Condair EL Operation Manual
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Condair EL Operation Manual

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OPERATION MANUAL
Steam humidifier
Condair EL
Humidification and Evaporative Cooling

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  • Page 1 OPERATION MANUAL Steam humidifier Condair EL Humidification and Evaporative Cooling...
  • Page 2 Condair Group AG, except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Group AG 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 Group AG. Copyright Notice Copyright 2016, Condair Ltd.

  • Page 3: Table Of Contents

    For your safety Product Overview Construction Condair EL steam humidifier Functional description System overview Condair EL for duct humidification System overview Condair EL for direct room humidification Operation First-time commissioning Display and operating elements Commissioning after an interruption of operation Notes on operation 4.4.1...
  • Page 4 Maintenance Important notes on maintenance Maintenance intervals Removing and installing components for maintenance 6.3.1 Removal and installation of the steam cylinder 6.3.2 Disassembly and assembly of the cleanable steam cylinder type D... 6.3.3 Removal and installation of the fill cup and the water hoses 6.3.4 Removal and installation of the drain pump 6.3.5...

  • Page 5: Introduction

    To the very beginning We thank you for having purchased the Condair EL steam humidifier. The Condair EL steam humidifier incorporates the latest technical ad van ces and meets all recognized safety standards. Nevertheless, improper use of the Condair EL steam humidifier may result in danger to the user or third parties and/or impairment of material assets.
  • Page 6 If the documentation gets misplaced, 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

    Condair EL safely and correctly. All icons, signs and markings applied to the components of the Condair EL must be observed and kept in readable state.
  • Page 8 Condair EL is no longer operating correctly – if connections and/or piping are not sealed All persons working with the Condair EL must report any alterations to the unit that may affect safety to the owner without delay. Prohibited modifications to the unit No modifications must be undertaken on the Condair EL without the express written consent of Condair.

  • Page 9: Product Overview

    21 Rating plate 10 Condensate connector (to cylinder) 22 Driver board 11 Condensate connector (to drain) 23 Terminal heating voltage supply (option) 12 Steam outlet 24 Main contactor Fig. 1: Construction Condair EL steam humidifier (figure shows medium sized unit) Product Overview...

  • Page 10: Functional Description

    Functional description The Condair EL steam humidifier is an atmospheric steam generator. It operates on the electrode heating principle and is designed for direct room air humidification (with blower pack) and indirect humidification (with steam distributor) in venti lating and air-conditioning systems.

  • Page 11: System Overview Condair El For Duct Humidification

    7 Manometer (recommended) 16 Humidity controller or humidity sensor 8 Open funnel with water trap 17 Humidity controller or humidity sensor 9 Drain hose (supplied) 18 High limit humidistat Fig. 2: System overview Condair EL for duct humidification Product Overview...

  • Page 12: System Overview Condair El For Direct Room Humidification

    6 Filter valve (accessory Z261) 14 Blower Pack (accessory BP) 7 Manometer (recommended) 15 Humidity controller or humidity sensor 8 Open funnel with water trap (building side) 16 High limit humidistat Fig. 3: System overview Condair EL for direct room humidification Product Overview...

  • Page 13: Operation

    Operation The Condair EL steam humidifier may be commissioned and operated only by persons familiar with the Condair EL steam humidifier and adequately qualified. It is the owner’s responsibility to verify proper qualification of the personnel. First-time commissioning The first-time commissioning must always be done by a service technician of your Condair representative or a well trained and authorised person of the customer.

  • Page 14: Commissioning After An Interruption Of Operation

    When the heat is sufficient, steam will be produced. Note: If the Condair EL is operated with water of low conductivity, it may happen that the requested steam capacity is not reached in the first few hours of operation. This is normal. As soon as the conductivity has reached a sufficient level (due to the vaporisation process) the humidifier will reach the requested steam capacity.

  • Page 15: Notes On Operation

    Notes on operation 4.4.1 Inspections during operation During operation the Condair EL and the humidification system have to be inspected weekly. On this occasion check the following: • the water and steam installation for any leakage. • the steam humidifier and the other system components for correct fixing and any damage.

  • Page 16: Draining Of The Steam Cylinder(S)

    Note: in order to stop the drain cycle press the <Cancel> button in the draining progress window. The drain cycle is stopped and the unit returns to the "Drain Tank/Cylinder" submenu. 4. If you have to carry out work on the Condair EL, switch off steam humidifier via the unit switch immediately after the countdown. Otherwise the steam cylinder may immediately fill if there is sufficient system demand.

  • Page 17: Taking The Unit Out Of Operation

    Taking the unit out of operation In order to take the Condair EL steam humidifier out of operation (e.g. for maintenance purpose), perform the following steps: 1. If the unit has to be switched off because of a malfunction, please note the fault code of the actual fault message shown.

  • Page 18: Operating The Control Software

    Operating the control software Standard operating display After switching on the Condair EL and the automatic system test the steam humidifier is in normal op- erating 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 control of the system and can deviate from the display shown below.

  • Page 19: Operating Status Indication

    "Service" submenu. A malfunction with status "Warning" is active. In addition, the humidifier's yellow warning LED light will be active. Depending upon the malfunction, the Condair EL is either be stopped or stays operable for a certain period of time.

  • Page 20: Navigating/Operating The Control Software

    Navigating/Operating the control software Navigation element Action Accessing main menu Accessing system informations Performing manual steam cylinder draining Accessing help screen If you press on a field with a blue arrow symbol a new screen with additional informations or settings appears. This symbol on the left side of the operating status field and of the mainte- nance/malfunctions indication field indicates, that the system is working ok.

  • Page 21: Information Functions

    Information functions 5.3.1 Accessing support informations In the standard operating display press the <Help> button. The screen with the support information appears. 5.3.2 Accessing system informations In the standard operating display press the <About> button. The system information screen appears. Use the arrow buttons to scroll up and down within the system information screens to access the different system information and operating data.
  • Page 22 Serial Number: Serial number of the steam humidifier. – Graph: With this function you can access the graphical display of the performance diagram of the Condair EL. – Export Trend Data: With this function you can save the data of the per- formance diagram as .csv file to a USB memory stick (FAT32 formatted).
  • Page 23 Operating Cylinder A Tab – Output: Actual steam output of steam cylinder A in kg/h or lb/h. – Current Sensor: Actual heating current of cylinder A in amperes. – Control Mode CH 1/3: Actual set humidity control type ("On/Off", "De- mand", "RH P"...
  • Page 24 Operating Cylinder B Tab Note: the tab "Operating Cylinder B" appears only on double units and large units with two steam cylinders. – Output: Actual steam output of steam cylinder B in kg/h or lb/h. – Current Sensor: Actual heating current of cylinder B in amperes. –...
  • Page 25 Note: This menu item appears only if the Modbus communication protocol is enabled, and the BACnet communication protocol is disabled. – Online Status: shows the connection status of the Condair EL to Condair Online("Connected" or "Disconnect'd"). – IP Address: shows the IP address of the Condair EL.

  • Page 26: Configuration

    Password: 8808 5.4.2 Determining unit settings – "Features menu" submenu In the "Features menu" submenu you can determine different operating parameters of the Condair EL. Water Management Tab – Drain Cool: with this function you can activate ("On") or deactivate ("Off") the optional drain cooling function.
  • Page 27 – Forced Drain Interval: with this setting you determine the period of time after which the forced cylinder draining takes place. Factory setting: 72 hours Setting range: 1 ... 100 hours – Dfactor: with this setting you can increase or decrease the drain time. Factory setting: Setting range: 0.0 ...
  • Page 28 Operation Tab – Manual Capacity A: with this button you can access the capacity limit settings menu. You can set the humidifier to operate with a fixed capacity limit or via the timer function with different capacity limits. Note: on large units with two steam cylinders and on double units the capacity limitation is valid for both steam cylinders (Module A and B).
  • Page 29 Configuration notes: – the settings of an event remain active up to the next event. – at least two events must be configured – the software does not check the plausibility of the timer settings. Therefore, make sure your settings make sense. –...
  • Page 30 On (the humidifier runs in short cycle mode) Off (the humidifier cycles normally) – Cyl. Type: with this setting you determine whether the Condair EL is equipped with a replaceable steam cylinder ("Disp.") or a cleanable steam cylinder ("Clean") .
  • Page 31 Accessory Board Tab Note: the "Accessory Board" tab with the corresponding settings appears only if the optional accessory board (for the control of an external fan of the ventilation system or the optional valve for flushing the water supply line) is installed. –...

  • Page 32: Humidity Control Settings - "Control Settings" Submenu

    Humidity control Settings – "Control Settings" submenu In the "Control Settings" submenu you determine the control settings for the Cond air EL steam humidi- fier. The control settings available depend on the selected signal source and the control mode as well as whether the steam humidifier is controlled with supply air limitation.
  • Page 33 – Setpoint Channel 1: with this button you can access the settings menu for the humidity setpoint. Here you determine whether the Condair EL is to be controlled with a fixed humidity setpoint (factory setting) or whether it is to be operated timer controlled with different humidity setpoints.
  • Page 34 – Operation with timer controlled capacity limitation Activate the timer function ("Setpoint Timers: On"). If the setpoint timer is activated, up to eight switching points (Event 1... Event 8) with different humidity setpoints can be defined. Each switching point is defined by a weekday or weekday range, the switching time and the humidity setpoint in %rh.
  • Page 35 – Band Channel 2: with this setting you set the proportional range for the internal P/PI supply air controller in %rh. Note: this setting appears only if "Control Mode CH 2/4" is set to "RH P" or "RH PI" and "Control Channels" is set to "Dual". Factory setting: 15 % Setting range:...
  • Page 36 RH Alerts Tab Note: The "RH Alerts" settings appear only if the internal P or PI controller is activated. – RH Alerts: with this setting you can enable ("On") or disable ("Off") the alert function that triggers a warning if sensed humidity is too high or too low.
  • Page 37 Multi Unit Operation Tab – Linkup: with this setting you determine whether the unit is part of a Linkup system and acts as "Main" or "Extension" unit or whether the unit is not part of a Linkup system. Note: the main unit must be set always to "Main". The further extension units in the chain must be set in ascending order to "Ext1"...
  • Page 38 – Sequence Interval: with this setting you determine the interval time the control system compares the operating hours of the cylinders in order to change the starting order if sequential cylinder rotation activated. Note: this setting appears only, if the "Sequence Rotation" function is activated ("On").

  • Page 39: Basic Settings - "General" Submenu

    5.4.4 Basic settings – "General" submenu In the "General" submenu you determine the basic settings for operating the Condair EL control software. Basic Tab – Date: with this setting you set the current date in the set format ("MM/DD/ YYYY" or "DD/MM/YYYY", see date and clock format settings below).

  • Page 40: Communication Settings - "Communication" Submenu

    Fixed (fixed assignment) – IP Address: with this setting you manually enter the IP Address of the Cond air EL. Note: This IP Address is used if "IP Type" is set (or reverts) to "Fixed". – Subnet Mask: with this setting you determine the Subnet Mask of the IP network.
  • Page 41 – 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 EL must be switched off and on again. Factory setting: Options: Off or On The following parameters appear only if the Modbus function is activated.
  • Page 42 – 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 EL for the communication via the BACnet/IP protocol. Factory setting: 1001 Setting range: 1-9999999 –...
  • Page 43 – 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 EL for the communication via the BACnet/MSTP/IP protocol. Factory setting: 1001 Setting range: 1-9999999 –...

  • Page 44: Maintenance Functions

    Maintenance functions 5.5.1 Accessing the "Service" submenu Password: 8808 5.5.2 Performing maintenance functions – "Service" submenu In the "Service" submenu you can reset the maintenance counters, access the fault and maintenance history and perform different diagnostic functions. General Service Tab –...
  • Page 45 Fault/Service History Tab Note: the fault and maintenance events stored can be correctly analysed only if the data and the time of day are correctly set. – Fault History: with this function you can access the fault history list where the last 40 fault events are stored.

  • Page 46: 5.5.2.1 Input Diagnostic Functions - "Input Diagnostics" Submenu

    5.5.2.1 Input diagnostic functions – "Input Diagnostics" submenu The following input values can be viewed after accessing the "Input Diagnostics" submenu. Note: the input values can be accessed and viewed too, via the "Service Info" selection field in the standard operating display. Cylinder A Tab (Cylinder B Tab) Note: the tabs of the input diagnostics for Cylinder B appear only on double units or large units with two steam cylinders.
  • Page 47 – Time Actual: this parameter shows the measured time in seconds for the current draw to decrease across predetermined thresholds during the last evaporation cycle. – Current Relative: this parameter shows the present percentage of cur- rent draw (amps) being observed for the cylinder relative to the current required to satisfy the demand.

  • Page 48: 5.5.2.2 Relay Diagnostic Functions - "Relay Diagnostics" Submenu

    5.5.2.2 Relay diagnostic functions – "Relay Diagnostics" submenu Remote Fault board Tab Note: when you leave this menu, the function of the relays will revert to automated operation. – Running: with this function you can activate ("On") and deactivate ("Off") the relay "Steam"...

  • Page 49: Administration Settings

    Administration settings 5.6.1 Accessing "Administrator" submenu Password: 8808 5.6.2 Switching on/off password protection and software updates function - submenu "Administrator" In the "Administrator" submenu you can activate and deactivate the password protection for the main menu and the setpoint, and download software updates via a USB stick connected to the USB connector. Password settings Tab –...
  • Page 50 Software Update Tab – Software Update: with this function you can update the control software of the integrated controller. See information in chapter 6.7. – Driver Board A.DB.A: with this function you can update the driver board software of steam humidifier A. See information in chapter 6.7.

  • Page 51: Maintenance

    Prevention: Before carrying out any work on the steam system set the Condair EL out of operation as described in 4.5, then wait until the components have cooled down sufficiently (see temperature...

  • Page 52: Maintenance Intervals

    Replacement of the disposable steam cylinder/Cleaning of the cleanable steam cylinder The control software of the Condair EL monitors the performance of the steam cylinder and indicates when replacement/cleaning of the steam cylinder is required. The steam cylinder status is set to initial state at the initial commissioning and any time the steam cylinder is reset via the cylinder reset function the "Service"...

  • Page 53: Removing And Installing Components For Maintenance

    Removing and installing components for maintenance 6.3.1 Removal and installation of the steam cylinder WARNING! Danger of burning! Before removal of the steam cylinder ensure the steam cylinder is empty and has cooled down, that no more burning danger exists. 1.
  • Page 54 CAUTION! Put steam cylinder down carefully to avoid damage to the lower connection piece! Installation of the steam cylinder Assembly of the steam cylinder takes place in reverse sequence of the removal. Please note the fol- lowing instructions: – For safety reasons the O-ring in the cylinder receptacle must be replaced by a new one. Before installing the steam cylinder, moisten the O-ring with water (do not use grease or oil).

  • Page 55: Disassembly And Assembly Of The Cleanable Steam Cylinder Type D

    6.3.2 Disassembly and assembly of the cleanable steam cylinder type D... 1. Pinch electrode snap fastenings and push electrodes approx. 2 cm downwards into the steam cyl- inder. 2. Release clamp clips of the cylinder cover and raise cover. 3. Remove carefully electrodes by lifting upwards. 4.

  • Page 56: Removal And Installation Of The Fill Cup And The Water Hoses

    Removal and installation of the fill cup and the water hoses 6.3.3 For removing the fill cup and the water hoses the steam cylinder must be removed first (see chapter 6.3.1). 1. Release hose clamps using pliers, then disconnect all hoses from the corresponding connectors and remove the hoses. Note: The hoses connected to the fill cup may also be removed together with the fill cup (see figure above) and then disconnected from the connectors of the fill cup outside the unit.

  • Page 57: Removal And Installation Of The Drain Pump

    6.3.4 Removal and installation of the drain pump For removing the drain pump the steam cylinder must be removed first (see chapter 6.3.1). 1. Detach electric cables (polarity of the cables need not be observed). 2. Release hose clamps and remove the hoses from the connectors. 3.

  • Page 58: Removal And Installation Of The Inlet Valve

    6.3.5 Removal and installation of the inlet valve For removing the inlet valve the steam cylinder must be removed (see chapter 6.3.1). 1. Detach electric cables (polarity of the cables need not be observed). Important: on multiple valves (units with option drain cooling) ensure to reconnect the connecting cables to same valve (note position).

  • Page 59: Removal And Installation Of The Steam Cylinder Receptacle

    6.3.6 Removal and installation of the steam cylinder receptacle For removing the steam cylinder receptacle the steam cylinder must be removed first (see chapter 6.3.1). 1. Release hose clamps and remove hoses from the connectors. 2. Undo the screw fixing the cylinder receptacle to the bottom of the housing with Phillips screwdriver. 3.

  • Page 60: Removal And Installation Of The Drain Cup

    6.3.7 Removal and installation of the drain cup For removing the drain cup the steam cylinder must be removed first (see chapter 6.3.1). 1. Release hose clamp and remove hose from the connector. 2. Release hose clamp of the external drain hose and remove hose. 3.

  • Page 61: Notes On Cleaning The Unit Components

    Notes on cleaning the unit components Unit component What to clean and how to clean • Knock off or brush away any limescale as much as Cleanable steam cylinder only: possible (do not use a wire brush). Steam cylinder cover If the parts are heavily calcified, place them in an 8% Steam cylinder body formic acid solution (observe safety notes in...
  • Page 62 Unit component What to clean and how to clean • Use a soft bristled brush (do not use a wire brush) to Inlet valve remove any limescale inside the inlet valve and on the strainer. • Rinse inlet valve and strainer insert with hot tap water. Let the inlet valve dry before reinstallation! Siebeinsatz •...

  • Page 63: Notes On Cleaning Agents

    Unit component What to clean and how to clean • Use a soft bristled brush (do not use a wire brush) to Drain cup remove any limescale from the drain cup and its con- nectors. If the drain cup is heavily calcified, place it in an 8% formic acid solution (observe safety notes in chapter 6.5), until the limescale comes off.

  • Page 64: Resetting The Cylinder Status

    Resetting the cylinder status CAUTION! DO NOT reset the cylinder status in the control software unless the steam cylinder has been replaced/cleaned. After the steam cylinder has been replaced/cleaned the cylinder status (for module A or module B or for both) must be reset.

  • Page 65: Performing Software And Firmware Updates

    The Condair EL is mains powered. Live parts may be exposed when the door panels of the steam humidifier are romoved. Touching live parts may cause severe injury or danger to life. Prevention: Before carrying out any work on the Condair EL switch off the unit, disconnect it from the mains and secure the unit against inadvertent power-up.
  • Page 66 10. Repeat steps 1 to 3, then carefully remove the USB memory stick. 11. Close control panel assembly, then close the door panel of the control compartment and lock it with the screw. 12. Repeat Step 6 and 7 to power up the humidifier. Maintenance...

  • Page 67: Fault Elimination

    LED below the touch panel will lights up. If such a malfunction occurs, the steam production of the Condair EL will be stopped automatically.

  • Page 68: Malfunction List

    External safety chain is open, humidification is stopped! Safety Loop Note: as soon as the safety chain is closed again the Condair EL continues to work normally. Ventilation interlock open. Check/switch on fan of the AHU.
  • Page 69 Code Message Information Warning Fault Possible causes Remedy Permissible filling time exceeded. Fill Timeout Water feed blocked, shut-off valve in Check water feed (filter, pipes, etc.), the water supply line closed, filter valve check/open shut-off valve, Check water closed or blocked). Water pressure pressure.
  • Page 70 Important: After replacement or clean- ing of the steam cylinder, reset the cylinder status (see chapter 6.6). Electrodes in steam cylinder spent. Condair EL has stopped operation. ––– Cylinder spent Electrodes spent, maximum operating Steam cylinder Type A: replace hours of the steam cylinder reached.
  • Page 71 RS4851 on the driver board not connected properly and J12 on the control board. Wrong version of driver board. Contact your Condair representative. The capacity limitation is currently controlled via Capacity Timer function. W125 ––– Capacity Timer The Capacity Timer is active and has No action is required.

  • Page 72: 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 EL can be saved to a USB memory stick for logging and further analysis. For this purpose proceed as follows: DANGER! Danger of electric hazard! The Condair EL is mains powered.

  • Page 73: Notes On Fault Elimination

    DANGER! Danger of electric hazard! Make sure the Condair EL is separated from the mains (check with voltage detector) and the shut- off valve in the water supply line is closed. – The elimination of faults must be carried out by qualified and well trained professionals only.

  • Page 74: Replacing The Fuses And Backup Battery In The Control Compartment

    Fig. 6: Position of the backup battery and the fuses on the driver board 5. Close control panel assembly. 6. Relocate front cover on control unit and lock it with the retaining screw. 7. Reconnect Condair EL to the mains by switching on the electrical isolator. Fault elimination...

  • Page 75: Taking Out Of Service/Disposal

    Taking out of service/Disposal Taking out of service If the Condair EL must be replaced or if the Condair EL is not needed any more, proceed as follows: 1. Take the Condair EL out of operation as described in chapter 4.5.

  • Page 76: Product Specification

    Product specification Performance data 200 V/1~/50...60Hz 230 V/1~/50...60Hz 240 V/1~/50...60Hz 200 V/3~/50...60Hz 230 V/3~/50...60Hz 400 V/3~/50...60Hz EL 5 19.0 16.3 16.3 10.9 3x 16 3x16 3x10 EL 8 30.0 10.0 26.1 26.1 17.3 3x 25 15.0 3x20 3x10 EL 10 –...
  • Page 77 415V/3~/50...60 Hz 440V/3~/50...60 Hz 460V/3~/50...60 Hz 480V/3~/50...60 Hz 500V/3~/50...60 Hz 600V/3~/50...60 Hz EL 5 3x10 EL 8 3x10 3x10 3x10 3x10 3x10 3x10 EL 10 10.4 3x16 3x16 3x16 3x16 3x10 3x10 EL 15 11.3 15.7 3x20 14.8 3x20 14.1 3 x 20 13.5...

  • Page 78: Operating Data

    Operating data Control steam output – active 0…5 VDC, 1…5 VDC, 0…10 VDC, 2…10 VDC, 0…20 VDC, 0…16 VDC, 3.2…16 VDC, 0…20 mADC, 4…20 mADC – passive all potentiometric humidity sensors from 140 Ω…10 kΩ – On/Off control <2.5 VDC --> Off; ≥2.5 VDC…20 VDC --> On Duct air pressure -0.8 kPa to 1.5 kPa;...
  • Page 80 CONSULTING, SALES AND SERVICE: Condair Group AG Talstrasse 35-37, CH-8808 Pfäffikon Phone +41 55 416 61 11, Fax +41 55 416 62 62 info@condair.com, www.condair.com...

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