Condair ME series Operation Manual
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Condair ME series Operation Manual

Air humidification and cooling system
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READ AND SAVE THESE INSTRUCTIONS
OPERATION MANUAL
Adiabatic air humidification/air cooling system
Condair ME Control
Humidification and Evaporative Cooling

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  • Page 1 READ AND SAVE THESE INSTRUCTIONS OPERATION MANUAL Adiabatic air humidification/air cooling system Condair ME Control Humidification and Evaporative Cooling...
  • Page 2 Condair Plc, except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Plc does not accept any liability due to incorrect installation or operation of the equipment or due to the use of parts/components/equipment that are not authorized by Condair Plc.

  • Page 3: Table Of Contents

    3.3.1 Construction of the evaporative module 3.3.2 Construction of the hydraulic module System overviews / Functional description 3.4.1 Typical system Condair ME Control (internally mounted) 3.4.2 Typical system Condair ME Control (externally mounted) Operation Important notes on operation Initial commissioning...
  • Page 4 Health and safety requirements Routine water sampling and testing Cleaning and disinfection Cleaning and disinfection method statement 6.10 Resetting the maintenance indication on Condair ME Control 6.11 Performing software and firmware updates Fault elimination Fault indication on Condair ME Control control unit...

  • Page 5: Introduction

    The Condair ME Control incorporates the latest technical ad van ces and meets all recognized safety standards. Nevertheless, improper use of the Condair ME Control may result in danger to the user or third parties and/or impairment of material assets.
  • Page 6 If the operation manual gets mislaid, please contact your Condair representative. Language versions This operation manual is available in various languages. Please contact your Condair representative for information. Introduction...

  • Page 7: For Your Safety

    For safety and warranty reasons any action beyond the scope of this manual must be carried out only by qualified personnel authorised by the manufacturer. It is assumed that all persons working with the Condair ME Control are familiar and comply with the appropriate local regulations on work safety and the prevention of accidents.
  • Page 8 When inadequately operated and/or poorly maintained micro-organisms (including the bacterium which causes Legionnaire’s disease) may grow in the evaporative module, the water tank and the water system of the Condair ME Control and may affect the air in the AHU/air duct.
  • Page 9 Preventing unsafe operation If it is suspected that safe and hygienic operation is no longer possible, then the Condair ME Control should immediately be shut down and secured against accidental power-up according to chapter 4.6 – Decommissioning the system. This can be the case under the following circumstances: –...

  • Page 10: Product Overview

    – Hydraulic module (mounted internal or external to the duct) – Control unit with integrated controller with touch panel According to your order the Condair ME Control can be equipped with the following options: – Droplet separator – Evaporative module blanking –...

  • Page 11: Product Designation / Which Model Do You Have

    Product designation / Which model do you have The product designation and the most important unit data (e.g. serial number, evaporative module product key, etc.) are found on the rating plates fixed on the left side of the evaporative module and on the right side of the control unit.

  • Page 12: Construction Of The System Components

    Construction of the system components 3.3.1 Construction of the evaporative module air flow direction Upstands Evaporative cassettes (F75, F85, F95, P85 or P95) Tank connector Tank connector ø50 mm, ø54 mm Distribution heads or 2" as applicable Blanking plates (option) Rating plate Mounting frame for evaporative cassettes Droplet separator, mandatory for face velocity >3.5...

  • Page 13: Construction Of The Hydraulic Module

    3.3.2 Construction of the hydraulic module Drain valve (normally open) Conductivity sensor (option) Drain pump 10 Fixing bracket Stage pump 5 with push-fit connector ø15 mm, 11 Push-fit connector ø15 mm, ø16 mm or 0.625" as ø16 mm or 0.625" as applicable applicable pressure equalisation (only used when Stage pump 3 with push-fit connector ø15 mm, mounted outside of AHU)

  • Page 14: System Overviews / Functional Description

    Wall feed through pump and stage pumps) Water supply line Vent drain pipe Air flow direction Inter connecting cable hydraulic module Tank drain with trap AHU drain with trap Fig. 4: Typical system Condair ME Control (internally mounted) Product Overview...

  • Page 15: Typical System Condair Me Control (Externally Mounted)

    Hydraulic module (with sup- Air flow direction ply valve, drain valve, drain pump and stage pumps) Vent drain pipe Tank drain with trap AHU drain with trap Fig. 5: Typical system Condair ME Control (externally mounted, side drain tank) Product Overview...
  • Page 16 Stage pumps 2... max. 5 sensor pump Gravity solenoid drain valve (NO) Drain trap (building side) Tundish (building side) Fig. 6: Schematic flow diagram Condair ME Control (internally mounted) Hydraulic module Shut-off valve with Inlet solenoid Pressure strainer) valve (NC) equalisation...
  • Page 17 Functional description The water tank is filled up to a preset upper level via the level-controlled inlet solenoid valve (NC). When the water level in the water tank drops below a certain limit, the level-controlled inlet solenoid valve opens until the upper limit is reached again. The Nortec ME Control provides On/Off or stage control by means of the Nortec ME Control control unit and the stage pumps.

  • Page 18: Operation

    Important notes on operation Qualification of personnel The Condair ME Control must be commissioned and op erated only by personnel familiar with the sys- tem and adequately qualified for the respective tasks. It is the owner’s responsibility to verify proper qualification of the operating personnel.

  • Page 19: Initial Commissioning

    If you are unsure of the quality of your water please consult your Condair distributor for advice.
  • Page 20 13. From full saturation – time drain cycle (with fan in design condition). 14. Test control devices. 15. Correctly configure Condair ME control unit (setpoints, control settings, etc.) according to the situa- tion on site (see chapter 5.4 –...

  • Page 21: Display And Operating Elements

    If the control unit is switched off all func- tions (including hygiene functions) of the Condair ME Control are deactivated. Fig. 8: Display and operating elements Condair ME Control DANGER! Risk of electric shock! There is still mains voltage inside the control unit even when you switch off the <Control unit On/ Off>...

  • Page 22: Start Up For Daily Operation

    It is assumed that initial commissioning has been carried out properly by the service technician of your Condair representative. If the Condair ME Control has been out of operation for a prolonged period of time, a complete system service has to be performed prior to the start up.

  • Page 23: Notes On Operation

    Demand present/system is humidifying/cooling “Unit on” The humidification system is switched on and under voltage 4.5.3 Recommended regular checks during operation During operation the Condair ME Control has to be checked periodically in accordance with the table below. Operations Checks Daily Weekly...

  • Page 24: Manual Draining Of The Water Tank

    Water level is correct (ensure unit Is not in drain cycle)  If the checks reveal any irregularities (e.g. leakage, error indication) or any damaged components take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system.

  • Page 25: Performing A Matrix Wash Over

    Password: 8808 Condair ME Control is in normal operation mode. 1. Select the “Service” submenu (displays 1-3) 2. Select “Matrix Wash Over” function in the “Service” submenu. The matrix wash over confirmation dialogue appears.

  • Page 26: Decommissioning The System

    For reasons of hygiene, we recommend that the control unit should be left powered on even if the Condair ME Control is not being used for a longer period of time. To prevent the Condair ME from humidifying/cooling set the "Operation" function in the service menu to "Off". This keeps the hygiene functions (e.g.

  • Page 27: Operating The Condair Me Control Software

    Operating the Condair ME control software Standard operating display After switching on the control unit and the automatic system test the control unit is in normal operating mode and the standard operating display is shown. Note: the appearance of the standard operating display depends on the current operating status and the configuration of the humidity/temperature regulation of the system and can deviate from the display shown below.

  • Page 28: Operating Status Indication

    After the demand has dropped to zero, the system drains a small amount of water to give space to the rest water held in the matrix. The Condair ME Control is draining the tank and uses the first section of the drain procedure to check whether the drain valve is working properly.

  • Page 29: Maintenance And Malfunction Indications

    A malfunction with status “Fault” is active. Additionally the red LED lights. Depending on the malfunction the humidification system is either be stopped or stays operable for a certain period of time. Operating the Condair ME control software...

  • Page 30: Navigating/Operating The Condair Me Control Software

    Navigating/operating the Condair ME control software Navigation element Action Accessing main menu Accessing system information Performing manual drain Accessing Help screen If you press on a field with a blue arrow symbol a new screen with additional information or settings appears.

  • Page 31: Information Functions

    Operating Tab – Actual Stage: Actual number of currently operating stages of the system. – Max Stage: Number of maximum stages set to operate. Max. Capacity: Maximum evaporating capacity in kg/h or lb/hr. – Operating the Condair ME control software...
  • Page 32 Drain Interval: Actual set tank drain interval time. – Dilution mode set to “Dilution Interval”: – Dilution Interval: Actual set dilution interval time, for periodic dilution of the water in the tank. – Drain Interval: Actual set tank drain interval time. Operating the Condair ME control software...
  • Page 33 BACnet Parameters Tab on page 44 for more details. BACnet IP Network – Node ID: shows the actual BACnet node ID for the Condair ME Control. Note: This field appears only if "BACnet IP" is enabled. Refer to BACnet Parameters Tab on page 44 for more details.
  • Page 34 General Tab Within the "General" tab various unit data is shown. Additionally you can access a graphical display of the Condair ME Control performance data, and you can save the performance data to a USB memory stick as a .csv file.

  • Page 35: Configuration

    The process of evaporative humidification/cooling leads to a build up of dissolved solids in the water tank. To control the degree of dissolved solids in the tank, the Condair ME Control will trigger a dilution cycle according to the set fill cycles, interval time, water temperature or conductivity limit. During the Dilution Cycle the Condair ME Control will open the gravity drain solenoid valve until a certain level is reached to drain dissolved solids away and replenish the tank with fresh water.
  • Page 36 0...50 °C (32... 122 °F) – Dilution Interval: set the desired interval time in minutes. A dilution cycle is triggered as soon as the interval time has elapsed. Factory setting: 60 minutes Setting range: 1...2160 minutes Operating the Condair ME control software...
  • Page 37 1...24 hours – Drain Time: set the desired time of day time (according to set time format) at which a drain cycle is triggered. Factory setting: 12:00 am Setting range: according to set time format Operating the Condair ME control software...

  • Page 38: Control Settings - "Control Settings" Submenu

    5.4.3 Control settings – “Control Settings” submenu In the “Control Settings” submenu you determine the control settings for the Condair ME Control. The control settings available depend on the selected signal source and the control mode. Basic Tab – Source: with this setting you determine whether the control signal comes...
  • Page 39 2 (if “System Mode” is set to “Cooling”) in minutes. Note: this setting appears only if the “Control Mode” is set to “RH PI”. Factory setting: 5 minutes Setting range: 1 ... 60 minutes Operating the Condair ME control software...
  • Page 40 – Limit: with this setting you set the limit of the relative humidity below which the Condair ME Control displays the "Demand Sensor" fault. Note: this setting appears only if "System Mode" is set to "Cooling" and "Control Mode" is set to "RH P" or "RH PI".

  • Page 41: Basic Settings - "General" Submenu

    5.4.4 Basic settings – “General” submenu In the “General” submenu you determine the basic settings for operating the Condair ME Control control unit. Basic Tab – Date: With this setting you determine the current date in the set format (”MM/DD/YYYY” or “DD/MM/YYYY”). Factory setting: 00/00/0000 –...

  • Page 42: Communication Settings - "Communication" Submenu

    Network Parameters Tab The following network settings are used for the communication via the inte- grated interface of the integrated controller of the Condair ME Control. – IP Type: with this setting you determine whether you want to assign the IP...
  • Page 43 – Modbus: with this setting you can activate ("On") or deactivate ("Off") communication via a Modbus network. Note: in order to activate the setting of this parameter the Condair ME Control must be switched off and on again. Factory setting:...
  • Page 44 – Device Location: with this setting you determine the designation of the unit location. – Node ID: with this setting you assign a node ID to the Condair ME Control for communications over the BACnet/IP protocol. Factory setting: 1001 Setting range: 1-9999999 –...
  • Page 45 – Device Location: with this setting you determine the designation of the unit location. – Node ID: with this setting you assign a node ID to the Condair ME Control for communications over the BACnet/MSTP/IP protocol. Factory setting: 1001 Setting range: 1-9999999 –...

  • Page 46: Service Functions

    After pressing on the “Activation Code” button a confirmation window ap- pears where you have to confirm the activation. Afterwards you can enter the four-digit activation code and confirm it. Note: contact your Condair representative to get the activation code. Operating the Condair ME control software...
  • Page 47 – Operation: with this function you can turn on or off the Condair ME Control humidification or cooling operation. The System remains energized and all hygiene functions will still be carried out. Factory Setting: Setting Range: On or Off Commissioning Reset: with this function you can reset the “Out of –...
  • Page 48 Detailed information on the individual relay diagnostic functions can be found in chapter 5.5.2.2 – Relay diagnostic functions – “Relay Diagnostics” submenu. Note: By accessing the “Relay Diagnostics” submenu the humidification system is automatically switched to standby operation. Operating the Condair ME control software...

  • Page 49: 5.5.2.1 Input Diagnostic Functions - "Input Diagnostics" Submenu

    – Dosing Pump Level Float: Actual level (“Empty”= Tank is empty or “OK”=Level in the tank is OK) in the liquid tank of the optional system for enhancing polyester media water absorption. Operating the Condair ME control software...
  • Page 50 Note: only Condair ME XL systems have pump 6. – Speed Pump 7: Actual speed of stage pump 7 in % of the maximum speed. Note: only Condair ME XL systems may have pump 7. Operating the Condair ME control software...

  • Page 51: 5.5.2.2 Relay Diagnostic Functions - "Relay Diagnostics" Submenu

    Note: only Condair ME XL systems have pump 6. – Stage Pump 7: Actual flow rate of stage pump 7 in kg/h or lb/hr. Note: only Condair ME XL systems may have pump 7. 5.5.2.2 Relay diagnostic functions – “Relay Diagnostics” submenu The following diagnostic functions are available after accessing the “Relay Diagnostics” submenu.

  • Page 52: Administration Settings

    (“Yes”) or not (“No”). Main Menu Password: with the function “Main Menu Password” you – can protect the access to the main menu with the user password “8808” against unauthorised access (“Yes”) or not (“No”). Operating the Condair ME control software...
  • Page 53 Load Logger Definition: this function allows logging of system parameters with a FAT32 formatted USB memory stick connected to the USB port on the control board. A factory supplied access file is required to enable operation. Operating the Condair ME control software...

  • Page 54: Maintenance

    The instructions and details for maintenance work must be followed and upheld. Only carry out the maintenance work described in this documentation. The Condair ME Control must be maintained in the prescribed intervals, the cleaning work must be carried out correctly.

  • Page 55: Maintenance Intervals

    Maintenance guide The Condair ME unit will form part or your hot and cold water system and as such require you to un- dertake certain duties with regards to local regulations and bylaws concerning the control of Legionella microbes in water systems.
  • Page 56 Operations Minor Complete Service System Service Clean front section of tank Clean internal of hydraulic module (use soft cloth only) Check operation of level float and conductivity sensor (if applic able) Clean level float and conductivity sensor ––– Check droplet separator (if applicable) and evaporator cassettes in suit- able condition Lightly brush evaporator cassettes if necessary, replace if heavily soiled –––...

  • Page 57: Dismantling And Installation Of Components For Maintenance

    Dismantling and installation of components for maintenance 6.4.1 Dismantling and installation of the evaporative module 1. Take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system and allow to drain and dry. 2. Switch the AHU off, and isolate the power and water supply to the AHU.

  • Page 58: Health And Safety Requirements

    This work should only be carried out by fully trained specialist organisations or individuals. 2. The control unit of the Condair ME Control must be left powered on to allow automatic flushing and cleaning cycles to occur. If the control unit Condair ME Control is powered off for prolonged periods, water stagnation might occur and contamination result, so the system, including any stor- age tanks or vessels should be drained and left dry.

  • Page 59: Routine Water Sampling And Testing

    4. Clean and disinfect the system in accordance with local regulations and bylaws, and the instructions in this manual. 5. The Condair ME Control system must be connected to a clean, wholesome mains water sup- ply and it is recommended that the supply water is chlorinated. It is the responsibility of the user to ensure that the water system complies with local regulations and bylaws, particularly those for the control of Legionella microbes.

  • Page 60: Cleaning And Disinfection

    Personal Protective Equipment are available to carry out disinfection. 1. Risk assess the situation. This should include but is not limited to observance of local regulations and the use of PPE, working from heights and ensuring a full understanding of the Condair ME Control.
  • Page 61 Recommended disinfection equipment – Disinfection solution in accordance with manufacturers guidelines. – Disinfection neutraliser (only if necessary). – Disinfection solution test kit (to measure strength). – Bucket of fresh water. – Cleaning equipment. – Mixing vessel / Measuring container. – Risk assessment / test record sheets.

  • Page 62: Cleaning And Disinfection Method Statement

    • Ensure the area is well ventilated. • Ensure the Condair ME system is OFF and isolated from external controls. • If the unit is already in operation there is low risks, check for correct operation before cleaning and dismantling.
  • Page 63 Add DISIFIN XL chemical to the tank. • Always leave work area clean, dry and tidy. Step 8 - Re-start the Condair ME system • Refer to the commissioning section of this manual. If in doubt always contact your Condair distributor.

  • Page 64: Resetting The Maintenance Indication On Condair Me Control

    6.10 Resetting the maintenance indication on Condair ME Control After completing maintenance work, the maintenance indication or the maintenance counter, respectively must be reset. Proceed as follows to reset the maintenance counter: 1. Select in the “Service” submenu the function “System Service Reset”...

  • Page 65: Performing Software And Firmware Updates

    6.11 Performing software and firmware updates To update the control software of the Condair ME Control or the firmware of one of its electronic boards, proceed as follows: 1. Set the <Control unit On/Off> switch on the right side of the control unit to the Off position, then switch off the voltage supply to the control unit via the external electrical isolator and secure switch in the Off position to prevent it from inadvertent power up.

  • Page 66: Fault Elimination

    LED below the touch panel will indicate an active fault on the Condair ME Control. If such a malfunction occurs, the operation of the system is limited only or the Condair ME Control will be stopped automatically.

  • Page 67: Malfunction List

    Contact your Condair representative. Safety Chain The Condair ME Control stopped operating as an external device opened the safety chain. E.g. ventilation Interlock, safety humidistat, etc.. Note: If – at any time – the safety chain is closed again, the system will continue with normal operation.
  • Page 68 Water Inlet Tank (re)fill timeout. The Condair ME Control stopped operation as the tank could not be (re)filled within a preset time. The Condair ME Control periodically tries to fill the tank. Note: If – at any time – the required water level is reached, the system will continue with normal operation.
  • Page 69 Sensor defective. Replace Sensor. ––– Water Temp Water supply temperature is too high, Condair ME Control changed to “Fill Cycle” mode dilution. The fault message must be reset after elimination of malfunction. Standing Water in inlet system. Check water supply system.
  • Page 70 Replace floater sensor. ––– Standing WTR Standing water outside the tank detected. The Condair ME Control stopped operat- ing as a leak of the tank or pipework has been detected. Water leakage on evaporative module or Check system and seal any leaky com- water piping inside the duct.
  • Page 71 ––– Local 24V Supply Local 24V supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Fuses on driver board defective. Check fuses on driver board and replace.
  • Page 72 Correctly connect drain pump. E131 Pump Error The controller was not able to activate one or more stage pumps. The Condair ME (Pump 1) Control will continue to attempt normal operation. The fault message must be reset after elimination of malfunction.

  • Page 73: Saving Fault And Service Histories To A Usb Memory Stick

    Saving fault and service histories to a USB memory stick The fault and service histories of the Condair ME Control can be saved to a USB memory stick for log- ging and further analysis. For this purpose proceed as follows: 1.

  • Page 74: Notes On Fault Elimination

    (ESD-protection) must be taken to prevent damage to electronic components. – Repair work and the replacement of faulty components must be carried out by your Condair repre- sentative’s service technician only! Resetting the fault status on Condair ME Control To reset the error indication: 1.

  • Page 75: Replacing The Fuses And Backup Battery In The Control Unit

    Replacing the fuses and backup battery in the control unit The fuses of the control unit must be replaced by authorized personnel only (e.g. electrician). Replace fuses of the control unit only with fuses matching the specifications below with the appropriate nominal current capacity. Never use refurbished fuses. Do not bridge the fuse holder. To replace the fuses or the backup battery proceed as follows: 1.

  • Page 76: Taking Out Of Service/Disposal

    Taking out of service/Disposal Taking out of service If the Condair ME Control must be replaced or if the humidification system is not needed any more, proceed as follows: 1. Take the Condair ME Control out of operation as described in chapter 4.6 –...

  • Page 77: Product Specifications

    Product specifications Technical data Condair ME Control Supply voltage control unit 100...240 VAC/50...60 Hz Supply voltage circulation pumps 24 Vdc (supplied by control unit) Power consumption < 278 W (5 stages, no options fitted) Control signals 0...5 VDC 1...5 VDC 0..10 VDC 2...10 VDC...

  • Page 78: Appendix

    Appendix 10.1 Wiring diagram Condair ME Control Appendix...
  • Page 80 CONSULTING, SALES AND SERVICE: Condair Plc Artex Avenue, Rustington, Littlehampton, West Sussex. BN16 3LN (UK) TEL: +44(0)1903 850 200 FAX: +44(0)1903 850 345 www.condair.co.uk...

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