Condair CS 2.0/4 · 3.4 Functional description The Condair CS steam humidifier is an unpressurized...
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INSTALLATION AND OPERATING INSTRUCTIONS 2545546 HLK EN 1408 HLK Version Resistive Humidifiers Condair CS 2.0/4.0
Transcript of Condair CS 2.0/4 · 3.4 Functional description The Condair CS steam humidifier is an unpressurized...
INSTALLATION AND OPERATING INSTRUCTIONS
2545
546
HLK
EN
140
8H
LK V
ersi
on
Resistive Humidifiers
Condair CS 2.0/4.0
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Contents
1 Introduction 41.1 To the very beginning 41.2 Notes on the installation and
operating instructions 4
2 For your safety 6
3 Product overview 83.1 Steamhumidifierconstruction 83.2 Function of the display and
operating elements 93.3 Product designation 93.4 Functional description 103.5 Humidificationsystemoverview 113.6 Options 123.7 Accessories 123.8 Standarddelivery 133.9 Storing/Transport/Packaging 13
4 Installation 144.1 Important notes on the installation 144.2 Installationoverview 154.3 Unitfitting 164.3.1 Noteonlocatingandfittingtheunit 164.3.2 Wall mounting 174.3.3 Floormounting 184.3.4 Inspecting the installed unit 194.4 Steam installation 204.4.1 Steam distribution pipe 204.4.1.1 Positioning of the steam distribution pipe 204.4.1.2 Installing the steam distribution pipe 224.4.2 Installation of the steam and
condensate line 234.4.2.1 LayoutwithsteamhoseDS60 234.4.2.2 Layoutwithfixedpiping 254.4.3 Inspecting the steam installation 274.5 Waterinstallation 284.5.1 Overviewwaterinstallation 284.5.2 Noteonwaterinstallation 294.5.3 Inspectingthewaterinstallation 304.6 Electric installation 314.6.1 Wiring diagram 314.6.2 Notes on electric installation 334.6.3 Inspecting the electrical installation 33
5 Operation 345.1 Putting into operation 345.2 Indication of the operating status
on the unit 355.3 Function of the remote indication
relays during operation 365.4 Notes on operation 365.5 Taking out of operation 36
6 Maintenance 376.1 Important notes on maintenance 376.2 Maintenanceintervals/Maintenancelist 386.3 Removing and installing parts for
maintenance 396.4 Notes on cleaning the unit components 466.5 Resetting the maintenance counter
(maintenanceindication) 48
7 Malfunctions 497.1 Fault indication 497.2 Malfunction list 497.3 Notes on fault elimination 527.4 Resetting error indication 52
8 Taking out of service/Disposal 538.1 Takingoutofservice 538.2 Disposal/Recycling 53
9 Productspecifications 549.1 Technical data 549.2 Unit dimensions 55
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LimitationThesubjectoftheseinstallationandoperatinginstructionsisthesteamhumidifierCondairCS.Thevariousaccessories(e.g.steamdistributor,filtervalve,etc.)areonlydescribedinsofarasthis is necessary for proper operation of the equipment. Further information on accessories can be obtained in the respective instructions.
These installation and operating instructions are restricted to the installation, commissioning, operation, servicing, and trouble-shootingofthesteamhumidifierCondairCSandismeantforwelltrainedpersonnelbeingsufficientlyqualifiedfortheirrespectivework.
The installation and operating instructions are supplemented by various separate items of documen-tation (spare parts list, manuals for accessories, etc.). Where necessary, appropriate cross-references are made to these publications in the installation and operating instructions.
1 Introduction
We thank you for having purchased the steamhumidifierCondairCS.
ThesteamhumidifierCondairCSincorporatesthelatesttechnicaladvancesandmeetsallrecog-nizedsafetystandards.Nevertheless,improperuseofthesteamhumidifierCondairCSmayresultin danger to the user or third parties and/or impairment of material assets.
Toensureasafe,proper,andeconomicaloperationof thesteamhumidifierCondairCS,pleaseobserveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallationand operating instructions.
Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyourCondairsupplier.Theywillbegladtoassistyou.
1.2 Notes on the installation and operating instructions
1.1 To the very beginning
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Symbols used in this manual
CAUTION!Thecatchword“CAUTION”designatesnotesinthisdocumentationthat,ifneglected,maycausedamage and/or malfunction of the unit or other material assets.
WARNING!
Thecatchword“WARNING”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyand danger notes in this documentation that, if neglected, may cause to injury to persons.
DANGER!
Thecatchword“DANGER”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyand danger notes in this documentation that, if neglected, may lead to severe injury or even death of persons.
SafekeepingPleasesafeguardtheseinstallationandoperatinginstructionsinasafeplace,wheretheycanbeimmediately accessed. If the equipment changes hands, the documentation must be passed on to thenewoperator.
Ifthedocumentationgetsmislaid,pleasecontactyourCondairsupplier.
Language versionsThese installation and operating instructions are available in various languages. Please contact your Condairsupplierforinformation.
Copyright protectionThepresentinstallationandoperatinginstructionsisprotectedundertheCopyrightAct.Passing-onandreproductionofthemanual(orpartthereof)aswellasexploitationandcommunicationofthecontentsareprohibitedwithoutwrittenpermissionbythemanufacturer.Violationofcopyrighttermsissubjecttolegalprosecutionandarisesliabilityforindemnification.
Themanufacturerreservestherighttofullyexploitcommercialpatentrights.
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2 For your safety
GeneralEverypersonworkingwith theCondairCSmusthave readandunderstood the installationandoperatinginstructionsbeforecarryingoutanywork.Knowingandunderstanding thecontentsof the installationandoperating instructions isabasicrequirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the unit safely and correctly.
All ideograms, signs and markings applied to the unit must be observed and kept in readable state.
QualificationofpersonnelAllwork(installation,operating,servicing,etc.)describedintheseinstallationandoperatinginstruc-tions mayonlybecarriedoutbyspecialistwhoarewelltrainedandadequatelyqualifiedandare authorized by the customer.Forsafetyandwarrantyreasonsanyactionbeyondthescopeofthismanualmustbecarriedoutonlybyqualifiedpersonnelauthorisedbythemanufacturer.
ItisassumedthatallpersonsworkingwiththeCondairCSarefamiliarandcomplywiththeappro-priateregulationsonworksafetyandthepreventionofaccidents.
Thisunitmaynotbeusedbypersons(includingchildren)withreducedphysical,sensoryormentalabilitiesorpersonswithlackingexperienceand/orknowledge,unlesstheyaresupervisedbyapersonresponsiblefortheirsafetyortheyreceivedinstructionsonhowtooperatetheunit.Childrenmustbesupervisedtomakesurethattheydonotplaywithunit.
Intended useSteamhumidifiersCondairCSareintendedexclusivelyfordirectairhumidificationviaasteamdistributor approved by the manufacturer withinthespecifiedoperatingconditions(seechapter9“Productspecifications”.Anyothertypeofapplication,withoutthewrittenconsentofyourCondairsupplier,isconsideredasnotconformingwiththeintendedpurposeandmayleadtotheCondairCSbecomingdangerous.Operation of the equipment in the intended manner requires that all the information in these ins-tructions are observed (in particular the safety instructions).
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Danger that may arise from the unit
DANGER!Danger of electrical shock!
The Condair CS is mains powered. One may get in touch with live parts when the unit is open. Touching live parts may cause severe injury or danger to life.Prevention:BeforecarryingoutanyworksettheCondairCSoutofoperationasdescribedinchapter5.5(switchofftheunit,disconnectitfromthemainsandstopthewatersupply)andsecuretheunitagainstinadvertentpower-up.
WARNING! Hot water vapour - Danger of scalding!
The Condair CS produces hot water vapour. There is danger of scalding when getting in touch with hot water vapour. Prevention:Donotcarryoutanyworkonthesteamsystemduringoperation(steamlines,steamdistributor,etc.).IfthesteamsystemisleakysettheCondairCSimmediatelyoutofoperationasdescribedinchapter5.5.Correctlysealthesteamsystembeforeputtingtheunitintooperationagain.
WARNING! Danger of burning!
During operation the components of the steam system get very hot (up to 100 °C). There is danger of burning when touching the hot components.Prevention: BeforecarryingoutanyworkonthesteamsystemsettheCondairCSoutofoperationasdescribedinchapter5.5,thenwaituntilthecomponentshavecooleddownsufficientlythuspreventing danger of burning.
Behaviour in case of dangerIf it is suspected that safe operation is no longer possible,thentheCondairCSshouldimmediatelybe shut down and secured against accidental power-up according to chapter 5.5. This can be thecaseunderthefollowingcircumstances:
– iftheCondairCSisdamaged– iftheCondairCSisnolongeroperatingcorrectly– if connections and/or piping are not sealed or cables are loose
AllpersonsworkingwiththeCondairCSmustreportanyalterationstotheunitthatmayaffectsafetytotheownerwithoutdelay.
ProhibitedmodificationstotheunitNomodificationsmustbeundertakenontheCondairCSwithouttheexpresswrittenconsentofthe manufacturer.
Forthereplacementofdefectivecomponentsuseexclusivelyoriginal accessories and spare parts availablefromyourCondairsupplier.
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3 Product overview
1 Drainkey 2 Unitswitch(On/Off) 3 LEDred“Error” 4 LEDyellow“Warning” 5 LEDgreen“Steamproduction” 6 Excesstemperatureswitchelectronic 7 Controlboard 8 Steamcylinder 9 Cylinderinsert 10 Heating elements 11 Water supply connector R 3/4" 12 Water drain connector ø 40 mm13 Excesstemperatureswitchsteamcylinder 14 Steam outlet connector ø 30 mm
3.1 Steamhumidifierconstruction
15 Steam cylinder support 16 Water cup 17 Water supply hose18 Fillinghose19 Overflow/drainhose20 Couplingsleeve21 Auxiliarydrainhose22 Drainpump23 Floatswitchbasetub 24 Pressure equalizing hose 25 Type plate 26 Inlet valve27 Cableopenings28 Connectionterminalmainssupply
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3.3 Product designation
Condair AG, CH-8808 Pfäffikon
Made in Switzerland
CS 4.0
Max. Dampf 4kg/hZuleitungsdruck 1...10 bar
AC 230V 50Hz 3.0 kWXXXXXXX 11.06
Type designation Serial number (7-digit) Month/Year
Supply voltage
Maximumsteamcapacity
Admissiblewatersupplypressure
Fieldwithcertificationsymbols
3.2 Function of the display and operating elements
Drain keyFunctions: – Manualflushing(watersupplyopen)ormanual
draining(watersupplyclosed)ofthesteamcyl-inder. By pressing the key the drain pump starts. By pressing the key again the drain pump stops.
– Resetting the maintenance counter/maintenance indication(yellowLED“Warning”flashes8x)
Withtheunitswitchedoff,depressandholdthedrainkeythen,switchontheunit.
Unit switchFunction: Switchingtheunitonandoff
green LED “Steam”Function: flashes1x:unitisreadyforoperation flashes2x:testoflevelunitinprogress lights:unitisproducingsteam
yellow LED “Warning”Function: flashesifamalfunctionispresentbutfurtheropera-
tionisstillpossible(thenumberofflashesindicatesthe type of malfunction, see chapter 7).
red LED “Error”Function: flashesifamalfunctionispresentwhichobstructs
furtheroperationoftheunit(thenumberofflashesindicates the type of malfunction, see chapter 7).
Theproductdesignationisfoundontheratingplate:
Powerconsumption
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3.4 Functional description
TheCondairCSsteamhumidifierisanunpressurizedsteamgenerator.Itoperatesontheresistanceheatingprincipleandisdesignedforairhumidificationviaasteamdistributionpipe.
Water supplyThewateristakenviaafiltervalve(accessory“Z261”)tothesteamhumidifier.Itreachesthesteamcylinderviatheinletvalve(levelcontrolled)andtheopenwatercup.
Level regulationThewaterlevelinthesteamcylinderiscontinuouslymonitoredwiththelevelunit.Ifthewaterlevelreachesapresetlevel(owingtotheevaporationprocess)thelevelunitsuppliesasignaltothecon-troller.Thisopenstheinletvalveandthesteamcylinderisfilledup.Whenthepresetoperatinglevelis reached, the level unit supplies another signal to the controller to close the inlet valve.Thepressureequalizingpipebetweenthesteamconnectionandthelevelunitensuresthatthewaterlevels are the same in the steam cylinder and the level unit.
Steam generation regulationThesteamisproducedinthesteamcylinderbytworesistanceheatingelements.Thesteampro-ductioniscontrolledviaanexternalhumidistat(On/Offcontrol)oranexternalcontinuoushumiditycontroller0...10V(continuouscontrol).
FlushingTheevaporationprocessincreasestheconcentrationofmineralsinthewaterofthesteamcylinder.Asuitablevolumeofwatermustbeflushedthroughthesteamcylinderfromtimetotimeandreplacedbyfreshwatertoensurethatthisconcentrationdoesnotexceedaspecificvalueunsuitableforoperation.TheCondairCSsteamhumidifierperformsanauto-adaptiveflushing.Thisconsistsofthefollowingtwoformsofflushing:
– Automaticflushingtakesplaceassoonasthewaterinthesteamcylinderexceedstheupperoperatinglevel(e.g.byfoamingofthewater).
– Flushing dependent on time performstheflushingprocessatpreselected time intervals (inaccordancewiththelocalwaterquality).
Automaticortime-dependentflushingtakesplacedependingonthewaterqualityandtheoperatingdata.Ifthelowestoperatinglevelisreachedduringtheflushingprocess,theinletvalveremainsopenuntilthewaterlevelinthesteamcylinderhasreachedthenormalworkinglevelagain.Ifthelowestoperating level is not reached, the inlet valve is closed.
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1 Steamhumidifier 2 Continuoushumiditycontroller0...10V
(room or duct) 3 On/Off humidistat (room or duct) 4 Humiditysensor0-10V
(supplyairlimitation,signalZl) 5 Safety humidistat (room or duct) 6 Voltagesupply 7 Water drain connector
3.5 Humidificationsystemoverview
8 Watersupplyconnector 9 Drainpipe(bycustomer)10 Watersupplyhose(accessory“WIT”)11 Filtervalve(accessory“Z261”) 12 Water drain building side
(funnelwithsiphon)13 Steamhose(accessory“DS60”)14 Condensatehose(accessory“KS10”)15 Steamdistributionpipe(accessory“61-..”)
1 ... 40 °C1 ... 10 bar
min. 1 °Cmax. 40 °C
max. 75 %rFR 3/4"
IP21
80...90 °C
ø40 mm
ø40/32 mm
ø10/8 mm
AC 230V 50Hz9
10
11
12
1
6
78
2
13
15
14
4
5
3
YZ
or or or
or
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3.6 Options
Option Designation Description
Pressure compensation kit PCK Kit of hoses for mounting the water cup above the unit cover of the Condair CS to compensate back pressure in the steam hose of up to 2'000 Pa.
3.7 Accessories
Accessories for water installation
Accessory Designation Description
Water supply hose WIT Water connection pipe ø10/8 mm made of plastic with R 3/4" union nut (pressure-proofed and certified for drinking water supply systems). Pipe length 2 m.
Filter valve Z261 Shut-off valve with integrated filter for the installation in the water supply line.
Accessories for steam installation
Accessory Designation Description
Steam hose ø29/38 DS60 Heat-resistant plastic hose specially designed for the steam line. Specify the length in meter when ordering.
Condensate hose KS10 Specify the length in meter when ordering.
Steam distribution pipe 61-.. Type 1) Length (L) 2) steam distribution pipe in mm
Duct width (B)in mm
61-200 200 250...40061-350 350 400...60061-500 500 550...75061-650 650 700...90061-800 800 900...1100
1) material: CrNi steel 2) special length on request
R 1/2"R 1/2"
R 3/4"
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3.8 Standard delivery
Thestandarddeliveryincludes:
– SteamhumidifierCondairCScompl.incardboardbox(WxHxD:445mmx440mmx330mm,transportweight:13kg)with:– watersupplyhose– Fixingset– Installation and operating instructions (this document)
– Orderedoptionswithoperatinginstructionsaccordingtochapter3.6,packedseparately.
– Orderedaccessorieswithoperatinginstructionsaccordingtochapter3.7,packedseparately.
3.9 Storing/Transport/Packaging
StoringStoretheunitinaprotectedareameetingthefollowingrequirements:
– roomtemperature:1...40°C– roomhumidity:10...75%rh
TransportForoptimumprotectionalwaystransporttheunitintheoriginalpackaging.
Totransporttheunitwithoutpackagingholdtheunitwithbothhandsonitsbasetub(netweightoftheunit:11.5kg).Alwaysplacetheunitonitsbottomside.
PackagingKeeptheoriginalpackagingoftheCondairCSforlateruse.
Incaseyouwishtodisposeofthepackaging,observethelocalregulationsonwastedisposal.Neverdispose of the packaging to the environment.
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4 Installation
QualificationofpersonnelAllmountingandinstallationworkmustbecarriedoutonlybywellqualifiedpersonnelauthorisedby the owner.Itistheowner’sresponsibilitytoverifyproperqualificationofthepersonnel.
General note Strictly observe and comply with all information given in the present installation and operating instructionsregardingthelocationoftheunitandtheinstallationofwater,steamandelectricity.Observe and comply with all local regulationsdealingwithwater,steamandelectricalinstallations.
SafetySomeinstallationworkrequiresremovaloftheunitcover.Pleasenotethefollowing:
DANGER!Danger of electrical shock!
Youmaygetintouchwithlivepartswhentheunitisopen.Thesteamhumidifiermustbeconnected to the mains only after all mounting and installation work has been completed and the cover has been relocated properly.
CAUTION!The electronic componentsinsidethehumidifierarevery sensitive to electrostatic discharge. Whentheunitisopenforinstallationwork,appropriatemeasuresmustbetakentoprotect these components against damage caused by electrostatic discharge (ESD protection).
4.1 Important notes on the installation
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4.2 Installation overview
Water installation, see chapter 4.5
Electrical installation, see chapter 4.6
Steamfinstallation, see chapter 4.4
Unitfitting, see chapter 4.3
AC 230V 50Hz
2
4
5
3
YZ
Ømin. 200 mm
min. 1 °Cmax. 40 °C
max. 75 %rh
> 32 mm
Rmin.
300 mm
max.
2 mRmin. 300 mm
IP21
min.
300 m
m
60...70 °C
ø40 mm
ø40/32 mm
ø10/8 mm
Z261
min. 5 %–
min. 5 %–
min. 20 %+
1 ... 40 °C1 ... 10 bar
min. 10 %–
R 3/4"
17 kg
Ømin. 200 mm
max. 2 m
61-..
KS10
KS10
DS60
61-..
or or or
or
16
min
. 300
mm
min. 250 mm
min. 250 mm
361 mm
min. 600 mm
350
mm
250 mm
4.3 Unitfitting
4.3.1 Noteonlocatingandfittingtheunit
Thefollowingpointsmustbeconsideredandobserved:
– Installthesteamhumidifiersothatthelengthofthesteamhoseiskeptasshortaspossible(max. 2 m) and the requirements regarding the leading of the steam hose can be met (see chapter 4.4).
– ThesteamhumidifiersCondairCSaredesignedforwall-andfloormounting.Makesurethattheconstruction(wall,pillar,floor-mountedconsole,etc.)towhichthehumidifieristobemounted,offersasufficientlyhighload-bearingcapacity(operatingweightofunit:17kg),andissuitablefor the installation.
CAUTION!Donotmountthesteamhumidifierdirectlytotheventilationduct(insufficientstability).
– ThehousingoftheCondairCSisretainingheatduringoperation(max.surfacetemperatureofthemetalhousingapprox.60-70°C).Makesure,therefore,thattheconstruction(wall,pillar,etc.)towhichtheunitistobemounted,doesnotconsistofheat-sensitivematerial.
– Installthesteamhumidifierinsuchamannerthatitisfreely accessiblewithsufficientspaceavailable for maintenance purposes (refer to the illustration above for minimum distances).
– TheCondairCSisprotectedaccordingtoIP21. Make sure the unit is installed in a drip-proof locationandtheadmissibleambientconditionsarecompliedwith.
Operating weight of the unit: 17 kgProtection class of the unit housing: IP21Surface temperature of housing during operation: 60 – 70 °CMax. admissible ambient temperature: 1 – 40 °CMax. admissible ambient humidity: 75 %rh
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4.3.2 Wall mounting
Procedure1. Markthethreeattachmentpointsonthewall.
2. Drillholes(diameter:8mm,depth:40mm).
3. Insertthesuppliedplasticplugsintotheholes,andtightenthescrewsuntilthedistancebetweenthewallandthescrewheadis4mm.
4. Unlockthetwoscrewsandremovetheunitcover.
5. Hanguptheunitonthescrews.Usethespiritleveltoadjusttheunithorizontallyandverticallythen,tightenthetopmostscrew.
6. Reattachtheunitcoverandlockitwiththetwoscrews.
– ThesteamhumidifierCondairCSmayonlybeinstalledinroomswithafloordrain.
CAUTION!IfforsomereasontheCondairCSmustbeinstalledinalocationwithoutfloordrain,itismandatorytoprovidealeakagemonitoringdevicetosafelyinterruptthewatersupplyincaseofleakage.
– WhenfixingtheCondairCS,useonlythefixingmaterialssuppliedwiththeunit.Iffixingwiththematerialssuppliedisnotpossibleinyourparticularcase,selectamethodoffixingthatisofsimilarstability.
300 mm
150 mm
15 m
m
100 mm100 mm
235
mm
ø 8
mm
40 mm 4 mm1. 2. 3.
6.
4.
5.
17 kg
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4.3.3 Floor mounting
Procedure1. Marktheattachmentpointsonthefloor(twooneachsideoftheunit).
Note:Themountingsurfacemustbeexactlyhorizontal(checkwithspiritlevel).
2. Drillholes(diameter:8mm,depth:40mm).
3. Insert the supplied plastic plugs into the holes.
4. Unlockthetwoscrewsandremovetheunitcover.
5. Fixtheunittothefloorusingthefourscrewssupplied.
6 Reattachtheunitcoverandlockitwiththetwoscrews.
ø 8 mm
40 m
m
2. 3.
6.
4.
5.
322 mm
209
42 mm
6,5 mm
157 mm42 mm
10 mm
8 mm
10 mm
3 mm
1.
17 kg
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4.3.4 Inspecting the installed unit
Checkthefollowingpoints:
Is the unit in the correct place (see chapter 4.3.1)?
Istheload-bearingcapacityoftheconstructiontowhichtheunitistobemountedsufficient?
Is the unit correctly aligned vertically and horizontally?
Is the unit properly secured (see chapters 4.3.2 and 4.3.3)?
Istheunitcoverreattachedandsecuredwiththetwoscrews?
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4.4 Steam installation
4.4.1 Steam distribution pipe
4.4.1.1 Positioning of the steam distribution pipe
The location for the steam distribution pipe should be determined at the time of dimensioning the airconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidificationoftheduct air.
CalculatingthehumidificationdistanceThewater vapour, emitting from the steam distribution pipes, requires a certain distance to beabsorbed by the ambient air so that it is no longer visible as steam. This distance is referred to as humidificationdistance“BN” and serves as a basis for the determination of the minimum distances from the upstream components in the system.
Humidificationdistance BN Expansionandmixingzone
ϕ1:Supplyairhumiditybeforehumidificationϕ2:Supplyairhumidityafterhumidification
Thecalculationof thehumidificationdistance “BN” isdependentonseveral factors.Fora roughestimationofthehumidificationdistance“BN”,thefollowingtableisuseful.Recommendedstandardvalueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevaluesonly apply to steam distribution pipe 61-....
Humidity at inletϕ1 in %rh
LengthofhumidificationdistanceBN in m Humidity at outlet ϕ2 in %rh
40 50 60 70 80 905 0,9 1,1 1,4 1,8 2,3 3,5
10 0,8 1,0 1,3 1,7 2,2 3,420 0,7 0,9 1,2 1,5 2,1 3,230 0,5 0,8 1,0 1,4 1,9 2,940 – 0,5 0,8 1,2 1,7 2,750 – – 0,5 1,0 1,5 2,460 – – – 0,7 1,2 2,170 – – – – 0,8 1,7
ϕ1in%rh: Relativesupplyairhumiditypriortohumidificationatthelowestsupplyairtemperatureϕ2in%rh: Relativesupplyairhumidityafterthesteamdistributionpipeatmaximumcapacity
Examplegiven: ϕ1=30%rh,ϕ2=70%rh
humidificationdistanceBN: 1,4 m
Note:Ifthehumidificationdistancehastobereducedfortechnicalreasons,theamountofsteammustbedividedbetweentwo steam distribution pipes.Ifthisisthecase,contactyourCondairsupplier.
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1.5 x BN * BN BN5 cm
Minimum distances to be observedTopreventthewatervapour,thatisemittingfromthesteamdistributionpipe,fromcondensingondownstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeobser-ved(dependsonthehumidificationdistance“BN”).
before/after constriction after expansion before bend
before branch before diffuser before control sensor
before/afterfilter/register before/afterfan,zoneexit
Caution!Thehumidificationdistanceandderivedfromittheminimumdistancebetweenthesteamdistributorandsystemcomponentslocateddownstreamintheductaredeterminedonthebasisoftheexpectedoperatingparameters(e.g.airspeed,supplyairtemperature,etc.)whenplanningthesystem. An alteration of these operating parameters at a later time may induce that the determined humidificationdistance isnotcorrectany longerandsteam iscondensatingduringoperationonsystemcomponentslocateddownstreamintheduct.Thismayleadtodamageofthesystemand/oranexcessivegrowingofgerms.
Installation notes and dimensionsThe steam distribution pipes are designed for either horizontalinstallation(ontheductwall)or,withaccessories, for vertical installation(intheductfloor).Theoutletorificesshouldalwayspointupwardsandatrightanglestotheairflow.
If possible, the steam distribution pipes should be installed on the pressure side of the duct (max. duct pressure 300 Pa). If the steam distribution pipes are installed on the suction side of the duct, the maximum vacuum must not exceed 300 Pa.
Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)andposition the steam distribution pipes in the duct so that a uniform distribution of steam is achieved.
2,5xBNbeforeaerosolfilter
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Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved:
hminhmin
1/2 H1/2
H
1/3
2/3H
H2/72/73/7
1/3 H1/31/3
2/7
2/7
3/7
H
1/21/2
hmin
gmin
g min.= 100 mmhmin.=85mm
H min.= 250 mm H≥400mm H min.= 200 mm
H min.= 400 mm H min.= 350 mm H min.= 300 mm
Guidelines for dimensioning the ventilation ducts– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufficiently
sized control opening should be planned.
– Withintherangeofthehumidificationdistance,theventilationductshouldbewaterproofed.
– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidifiedairfromcon-densingalongtheductwall.
– Poorairflowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canleadtocondensationofthehumidifiedair.
– Steam distribution pipes must not be mounted to round ducts.
IfyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithsteamhumidifiersCondairCS,contactyourCondairsupplier.
4.4.1.2 Installing the steam distribution pipe
Detailedinformationontheinstallationofsteamdistributionpipe61-...canbefoundintheseparateMounting Instructions for this products.
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min.
300 m
m
Ømin. 200 mmKS10
61-....
Rmin.
300 mm
max.
2 mRmin. 300 mm min.
300 m
m
min. 5 %–
min. 5 %–
min. 20 %+
max. 2 m
DS60
1 23
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5
6
ø29/38 mm
min. 20 %–
min
. 300
mm
Ømin. 200 mmKS10
61-....
4.4.2 Installation of the steam and condensate line
4.4.2.1 Layout with steam hose DS60
Overview
CAUTION!Use original Condair steam hose and condensate hose exclusively. Other types of hoses can cause undesired operational malfunctions.
1 Steam distribution pipe 61-... 2 Hose clamps 3 SteamhoseDS60(ø29/38mm) 4 Steamconnector(ø30/28mm) 5 CondensatehoseKS10 6 Drainfunnelwithsiphon(byclient)
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Note on leading the steam hose– Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge
ofthehumidifier, then lead thehosewithaminimum upslope of 20% and/or a minimum downslope of 5% to the steam distribution pipe.
– The steam hose should be kept as short as possible (max. 2 m)whileobservingtheminimum bend radius of 300 mm.Note:themaximum admissible pressure loss over the entire steam line is 300 Pa.Allowancemust be made for a pressure loss of 10 mm water column (approx. 100 Pa) per meter steam hoseorper90°bow.
Note:Ifyourparticularinstallationexceedsthemaximumsteamhoselengthof2mcontactyourCondairrepresentative.Inanycase,steam hoses longer than 2 m must be insulated in their entire length.
–DANGER!
Reducing the cross section or the complete closure of the steam pipe will cause an ex-cessive increase in pressure in the steam cylinder when the unit is operating and could lead to the risk of scalding accidents. Therefore you must comply with the following instructions:– When installing make sure the steam pipe is open over the entire length and through the
wholecrosssection.Anysealingplugs,adhesivesealingsheetsetc.mustberemovedbeforeconnectingthesteampipeandreductionsincrosssectionbykinking,forexample,mustbeavoided.
– Steam hoses must be prevented from sagging (condensate pockets); if necessary, support steamhosewithpipeclamps,trough,orwallbrackets,orinstallacondensatedrainatlowestpoint in the steam hose.
– It is not permitted to install a stop valve (e.g. a manually controlled stop valve, solenoid valve, etc.) in the steam pipe.
– Important! When deciding on the length and layout of the hose, it should be noted that the steam hosemaybecomesomewhatshorterwithprogressiveageing.
Securing the hoseThesteamhosemustbesecuredtothesteamdistributionpipeandthehumidifiersteamoutletbymeans of hose clamps.
CAUTION!To prevent the steam connector of the unit to be damaged, do not overtighten the hose clamp.
After having secured the steam hose to the steam outlet of the unit reattach the unit cover and lock itwiththetwoscrews.
Note on leading the condensate hoseCondensatehoseisleddownwithaminimum slope of 20 %, in the form of a siphon (min. hose bend diameter Ø200 mm),directlyintoadischargefunnelwithsiphon.
Note:Ifyourunitfeedsanumberofsteamdistributionpipes,theindividualcondensatehosesareto be led into the discharge funnel.
Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
25
4.4.2.2 Layoutwithfixedpiping
Overview
1 Steam distribution pipe 61-... 2 Hose clamps 3 Pieceofsteamhose(DS60) 4 Steamlinemadefromstainlesssteel(min.DIN1.4301) 5 Insulation (mandatory) 6 Steamconnector(ø30/28mm) 7 CondensatehoseKS10 8 Drainfunnelwithsiphon(byclient)
min.
300 m
m
Ømin. 200 mm
KS10
61-....
1
min.
300 m
m
min. 5 %–
min. 20 %+
Rmin.
100 mm
2
23
6
2
3
45
ø 24/28 mm
max. 2 m
7
8
CAUTION!Use original Condair condensate hose exclusively. Other types of condensate hoses can cause undesired operational malfunctions.
26
NotesonmakingthesteamlinewithfixedpipingForsteamlineswithfixedpiping,thesameinstructionsapplytothelayingandthemaximumlengthofthepiping,asfortheversionwithsteamhoseDS60.Thefollowingadditionalnotesmustbeobserved:
– The minimum internal diameter of 24 mmmustbeappliedoverthewholelengthofthepiping.
– Useexclusivelystainlesssteelpiping(min.DIN1.4301).
– To minimize the condensate formation (=loss), the steam pipes must be insulated over the entire length.
– The minimum bend radius for rigid piping is 100 mm.
– Allowancemustbemadeforapressure loss of 10 mm water column (approx. 100 Pa) per meterlinelengthorper90°angle.
Securing the steam lineThe connection of the steam pipe to the steam distributor and the steam outlet of the steam humi-difieriseffectedbymeansofshortlengthsofsteamhose(use steam hose DS60)securedwithhose clamps.
CAUTION!To prevent the steam connector of the unit to be damaged, do not overtighten the hose clamp.
After having secured the pieces of steam hose to the steam outlet of the unit reattach the unit cover andlockitwiththetwoscrews.
Note on leading the condensate hoseCondensatehoseisleddownwithaminimum slope of 20 %, in the form of a siphon (min. hose bend diameter Ø200 mm),directlyintoadischargefunnelwithsiphon.
Note:Ifyourunitfeedsanumberofsteamdistributionpipes,theindividualcondensatehosesareto be led into the discharge funnel.
Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
27
4.4.3 Inspecting the steam installation
Checkthefollowingpoints:
– Steam distribution pipe
Steam distributors (steam distribution pipe or OptiSorp steam distribution system) correctly positionedandsecured(screwstightened)?
Aretheoutletorificesatrightanglestotheairflowdirection?
– Steam line
Isthemaximumlengthof2mmaintained?
Istheminimumbendradiusof300mm(100mmwithfixedpiping)maintained?
Have the instructions for layoutof thesteam linebeen followed (seechapter4.4.2.1and4.4.2.2)?
Isthesteampipeopenovertheentirelengthandthroughthewholecrosssection?
Steamhose:nosagging(condensatepocket)orisacondensatedrainwithsiphon(hosebendwithmin.diameterof200mm)installedatthelowestpointinthesteamline?
Rigid steam lines: properly insulated?Correct installationmaterial used?Minimal internaldiameter maintained?
Steamhose(orpiecesofsteamhose,respectively)securelyattachedwithclamps?
Heatexpansionduringoperationandshorteningofthehosewithageingtakenintoconside-ration?
Istheunitcoverreattachedandsecuredwiththetwoscrews?
– Condensatehose
Downslopeofatleast20%?
Siphon(min.ø200mm)existingandfilledwithwater?
Condensatehosecorrectlyfixedandnotkinked?
28
4.5 Water installation
4.5.1 Overview water installation
1 Supply line (min. inner diameter: 8 mm) 2 Manometer (installation recommended, building side) 3 Filter valve (accessory “Z261”, installation mandatory) 4 Water supply hose 90° with union nut R 3/4" (accessory “WIT”) 5 Water supply connector, outside thread R 3/4" 6 Water drain connector, inner diameter 40 mm 7 Drain line (building side, min. inner diameter: 32 mm, min. down-slope 10%) 8 Drain line building side
(funnel with siphon, min. inner diameter: 32 mm)
> 32 mm
R 3/4"
80...90 °C
ø40 mm
ø40/32 mm
ø10/8 mm
ø10/8 mmZ261
1 ... 40 °C1 ... 10 bar
min. 10 %–
min. 10 %–
1
2
3
4
8
7
5
6
29
4.5.2 Note on water installation
Important: Before connecting the water supply and water drain remove plastic sealing caps from the connectors on the unit.
Water supplyThe water supply is to be carried out according to the figure found in chapter 4.5.1 and the applicable local regulations for water installations. The indicated connection specifications must be observed.
– The installation of the filter valve (accessory Z261, alternatively, a shut-off valve and a water filter may be installed) should be made as close as possible to the steam humidifier
CAUTION!The thread at the humidifier connection is made of plastic. To avoid overtightening, the union nut of the water pipe must be tightened by hand only.
– Notes on water quality:
– For the water supply of the Condair CS, use fully demineralised water.Note: The use of fully demineralised water reduces the time for maintenance and cleaning to a minimum.
– The use of additives such as corrosion inhibitors, disinfectants, etc. is not allowed, since these additives may endanger health and affect proper operation.
– If the Condair CS shall be operated with untreated drinking water, softened or partly softened water, please contact your Condair supplier.
– The connection material must be pressure-proof and certified for use in drinking water supply systems.
When making connections to a fully demineralised water system, use exclusively plastic or stainless steel installation materials (min. DIN 1.4301). Other materials will be attacked by the fully demineralised water.
– Important! Before connecting the water line to the unit, the line must be flushed thoroughly.
Water drainThe water drain is to be carried out according to the figure found in chapter 4.5.1 and the applicable local regulations for water installations. The indicated connection specifications must be observed.
– Make certain that the drain pipe is correctly fixed and easily accessible for inspections and cleaning purposes.
– The drainage temperature is: 80…90 °C. Use only temperature-resistant installation material!
– When operating the Condair CS with fully demineralised water, use exclusively plastic or stain-less steel installation materials (min. DIN 1.4301). Other materials will be attacked by the fully demineralised water.
30
4.5.3 Inspecting the water installation
Checkthefollowingpoints:
– Water supply
Hasfiltervalveorshut-offvalveandfilter5µmrespectivelybeeninstalledinsupplyline?
Haveadmissiblewaterpressure(1–10bar)andtemperature(1–40°C)beenobserved?
Is the minimum inside diameter of the supply pipe maintained throughout the entire length?
Are all pipes properly secured (threaded connections tightened)?
Is the feed pipe properly sealed?
Doesthewatersupplyinstallationmeettherequirementsofthelocalregulationsforwaterinstallations?
– Water drain
Is the minimum inside diameter of the drain pipe of 40 mm maintained throughout the entire length?
Hasdrainpipebeeninstalledwithadownslopeofatleast10%?
Hastheheatresistanceofthematerialusedbeenverifiedtobeatleast100°C?
Are hoses and lines properly secured (hose clamps and threaded connections tightened)?
Doesthewaterdraininstallationmeettherequirementsofthelocalregulationsforwaterinstallations?
31
4.6 Electric installation
4.6.1 Wiring diagram
F6 External fuse voltage supply (16 A, slow acting)J1 Short circuited, if no external monitoring devices (e.g. ventilation
interlock “B1”, airflow monitor “B2”, Safety humidistat “B3”) are connected to connection terminal X12
Q External service switch (with minimum contact opening of 3 mm)S1 DIP switch (function see table in the above wiring diagram)X0 Connection terminal voltage supply (see following table)X.. Connection terminal (see following table)
11
1
111
4 3 2 1
OFF
ON
1
1 2
12
31
23
12
31
23
45
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
4 3 2 1
GND
24 VDC/6W
X4
12
3
P
N
PE
X18
X5
X6
X7
X8X9X11 X10X12
X14
X15
X16
X17
F4
Stea
mM
aint
enan
ceEr
ror
On
Ext. Safety chain
B3B2B1J1
X1
12
3
P
N
PE
X2
12
3
P
N
PE
X3
12
3
P
N
PE
F1X0
F5
F2
Mai
ns
L1NPE
L1
N
PE
Q
230
V/1~
/ 50H
z
F6
12
34
56
78
Z-GND
R
R-GND
Z
GND
24 VDC
X13
S1Z
GND
A2
ON-OFF
45
6
Z-GND
R
24 VDC
78
A3
–+φ 56
Z
Z-GND
A1
–+
P / PI
A1 Continuous humidity controller 0...10 V (signal Y)A2 On/Off humidistatA3 Humidity sensor 0...10 V (supply air limitation signal Z)B1 Ventilation interlockB2 Airflow monitorB3 Safety humidistatF1 Fuse control board (3,15 A, slow acting)F2 Fuse Heating High (10 A, slow acting) F4 Fuse Heating Low (10 A, slow acting)F5 Fuse drain pump (500 mA, slow acting)
S1 Function1 OFF: cylinder draining after 15 filling cycles
(factory setting)ON: cylinder draining after 30 filling cycles
2 OFF: standard switching on threshold (factory setting)
ON: increased switching on threshold (de-mand >15%)
3 OFF: maintenance interval 1000 hON: maintenance interval 500 h
(factory setting)Note: a modification of the setting becomes only active after resetting the maintenance counter (see chapter 6.5).
4 OFF: no cylinder draining in standby operati-on (factory setting)
ON: cylinder draining after 24 h without humidity demand
32
Connection Description Connection-No.
Designation of connection
Cable cross section in mm2
X0 Mains supply AC 230V 50Hz N Neutral 1.5
L1 Phase 1.5
PE Ground 1.5
X12 External safety chainCable bridge “J” installed
1 -- 0.34
2 -- 0.34
X13 External continuous humidity controller 0...10 V, connected to terminals 3 (–) and 4 (+)orExternal On/Off humidistat, connected to terminals 4 and 8––––––––––––––––––––––––––––Supply air limitation signal: humidity sensor 0...10 V, connected to terminals 5 (–) and 6 (+)
1 -- --
2 -- --
3 R-GND 0.34
4 Request 0.34
5 Z-GND 0.34
6 Z 0.34
7 GND 0.34
8 24 VDC 0.34
X14 Relay outlet “On”The relay is activated if the unit is swit-ched on and in stand-by mode (no steam production in progress).
Max. contact loading: 24V/1A (AC/DC)
1 Common 0.34
2 NC 0.34
3 NO 0.34
4 GND 0.34
5 24 VDC 0.34
X15 Relay outlet “Error”The relay is activated if a malfunction is present.
Max. contact loading: 24V/1A (AC/DC)
1 Common 0.34
2 NC 0.34
3 NO 0.34
X16 Relay outlet “Service”The relay is activated as soon as the maintenance counter has expired.
Max. contact loading: 24V/1A (AC/DC)
1 Common 0.34
2 NC 0.34
3 NO 0.34
X17 Relay outlet “Steam”The relay is activated as soon as steam is produced. If the water supply is interrupted the relay is activated and deactivated 3 times for a short time followed by a longer period of inactivity.
Max. contact loading: 24V/1A (AC/DC)
1 Common 0.34
2 NC 0.34
3 NO 0.34
33
4.6.2 Notes on electric installation
– Theelectricinstallationmustbecarriedoutaccordingtothewiringdiagraminchapter4.6.1andtheapplicablelocalregulations.Allinformationgiveninthewiringdiagramantheconnectiontabletothewiringdiagrammustbefollowedandobserved.
– All cables must be lead into the unit via the cable openings and must be secured to the latches inthehousingwallbymeansofcablestraps(strainrelief).
4.6.3 Inspecting the electrical installation
Checkthefollowingpoints:
Doesthemainsvoltageappliedcorrespondtotherespectivedatastatedonthetypeplate?
Istheserviceswitch“Q”(withaminimumcontactopeningof3mm)installedinthemainssupplyline?
Areallcomponentscorrectlyconnectedinaccordancewiththewiringdiagram(seechapter4.6.1?
Are the minimum cross sections of the cables maintained (see table in chapter 4.6.1)?
Areallcablesleadintotheunitviathecableopeningsandcorrectlysecuredwithcablestrapstothelashesinthehousingwall?
Doestheelectricinstallationmeettheapplicablelocalregulationsforelectricinstallations?
Istheunitcoverreattachedandsecuredwiththetwoscrews?
34
5 Operation
5.1 Putting into operation
Proceedasfollowswhenputtingtheunitintooperation:
1. Whenputtingthesteamhumidifierintooperationthefirsttimeorwhenputtingthesteamhumidifierintooperationafterworkhasbeencarriedoutonthesteamsystem,thecommissioningpersonnelmustmandatorycheckwhetherthesteampipeisopenovertheentirelength.Todothisproceedasfollows:
• UndothetwoscrewsoftheCondairCSunitcover,thenremovethecover.
• Undothehoseclampofthesteamhose,thenremovesteamhosefromtheconnectorofthesteam cylinder.
• Startuptheventilationsystemandcheckwhetheracleardraughtthatcorrespondsapproxi-mately to the pressure in the ventilation system (positive or negative pressure) can be detected at the open end of the steam hose removed.
DANGER!
A steam pipe that is reduced in cross section or completely closed will cause an exces-sive increase in pressure in the steam cylinder when the unit is operating and could lead to the risk of scalding accidents! Therefore: If no draught or only a slight one can be detected the steam pipe must be checked for blockagesandreductionsincrosssectionbeforecontinuingwithcommissioningandyoumustensurethatthesteampipeisopenacrosstheentirelengthandthroughthewholecrosssection.
2. Examinethesteamhumidifierandinstallationforpossibledamage.
DANGER!
Damageddevicesordeviceswithdamagedinstallationmaypresentdangertohumanlifeorcause severe damage to material assets. Damaged units and/or units with damaged or faulty installation must not be operated.
3. Mountunitcoverandfixitwiththetwoscrews.
4. Open the filtervalve / shut-off valveinthewatersupplyline.5. Switchontheserviceswitchforthemainssupply.
6. Switchonthesteamhumidifiermainswitch.
Theswitchlights.Thesteamhumidifiercarriesoutasystem test.ThethreeLEDslightforapprox.3 seconds.If a fault is detected during the system test, a corresponding fault message is triggered (see chapter 7).
Ifthesystemtestissuccessful,thesteamcylinderfillsupandafloattest is carried out (function checkonthelevelunit).DuringthefloattestthegreenLEDflashes2x.Note: Ifa fault isdetectedduring thefloat test,acorresponding faultmessage is triggered(seechapter 7).
Ifthefloattestissuccessful,theCondairCSwillbeinstand-by mode.ThegreenLEDflashes1x.
35
TheLEDsontheunitindicatethefollowingoperatingstatus:
Indication on unit Meaning
green LED “Steam”
flashes 1x The unit is switched on ready for operation.
flashes 2x The unit performs a float test.
lights The unit produces steam.
yellow LED “Warning”
flashes with different intervals
A Warning is present (e.g. Maintenance due, yellow LED flashes 8x).---> see chapter 7 “Malfunctions”
red LED “Error”
flashes with different intervals
An Error is present.---> see chapter 7 “Malfunctions”
5.2 Indication of the operating status on the unit
7. The following procedure must be carried out only on the initial commissioning:• Checkforcorrectfunctioningofthemonitoringequipment(externalsafetycircuit).
• Checkthefunctionofthesteamhumidifier:Switchonthehumidificationby raising the set humidity value on the humidity controller/humidistat.Switchoffthehumidificationbyloweringthesethumidityvalueonthehumiditycontroller/humidistat.
• Setthedesiredhumidityvalueonthehumiditycontroller/humidistat.
Assoonas thehumidistator thehumiditycontroller requireshumidity,power isswitchedon forheating.ThegreenLEDlightsupandafterafewminutes(approx.10minutes)steamisproduced.
36
DuringoperationoftheCondairCSthehumidificationsystemhastobeinspectedweekly.Onthisoccasioncheckthefollowing:
• thewaterandsteaminstallationforanyleakage.
• thesteamhumidifierandtheothersystemcomponentsforcorrectfixingandanydamage.
• theelectricinstallationforanydamage.
If the inspection reveals any irregularities (e.g. leakage, error indication) or any damaged components taketheCondairCSoutofoperationasdescribedinchapter5.5.Then,havethemalfunctionbeeliminatedorthedamagedcomponentbereplacedbyawelltrainedspecialist.
5.4 Notes on operation
5.5 Taking out of operation
Thefollowingprocedureisfollowedwhenitisrequiredtoshutdownthesteamhumidifier:
1. Iftheunithastobeswitchedoffbecauseofamalfunction,pleasenotetheerrorcode(numberofflashesoftheyelloworredLED).
2. Closethefiltervalve/shut-offvalveinthewatersupplyline.
3. Thisstepmustonlybecarriedoutiftheunithasbeopened(e.g.formaintenancework)oriftheunitistakenoutofoperationforanextendedperiodoftime:Pressthedrainkey,waituntilthepump has emptied the steam cylinder then, press the drain key again (drain pump stops).Ifthedrainpumpisdefectiveorifamalfunctionispresent(redLEDflashes)thesteamcylindermust be drained manually via the drain hose. After draining the steam cylinder close drain hose correctly and reattach the hose to the corresponding holder in the unit.
4. Actuatetheunitswitch.
5. Isolatethesteamhumidifierfromthemains:Switchoffserviceswitchinthemainssupplyline. Mark the service switchtopreventitfrombeingswitchedoninaccidentally.
WARNING! Danger of burning!
Ifsteamwasproducedjustbeforetheunitistakenoutofoperation,waitbeforeopeningtheunitandletthesteamcylindercooldowntopreventdangerofburning.
5.3 Function of the remote indication relays during operation
Detailedinformationregardingthefunctionoftheremoteindicationrelaysduringoperationcanbefoundinthetabletothewiringdiagraminchapter4.6.1.
37
6 Maintenance
6.1 Important notes on maintenance
QualificationofpersonnelAllmaintenanceworkmustbecarriedoutonlybywellqualifiedandtrainedpersonnelauthorisedby the owner.Itistheowner’sresponsibilitytoverifyproperqualificationofthepersonnel.
General note Theinstructionsanddetailsformaintenanceworkmustbefollowedandupheld.
Onlythemaintenanceworkdescribedinthisdocumentationmaybecarriedout.
OnlyuseoriginalCondairsparepartstoreplacefaultyparts.
SafetySomemaintenanceworkrequiresremovaloftheunitcover.Pleasenotethefollowing:
DANGER!Danger of electrical shock!
You may get in touch with live parts when the unit is open. Touching live parts may cause severe injury or even lethal violation.Prevention: BeforecarryingoutanymaintenanceworksettheCondairCSoutofoperationasdescribedinchapter5.5(switchofftheunit,disconnectitfromthemainsandstopthewatersupply)andsecuretheunitagainstinadvertentpower-up.
CAUTION!The electronic componentsinsidethehumidifierarevery sensitive to electrostatic discharge.Prevention: Beforecarryingoutanymaintenanceworktotheelectricalorelectronicequipmentofthehumidifier,appropriatemeasures must be taken to protect the respective components against damage caused by electrostatic discharge (ESD protection).
38
6.2 Maintenance intervals/Maintenance list
TheCondairCSisequippedwithamaintenancecounterwhichtriggersamaintenanceindicationafteraspecificperiodofoperation.Theintervaltimedependsonthewaterqualityandtheamountofsteamproduced.Exworks,thesetintervaltimeofthemaintenancecounterisbasedonawaterhardnessof11°DH.
As soon as the maintenance indicationappears:yellowLEDflashes8xa complete maintenancemustbecarriedout.Thecompletemaintenanceincludesthefollowingwork:
• Inspectthewaterandsteaminstallationsforcorrectsealinganddamage.
• Inspect the drain line for soiling, clean if necessary.
• Inspect the electrical installation for loose cables and damaged components.
• Inspectthesteam-airhumidifierfordamage.
• Dismantlethesteamcylinderandthecomponentsoftheinternalwatersystemaccordingchap-ter 6.3.
• Checkandcleanthesteamcylinder,thecomponentsoftheinternalwatersystemandtheunitinner chamber according chapter 6.4.
Note:Ifyoudiscoveranexcessivecalcifyingofthecomponentswhenmaintainingtheunitthemain-tenanceintervaltimemustbedecreased.InthatcasepleasecontactyourCondairrepresentative.
Note:The customer is responsible for the regular inspection, cleaning and disinfection of the duct sectioninwhichthesteamdistributorisinstalled.Thismustbeperformedinaccordancewiththehygiene regulations in force for operating air handling units.
39
6.3 Removing and installing parts for maintenance
2. Undothetwoscrewsoftheunitcover,thenremovetheunitcover.
3. Disconnectthecablesoftheheatingelementsonthecontrolboard(terminalsX3andX4),thencarefully pull the cables through the openings into the cylinder compartment.
1. Set the Condair CS out of operation as described in chapter 5.5, disconnect it from the mains and secure the unit against inadvertent power-up.
32
54
4. Pushtheprotectingsleeveoftheexcesstemperatureswitchupwards,thencarefullydisconnectcables.
5. Release the hose clamp on the steam outlet of the unit, then detach the hose from the steam outlet connection.
X4
X3
40
6. Undothetwoscrewsofthesteamcylindersupport,thenremovethecylindersupport.
7. Pushthelockofthecontrolboardassemblyupwards,thenslightlyliftthecontrolboardassemblyand turn it to the right until it comes to a stop.
76
98
8. Releasethehoseclampsonthesteamcylinderandonthelevelunitusingscrewdriver, thendetach the pressure compensating hose from the connections.
9. Carefullyliftthesteamcylinderoutofthecouplingsleeve,thenremoveittothefront.
CAUTION!Putsteamcylinderdowncarefullytoavoiddamagetothelowerconnectionpiece!
41
1110
10. Open and remove the steam cylinder cover clamping ring.
11.Carefullyliftoffthecoverwiththeheatingelements,thenremoveDurosealantfromthecover.
CAUTION!Takecarewiththecoverwhilstitisremoved,soasnot to damage the heating elements.
Ifthecovercannotberemovedduetoheavycalcification(maintenanceperiodexceeded),placethesteamcylinderinabasinofformicacid(8%)untilitcanberemoved(Caution! Therefore observe instructions on the safe use of this cleaning agent).
WARNING!
Formic acid attacks the mucous membranes. Therefore observe instructions on the safe use of this cleaning agent,weargogglesandglovesandworkinawellventilatedroomoroutside.
12. If necessary, loosen the cylinder insert by lightly rotating it in either direction and lift it from the steam cylinder.
12
42
13
13. If a heating element has to be replaced during servicing, dismantle the corresponding heating elementdownwardsasshownintheillustrationabove.
Assembly and installation of the steam cylinderAssembly of the steam cylinder takes place in reverse sequence of the steps 2 to 13. Please note thefollowinginstructions:
– Installationofanyheatingelementswhichhavebeenremovedshouldfollowtheillustrationinstep13.Theheatingelementsareidenticalandcanbeinterchangedamongeachother.ConnectthecablesoftheheatingelementstoterminalsPandNoftheterminalstripsX3orX4onthecontrolboard.
– BeforeinstallationofthesteamcylindercoverplacetheDurosealantaroundtheedgeofthecover.TheDurosealantmustbecleanandundamaged(replaceifnecessary).
– Before installation of the steam cylinder in the unit check O-rings in the coupling bush for damage and replace if necessary.
– Align steam cylinder in the unit so that the pressure compensation hose can be connected to the respectiveconnectiononthesteamcylinderwithouttension.
– Fastensteamhosewithhoseclamps.Aleakysteamhosecancausedampdamageintheinteriorof the unit.
43
14.BecauseofthecompactdesignoftheCondairCSwerecommendtoremovethecomponentsoftheinternalwatersystemsasanassemblyanddisassembletheindividualcomponentsafterwards.Proceedasfollows:
a) Undothetwoscrewsatthewatersupplyconnectorandpushtheinletvalveintotheunit.
b) Releasethehoseclampofthewaterdrainhoseinsidetheunit,thenremovethehosefromthe connection.
c) Undothescrew,thenremovetheauxiliarydrainhosefromtheholder.
d) Carefullypullfixingclipofthewatercuptothefront,thenpushwatercupdownandforwardand free it from the holding device.
e) Carefully compress the holding device of the level unit (from outside), then pull the level unit andfreeitfromtheunitwall.
f) Undothetwoscrewsofthedrainpumpsupportontherightsideoftheunit.
g) Undothefourscrewsofthecouplingsleeve.
Nowremovetheelectricalcablesfromtherespectiveconnectionsoftheinletvalve,thelevelunitandthedrainpump.Placethecablesinawaythattheycannotbedamagedwhenthewatersystem assembly is removed.
14
a
bc
e
f
g
d
44
15
15.Carefullyliftthewatersystemassemblyandremoveittothefront.
45
16.Disassemblethecomponentsofthewatersystemasshowninthefigureabove.
Assembly and installation of the water systemTheassemblyandtheinstallationofthewatersystemtakesplaceinreversesequenceofthesteps14to16.Observethefollowingnotes:
• Assemblethewatersystemasshownintheillustrationinstep16butdonottightenthehoseclamps yet.
• Afterinstallingandfixingthewatersystemassemblyintheunit(step14)alignallhosesandfixthemwiththehoseclamps.
16
46
Unit component What to clean and how to clean
Steam cylinder and steam cylinder insert
• Knockoffany limescaleasmuchaspossible. If thepartsareheavilycalcified,placetheminan8%formicacid solution, until the lime scale comes off.
• Finallywashpartsinalukewarmsoapsolutionand rinse wellwithtapwater.
Cover with heating elements • Immersecoverwiththefittedheatingelements(upto2cmbelow the rimof thecover) inacontainerwith8-percentformicacid.Allowtheacidtotakeeffectuntilthe scale coating has dissolved.
Note:Theheatingelementsdonothavetobeentirelyfree from scale.
• Finallyrinsetheheatingelementswellwithtapwater.
CAUTION! Ensure that the electrical connections and the electronic parts remain dry.
CAUTION! On no account remove lime scale from the heatingelementsusingtools(screwdriver,scraper,etc.)or by striking. This could damage the heating elements.
Coupling sleeve
Orificeø6mm
• RemoveO-ringsfromthecouplingsleeve.Useabrushto remove any lime scale from the coupling sleeve (do notuseawirebrush).Checktheorificewithadrillø6mm.
• Finallywashcouplingsleeveinalukewarmsoapsolu-tion andrinsewellwithtapwater.Then,refitO-rings.
Hoses • Removeanylimescalebyslightlyknockingonthetubesusingarubberhammer.Then,rinsethetubeswellwithhottapwater.
6.4 Notes on cleaning the unit components
47
Unit component What to clean and how to clean
Level unit
Opening ø5 mm
• Flush level unitwith a lukewarmsoap solution, then flushwellwithtapwater.
• Iftheloweropeningisheavilycalcified:Undothethreescrews,thenremovefloat.Useabrushtoremoveanylimescalefromthehousingandthefloat(donotuseawirebrush).Freeupperandloweropeningusingadrillø5mm.Washcomponentswithalukewarmsoapsolu-tion,thenrinsewellwithtapwater.Finallyreassemblethe level unit.
Inlet valve
Strainer insert
• Removestrainerinsertwithpointedpliers.Useabrush(donotuseawirebrush)toremoveanylimescale.
• Washstrainerinsertwithalukewarmsoapsolution, then rinsewellwithtapwater.Remountstrainerinsert.
CAUTION! Ensure that the electrical connections re-main dry.
Drain pump
O-ring
pumpwheel
• Disassemblethedrainpump(bajonetcatchwithlock).
• Useabrushtoremoveanylimescalefromthepumphousingandthepumpwheel(donotuseawirebrush).Wash the pump withalukewarmsoapsolutionandrinsewellwithtapwater.
• Reassemblethedrainpump:moistentheO-ringandthe centering of the housing, then place O-ring on the centeringcollar.Assemblethepumpandlockit(bajonetcatch).
CAUTION! Ensure that the electrical connections re-main dry.
Interior of the unit (water side only) • Wipetheinterioroftheunitwithadampclothwithoutusing any cleaning agent.
CAUTION! Ensure that the electrical connections and electronic components remain dry.
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Notes on cleaning agentsOnly use cleaning agents stated in the table above. The use of disinfectants is only permitted if theyleavenotoxicresidues.Thecomponentsmustberinsedthoroughlywithwateraftercleaningin all cases.
WARNING!
Formic acid is indeed harmless to the skin, but it attacks the mucous membranes. Therefore prevent youreyesandrespiratorytractsfromgettingintouchwiththeacidanditsvapours(weargogglesandworkinawellventilatedroomoroutside).
CAUTION!Do not use any solvents, aromatized or halogenized hydrocarbons or other aggressive substances as they may cause damage to the components of the unit.
Itismandatorytoobserveandcomplywiththeinformationandinstructionsregardingcleaningagents.Observeinparticular:allinformationrelatingtotheprotectionofpersonnel,environmentalprotectionand restrictions regarding usage.
6.5 Resetting the maintenance counter (maintenance indication)
Whenmaintenanceworkhasbeencompleted,themaintenance countercanberesetasfollows:1. With the unit switched off,depressandholdthedrainswitch.2. Switchonthesteam-airhumidifierwiththeunitswitch.
3. Releasedrainswitch.
The maintenance counter is reset and the unit ready for operation.
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7 Malfunctions
Warning:yellowLEDflashes
Incaseofmalfunctionduringoperation,thehumidifiercontrolcheckswhetherthereisatemporaryproblem(e.g.watersupplyinterruptedforashorttime)orwhetheritcanresolvetheproblembytaking necessary measures. As long as the control tries to resolve the problem the yellow LED “Warning"flashes.Ifthecauseofthemalfunctiondisappearsofitsownaccordorifthecontrolcanrepairthemalfunc-tion,thewarningmessagewillautomaticallyswitchoff.
Error:redLEDflashes
If the control, after several attempts, fails to solve the problem (number of attempts depends on the type of malfunction) or if the problem obstructs further operation, the heating voltage is interrupted and the red LED “Error” blinks.
7.1 Fault indication
7.2 Malfunction list
Most operational malfunctions are not caused by faulty equipment but rather by improper installati-onordisregardingofplanningguidelines.Therefore,acompletefaultdiagnosisalwaysinvolvesathoroughexaminationoftheentiresystem.Often,thesteamhoseconnectionhasnotbeenproperlyexecuted,orthefaultlieswiththehumiditycontrolsystem.Thefollowingtablegivesalistofpossiblemalfunctions,theappropriatewarningorerrormessage,detailsoftheircause,andnotesonhowtodealwitheachproblem.
Malfunction/Indication Cause Remedy
Warningyellow LED
flashes...
Errorred LED
flashes...
1xMin.fillingtime
not reached (Warning only)
––– Water feed to steam cylinder heavilycalcified.Levelinsteamcylinder and level unit do not match.
Carryoutacompletemainte-nance.
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Malfunction/Indication Cause Remedy
Warningyellow LED
flashes...
Errorred LED
flashes...
2xExternal
safety chain interrupted
––– One or more monitoring devices (ventilatorinterlock,flowmoni-tor, safety humidistat, etc.) in theexternalsafetychainhavetriggered.
Checkmonitoringdevicesintheexternalsafetychain(ventilatorinterlock,flowmonitor,safetyhu-midistat, etc.) or check ventilation system and control system for malfunctions.
––– 2xInternal
safety chain interrupted
Connectiontoover-temperatureswitchonsteamcylinderbrokenorover-temperatureswitchfaulty.
Checkconnectionsorreplaceover-temperatureswitch.
Ambient temperature sensor defective.
Replace ambient temperature sensor.
Steam cylinder overheating, over-temperatureswitchhasresponded.
Inspect steam cylinder, clean if necessary.Resetexcesstempe-ratureswitchbypressingtheredbutton.
Electronictohot,excesstempe-ratureswitchonthecontrolboardhas triggered.
Switchoffunitandwaitforapprox.30minutes.Then,resetexcesstemperatureswitchbypressing the red button.
3xMax.filling
timeexceeded (Warning only)
––– Waterfeedblocked(mainwatertapclosed,filtervalveclosedorblocked).
Checkwaterfeed(openmainwa-tertap,openorcleanfiltervalve.
Waterpressuretoolow. Raisewaterpressure (range 1 to 10 bar)
Inletvalvedoesnotopen,filtersieve in Inlet valve blocked or inlet valve faulty.
Inspect electrical connections and fuseF2onsupplymodule.CleanfiltersieveorreplaceInletvalve.
Feed hoses inside the steam hu-midifiernotconnectedorkinked.
Inspect hoses inside unit and connect if necessary. Replace faulty hoses.
Level unit not connected. Connectlevelunit.
Float in the level unit sticking or level unit faulty.
Cleanorreplacelevelunit.
4x 4x Individual heating elements faulty. Replace faulty heating elements.
Max.vaporizationtime exceeded
Fuses F2 and/or F4 on the control board faulty.
Replace fuses on control board.
Mainsvoltagetoolow. Checkmainsvoltageandcon-nections
Steam lead too long or not insu-lated.
Maintainmaximumleadlengths(max.2m),Insulatesteamlead.
This error may also occur upon a cold start.
None.
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Malfunction/Indication Cause Remedy
Warningyellow LED
flashes...
Errorred LED
flashes...
5x 5x Drainpumpnotconnectedorfaulty.
Connectorreplacedrainpump.
Max.flushingtimeexceeded
Drainhoseinunitkinkedorblocked.
Inspect drain hose in unit, replace if necessary.
Wateroutletblocked(externaldrain pipe or siphon blocked).
Cleanwateroutletleadandsiphon.
Hoses to level unit blocked. Cleanorreplacehoses.
––– 6xInvalid level (Error only)
Level unit faulty. Replace level unit.
Magneticfieldinvicinityoflevelunit.
Eliminatemagneticfield.
––– 7xSteam pressu-re supervision
(Error only)
Steam hose blocked or restricted (watertrap).
Checksteamhose,cleanifnecessary and /or improve steam hose installation.
Back pressure in steam hose too high because of a too long steam hose.
Reduce length of steam hose.
––– 8xSafety level switchinbasetub has trig-
gered
Water accumulation in base tub, safetylevelswitchhastriggered.
Removewaterfrombasetub,thenfindthecauseforthewaterleakage and eliminate leakage.
Safetylevelswitchdefective. Replacesafetylevelswitch.
8xMaintenance
indication
––– Maintenanceintervalexpired. Perform maintenance.
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7.3 Notes on fault elimination
DANGER!
Inorder toeliminate faults, thesteamhumidifiermust be switched off and secured against unintentional reconnection as described in chapter 5.5. Take care that the electricity supply to themaincontactorisdisconnected(checkwithvoltagetester).
Onlyallowtrainedandqualifiedpersonneltorepairfaults.Faultsrelatingtoelectricalinstallation(e.g.changeofunitfuse)mustonlybecarriedoutbyauthorizedpersonneloryourCondairrepresentative’sservice technician.
Repair work and replacement of faulty components must only be carried out by your Condairrepresentative’sservicetechnician!
7.4 Resetting error indication
Toresettheerrorindication(redLEDflashes):
Switchoffsteamhumidifierforapprox.5secondsandthenswitchonagain.
Note:Ifthefaulthasnotbeeneliminatedtheerrorindicationappearsagainafterashorttime.
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8 Taking out of service/Disposal
8.1 Taking out of service
IftheCondairCSmustbereplacedorifthehumidificationsystemisnotneededanymore,proceedasfollows:
1. Take the unit out of operation as described in chapter 5.5.
2. Havetheunit(andallothersystemcomponents,ifnecessary)unmountedbyaqualifiedservicetechnician.
8.2 Disposal/Recycling
At the end of the service life the unit and its components must be returned to the manufacturer or to a collecting point for disposal or recycling according to the local regulations.
IncaseofdoubtpleasecontactyourlocaladministrationoryourCondairsupplier.
54
9 Productspecifications
Condair CS 2.0 Condair CS 4.0
Max.Steamcapacity 2 kg/h 4 kg/h
Nominalpowerconsumption 1.5 kW 3.0 kW
Nominal current 6.5 A 13.0 A
Unit voltage AC230V50Hz
Control viaanexternalOn/Offhumidistator anexternalcontinuoushumiditycontroller0...10V
Admissible ambient temperature 1...40°C
Admissible ambient humidity 1...75%rh
Steam connection 30 mm (outside diameter of connector)
Max.backpressureatsteamconnection 300 Pa
Water supply–Connection–Admissiblewaterpressure–Admissiblewatertemperature– Water quality
Outside thread R 3/4"1 ... 10 bar1...40°C
fullydemineralisedwaterwithmax.20µS/cm
Water drain–Connection–Draintemperature
Drainsleevewithinnerdiameter40mmmax.90°C
Weights–Transportweight–Netweight–Operationweight
13 kg11.5 kg17 kg
Dimensions(HxWxD) 350x250x361mm
Conformity CE,VDE,GS
Protection class IP21
9.1 Technical data
55
9.2 Unit dimensions
ø 30
138
115
361
350
18
250
74
49
18
22 2021
1515
1515
59 303
26
25
157
60
40
R 3/4"
Dimensionsinmm
Notes
Notes
Notes
© Condair Ltd., Printed in SwitzerlandTechnical modifications reserved
CONSULTING, SALES AND SERVICE:
Manufacturer:Condair Ltd.Talstrasse 35-37, 8808 Pfäffikon, SwitzerlandPh. +41 55 416 61 11, Fax +41 55 416 62 [email protected], www.condair.com
Reg.No. 40002-2
