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Condair ME Series Installation Manual

Adiabatic air humidification/air cooling system
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READ AND SAVE THESE INSTRUCTIONS
INSTALLATION 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 INSTALLATION MANUAL Adiabatic air humidification/air cooling system Condair ME Control Humidification and Evaporative Cooling...
  • Page 2 Condair Ltd., except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Ltd. 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 Ltd.

  • Page 3: Table Of Contents

    Product designation / Which model do you have UL approved installation Installation Installation overviews 4.1.1 Typical installation Condair ME Control (internal installation) 4.1.2 Typical installation Condair ME Control (external installation) Mounting the evaporative module 4.2.1 Notes on positioning the evaporative module 4.2.2...

  • Page 4: Introduction

    Improper use of the Condair ME Control may result in danger to the user or third parties and/or impairment of material assets. If you have questions after reading this documentation, please contact your Condair representative.
  • Page 5 If the documentation gets mislaid, please contact your Condair representative. Language versions This installation manual is available in various languages. Please contact your Condair representative for information. Introduction...

  • Page 6: For Your Safety

    For safety and warranty reasons any action beyond the scope of this manual must only be carried out by personnel with appropriate industry recognized qualifications or training. 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 7 Preventing unsafe operation All persons working with the Condair ME Control are obliged to report any alterations to the unit that may affect safety to the owner without delay and to secure such systems against accidental power-up.

  • Page 8: Important Notes

    Check packing slip to ensure all parts has been delivered. All material shortages are to be reported to your Condair representative within 48 hours after receipt of the goods. Condair assumes no responsibility for any material shortages beyond this period.

  • Page 9: Product Designation / Which Model Do You Have

    Note: water quality should be considered when selecting an appropriate material (i.e. copper is not suitable for RO water). 3. The Condair ME Control unit contains a large reservoir of water when in operation. Install the ME unit where there is no risk of water damage, otherwise make provisions to contain any leakage.

  • Page 10: Installation

    2 - Mounting the hydraulic module --> see chapter 4.3 3 - Water installation --> see chapter 4.5 4 - Mounting the control unit --> see chapter 4.5.4 5 - Electrical installation --> see chapter 4.6 Fig. 1: Typical installation Condair ME Control (internal installation) Installation...

  • Page 11: Typical Installation Condair Me Control (External Installation)

    2 - Mounting the hydraulic module --> see chapter 4.3 3 - Water installation --> see chapter 4.5 4 - Mounting the control unit --> see chapter 4.5.4 5 - Electrical installation --> see chapter 4.6 Fig. 2: Typical installation Condair ME Control (external installation) Installation...

  • Page 12: Mounting The Evaporative Module

    Mounting the evaporative module 4.2.1 Notes on positioning the evaporative module The design and dimensioning of the AHU/air duct as well as the location of the evaporative module inside the duct are determined, recorded and set compulsory when planning the entire system. Prior to installation, however, make sure the following criteria have been taken into consideration: –...
  • Page 13 Air flow direction Recommended service access Recommended inspection access min. 600 mm / 24" 600 mm / 24" (min. 200 mm / 7.9" clearance) Dimension "a": ME Control (internal mounting): 272 mm / 10.7" ME Control (external mounting): 111 mm / 4.4" Dimension "b": F-Type fibre cassettes F75/F85/F95: 395 mm / 15.6"...
  • Page 14 Air flow direction Recommended service access Recommended inspection access min. 600 mm / 24" 600 mm / 24" (min. 200 mm / 7.9" clearance) Dimension "a": F-type fibre cassettes F75/F85/F95: 395 mm / 15.6" C-type fibre cassettes C85/C95: 525 mm / 20.7" Polyester cassettes P85/P95: 525 mm / 20.7"...

  • Page 15: Installation Procedure Evaporative Module

    4.2.2 Installation procedure evaporative module WARNING! A full risk assessment must be completed by suitably trained personnel prior to installing the ME unit. There may be increased risk when installing systems that necessitate working at height. The following risks should be considered (this list is not exhaustive, and there may be additional site specific risks that will need to be considered): –...
  • Page 16 1. Mounting the tank upstands to the tank: • Mounting the tank upstands supplied by Condair: fix tank upstands to the tank as shown in the figure below using the nuts (M8, AF: 13 mm) and washers supplied. Fig. 5: Mounting the tank upstands to the tank...
  • Page 17 2. Mounting the tank: • Insert the tank into the AHU/air duct. WARNING! Use an appropriate lifting device or handle the tank with the help of another person to posi- tion it inside the duct. It is the customer's responsibility to ensure that operators are trained in handling heavy goods and to enforce the relevant lifting regulations.
  • Page 18 3. Fix frame to the tank: • Fix the vertical supports to the tank using the nyloc nuts (M6, AF: 10 mm) and M6 washers. Then, align the vertical supports exactly vertical using a level and tighten the nuts. • Fix the cross member to the vertical supports using the nyloc nuts (M6, AF: 10 mm) and M6 washers.
  • Page 19 4. Fix cross member of frame to AHU/duct ceiling: • Fix the cross member to the AHU/duct ceiling using appropriate fixings (supplied as part of the installation kit). Before tightening the screws (not supplied) align the vertical supports exactly vertical using a level. WARNING! If the cross member is not secured to the AHU/duct ceiling there is a risk that the evaporative module could fall over, potentially causing injury or damage.
  • Page 20 5. Mount the blanking plates on the air inlet side (blanking plates available as option): • Starting on each duct side at the bottom fix the side blanking plates to the duct wall using ap- propriate fixings. Before fixing make sure the side blanking plates are aligned exactly vertical and the free end of the blanking plates touches the side of the corresponding vertical support.
  • Page 21 6. Mounting the crossbar: • This step must be carried out only on larger systems to prevent bending of the crossbar: Fix the supplied crossbar support(s) to the tank using the M6 cross-head bolt and the two stop nuts (M8, AF: 13 mm) according to the figure below. Fig.
  • Page 22 • Put the cross bar on the corresponding cross bar bracket with a distance of "A" to the vertical support (see table below). The cross bar should be positioned so that the evaporative cassettes sit on the edge of the cross bar, and the slots in the side of the cross bar should face the air-off side of the evaporative module as shown below.
  • Page 23 7. Mount optional submerged UV, if applicable: If your system is equipped with the submerged UV mount UV bulb assembly to the cross bar and the junction box to the tank in accordance with the separate manual for this option. 8.
  • Page 24 9. Mount evaporative cassettes: Note: to avoid damage to the evaporative cassettes during transit, we recommend that the evapora- tive cassettes are fitted on site. • Before installing the evaporative cassettes sweep the interior of the tank. • Starting with the tallest evaporative cassettes on the bottom and working up to the shortest evaporative cassette on the top, hook the cassettes into the vertical supports.
  • Page 25 r r o Fig. 15: Mounting order and positioning of the evaporative cassettes Installation...
  • Page 26 10. Mount the droplet separator cassettes (this step must only be carried out, if your system is equipped with a droplet separator): Note: to avoid damage to the droplet separator cassettes during transit, the droplet separator cas- settes should be fitted on site. •...
  • Page 27 • Hook the lower separator brackets into the cross bar. • Then, starting on one side mount one separator bank after the other, align it and secure it with the upper separator brackets. Make sure separator metalwork aligns with evaporator cassette metalwork.

  • Page 28: Mounting The Hydraulic Module

    Mounting the hydraulic module The mounting procedure of the hydraulic module depends on whether or not the hydraulic module is mounted internal or external to the duct. 4.3.1 Mounting the hydraulic module (internal installation) 1. Apply silicone free grease (e.g. gasket grease) onto the surface of the tank connector and onto the surface of the rubber sealing inside the connector of the hydraulic module.

  • Page 29: Mounting The Hydraulic Module (External Installation)

    4.3.2 Mounting the hydraulic module (external installation) Clearances to be observed MINIMUM 300 MM (11.81") CLEARANCE RECOMMENDED FOR SERVICE ACCESS DETAIL A HYDRAULIC MOUNTING MINIMUM 600 MM (23.62") BRACKET CLEARANCE RECOMMENDED FOR SERVICE ACCESS 173.2 mm 156.8 mm (6.82") (6.17") Ø80 mm (3.15") HOLE 272 mm...
  • Page 30 Mounting procedure 1. Mark position of the hole for the drain pipe feed through on the AHU/duct wall. Important: when mounted the drain pipe must have a downslope of 1 to max. 2 % towards the AHU/duct wall. 2. Drill hole (ø55 mm (2.2") for centre drain systems or ø65 mm (2.6") for side drain systems) for the drain pipe into AHU/duct wall.
  • Page 31 Tank spigot Push-on pipe fitting to connect tank spigot to hydraulic module 2 " 2 . 5 Fig. 21: Mounting the hydraulic module (external installation, side drain tank) Installation...

  • Page 32: Mounting The Wall Feed Through Plates

    Mounting the wall feed through plates 1. Push out or pierce the centre of grommets that will have pipes or cable passing through them. Large grommets are for pipe work, and small grommets are for cables. Note: on feed through plates for use with externally installed hydraulics the large grommets are spaced to match the stage pipe spacing on the hydraulic module, with a wider spaced large grommet at the right end for the pressure equalization pipe.
  • Page 33 3. Drill holes through the AHU wall for the pipes and cables. Holes should be as small as possible for the pipe or cable passing through them, and no larger than ø12 mm (ø0.47") for the (small) cable grommets, and ø20 mm (ø0.79") for the (large) pipe work grommets. Fig.
  • Page 34 4. Feed the pipe work (see notes in chapter 4.5) and cables through the outer feed through plate, then through the AHU wall and finally through the feed through plate on the inner side of the AHU wall. This side of the feed This side of the feed through plate must face through plate must face...
  • Page 35 Fig. 28: Fixing the feed through plate to the Fig. 29: Fixing the feed through plate to the duct wall (external installation) duct wall (internal installation) Installation...

  • Page 36: Water Installation

    The wall feed through for the water supply is provided as part of the installation kit. Important: after installation the water supply pipe has to be sealed around the feed through using silicone-free sealant, if not using a Condair supplied feed through. –...
  • Page 37 – Notes on water drain – The water drain is to be carried out according to the figures found in chapter 4.5.2 chapter and the applicable local regulations for water installations. The indicated connection speci- 4.5.3 fications must be observed. The installation material must be supplied by the customer. –...
  • Page 38 General notes on installation of the hoses (Internal Installation) – Use the supplied 0.625" flexible plastic hoses only. For hygienic reasons do not use other hoses (except products supplied by your Condair distributor). – When cutting hoses use an appropriate cutting tool providing straight, kink-free cuts.

  • Page 39: Water Installation (Internal Installation)

    4.5.2 Water installation (internal installation) Stages Connection layout (box rows) distribution hoses Distribution hoses ø0.625" with constant slope (no sagging) 2...5 bar Feed through Water supply (optional kit) push-fit connector Shut-off valve (supplied) with compression connector ø0.625" Drain pipe vent (mandatory, not sup- Drain pipe ø1.125"...

  • Page 40: Water Installation (External Installation)

    4.5.3 Water installation (external installation) Stages Connection layout (box rows) distribution hoses Distribution hoses ø0.625" constant slope (no sagging) Shut-off valve (supplied) with compression connector ø0.625" Pressure equalization pipe (supplied) Feed through 2...5 bar (supplied) Drain pipe vent (mandatory, Water supply not supplied), highest point push-fit connector of vent tube must be above...

  • Page 41: Mounting The Control Unit

    The control unit should ideally be positioned as close to the evaporative module as possible for ease of servicing and maintenance. Note: the hydraulic module of the Condair ME Control is equipped with a 10 m (32.8’) multi-core electrical inter-connecting cable for connection to the control unit. Make sure the control unit is mounted within the range of the inter-connecting cable.

  • Page 42: Mounting The Control Unit

    Open Closed position position Fig. 33: Mounting the control unit of Condair ME Controls Mounting procedure: 1. Mark the attachment points for the upper and lower wall support at the desired position with the help of a level. 2. Fix the wall supports to the wall using appropriate fixings. Before tightening the fixings adjust the wall supports horizontally using a level.

  • Page 43: Electrical Installation

    Electrical installation 4.6.1 Notes on electrical installation DANGER! Risk of electric shock! The control unit contains live mains voltage. Live parts may be exposed when the control unit is open. Touching live parts may cause severe injury or danger to life. Prevention: The control unit must be isolated from the mains before commencing any installation work.
  • Page 44 – All cables from the hydraulic module mounted inside the AHU/air duct must be led via appropriate cable gland(s) out of the AHU/air duct. – Ensure cables are secured in such a way that the insulation is not damaged by sharp edges and so that they do not create a trip hazard.

  • Page 45: Wiring Diagram Condair Me Control

    4.6.2 Wiring diagram Condair ME Control Installation...
  • Page 46 Cable bridge if no safety chain is connected Jumper for activating the terminating resistor for Modbus network (Jumper must be fitted, if Condair ME is the last unit in the Modbus network) Jumper fitted: Modbus communication via RS 485 interface (J6)

  • Page 47: Installation Work

    Note: for the connection of the available options please refer to the addendum manual of the corre- sponding option. Control signal (Y) Note: the control settings must be done via the control software of the Condair ME Control. Please refer to the operation manual of the Condair ME Control. External continuous humidity or temperature con-...
  • Page 48 Temperature sensor A temperature sensor is to be connected to the contacts "TMP" (+) and "GND" (–) of the terminal block "X16" on the driver board. The admissible signal values can be 24/10V found in the technical data table in the operation manual. The connecting cable must either be fed through the rectangular cable feed through or a free cable gland 24V E...
  • Page 49 External safety circuit To guarantee the safety of the humidification/cooling system, monitoring the operation by means of a safety circuit "K1" is an absolute requirement. To accomplish this, the potential-free contacts of ex- ternal moni t or ing devices (e.g. ventilation interlock "B1", safety high limit humidistat "B2", airflow monitor "B3", etc.) are connected in series to the contacts "SC1"...
  • Page 50 Connecting the multi-core inter-connecting cable from the hydraulic module The multi-core inter-connecting cable "K2" from the hydraulic module is to be connected to terminal "X4" 1 2 3 4 5 6 7 8 9 10 11 12 13 14 according to the numbering label on terminal "X4". The multi-core inter-connecting cable must be fed through 1 2 3 4 5 6 7 8 9 10 11 12 13 14 the rectangular cable feed through into the control unit.
  • Page 51 1 2 3 4 5 6 9 10 – "Running" (Humidification/Cooling): This relay closes as soon as the Condair ME is hu- midifying/cooling. Control unit – "Unit on": This relay closes as soon as the voltage supply to the control unit of the Condair ME is switched on.

  • Page 52: Appendix

    ME. "Effluent treated water", must be treated by an appropriate water treatment method and risk assessed to ensure it is safe and suitable for use in the Condair ME unit. It is the responsibility of the user to ensure that the water supply system is part of a managed, hygiene monitored water system, risk assessed and complies with the local regulations and bylaws.
  • Page 53 Bromate Cadmium Chromium Cyanide 1,2-dichloroethane Epichlorohydrin Fluoride Lead Mercury Nickel Pesticides Polycyclic aromatic hydrocarbons Selenium Tetrachloroethene and Trichloroethene Trihalomethanes Vinyl chloride Water Monitoring The Condair ME water system must be monitored for hygiene as part of the maintenance programme. Appendix...
  • Page 54 Notes...
  • Page 55 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 56 U.S.A. 826 Proctor Avenue Ogdensburg, NY 13669 CANADA 2740 Fenton Road Ottawa, Ontario K1T 3T7 TEL: 1.866.667.8321 FAX: 613.822.7964 EMAIL: na.info@condair.com WEBSITE: www.condair.com...

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