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Condair GS OC Series Installation, Commissioning And Service Instructions

Gasfired steam humidifier - outdoor version
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Condair GS...OC
C series
Gasfired steam humidifier - outdoor version
INStallatION, COmmISSIONING aNd
SErvICE INStruCtIONS

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Summary of Contents for Condair GS OC Series

  • Page 1 Condair GS...OC C series Gasfired steam humidifier - outdoor version INStallatION, COmmISSIONING aNd SErvICE INStruCtIONS...

  • Page 3: Table Of Contents

    Maintenance 8.1 Maintenance instructions 8.2 Dismantling work for maintenance and the replacement of components Notes on cleaning agents Resetting the maintenance reminder Troubleshooting 9.1 Important notes on troubleshooting 9.2 Error indication 9.3 Resetting the error indication 9.4 Replacing the backup battery on the control board of the Condair GS...OC Taking out of service/Disposal 10.1 Taking out of service 10.2 Disposal/Recycling Specifications 11.1 Technical Data 11.2 Flue gas specifications...

  • Page 4: Introduction

    The Condair GS...OC incorporates the latest technical ad v an c es and satisfies the requirements of the European Gas Equipment Directive (90/396/EEC) and all known safety standards. Nevertheless, improper use may result in danger to the user or third parties and/or impairment of the installation or other material assets. To ensure a safe, proper, and economical operation of the Condair GS...OC, please observe and comply with all information and safety instructions contained in the present installation, com- missioning and service instructions. If you have questions, which are not or insufficiently answered in this documentation, please contact your Condair supplier. They will be glad to assist you.

  • Page 5: For Your Safety

    – Warning! Do not use this appliance if any part has been exposed to excess humidity. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water. – The Condair GS...OC humidifier must only be installed, o perated, and serviced by persons familiar with the product and sufficiently qualified for the respective task. It is the customer’s responsibility to ensure that the present...
  • Page 6 – Before carrying out working steps on particular components of the Condair GS...OC humidifier set the humidifier out of service, disconnect it from the power supply by setting the service switch to “Off”, close the gas supply and secure the unit against unintentional oper ation. Warning! If the ambient temperature is below the freezing-point the water tank must be drained (see also chapter 7.4). – Warning! Before carrying out maintenance or repair works, especially under extreme weather conditions (e.g. rain, snow), protect the unit in a way that no electrical or other components inside the unit can get wet (cover unit with a tent).
  • Page 7 – after longtime storage under unfavorable conditions. – after transportation under unfavorable conditions. – The Condair GS...OC must be installed only in locations equipped with a water drain or with sensors that safely interrupt water supply in case of leak a ge. – To prevent excess humidification the operation of the Condair GS...OC must be moni­ tored by a high limit on/off humidistat (see chapters 5.8/5.9). – Use only genuine accessories and spare parts available from your Condair supplier. – The Condair GS...OC humidifier and the optional accessories must not be modified in any way without the written consent of the manufacturer. The worldwide well­organized Condair distributor network provides service at all times by qualified technicians. Please contact your Condair supplier in case of trouble or if you have any questions concerning the GS...OC humidifier and humidification technology in general.

  • Page 8: Product Overview

    Product Overview Product versions/Model designations The Condair GS...OC gasfired steam humidifier is available in 6 different models with different maximum steam output performance (40, 80, 120, 160, 200 and 240 kg/h). All models can be operated with natural gas or propane (ex­works the unit is supplied for a specific type of gas operation, as stated on the rating plate). Model designation Product line (gasfired steam humidifier with operation and display unit)

  • Page 9: Humidification System Overview

    3.3 Humidification system overview 1 Gasfired steam humidifier 11 Drain water line (building side) 2 Flue gas pipe with rain cap and storm collar 12 Shut­off valve water supply (building side) (included in the delivery) 13 Auxiliary drain connection Steam supply pipe (building side) Electrical connections (building side) Gas supply connection Filter valve (accessory “Z261”) 5 Shut­off valve gas supply line (building side) Water supply line (building side) Gas supply line (building side) 17 Funnel with trap (building side) Sediment trap (building side) Steam hose adapter (accessory “SA...”)

  • Page 10: Construction Of The Gasfired Steam Humidifier

    3.4 Construction of the gasfired steam humidifier 1 Water tank Ignition modules Steam outlet connection Burner electronic 3 Heat exchanger (1 to 3) 17 Combustion air blower (1 to 6) Burner (1 to 6) Flame sensor Level unit 19 Igniter 6 Key pad and display unit 20 Drain pump Indication LED’s 21 Air pressure switch green: “Steam production” Gas pressure control valve (1 to 6) yellow: “Maintenance”...

  • Page 11: Principle Of Operation

    Principle of operation Combustion System The combustion system is based on a fully modulating forced draft com b ustion air blower, a nega­ tive pressure regulator gas valve and a 100% premix burner. On a call for humidity, the combustion air blower starts and creates a negative pressure across an orifice located at the air inlet. The blower starts for a moment to purge the system, then the hot surface ignitor is activated. During this time the electronic ignition module does a diagnostic check of safety systems including the air proving switch which senses the negative pressure at the air inlet. After the function of the safety systems has been verified, the gas valve will open and the gas/air mixture is ignited by the hot surface ignitor. If flame is sensed by the flame sensor within 7 seconds the gas valve remains open and combustion continues. If flame is not sensed, the above sequence is repeated a maximum of three times after which the ignition module will lock out and a respective error...
  • Page 12 The level in the water tank is continuously monitored by the level unit. On initial start­up, the control unit checks the function of the level unit. During this test the tank is filled up first to level “A”, then drained to level “C” and filled up again to level “A”. As soon as level “B” is reached and the test of the level unit was successful the humidifier is ready for operation, if a humidification demand is present the combus­ tion process starts. When the water level due to the evaporation process reaches level “B”, the level unit sends a signal to the control system, which opens the double inlet valve and the water tank is filled up. On reaching level “A”, the level unit again sends a signal to the control system and the double inlet valve is closed. If the water level goes below level “C”, the combustion will be interrupted until the water level reaches “C” again. To ensure safe operation, the control system constantly monitors the proper function of the level unit in regular intervals.

  • Page 13: Basic Planning

    Basic planning All the data necessary for the selection and layout of a Condair GS...OC humidifier system are provided in the following chapters. Selecting the unit The selection of the unit is reflected in the type description: Condair GS 80 OC 1. Required maximum steam capacity 2. Required combustion gas 4.1.1 Calculating the maximum required steam capacity The maximum required steam capacity is calculated from the following formulas: V • ρ • (x2 - x1) • (x2 - x1) 1000 1000 • ε : maximum steam demand in kg/h volume of supply air portion per hour in m /h (for indirect room humidification) or room volume to be humidified per hour in m /h (for direct room humidification) ρ: specific gravity of air in kg/m ε:...
  • Page 14 In addition, the calculated steam capacity does not consider any losses caused by the draining rate depending on the water quality. The total amount of losses depends on the entire system and must be taken into consideration when calculating the required steam capacity. If you have any questions regarding the calculation of the steam capacity please contact your Condair supplier. – For systems where the max. required steam capacity varies extensively (e.g. for test facilities or for systems with variable air volume flow, etc.), please contact your Condair supplier. 4.1.2 Combustion gas The Condair GS...OC can be operated with natural gas or propane. The equipment is configured ex­works for the respective combustion gas that is to be employed. If required, the equipment can be converted at a later date to work with one of the other combustion gas.

  • Page 15: Selecting The Control System

    4.2 Selecting the control system The various control systems – System 1: Room humidity control System 1 is suited for air conditioning systems with mainly recirculated air. The humidity sensor is preferably located in the room itself or in the exhaust air duct. humidity sensor ventilation interlock airflow monitor safety humidistat external continuous controller (e.g. PI-controller) internal continuous controller (PID controller) input signal from A1 – System 2: Room humidity control with continuous limitation of the supply air humidity System 2 is suited for air conditioning systems with a large portion of supply air, low supply air temperature, post-humidification, or variable airflow volume. If the supply air hum i dity exceeds the preset value, the continuous limitation is effected prior to the room hum idity control.
  • Page 16 System 1 or 2 System 2 or 3 Supply air portion up to 100% System 2 System 3 Supply air humidity control ––– System 3 Please contact your Condair supplier, if your application meets the following conditions: – Humidification of small rooms up to 200 m – Air conditioning systems with a high number of air exchanges – Systems with variable air volume flow – Test facilities with extreme control accuracy requirements – Rooms with a high variation in max. steam capacity – Systems with temperature fluctuations – Cold rooms and systems with dehumidification...

  • Page 17: Options

    – 1 ... 5 VDC Further information is provided in Chapter 5.9. Output signals The Condair GS...OC provides the following output signals: – 10 VDC (max. 20 mA) – Remote operating and fault signals (4 potential­free contacts) Further information is provided in Chapter 5.9. Options At the moment no options are needed for the Condair GS...OC. Accessories 4.4.1 Accessories overview Model Condair GS...OC 40 ... 80 ... 120 ... 160 ...
  • Page 18 Appropriate fittings are available on request. Note: If the humidification distance (see chapter 5.3.1) has to be reduced for technical reasons, the steam output of your unit must be divided between two steam distribution pipes or the OptiSorp steam distribution system must be used. If this is the case, contact your Condair supplier. OptiSorp steam distribution system The OptiSorp steam distribution system is used in ventilation ducts with a short humidification distance (for the calculation of the humidification distance refer to chapter 5.3.1). When ordering an OptiSorp system the duct dimension must be specified. Please consult the data in the following table.

  • Page 19: Mounting And Installation Works

    Caution - Danger from electric shock! The connection of the steam humidifier to the mains electrical supply must not be made until all installation work has been completed. Caution! Incorrectly executed installations can result in personal injury and/or damage to property through explosions, fires, carbon monoxide poisoning, electric shock, etc. If you require assistance, please contact a qualified installer, your local gas supplier or your Condair representative. In the installation itself, use only materials available from your Condair representative and accessories approved by him. 5.2 Unit fitting 5.2.1 Humidifier location To ensure proper functioning of the steam humidifier Condair GS...OC and to obtain optimum efficiency, the following points must be considered and observed when choosing the location for the steam humidifier: – The Condair GS...OC must be mounted only outside of buildings where the flue gases can escape freely.
  • Page 20 – The Condair GS...OC gasfired steam humidifiers are designed for mounting on a curb. Caution! The curb and the place of installation must be built to structurally support the entire weight of the humidifier when in operation. – The sheet covering of the Condair GS...OC heats up during operation (max. surface temperature approx. 60 ­ 70 °C). Therefore make sure that no heat­sensitive materials are placed in the immedi­ ate vicinity of the humidifier. – No combustible materials must be placed in the immediate vicinity of the Condair GS...OC hu­ midifier (Insulation materials, wooden floor coverings, etc.). Observe local regulations! – Do not mount the humidifier on a base that is subject to vibration. If necessary, please contact your Condair representative. – Do not cover the air openings (louvers) in the panels of the unit, otherwise the air flow may be insuf­ ficient. – Do not place the unit in a narrow niche or a closed compartment. Place the humidifier so that the unit is easily accessible and there is sufficient space for maintenance work. The minimum distances shown in the following illustration must be m aintained. min. 3000 mm min.
  • Page 21 Dimensions (in mm) Steam outlet GS 40 GS 80 GS 120 1104 GS 160 1104 GS 200 1500 GS 240 1500 Flue gas outlet with storm collar and rain cap Steam outlet Gas supply 1262 Connections and weights Model Connections Operating weight weight...
  • Page 22 3. Lift the unit on the curb using a crane. Caution! Please observe the safety instructions for transporting the unit (see above). Caution! To make sure positive or negative pressure of the building does not affect the operation of the Condair GS..OC the pipe chase in the unit base must be sealed after completion of the installation of the water piping and the electrical wiring.

  • Page 23: Steam Installation

    Relative supply air humidity prior to humidification at the lowest supply air temperature φ2 in %rh: Relative supply air humidity after the steam distribution pipe at maximum capacity Example given: φ1= 30 %rh, φ2= 70 %rh humidification distance B 1.4 m (0.36 m for steam distribution system OptiSorp) Note: If the humidification distance has to be reduced for technical reasons, the amount of steam per steam outlet must be divided between two steam distribution pipes or the steam distribution system OptiSorp must be used. If this is the case, contact your Condair supplier.
  • Page 24 Minimum distances to be observed To prevent the water vapor, that is emitting from the steam distribution pipe, from condensing on downstream system components, a minimum distance to the steam distribution pipe must be observed (depends on the humidification distance “B ”). before/after constriction after expansion before bend 0.5 x B 0.5 x B before branch before diffuser before control/temperature sensor 5 x B before/after filter/register before/after fan, zone exit 1.5 x B 5 cm * 2,5 x B before submicron particle filter Installation notes and dimensions...
  • Page 25 In positioning the steam distribution pipes, the following dimensions should be observed: 1 / 2 1 / 2 1 / 2 1 / 2 2 / 3 = 100 mm 1 / 3 = 85 mm m i n min. H= 250 mm H ≥ 400 mm min. H= 200 mm 1 / 3 1 / 3 1 / 3 m i n 3 / 7 3 / 7 2 / 7...
  • Page 26 – Steam distribution pipes must not be mounted to round ducts. – Exercise extreme caution when installing in fiberglass or internally lined ducts. If necessary, remove 10­15 cm of the lining where the steam is being introduced. If you have questions relating to the dimensioning of ventilation ducts in combination with Condair steam humidifiers, contact your Condair supplier. Installing the steam distribution pipes/OptiSorp steam distribution system Detailed information on the installation of steam distribution pipes and OptiSorp steam distribution system can be found in the separate “Mounting Instructions” for this products.
  • Page 27 5.3.2 Installing the main steam pipe The steam pipe between the steam outlet of the unit and the steam hose adapter (main steam pipe) must be made with solid piping. steam hose adapter Main steam pipe (max. length 6 m) steam hoses (max. length 4 m) The following notes must be observed: – The internal diameter of the steam outlet on the unit must be maintained over the entire length of the main steam piping. – The maximum length of the main steam pipe is 6 m. Important! Allowance must be made for a pressure loss of 10 mm water column (approx. 100 Pa) per meter length or per 90° bend.
  • Page 28 5.3.3 Installing the steam hoses between steam hose adapter and steam distributors Important! Use original Condair steam hose exclusively. Other types of steam hoses can cause un­ desired operational malfunctions. min. 20 % min. 5 % The following notes must be observed: – Lead the steam hose with an upslope of at least 20% or with a minimum downslope of 5% to the steam distribution pipe. – The steam hose should be kept as short as possible (ideally 2 m, max. 4 m) while observing the minimum bend radius of 300 mm. Important! Allowance must be made for a pressure loss of 10 mm water column (approx. 100 Pa) per meter steam hose. – Reductions in the cross section such as kinks should be avoided throughout the entire length of the hose. The installation of a stop cock in the steam hose is not permissible. – Steam hoses must be prevented from sagging (condensate pockets); if necessary, support with pipe clamps, rails or wall brackets. If sagging can not be prevented (e.g. when passing by obstacles) a...
  • Page 29 – Important! Allowance must be made for a pressure loss of 10 mm water column (approx. 100 Pa) per meter length or per 90° bend. – Connection of the steam pipes to the steam distribution pipe and steam humidifier is effected by means of short lengths of steam hose secured with hose clamps. 5.3.4 Installing the condensate hoses min. 20 % Important! Use original Condair condensate hose exclusively. Other types of hoses can cause oper­ ational malfunctions. The individual condensate hoses of the main steam pipe (if present), the steam hose adapter (if present) and the steam distribution pipes must be led down with a minimum downslope of 20 % via a siphon (min. hose bend ø200 mm) into a discharge funnel. Important! Before putting the unit into operation, the siphon of the condensate hose must be filled with water.

  • Page 30: Water Installation

    Water installation All installation work must be carried out in accordance with the locally applicable water installation regulations. All work concerning the water installation must be performed only by adequately qualified personnel (e.g. plumbers). Warning - danger of electric shock! For all installation work, the Condair GS...OC must be disconnected from the mains supply and secured against unintentional reconnection. 5.4.1 Performing the water installation Overview water installation min. 15 cm 1 Filling water connection BSP 1/2" (outside thread) 8 Pressure reducing valve (compulsory for water pressures >8 bar, building side)
  • Page 31 3.0 bar). For mains pressures <3.0 bar please contact your Condair supplier. – Supply rate: 10 l/min – Admissible supply temperature: 1…30 °C – Notes on water quality: – For the water supply of the Condair GS...OC, use exclusively untreated drinking water or fully demineralized water. Note: The use of fully demineralized water reduces the maintenance and the cleaning of the water tank to a minimum. – The use of additives such as corrosion inhibitors, disinfectants, etc. is not allowed, since these additives may endanger health and affect proper operation.
  • Page 32 Water drain and auxiliary water drain Both drain lines should be connected to the corresponding connection on the unit using a hose coupling. Lead the drain lines via the pipe chase downwards into an open drain funnel (min. height 15 cm) inside the building. The drain funnel is then connected via a siphon to the building drain line. The minimum internal diameter of 45 mm must be maintained over the full length of the building drain line. Make sure that the drain line is correctly attached and easily accessible for the purpose of inspection and cleaning.

  • Page 33: Gas Installation

    Gas installation All installation work must be carried out in accordance with the applicable local building and installation regulations. All work concerning the water installation must be performed only by adequately qualified personnel (e.g. plumbers). Ascertaining the qualifications is the customers responsibility. Warning - danger of electric shock! For all installation work, the Condair GS...OC must be disconnected from the mains supply and secured against unintentional reconnection. 5.5.1 Performing the gas installation Overview Gas installation 1 Gas supply connection Model Connection GS 40 OC BSP 1/2" GS 80 OC BSP 3/4"...
  • Page 34 5.5.2 Leak testing After completion of the installation work, the whole gas line must be tested to a maximum pressure of 40 mbar (4.0 kPa) for natural gas or 150 mbar (15 kPa) for propane and checked for leaks using a commercially available soap solution. The bubbles indicate leaks. All leaks must be eliminated before the humidifier is put into operation. Caution! Never use an open flame to check for leaks. The presence of any leakage is a source of danger to persons and to property, due to the possibility of fire and explosion. If the gas circuit must be tested to a pressure of over 150 mbar (15 kPa), the gas supply pipe must be removed from the unit connection. After the test, the gas line must be depressurized before it is recon­ nected to the unit. Caution! Non-observance of the above instruction can lead to damage to the gas pressure regulating valve. Gas pressure valves overloaded due to high pressure are not covered by the manufacturer‘s guarantee. 5.5.3 Conversion instructions for operating the humidifier with another type of gas Ex works the appliance is equipped to operate on one type of gas. To convert an appliance for opera­ tion on another type of gas, follow the directions below (see also illustration on the following page). The conversion shall be carried out by a manufacturer’s authorized representative or person trained and licenced for such activities, in accordance with the requirements of the manufacturer or local authorities having jurisdiction in the area of installation.
  • Page 35 13. Reconnect the flexible gas pipe to the gas pressure regulating valve and tighten the coupling. 14. Fix the inlet elbow with the hose clamp to the venturi manifold. 15. Reconnect the hose between the air pressure switch and the inlet elbow. 16. Reconnect the electrical cables to the gas pressure regulating valve and the air pressure switch. 17. On multiple burner units repeat steps 4 to 16 for each gas valve assembly. Hose to pressure switch Inlet elbow Hose clamp Venturi manifold Pressure switch Gas pressure regulating valve Flexible gas pipe Cork gasket gas pipe connection O-ring Combustion air blower...

  • Page 36: Flue Gas Installation

    Flue gas installation Warning! Since the regulations for the installation of flueing systems differ from country to country, the relevant local regulations must be adhered to without reservation. All work concerning the flue pipe installation must be performed only by adequately quali- fied personnel. Ascertaining the qualifications is the customers responsibility. 5.6.1 Performing flue gas installation Overview 1 Flue gas connection on the unit – GS 40 OC: ø76 mm (3") – GS 80 OC: ø101 mm (4") –...
  • Page 37 Installation notes The following instruction notes must be observed: – Flue gas specifications: ---> see table in chapter 10.2 – The flue gas temperature during normal application and when the maintenance schedule is fulfilled is between 160 ­ 180 °C. If the unit is not maintained properly the flue gas temperature could increase. In this case the temperature switch would shut down the unit if the temperature exceeds 200 °C for safety reasons. – Use the supplied flue gas pipe with storm collar and rain cap exclusively. – The supplied flue pipe extension and the rain cap have built­in mechanical locking band and gasket. Simply push each component to the stop bead, which provides an air­ and water­tight seal. Then, tighten the integrated locking band on each component to complete the installation of the flue gas venting. – Make sure the rain cap is at least 60 cm above any ridge within 3 m of the unit. Note: if the flue gas venting needs to be longer for any reason please contact your Condair repre­ sentative.

  • Page 38: Installation Of Control And Monitoring Devices

    5.7 Installation of control and monitoring devices – Install the room humidity sensor and the safety humidistat at the same height as thermostats and in a location where the measured humidity corresponds to that of the room. Under no circumstances should the humidity sensors be positioned in the vicinity of the air flow from ventilator units or air intake grids. Do not mount humidity sensors on an outer wall, where temperature fluctuations can affect the control behavior. – Install the duct humidity sensor in a position where the measured humidity corresponds to that of the room that is being humidified (usually in the duct return circuit). Do not position humidity sensors in the immediate vicinity of steam distribution pipes, nor in sections of a duct subject to air turbulence, nor within the path of the humidification process itself.

  • Page 39: Electrical Installation

    Electrical Installation Wiring diagram 0…10 VDC 0…10 mADC 2…10 VDC 2…20 mADC 0…5 VDC 0…20 mADC 1…5 VDC 4…20 mADC JP3: 5 Vdc, max. 500 mA JP4: 24 Vdc, max.150 mA 1 2 3 4 5 6 7 8 Control Board J10-Modul J13-Feedback 24VAC...
  • Page 40 – External safety circuit (K1) To guarantee the safety of the humidification system, monitoring the operation by means of a safety circuit is an absolute requirement. To accomplish this, the potential­free contacts (250V/2A) of exter­ nal moni t or i ng devices (B1: safety high limit humidistat, B2: airflow monitor, B3: ventilation interlock, etc.) are connected in series to terminals 1 and 2. – Control or sensor signal The signal line (signal Y) is connected to terminals 3 and 4. The signal line (signal Z) is connected terminals 3 and 5. By default the Condair GS is configured for a 0…10 VDC control signals. The control signal type can be modified via the software (see menu “user settings”, in the operating instructions for the Condair GS control). The configuration whether the Condair GS is controlled via the internal or via an external controller is also done via the software.
  • Page 41 – Output (A3) This output is available for custom purposes. The lines are connected to terminals 6 and 7. output signal type is configured by setting the jumper on JP3 (5 Vdc max. 500 mA) or on JP4 (24Vdc max. 150 mA). – Full tank blow down 24 VAC (S1) This input signal can be used for remote triggering a full tank blowdown. If a 24 VAC signal is present for more than 60 seconds the tank blows down. The signal line is connected to terminals 8 and 7.

  • Page 42: Inspecting The Installations (Check List)

    Inspecting the installations (Check list) Before the Condair GS...OC is operated for the first time, the responsible personnel must inspect all installations for correct execution (observing of local regulations) and check that the unit is correctly configured. All deficiencies must be corrected by specialist action before commissioning takes place. Use the following check list to ascertain that the installations were performed correctly: – Unit installation Is the unit in the correct place (see chapter 5.2.1)? Is the unit correctly aligned vertically and horizontally? – Steam installation –...
  • Page 43 Is the flue gas outlet at least 60 cm above any ridge within 3 m of the unit? – Electrical installation Does the electrical installation comply with the local regulations? Do the mains voltages applied correspond to the supply voltage stated on the rating plate of the unit? Is the voltage supply correctly fused? Is the service switch “Q” installed in the supply cable and located in the compartment outside the unit, above the electrical service door? Are all components correctly connected in accordance with the wiring diagram? Are all connection cables fixed? Are the connecting cables free of tension (fitted through cable glands/secured with cable clamps?) Is the Condair GS...OC correctly configured?

  • Page 44: Operation

    Operation Safety instructions for operation The Condair GS...OC must only be commissioned and operated by persons who are familiar with equipment and adequately qualified to undertake this work. Monitoring such qualification is a matter for the customer. Initial commissioning must only be undertaken by the Condair service technician or by the customer‘s own specially trained personnel. The safety instructions in Chapter 2 must be followed and adhered to! Caution – Danger of electric shock! With the lid of the unit open, contact with current conducting components is a possibility. Before switching the service switch On in the electrical supply circuit, all covers on the unit must be closed and locked.

  • Page 45: Function Of The Display And Operating Elements

    7.2 Function of the display and operating elements Display and control unit Function: Configuration of the Condair GS...OC. Indication of operating parameters. Reset of maintenance counter. red LED “Fault” Function: The LED lights in case of a severe malfunction of the unit (Fault status). Further operation is not possible any longer. A corresponding fault message is shown in the display.

  • Page 46: Commissioning And Notes On Operation

    7.3 Commissioning and notes on operation Caution! Before the Condair GS...OC is operated for the first time, the responsible per­ sonnel must inspect all installations for correct execution and check that the unit is correctly configured (see check list in chapter 6). All deficiencies must be corrected by specialist action before commissioning takes place. The humidifier is operated as follows: • Examine the humidifier and all installations for possible damage. Caution! Damaged units and units with damaged installations must not be operated. • Check the cleanliness of the outer cabinet: The panels may be cleaned with a damp cloth and warm soapy water. Caution! Make sure no water is dripping into the cabinet through the ventilation openings in panels of the unit housing.
  • Page 47 • Reconnect all ignitors to the ignition modules. • Start the humidifier: • Open the shut­off valve in the water supply pipe. • Open the shut­off valve in the gas supply pipe. • Switch on the external service switch. • Switch the humidifier On at the unit switch. The Condair GS...OC carries out a system and level test, during which all Condair GS 240 START UP the LEDs light up. If a failure occurs on the system test, a corresponding error message is shown in the display. After the system test the unit is in normal operation mode. The display Condair GS 240 shows the standard operating display (first page of the indication level).

  • Page 48: Taking Out Of Operation

    Note: for detailed information regarding the operation of the control unit and the configuration settings please observe the information given in the separate operating instructions to the Condair GS control. Operating status display The unit operating status is signaled via the display and the indicator LED’s on the humidifier as well as via the remote operating and fault indication, as follows: Operating status / meaning Indication on unit Activated remote relay Warning present (humidification continuing) Yellow LED lights. A warning message alternates with the normal operating mode display.

  • Page 49: Maintenance

    All maintenance work must only be carried out by experienced and trained person- nel, who are familiar with the procedures required. The instructions and data relating to the maintenance work must be followed explicitly. The only maintenance work permitted is that described in this chapter. Use only original Condair spares to replace defective components. Before commencing the maintenance work, the Condair GS...OC has to be taken out of operation, as described in chapter 7.4 and secured against inadvertent start up. Warning! Before carrying out maintenance or repair work under extreme weather conditions (e.g. rain, snow) protect the unit in a way that no electrical or other components inside the unit can get wet (cover unit with a tent).
  • Page 50 Components Interval Work required Flue gas temperature sensor Visual check that sensor is intact, wired and attached to the exhaust. Flue gas outlet pipe Check flue gas outlet pipe for sealing and remove all traces of condensate. If specified, have the flue gas system inspected by an appropriate specialist.

  • Page 51: Of Components

    8.2 Dismantling work for maintenance and the replacement of components Prepare water tank for cleaning Torque: 5.7 Nm (50 in-Lb) 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the left front panel. Then, unscrew the nuts of the side tank cover and remove the cover. 3. On GS...OC 120 ... 240 only: unlock and remove the left top panel. Then, unscrew the nuts of the top tank cover and remove the cover. The re­assembly of the water tank takes place in the reverse sequence. Make sure that the seals of the tank covers are not damaged (replace if necessary). Important! Tighten the nuts of the tank cover(s) with a torque wrench (torque: 5.7 Nm). Do not over­ tighten the nuts. Cleaning the water tank Caution – Danger of combustion! The water and all lime deposits in the tank can be extremely hot and may lead to burning on contact. Therefore, allow the humidifier to cool before commenc­ ing cleaning work.
  • Page 52 Removal and installation of the combustion air blower 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel(s). 3. Disconnect cables to combustion air blower, gas pressure regulating valve and pressure switch (note assign ment of the connections). 4. Undo the coupling of the corresponding flexible gas pipe and disconnect the gas pipe. 5. Undo the two screws of the venturi manifold and lift up the manifold together with the gas pres­ sure re gulat ing valve. 6. Undo the two screws of the electronic board (if present) and remove electronic board. 7. Undo the nuts on the outlet side of the blower and remove the blower unit. Reinstallation is achieved by following the reverse sequence. Replace defective seals with new ones. Make sure that all seals are inserted correctly and all cables are connected correctly. Caution – Danger of explosion! Following maintenance work on the gas system, a leakage test must always be undertaken in accordance with chapter 5.5.2.
  • Page 53 Removal and installation of the burner Hold burner only on metal pipe Ceramic matting, do not touch! 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel(s). 3. Remove the combustion air blower (see the section “Removal and installation of the combustion air blower” above). 4. Disconnect the cables to the igniter and to the flame monitoring unit and remove the components (see the section on “Removal and installation of the igniter and the flame sensor”). 5. Unscrew the four nuts in the burner flange and carefully remove the burner unit . Make sure that the burner is not damaged. Note: Grease, dirt and dust at the ceramic matting can affect the performance of the burner. Re­installation is achieved by following the reverse sequence. Renew the flange seal and replace igniter and flame sensor if necessary. Tight the nuts of the burner flange with a torque wrench (torque: 10 Nm).
  • Page 54 Removal and installation of the gas pressure regulating valve 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel(s). 3. Disconnect electrical wiring to the gas pressure regulating valve and the pressure switch (note the connection layout). 4. Undo the coupling of the corresponding flexible gas pipe and disconnect the gas pipe. 5. Undo the two screws of the venturi manifold and lift up the manifold together with the gas pres­ sure re gulat ing valve. 6. Undo the four screws and remove the gas pipe connection of the gas pressure regulating valve. Pull off the hose connected to the pressure switch (note the connection layout). Then, undo the three screws of the pressure switch support and remove pressure switch assembly from the gas regulating valve. Undo the three screws fixing the gas pressure regulating valve to the venturi manifold then, remove the gas pressure regulating valve from the venturi manifold. Reinstallation is achieved by following the reverse sequence. Replace defective seals with new ones. Make sure that all seals are inserted correctly and all cables are connected correctly. Caution – Danger of explosion! Following maintenance work on the gas system, a leakage test must always be undertaken in accordance with chapter 5.5.2.
  • Page 55 Removal and installation of the igniter and the flame sensor Caution! When replacing the igniter and the flame sensor, use only the set of spares “burner spare parts subject to wear” available from your Condair supplier, since otherwise the humidifier could be damaged. 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel(s). 3. Disconnect the wiring connection to the igniter and to the flame sensor. 4. Unscrew the fixing nuts for the igniter and the flame sensor. Now carefully remove the igniter and flame sensor. Caution! The silicon carbide igniter is breakable. Therefore handle it with great care to avoid damage. Reinstallation is achieved by following the reverse sequence. Inspect gaskets and replace if defective. Make sure that all gaskets are inserted correctly and all cables are connected correctly.
  • Page 56 Replacement of the ignition module 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right front panel 3. Note the cable assignment, then remove all connection cables to the ignition module. 4. Unscrew the two fixing screws securing the ignition module and then remove ignition module. Re­installation follows in the reverse sequence. Make sure the connecting cables are connected correctly. Replacement of the air pressure switch 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel(s). 3. Pull off the hose connected to the pressure switch (note the connection layout). 4. Remove the connection cable to the pressure switch (note assignment before removal). 5. Unscrew the two fixing screws and remove the air pressure switch. Re­installation follows in the reverse sequence. Make sure the cables and the hose are connected correctly.
  • Page 57 Replacing the transformer 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right front panel 3. Remove the connection cables to the transformer, if necessary labeling the cables before removal. 4. Unscrew the two nuts and remove he transformer. Re­installation is carried out in the reverse sequence. Make sure the cables are connected correctly. Replacing the drain pump 1. Take the humidifier out of operation, as described in chapter 7.4. Important! If drain pump is defective, drain tank manually via the auxiliary drain. 2. Undo the brackets and open the right side panel. 3. Remove the connection cables to the drain pump (note assignment before removal). 4.
  • Page 58 Replacing the auxiliary drain valve 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel. 3. Remove the connection cables to the auxiliary drain valve (note assignment before removal). 4. Disconnect the auxiliary drain valve from the tank connection and remove. Re­installation is carried out in the reverse sequence. Make sure the cables are connected correctly. Replacing the fill valve 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel. 3. Remove the connection cables to the fill valve (note assignment before removal). 4. Remove hose clamps on the fill valve connections and pull off the hoses. 5. Undo the two screws fixing the fill valve to the housing, then remove the fill valve. Re­installation is carried out in the reverse sequence. Make sure the hoses are correctly secured with the hose clamps and the cables are connected correctly.
  • Page 59 Replacing the water level unit 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the left front panel 3. Remove the connection cable to the level unit. 4. Remove hose clamps on the level unit connections and pull off the hoses. 5 Squeeze both sides of the mounting bracket to release it from the slots in the support bracket behind the water level unit, then remove the level unit. Re­installation is carried out in the reverse sequence. Make sure the hose are correctly secured with the hose clamps and the cable is connected correctly.
  • Page 60 Replacing the filling chamber 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Undo the brackets and open the right side panel. 3. Remove hose clamps on the filling chamber connections and pull off the hoses. 4 Undo the two nuts securing the filling chamber to the face of the tank, then remove the filling cham­ ber. Re­installation is carried out in the reverse sequence. Make sure the hose are correctly secured with the hose clamps.
  • Page 61 Removal of the heat exchanger (see following illustration) 1. Take the humidifier out of operation, as described in chapter 7.4. 2. Disconnect the gas supply pipe from the connection on the humidifier and close off the pipe. 3. Undo the brackets and open the right side panel(s). 4. Dismount flue gas pipe extension at the connection of the flue gas manifold. 5. Free all cable connections to the components (combustion blower, ignition module, air pressure switch, etc.) of the respective heat exchanger. Important! Note the connector assignment. 6. Undo the coupling of the respective flexible gas pipe and remove the flexible gas pipe. 7. Dismount the burner with the air blower and the gas pressure regulating valve of the respective heat exchanger. 8. Unscrew the nuts and remove the flue gas manifold from the heat exchanger. 9. Unscrew the nuts on the heat exchanger and pull out the heat exchanger from the tank. Re­installation is carried out in the reverse sequence. Replace all seals with new ones. Make sure all cables are connected correctly. Caution – Danger of explosion! Following maintenance work on the gas system, a leakage test must always be undertaken in accordance with chapter 5.5.2.

  • Page 62: Notes On Cleaning Agents

    The use of disinfectants is only permitted if they deposit no poisonous residues. In all cases, the components that have been cleaned in this way are to be rinsed with water. Caution! Do not use solvents for cleaning purposes, nor aromatized or halogenized hy- drocarbons or other aggressive substances. Follow local environmental protection regulations without reservation. 8.4 Resetting the maintenance reminder After completing maintenance work, the maintenance reminder message must be reset via the reset function in menu mode of the control (see chapter 5.6 in the separate operating instructions for Condair GS control).

  • Page 63: Troubleshooting

    Error indication Malfunctions during operation are indicated by a corresponding warning message (operation still pos­ sible, yellow LED lights) or a fault message (operation not possible any longer, red LED lights) in the display of the operating and control unit. Detailed information thereto can be found in the separate operating instructions for Condair GS control. Resetting the error indication To reset the error indication: Disconnect the Condair GS from the mains for approx. 5 seconds, then reconnect again. Note: If the fault has not been eliminated, the error indication reappears after a short while.

  • Page 64: Condair Gs...oc

    Replacing the backup battery on the control board of the Condair GS...OC 1. Set the Condair GS...OC out of operation as described in chapter 7.4. 2. Undo the brackets and open the right front panel. Caution! The electronic components inside the humidifier are very sensitive to electro- static discharge.Before carrying out the next step, appropriate measures must be taken to protect the electronic components against damage caused by electrostatic discharge (ESD protection). 3. Undo the 2 screws “A” of the display and control unit, then carefully remove the display and control unit to the front.

  • Page 65: Taking Out Of Service/Disposal

    Taking out of service/Disposal 10.1 Taking out of service If the Condair GS...OC must be replaced or if the humidification system is not needed any more, pro­ ceed as follows: 1. Take the unit out of operation as described in chapter 7.4. 2. Have the unit (and all other system components, if necessary) unmounted by a qualified service technician. 10.2 Disposal/Recycling Components not used any more must not be disposed of in the domestic waste. Please dispose of the unit or the individual components in accordance with local regulations at the authorised collecting point. If you have any questions, please contact the responsible authority or your local Condair representative. Thank you for your contribution to environmental protection.

  • Page 66: Specifications

    Specifications 11.1 Technical Data Condair GS...OC Type Steam output kg/h 10…40 10…80 10…120 10…160 10…200 10…240 Energy consumption 36.5 73.0 109.5 146.0 182.5 219.0 Gasous fuel Natural gas (G20, G25, G25.1, G27, GZ350) or Propane gas (G31) Electric connections power supply 230V/50…60Hz/1Phase...

  • Page 67: Flue Gas Specifications

    20.8682 0.8695 24.2659 1.0111 exhaust temperature °C exhaust mass flow kg/s 0.09 0.0196 0.102 0.0335 ­content flue gas pressure exhaust diameter When operating with natural gas G25.1, G27, GZ350 or propane gas (G31), please contact your Condair supplier for the correspond- ing flue gas specifications...
  • Page 69 Notes...
  • Page 70 Notes...
  • Page 71 © Condair ltd., Printed in Switzerland technical modifications reserved...
  • Page 72 CONSultING, SalES aNd SErvICE: reg.No. 40002-2 manufacturer: Condair ltd. member of the Walter meier Group talstrasse 35-37, 8808 Pfäffikon, Switzerland Ph. +41 55 416 61 11, Fax +41 55 416 62 62 info@condair.com, www.condair.com...

This manual is also suitable for:

Gs 40 ocGs 80 ocGs 120 ocGs 200 ocGs 160 ocGs 240 oc

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