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Condair HP Series Installation And Operation Manual

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Important: Read and save these instructions. This guide to be left with equipment owner.
HP Series
Installation and
Operation Manual
Includes installation, operation
maintenance and troubleshooting
information for your HP Series
humidifier
1507183-E| 17 JUN 2016

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  • Page 1 Important: Read and save these instructions. This guide to be left with equipment owner. HP Series Installation and Operation Manual Includes installation, operation maintenance and troubleshooting information for your HP Series humidifier 1507183-E| 17 JUN 2016...
  • Page 2 CYLINDER # Proprietary Notice This document and the information disclosed herein are proprietary data of Condair Ltd. Neither this document nor the information contained herein shall be reproduced, used, or disclosed to others without the written authorization of Condair Ltd., except to the extent required for installation or maintenance of recipient’s equipment.

  • Page 3: Table Of Contents

    Contents 2 Introduction 43 Startup, Operation, and Maintenance About HP Initial Commissioning and Startup Receiving and Unpacking Equipment HP High Pressure Atomizing Absorption Distances Humidifier Start-up Checklist Components Operation Multiple Zones Setting the Unit Into Daily Water Quality Operation 17 Installation Inspection During Operation Important Notes on Installation Shutting Down the Unit...
  • Page 4  Regardless of selecting on/off or modulating control method, Condair humidifiers must have a closed circuit across its on/off security loop control terminal to operate. Condair highly recommends the use of a duct high limit humidistat. 1 | HP Series Installation Manual...

  • Page 5: Introduction

    Introduction HP (Adiabatic Humidification System) Congratulations on the purchase of your Condair HP humidification system. This system was designed to be efficient and reliable, and is manufactured from high quality materials to provide long trouble free operation. In order for the system to operate as intended it must be installed properly.

  • Page 6: Receiving And Unpacking Equipment

    Receiving and Unpacking Equipment  Check packing slip to ensure ALL material has been delivered.  All material shortages are to be reported to Condair within 48 hours from receipt of goods. Condair assumes no responsibility for any material shortages beyond this period.
  • Page 7 3 High pressure piping between pump skid and manifolds 4 Flex hose 5 P-traps 6 Drain funnels 7 Wet duct section (drain pans, wall sections, sealants, fasteners) 8 Pump skid vibration dampening 9 Electricity, water, and airflow HP Series Installation Manual | 4...

  • Page 8: Multiple Zones

    Oftentimes a single pump package will be used to serve different ducts or zones. In this case each duct will have its own set of manifolds, valve controller and valve block making it fully 5 | HP Series Installation Manual...
  • Page 9 Figure 2: Typical Installation with Master/Slave Configuration All units must be located at the same elevation. The maximum length of high pressure piping from the pump station to the last Slave unit must not exceed 200 ft. HP Series Installation Manual | 6...

  • Page 10: Water Quality

    For this reason only Reverse Osmosis (RO) or De-Ionized (DI) water can be used with a Condair HP humidification system. DI water is very aggressive, in applications where DI water is used all components (including wet section of ducting and drains) must be constructed from stainless steel.
  • Page 11 Component Overview Pump Station Figure 3: HP Pump Station Figure 4: HP Flow Diagram HP Series Installation Manual | 8...
  • Page 12 Pump Station: The water-lubricated high pressure stainless steel pump is directly mounted to the electric motor and operates at a pressure of 435 to 1015 psi (30 - 70 bar). 9 | HP Series Installation Manual...
  • Page 13 The pump station is electrically wired at the factory. At the installation site, the power supply, the humidity controller or humidity sensor, the remote operating and fault indication (option), the external safety chain and the step valves must be electrically connected to the control unit. HP Series Installation Manual | 10...
  • Page 14 9 Water drain after nozzles 10 Open drain funnel (by others) 11 Mist Eliminator/Droplet Separator (option or by others) 12 Water drain after humidifier unit 13 P-Trap (by others, height adapted to duct pressure) 11 | HP Series Installation Manual...
  • Page 15 The installation of a mist eliminator is the customers responsibility. An optional Condair mist eliminator is available for the Condair HP. Note regarding the Condair mist eliminator: Due to the special surface finish of the mist eliminator material, the Condair mist eliminator will reach peak performance about 4-8 weeks after the initial installation (time depending on the water quality).
  • Page 16 Figure 6: HP System Layout, Stand Alone System 13 | HP Series Installation Manual...
  • Page 17 Figure 7: HP System Layout, Master/Slave System HP Series Installation Manual | 14...
  • Page 18 As standard, the HP features 7-Stage valve control as outlined in the figure below. An additional step valve is available as an option, and increases the total number of stages to 15. 15 | HP Series Installation Manual...
  • Page 19 In addition, the control unit of the pump station and the salve control units can be equipped with a remote operating and fault indication board. Thus the following operating conditions can be displayed over the appropriate relays: “Error”, “Humidification”, “Maintenance” and “Unit on”. HP Series Installation Manual | 16...

  • Page 20: Installation

    Installation 17 | HP Series Installation Manual...

  • Page 21: Important Notes On Installation

    (electrician or workman with equivalent training). Safety For all installation work, the ventilation system in which the Condair HP will be installed is to be rendered inoperative and prevented from further inadvertent operation. The pump station and possible Slave control units may be connected to electric mains only after all installation work has been completed.
  • Page 22 Hose feed through, 3 pc. for single walled duct’s  Special cable to step valves REG1, REG2, REG3  Alarm switch (NC)  Installation and operating instructions (the document you are currently reading)  Installation drawing with mounting dimensions  Tubing diagram 19 | HP Series Installation Manual...

  • Page 23: Pre-Installation

     Follow manufacturer’s instructions when installing fittings.  Recommended tube material: 304L stainless steel tube, ½” Outside Diameter, 0.049” Wall thickness  Recommended fittings: 316 stainless steel, ½”, double ferrule compression connections. HP Series Installation Manual | 20...
  • Page 24  A length (9.8 ft. / 3m) of high pressure hose is supplied with each unit for piping between the pump station and step valves. Additional hose can be purchased from Condair. Hoses provided by others are not  recommended.

  • Page 25: Construction Of A Wet Duct Section

    The section of ductwork that the HP manifolds are installed to be in needs to be capable of handling excess water that is not absorbed by the air. Condair requires that a wet section be installed in the duct. The wet section should be as long as expected wetting distance. In most cases Condair recommends the wet section extend 1.5 feet upstream and 6 feet downstream...

  • Page 26: Pump Module

     Do not install the pump station on vibrating surfaces or components. Running the pump on any voltage other than what is listed on the spec label can cause serious equipment damage and may ignite a fire. 23 | HP Series Installation Manual...
  • Page 27 Weight [lb] HP 100 (200 VFD) 19.7 26.0 51.2 110 – 143 HP 300 (500 VFD) 19.7 26.0 51.2 121 – 154 HP 500 (800VFD) 19.7 26.0 51.2 HP 800 (1300VFD) 19.7 26.0 51.2 HP Series Installation Manual | 24...

  • Page 28: Mounting The Pump Station

    The pump station must be placed in a location with an accessible floor drain to prevent flooding in case of a leak. Ensure that the pump station is mounted level using the four adjustable supports (see figure below) Figure 10: Front View – HP 100-300 Pump Station 25 | HP Series Installation Manual...

  • Page 29: Water Installation

    Figure 11: Water Connections Before connecting water lines, all water lines must be flushed with fully demineralized water for at least 10 min. Remove the sealing caps from the connections just before installing the hoses. HP Series Installation Manual | 26...
  • Page 30 The high pressure hose between the high pressure pump and high pressure manifold must not be installed before bleeding of the high pressure pump has been done. See page 42: Initial Commissioning and Start-Up 27 | HP Series Installation Manual...
  • Page 31  The wiring diagram can be found inside the control unit of electrical cabinet. Note: The Condair HP is equipped with a 3-Phase monitoring relay for detection of incorrect phase sequence, total and partial phase loss. Instructions can be found on a sticker inside the electrical cabinet.

  • Page 32: Hp Manifolds

     The minimum distance between the nozzle manifold and a heating element must not be less than 16 inches.  The duct velocity before the humidifier must be within 100 – 787 fpm. 29 | HP Series Installation Manual...
  • Page 33 Make sure that the fixing holes on the left and right of the duct ceiling are aligned. 2 Fix the top brackets to the ceiling of the duct with self-tapping screws or bolts provided. Figure 15: Top Bracket Installation HP Series Installation Manual | 30...
  • Page 34 Do not remove the film from the adhesive pad underneath the bottom bracket. 5 Bolt the two pipe fixtures together as shown in Fig. 17. Adjust the length such that the bottom bracket can slide up and down. Hand tighten. 31 | HP Series Installation Manual...
  • Page 35 Ensure that the pipe outlets are aligned horizontally in the direction of flow. Note: The clamps and rubber ferrules both comes in two different widths, the broad ones are used where two pipe fixture rods overlap (on taller units). HP Series Installation Manual | 32...
  • Page 36 Mounting the Step Valve Block Figure 20: Installation of Step Valve Block 1 Mount the step valve block outside of the duct near the nozzle manifolds using the self- tapping screws or bolts provided. 33 | HP Series Installation Manual...
  • Page 37 Maintain the following minimum bend radius: – for hoses DN6 = 4 in. (100 mm) – for hoses DN8 = 5 in. (130 mm) – for hoses DN10 = 7 in. (180 mm) Figure 21: Hose Connections HP Series Installation Manual | 34...

  • Page 38: Mist Eliminator

    Mounting the Condair HP Mist Eliminator General The Condair Mist Eliminator is a single bank water droplet removal system installed at a pre- defined distance from the water entry point. The highly humidified air is to come into contact with the Mist Eliminator and any un-absorbed droplets of water are removed from the air stream.
  • Page 39 Figure 24: Mounting Angles. Using field supplied self-taping screws attach the mounting angle to the duct via the round mounting holes. A screw every 18 inches is recommended. Figure 23: Drainage and Drains Figure 24: Mounting Angles HP Series Installation Manual | 36...
  • Page 40 If the duct height greater than 8 feet a channel extension is needed in order to link 2 mounting channels together. The extension slides inside the mounting channel. Use 4 ½ inch factory supplied screws for each mounting channel as shown in Figure 28: Mounting Channel Extension Kit. 37 | HP Series Installation Manual...
  • Page 41 Figure 25: Mounting Channel Location Figure 26: Large Duct Mounting Channel Locations Figure 28: Mounting Channel Extension Kit Figure 27: Mounting Channel Installation HP Series Installation Manual | 38...
  • Page 42 Be sure to install the wire mesh square when first fastened otherwise it will not align properly at the opposing end. Notch around screws previously installed for best results. Figure 30: Mesh Installation 39 | HP Series Installation Manual...
  • Page 43 Place the strips so the 1 inch screw/studs pass through the slotted holes on the media clamping strip then fasten a factory supplied nut to hold the assembly in place. See Figure 32: Clamping Strip Installation. Figure 32: Clamping Strip Installation HP Series Installation Manual | 40...

  • Page 44: Startup, Operation, And Maintenance

    Start-up, Operation, & Maintenance 41 | HP Series Installation Manual...

  • Page 45: Initial Commissioning And Startup

    Figure 33: Removing Filter Housing 2 Bleeding the filter. a. Remove the bleeding screw on top of the filter. b. Slowly open the water supply and fill the filter. c. Refit the bleeding screw. HP Series Installation Manual | 42...
  • Page 46 3 Remove the protective plug from the high-pressure hose (from the REG valve block) and put the open end of the hose to a drain. Fix the hose in this position so it cannot move. Figure 35: Protective Plug 43 | HP Series Installation Manual...
  • Page 47 They system is now ready for operation. As soon as a humidity demand is present, the supply valve will open and the HP pump will start. When the necessary pressure is reached, one, two, or all three step valves will open depending on the current humidity demand. HP Series Installation Manual | 44...

  • Page 48: Hp High Pressure Atomizing Humidifier Start-Up Checklist

     Are the step valve cables wired correctly?  Is the control signal wired correctly?  Is the external safety loop wired correctly (Master and Slaves) or is a jumper installed?  Is the power supply wired correctly and correctly fused? 45 | HP Series Installation Manual...
  • Page 49 Spray angle of the nozzles (Min. 50°, Optimal 70°)  Minimum distance from the first nozzle to the duct wall is correct (no droplet  formation on the duct wall)? Step 1/7  Step 2/7  HP Series Installation Manual | 46...
  • Page 50 No droplet carry over after at least 1 hour of full output (fan and humidifier)  Notes: _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ _________________________________________________________________________________ __________________________________________________________________________ Installed by:___________________________________________________________________ (Company Name and Business Address) Inspected by:__________________________________________________________________ (Company Name and Business Address) Signed: _____________________________ Date: _____________________________ 47 | HP Series Installation Manual...

  • Page 51: Operation

    Remember to enter any comma that may be needed. In case you make an incorrect entry, this can be deleted by means of the Backspace button. Once a new value has been entered, press Enter at the bottom right of the image using the numerical keyboard. HP Series Installation Manual | 48...
  • Page 52  High Pressure Too High – The pressure in the hoses is too high, (default >80 bar / 1160 psi) the system is stopped and must be restarted using the reset button. 49 | HP Series Installation Manual...
  • Page 53 Once an adequate level has been reached, the system will start automatically.  Pump Will Start Automatically After Delay – The pump has been set on pause, e.g. after disinfection. The pump will start automatically after the expiry of the set time. HP Series Installation Manual | 50...
  • Page 54 Register Mode 3 Valves – 7 Step 4 Valves – 15 Step 5 Valves – 31 Step RO Options No EC Monitoring EC Monitoring EC Monitoring + RV/CO2 EC Monitoring + MB + CO2 51 | HP Series Installation Manual...
  • Page 55 Setting of the clock and date. Once settings have been chosen, press F3. HP Series Installation Manual | 52...
  • Page 56 In case an alarm or message is triggered, a bar will appear across the screen showing the message. The menu page and alarm page can be reached via the buttons on the screen. 53 | HP Series Installation Manual...
  • Page 57 Please note that the alarm log will be reset after a power cut. Parameter Change Menu Menu for the pages where the different parameters can be changed. HP Series Installation Manual | 54...
  • Page 58 Reg.Up/Reg.Down – Indicates the regulation rate in seconds. Section parameters for sensor scaling: HIE – Highest electrical signal LOE – Lowest electrical signal HI – Reading at HIE LO – Reading at LOE 55 | HP Series Installation Manual...
  • Page 59 These values should be changed by Condair Technicians only. Settings for the High Pressure Guard These values should be changed by Condair Technicians only. Hour counter for the pump and for each section, which show the total running time. HP Series Installation Manual | 56...

  • Page 60: Setting The Unit Into Daily Operation

    Proceed as follows to set the Condair HP into operation: 1 Check all system components and installations for possible damage.

  • Page 61: Inspection During Operation

    9 Detailed information regarding the operation of the control unit and the settings can be found on pg. 48. Inspections During Operation During operation, the Condair HP and the humidification system have to be inspected weekly. On occasion, check the following: ...

  • Page 62: Shutting Down The Unit

    Shutting Down the Unit For hygienic reasons, it is highly recommended to leave the Condair HP on all the time, even in periods when no humidification is required. This ensures that the water circuit is flushed on a regular schedule thus preventing standing water within the system.

  • Page 63: Maintenance

    The instructions and details for maintenance work must be followed and complied with. Only the maintenance work described in this document may be carried out. Only the use of original Condair spare parts are permitted. Poorly maintained humidification systems may endanger health. Therefore it is mandatory to follow the specified maintenance intervals and to carry out maintenance work in strict accordance with the instructions.
  • Page 64 Maintenance Intervals In order ensure safe, hygienic and economic operation of the Condair HP, components must be periodically checked and maintained according to the table below. The maintenance intervals and maintenance work stated below are guidelines only. Depending on the system specific conditions (quality of the supply air, the water, etc.), the maintenance intervals may be reduced.
  • Page 65 Check mist eliminator (Condair and third-party products) for possible damage. Repair or replace defective components. Clean Condair mist eliminator. Un-mount the boxes and clean all components including the base frame inside the duct with a combined cleaning and disinfecting agent. Then rinse all components with water from the system and then dry components.

  • Page 66: Preventative Replacement Parts

    600m3 / Check Change Change Change 5600 E/XP (Change by 12 months 600m3) Service kit, 24 months Check Check Change Change Kinetico 30/2030 - 60/2060 Kinetico ion 48 months Check Check Check Check exchange substance 63 | HP Series Installation Manual...
  • Page 67 Check Check Change 230VAC 9A – Glow lamp for 24 months Check Check Change Change start/reset PAH Pump (Max 8000 hr.) Service kit PAH 2 8000 hr. / Check Check Overhaul Overha 24 months HP Series Installation Manual | 64...
  • Page 68 +/- 10% Check Check Check Check humidity sensor Filter for Sensor 48 months Check Check Check Check CC Converter, 4- Check Check Check Check 20mA Max Hygrostat +/- 10% Check Check Check Check Pressure Regulator 65 | HP Series Installation Manual...
  • Page 69 Use for Use for e 3% 1L service service service service service Water Sample BQ Water Use for Use for Use for Use for Use for analysis incl. service service service service service materials HP Series Installation Manual | 66...
  • Page 70 Maintenance Indications The Condair HP RO as fixed adjusted maintenance counters. See pg. 56 for menu access. Removal of Components Removal/Installation of Spray Nozzles 1 Put the system out of service (see section: Shutting Down the Unit) and secure it to prevent inadvertent start-up.

  • Page 71: Troubleshooting

    Troubleshooting HP Series Installation Manual | 68...
  • Page 72 Repair work on the high pressure pump may only be carried out by your Condair representative’s service technician. Safety – When eliminating faults, the Condair HP must be taken out of operation (see section: Shutting Down the Unit) and prevented from inadvertent operation.
  • Page 73 The pump will start automatically once the start level has been reached. 3 If the temperature exceeds 50°C (122°F), the pump will stop immediately and must be reactivated via the reset button once the temperature has dropped again. HP Series Installation Manual | 70...
  • Page 74 Relocate nozzles and/or connecting hoses as required. Condair HP runs continuously Nominal humidity value to high Reduce set-point humidity value. Ambient humidity very low No measures to be taken, just wait.

  • Page 75: Warranty

    Warranty Condair Inc. and/or Condair Ltd. (hereinafter collectively referred to as THE COMPANY), warrant for a period of two years after installation or 30 months from manufacturer’s ship date, whichever date is earlier, that THE COMPANY’s manufactured and assembled products, not otherwise expressly warranted, are free from defects in material and workmanship.
  • Page 76 U.S.A. 2700 90 Sturtevant, WI 53177 835 Commerce Park Dr. Ogdensburg, NY 13669-2209 CANADA 2740 Fenton Road Ottawa, Ontario K1T 3T7 TEL: 1.866.NORTEC1 EMAIL: na.info@condair.com WEBSITE: www.condair.com...

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