List

NOTICE
The steam injection humidifier may only be
operated by qualified and authorised person-
nel.

Before switching on the steam injection

humidifier please check for correct installa-
tion by going through the following check list:

• Have the steam supply lines been

flushed out?
• Are the steam supply and condensate
lines properly connected and secure?
• Is a condensate trap installed directly
before the DDS?
• Has the entire steam supply line up to
the control valve been checked for
leaks?
• Is the specified system pressure pres-
ent?
• Is there a proper filter fitted before the
separator? (normally part of the system
delivery)
• Is the operating pressure at least 0,5
barg and maximum 4,5 barg?
Electrical installation checks must be carried
out in accordance with customer require-
ments and public power utility regulations. All
electrical connections must be according to
the circuit wiring diagrams.

Page 36
8. Electrical connection
Please note
• If control units from other manufactur-
! WARNING
ers are used, the customer must
All work relating to the electrical installation ensure compatibility with the pressur-
may only be carried out by designated spe- ized steam humidifier.
cialist personnel (electrician or qualified per-
son with equivalent training). • A humidity control unit should be pro-
vided for the operation of the humidifier,
Do not connect the steam humidifier to the which must be installed according to
live power supply before all installation work the manufacturer's instructions.
has been completed.
• We recommend that you integrate a
Max hygrostat into the safety chain.
The Max hygrostat serves as a safety
element in the event of a malfunction of
Please note the humidity sensor. Install the
The customer is responsible for monitoring hygrostat approx. 5 times the calcu-
the qualifications of the specialist personnel. lated absorbtiondistance behind the
entry point of the lances in the duct.
• Install a pressure monitor in the duct
General installation rules and integrate it into the safety chain.
The pressure monitor prevents over-
• All local rules concerning the imple- humidification of the duct in the event
mentation of electrical installations of fan failure.
must be obeyed
• Electric connector cables to be laid pro-
fessionally
• Install the electrical connections
according to the wiring diagram

NOTICE
Possible electronical components de-
struction through electrostatical dis-
charge!
Prior to commencing electrical installation
work, steps must be taken to guard the sensi-
tive electronical components of the unit con-
trol against damage from electrostatical
discharge.

Page 37
Wiring diagram for HygroMatik actuator

The wiring diagrams for alternative actuators

can be found in the corresponding installation
documents!

Page 38
9. Commissioning Turning the steam injection humidifier on

Risk of operating error! NOTICE

Start-up of the unit is restricted to expert staff
If the actuator is not a controlled actuator
only.
then verify that the control valve is in the
For actuator initial operation please refer to closed position.
the instrutions of the regulator ans/or installa-
tions company. Initial operation should only » Slowly open the separator shut-off
be done by a trained expert or service techni- valve and, if there is one present,
cian. the shut-off valve to the steam lance
heating system.
» Check the entire steam supply up to
Follow the instructions below to ensure cor- the control valve for leaks.
rect operation of your steam injection humidi-
» Repair leaks as necessary.
fier.
» Check specified system pressure
using the pressure gauge.
NOTICE » Wait 10 - 15 minutes so that the
During most installations dirt will have man- steam injection humidifier can warm
aged to enter the steam supply. Therefore it up. The pipes between the separa-
is advisable to flush out the piping before ini- tor and the steam trap should be
tial operation. about the same temperature.
» Set the Max. Hygrostat to the
desired value.
Turning off the steam injection humidifier » Set the humidity sensor to the
desired value and activate the actu-
Before starting up the steam injection humifi- ator.
fier it is essential to know how to switch it off.
» Close shut-off valve on the steam
supply to the separator .
» If applicable, also close the shut-off
valve to the separate steam supply
to the steam lance heating heating
system.

Page 39
 NOTICE
Periodic filter cleaning is recommended in
order to prevent the control valve from exces-
sive wear. Before cleaning the filter always
shut off the steam supply and allow the sys-
tem to cool down.

The following operations are active:

• Accumulated condensate in the steam
supply is forced into the separator
where it is fed into the condensate net-
work via the ball float steam trap.
• Some of the dry steam in the top top
part of the separator supplies the
steam lance heating system and heats
the steam lances.
• As soon as the actuator indicates that
steam is required the control valve
opens and sends steam into the steam
lances.

NOTICE
For units with a start-up safety switch the
control valve is released only when the piping
between separator and ball float steam trap
has reached its designated temperature.

Risk of electrical shock!

Hazardous electrical voltage!
Follow safety instructions for work on live
components.

Page 40
10. Maintenance 10.1 Strainer
The HygroMatik steam injection humidifier is
easy to maintain. However, inadequate or Maintenance „SIH Type A“
improper maintenance can lead to opera- » Loosen the screws (M12/M16) on
tional malfunctions. Regular maintenance is the flange connection (D) at the
essential so that your steam injection humidi- steam entry point. Warning: steam
fier achieves a long, trouble free life span. supply and SIHystem should be
fixed according to the assembly
instructions
! WARNING
» Steam supply pipes should be pulled
Risk of scalding.
free of the entry flange if possible.
Before starting any maintenance work, make » If there is not enough room to
sure that the feed and drain are shut off and exchange the filter then de-install
that the unit is depressurized and cooled the separator.
down.
» Exchange filter (C) and seal (B).
! WARNING » Re-connect the flange with seal to
the steam entry point.
Risk of scalding. » Check the flange for leakage after
In case of leakage, uncontrolled steam can re-starting the system.
cause serious injuries. Shut off the steam
supply and let the device cool down. Elimi-
nate damage immediately.

Caution: When performing maintenance

work please note:

• The steam injection humidifier is only to

be serviced by qualified and authorised
personnel.
• Follow safety instructions.
• Switch off the humidifier and protect
against re-start. Allow the humidifier to
cool down.
• After performing maintenance work
have the steam injection humidifier
checked for safe operation by qualified
personnel.

The steam injection humidifier‘s performance

and maintenance intervals depend primarily
upon the steam quality and the humidification
volume since the last maintenance. Different
steam quality can shorten or lengthen main-
tenance intervals.
Recommendations on maintenance intervals
are based exclusively upon typical, empiri-
cally established values.

Page 41
Maintenance „SIH Type C“ 10.2 Ball float condensate drain
» Unscrew filter holder (C) , (SW27 or
SW50). Maintenance „SIH Type A“
» Extract filter (B) and clean or
» Release condensate drain from
replace.
separator.
» Replace seal (A).
» Loosen both Allen screws (size 6/8)
» Re-position filter. of the lower separator screw clamp
» Screw filter holder in. and remove clamp (A).
» Check for leakage by re-start » Release lower separator part (B)
» Remove C clamp (C).
» Release cone (D) with seal (E)
» Loosen seal screw and replace seal
if necessary
» Tighten seal screw a little and lock
down with nut without damaging the
seal.
» Re-fit cone and seal and fix at the
separator base using C clamp.
» Position new flange seal (F) at the
bottom and fix with screw clamp to
the separator.
» Screw down both Allen screws
simultaneously.
Ball float condensate drain
» Check for leakages by re-start.

Maintenance „SIH C“

The float steam trap SIH C is designed to be

maintenance-free. In case of malfunction,
replace it completely.

10.3 Thermostatic Capsule Steam

trap Type MST21

The Thermostatic Capsule Steam trap SIH C

is designed to be maintenance-free. In case
of malfunction, replace it completely.

D E C B

F A

Page 42
11. Malfunctions

Problem Possible Cause to do

No steam is coming • Defective Hygrostat or humidity sensor • Check Hygrostaten and/or
out of steam lance humility sensor and repair or
replace as necessary.
• Defective Control Valve • Check valve and clean it or
replace as necessary.
• Defective Actuator • Measure control signal. Check,
repair or replace as necessary.
• Inaccurate or defective control • Check actuator, reset, repair or
replace.
• Fouled or blocked coarse strainer in • Remove coarse strainer and
the filter before separator clean or replace.
• Shut-off valve in steam supply line is • Open shut-off valve
closed. • Clean pressure reduction valve,
• Pressure reduction valve, if installed, is possibly reset operational pres-
out of order. sure.
Steam is coming • Foreign objects between valve cone • Check and clean valve valve.
out of steam lance and face prevent valve from closing
although desired properly.
humidity value is • Defective or falsely set Hygrostat or • Check humidity or Hygrostat
reached. humidity sensor. and re-set or repair.
• Actuator does not close properly. • Re-adjust actuator to control
valve.
• Residual condensate evaporates in • Check out steam supply pres-
the steam lance and exits the lance as sure for the steam lance heating
pressure-less steam (re-evaporation system. Supply steam lance
effect) This process can take up to 20 heating system from a separate
minutes. dry steam steam reservoir
(max. 4,5 barg).
Condensate is com- • Insufficient installation of the steam • Check Installation.
ing out of steam supply line to the humidifier.
lance • Defective or dirty steam trap on the • Clean or replace steam trap.
steam dryer or steam lance heating
system.
• The back pressure from the conden- • Reduce pressure in the conden-
sate network is higher than the operat- sate return line.
ing pressure of the pressurised steam • If this is not possible, connect
humidifier. steam trap to separate return
line.

Page 43
 Problem Possible Cause to do
Condensate is com- • Steam trap drain is considerably • Install condensate drain
ing out of steam higher that the SIH system. beneath the humidifier level and
lance. pump out the resultant conden-
sate to a suitable place.
• Start-up safety feature does not work • Check wiring and function of
properly. start-up safety feature.
• Defective or unsuitable thermostatic • Check out condensate drain
capsule condensate drain attached to and integrated elements. Type
steam lance heating system. E must be used. Clean conden-
sate drain.
• Steam heating for steam lance heating • Optimum heating effect occurs
system insufficient. from pressure over 1 bar. Less
pressure can lead to lengthier
pre-heating times.

! CAUTION
Risk of injuries!
Switch off unit immediately in case of a mal-
function being detected. Malfunctions may
only be repaired by qualified personnel under
observation of all safety instructions

Page 44
12. Dimensions and Installation Schematic
Steam Injection System Type A (stainless steel)

/ /

<
&

<
$

/ '

Steam Injection System Type C (mixed materials)

/ /
<
&

<
%
$

/ '

DDS20 A DDS40 A DDS20 C DDS40 C

[mm] [mm] [mm] [mm]
L1 310…330 440...500 420…440 660…700
L2
170 200 170 200
one lance system
L2
250 300 250 300
multiple lance system
L3
70 100 70 100
one lance system
L3
150 200 150 200
multiple lance system
A 310 330 260 350
B / / 43 70
C 310 330 330 360
Y* 300 / 450
D see technical data lance
Distance lance/duct wall: 100 mm (L2‐L3)
* other distances possible on demand

Page 45
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Page 46
 13. Spare Parts

Type A Type C
Model Model Article Number Description
20 40 20 40
Separators
X E-4111252 Separator, without additions
X E-4111254 Separator, without additions
X B-4500001 Separator DDS20 incl. ball float steam trap and dirt trap

X B-4500003 Separator DDS40 incl. ball float steam trap and dirt trap

X B-4111917 maintenance set DDS20 Version A (encloses: seals, dirt trap)

X B-4111919 maintenance set DDS40 Version A (encloses: seals, dirt trap)

Dirt trap
X X E-4112202 dirt trap type 316 connection 3/4", stainless steel
X X E-4112204 dirt trap type 316 connection 1 1/2", stainless steel
Steam trap
X X X X B-4115603 thermostatic capsule steam trap type MST 21 -G, 1/4" -female thread

X X X X B-4511813 repair kit, inner parts for MST 21

X X E-4111702 ball float-steam trap FT14-4,5TV, female thread 1/2", cast iron
X X E-4111704 ball float-steam trap FTS14-4,5TV, female thread 1/2", stainless steel
Start-up safety switch
X X X X E-4111952 start-up safety switch, electrical, switching temperature 80°C, with plug
X X X X E-4111954 start-up safety switch, pneumatic
Valve ARI
cast iron type
X E-4115092 valve BR440, Kvs 0,25, DN15PN16
X E-4115094 valve BR440, Kvs 0,4, DN15PN16
X E-4115096 valve BR440, Kvs 0,63, DN15PN16
X E-4115098 valve BR440, Kvs 1,0, DN15PN16
X E-4115100 valve BR440, Kvs 1,6, DN15PN16
X E-4115102 valve BR440, Kvs 2,5, DN15PN16
X E-4115104 valve BR440, Kvs 4,0, DN15PN16
X X E-4115106 valve BR440, Kvs 6,3, DN20PN16
X E-4115108 valve BR440, Kvs 10,0, DN25PN16
X E-4115110 valve BR440, Kvs 16,0, DN32PN16
X E-4115112 valve BR440, Kvs 25,0, DN40PN16
stainless steel type
X E-4511738 valve BR440, Kvs 0.25, DN15PN40
X E-4511740 valve BR440, Kvs 0.4, DN15PN40
X E-4511742 valve BR440, Kvs 0.63, DN15PN40
X E-4511744 valve BR440, Kvs 1 ,0, DN15PN40
X E-4511746 valve BR440, Kvs 1 ,6, DN15PN40
X E-4511748 valve BR440, Kvs 2,5, DN15PN40
X E-4511750 valve BR440, Kvs 4,0, DN15PN40
X X E-4511752 valve BR440, Kvs 6,3, DN20PN40
X X E-4511754 valve BR440, Kvs 10,0, DN25PN40
X E-4511756 valve BR440, Kvs 16,0, DN32PN40
X E-4511758 valve BR440, Kvs 25,0, DN40PN40

Page 47
 Version A Version C
Typ Typ Artikelnummer
20 40 20 40
Steam lance
X X E-4111000 steam lance 20, Code 1, 218 mm fitting lenght
x X E4111002 steam lance 20, Code 1.5, 393 mm fitting lenght
X X E-4111004 steam lance 20, Code 2, 568 mm fitting lenght
X X E-4111006 steam lance 20, Code 3, 838 mm fitting lenght
X X E-4111008 steam lance 20, Code 4, 1148 mm fitting lenght
X X E-4111010 steam lance 20, Code 5, 1408 mm fitting lenght
X X E-4111012 steam lance 20, Code 6, 1718 mm fitting lenght
X X E-4111014 steam lance 20, Code 7, 2018 mm fitting lenght
X X E-4111016 steam lance 20, Code 8, 2318 mm fitting lenght
X X E-4111018 steam lance 20, Code 9, 2628 mm fitting lenght
X X E-4111020 steam lance 20, Code 10, 2938 mm fitting lenght
X X E-4111022 steam lance 20, Code 11, 3238 mm fitting lenght
X X E-4111024 steam lance 20, Code 12, 3548 mm fitting lenght
X X E-4111050 steam lance 40, Code 1, 217 mm fitting lenght
X X E-4111052 steam lance 40, Code 1.5, 392 mm fitting lenght
X X E-4111054 steam lance 40, Code 2, 567 mm fitting lenght
X X E-4111056 steam lance 40, Code 3, 837 mm fitting lenght
X X E-4111058 steam lance 40, Code 4, 1147 mm fitting lenght
X X E-4111060 steam lance 40, Code 5, 1407 mm fitting lenght
X X E-4111062 steam lance 40, Code 6, 1717 mm fitting lenght
X X E-4111064 steam lance 40, Code 7, 2017 mm fitting lenght
X X E-4111066 steam lance 40, Code 8, 2317 mm fitting lenght
X X E-4111068 steam lance 40, Code 9, 2627 mm fitting lenght
X X E-4111070 steam lance 40, Code 10, 2937 mm fitting lenght
X X E-4111072 steam lance 40, Code 11, 3237 mm fitting lenght
X X E-4111074 steam lance 40, Code 12, 3547 mm fitting lenght
Piping
X X X X E-4111980 Pipe 8x1mm, for pre heating system

X X E-4111984 Connecting screw, for lance heating, steel zinc plated

X X E-4112984 Connecting screw, for lance heating, stainless steel
X X B-4111981 steam lance piping in center for 2 lances, type 20, 300 mm fitting lenght

X X B-4111983 steam lance piping in center for 2 lances, type 20, 450 mm fitting lenght

X X B-4111989 steam lance piping in center for 2 lances, type 40, 300 mm fitting lenght

X X B-4111991 steam lance piping in center for 2 lances, type 40, 450 mm fitting lenght

X X B-4111935 connection for another steam lance, type 20, 300 mm lenght
X X B-4111937 connection for another steam lance, type 20, 450 mm lenght
X X B-4111943 connection for another steam lance, type 40, 300 mm lenght
X X B-4111945 connection for another steam lance, type 40, 450 mm lenght
Actuators and accessories
X X X X E-4111680 actuator, electrical, 24V/0-10V or 4-20mA control signal
X X X X E-4115082 actuator pneumatic, PN9220E, control signal 0,2 - 1 bar proportional, wihtout
accessories
E-4111662 EP5 positioner, electropneumatic
E-4111666 PP5 positioner, pneumatic, control signal 0,2 - 1,0 bar
E-4111668 gauge block for PP5, complete with 1 x 2barg and 1 x 7barg

For ordering spare parts, a template can be found on the www.hygromatik.com website under
the „Contact“ tab. Your spare parts order may as well be directed per e-mail to the HygroMatik
main office using the address [email protected].
Please make sure to specify your unit model and serial number.

Page 48
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Page 49
 14. Technical Data
Technical Data Seperator
Typ DDS 20 DDS 40
Version A C A C
Thread connections B 1/4“
C 1/2“ inner thread 1
C2 1/2“ external thread / 1/2“ external thread /
O 1" inner thread 3/4“ external thread 1 1/2" inner thread 1 1/2" external thread
I DN 25 Flange 3/4“ inner thread* DN 40 Flange 1 1/2" inner thread*
Weight [kg] 3,6 1,46 7,3 3,7
Dimensions [mm] d / 43 / 70
e 230 187 340 278
D 110 104 122 154
W 175 164 218 236
h 290 270 426 392

Materials Housing 1.4404 AISI 316L 1.4301 AISI 304 1.4404 AISI 316L 1.4301 AISI 304

Max. Humidification output [kg/h] 270 180 770 730

Steam Pressure max 4,5 barg
* Connection to the complete system is inner thread (because the strainer is mounted). Seperator without strainer has an external thread.

Seperator DDS C Seperator DDS A

Z Z
' '
% %
2
2
,
G

K
K

,
H
H

& & &

Strainer DDS C
A
Technical Data Strainer
Strainer 12.1 for version C Type 20 Type 40
Nominal pressure setting PN 25 D
Female thread 3/4“ 1 1/2“
Weight 0,6 2,4
Dimensions [mm] A 74 108 B
B 56 80
D 32 54
Materials Housing 1.4408 / AISI 316

Page 50
 Technical Data Steamlances
Type 20 Type 40
Lancecode h (mm) j (mm) Weight (kg) h (mm) j (mm) Weight (kg)
1 218 338 0,88 218 345 1,54
1,5 392 512 1,14 392 519 1,97
2 568 688 1,4 568 695 2,39
3 838 958 1,8 838 965 3,03
4 1148 1268 2,26 1148 1275 3,78
5 1408 1528 2,65 1408 1535 4,4
6 1718 1838 3,11 1718 1845 5,15
7 2018 2138 3,55 2018 2145 5,87
8 2318 2438 4 2318 2445 6,59
9 2628 2748 4,46 2628 2755 7,34
10 2938 3058 4,92 2938 3065 8,08
11 3238 3358 5,37 3238 3365 8,8
12 3548 3668 5,83 3548 3675 9,55

*h ‐ installation length
*j ‐ total length
*X‐ Installation length min. 1m (see Steam Lance heating system)

Steam lances are available as type 20 and 40 in various lengths,

suitable for duct widths from 280mm to 3855 mm.

 














 


 
 
 

 


DDS A DDS C
1/2:Separator interface/ Strainer
3: Separator 5: Start-up safety feature
Duct height Number of lances
4: Float controlled Condensation Drain
up to 1000 mm 1
1000 ‐ 1700 mm 2 6: connection steam lance heating system
1700 ‐ 2200 mm 3 7: control valve 11: Actuator
2200 ‐ 2600 mm 4 8/9: Steam lances / steam nozzles
over 2600 mm 5 10: Capsule Condensation Drain
12: steam lance heating system

List Lancecodes

Inst. length h mm 218 390 568 838 1148 1408 1718 2018 2318 2628 2938 3238 3548
Duct width (max.)* mm 390 565 835 1130 1405 1715 2015 2315 2625 2935 3245 3545 3855
Duct width (min.)* mm 220 395 570 840 1150 1410 1720 2020 2320 2630 2940 3240 3550
Lancecode 1 1,5 2 3 4 5 6 7 8 9 10 11 12

Page 51
 Lise-Meitner-Str.3 D-24558 Henstedt-Ulzburg
Phone +49(0)4193/ 895-0  Fax -33
eMail [email protected]  www.hygromatik.com
member of CAREL Group
Ein Unternehmen der Gruppe

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