Condair Omega Pro Operation Manual
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Condair Omega Pro Operation Manual

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OPERATION MANUAL
Steam generator
Condair Omega Pro
Humidification and Evaporative Cooling

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  • Page 1 OPERATION MANUAL Steam generator Condair Omega Pro 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 authorised by Condair Group AG. Copyright Notice ©...

  • Page 3: Table Of Contents

    4.4.3 Draining of the steam cylinder 4.4.4 Flushing the Condair RO-A water supply system 4.4.5 Performing a complete flushing of the Condair RO-A system Taking the unit out of operation Operating the control software Standard operating display 5.1.1 Operating status indication 5.1.2...
  • Page 4 Important notes on maintenance Maintenance intervals Maintenance list Removing and installing components for maintenance 6.4.1 Preparing the Condair Omega Pro for the removal of components 6.4.2 Removal and installation of the scale collector tank 6.4.3 Removal and installation of the steam cylinder 6.4.4...

  • Page 5: Introduction

    We thank you for having purchased the Condair Omega Pro steam generator. The Condair Omega Pro steam generator incorporates the latest technical ad van ces and meets all recognized safety standards. Nevertheless, improper use of the Condair Omega Pro steam generator may result in danger to the user or third parties and/or damage to property.
  • Page 6 If the documentation gets misplaced, please contact your Condair representative. Language versions This operation manual is available in other languages. Please contact your Condair representative for information. Introduction...

  • Page 7: For Your Safety

    For safety and warranty reasons any action beyond the scope of this manual must be carried out only by qualified personnel authorised by Condair. It is assumed that all persons working with the Condair Omega Pro are familiar and comply with the appropriate regulations on work safety and the prevention of accidents.
  • Page 8 Condair Omega Pro is no longer operating correctly – if connections and/or piping are not sealed All persons working with the Condair Omega Pro 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 Omega Pro without the express written consent of Condair.

  • Page 9: Product Overview

    Filling cup Ground terminals Condensate connector (to cylinder) Main contactor Condensate connector (to drain) Heating contactors Steam connector (ø45 mm) Power board Steam outlet hose Fig. 1: Construction Condair Omega Pro steam generator (figure shows medium sized unit) Product Overview...

  • Page 10: Functional Description

    3.4). Detailed instructions on the Condair RO-A pure water system can be found in the separate manual for this product. Level regulation The water level in the steam cylinder is continuously monitored with the level unit. If the water level reaches a preset level (due to the evaporation process) the level unit supplies a signal to the controller.

  • Page 11: System Overview Spa Cabin Humidification

    12 Steam line (accessory DS80) 4 Water supply connector 13 Steam distributor (by others) 5 Water supply line 14 Electrical isolator voltage supply Condair Delta 6 Manometer (recommended) SPA Control Box 7 Filter valve (accessory Z261) 15 Condair Delta SPA Control Box...

  • Page 12: System Overview Direct Room Humidification

    15 Humidity controller or humidity sensor 7 Filter valve (accessory Z261) 16 High limit humidistat 8 Open funnel with water trap 17 Pure water system Condair RO-A (option) 9 Drain hose (supplied) Fig. 3: System overview direct room humidification Product Overview...

  • Page 13: Operation

    DANGER! Risk of electric shock! After switching off the unit switch, there is still live voltage inside the control compartment of the Condair Omega Pro. Therefore, before opening the unit the steam generator must be always separated from the mains supplies (heating and control voltage) via the electrical isolators.

  • Page 14: Commissioning After An Interruption Of Operation

    5.1.2). If the function check on the level unit is successful, the Condair Omega Pro will be in normal op- erating mode and the standard operating display is shown. The heating current switches on as soon as the controller/sensor demands for steam. The LED lights green and steam is produced after a short delay.

  • Page 15: Notes On Operation

    Notes on operation 4.4.1 Inspections during operation During operation the Condair Omega Pro 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 generator and the other system components for correct fixing and any damage.

  • Page 16: Draining Of The Steam Cylinder

    The drain cycle is stopped and the unit returns to the "Manual" submenu. 4. If you have to carry out work on the Condair Omega Pro, switch off steam generator via the unit switch. Otherwise the steam cylinder is immediately filled again.

  • Page 17: Performing A Complete Flushing Of The Condair Ro-A System

    4.4.5 Performing a complete flushing of the Condair RO-A system Note: the FWA flushing function in the "manual" submenu appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu. To perform a complete flushing of the RO system proceed as follows: 1.

  • Page 18: Operating The Control Software

    Operating the control software Standard operating display After switching on the Condair Omega Pro and the automatic system test the steam generator is in normal operating mode and the standard operating display is shown. Note: the appearance of the standard operating display depends on the current operating status and the configuration of the control of the system and can deviate from the display shown below.

  • Page 19: Operating Status Indication

    The Condair Omega Pro checks the function of the level unit. The Condair Omega Pro is connected to a BMS, and the BMS has activated the diagnostic mode. The Condair Omega Pro has been stopped via an external enable contact (remote enable/disable).

  • 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

    Humidifier Model: Designation of the steam generator with steam output in kg/h oder lb/h. – RO Model: Model of the Condair RO system the Condair Omega Pro is connected to. Note: this menu item appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.
  • Page 22 Driver C.DB.A Version: Actual software version of the driver board of the Condair RO-A reverse osmosis system. Note: this menu item appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.
  • Page 23 Operating Hour RO: Operating hours of the reverse osmosis system since initial commissioning. Note: this menu item appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.
  • Page 24 Features Tab Manual Capacity A: Actual set capacity limitation in % of the maximum – capacity. – Idle Mode: Actual set standby mode ("Idle Drain", "Keep Warm", "Standby"). – Softstart Mode: Actual status of the softstart function ("On" or "Off"). –...
  • 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 Omega Pro to Condair Online("Connected" or "Disconnect'd"). – IP Address: shows the IP address of the Condair Omega Pro.

  • Page 26: Configuration

    Accessing the "Configuration" submenu Password: 8808 5.4.2 Activating/deactivating and configuration of options – "Features" submenu In the "Features" submenu you can determine different operating parameters of the Condair Omega Pro. Water Management Tab – Water Mode: with this setting you determine whether the flushing interval time and the maintenance interval time for the small and the extended maintenance are calculated automatically on the basis of parameters water quality and water hardness (Setting: "Calculated") or whether the...
  • Page 27 The following settings appear only, if "Water Mode" is set to "Manual". Note: The settings for the parameters to be selected depend on the supply water quality and the steam capacity of the unit and must be set in ac- cordance with the following table.
  • Page 28 The following settings appear only, if "Water Mode" is set to "Calculated". Important: the water quality and the water hardness of the supply water must be known. Using wrong values for these two parameters may lead to increased maintenance work and operating malfunctions. –...
  • Page 29 Idle Mode Tab – Idle Mode: with this setting you determine the operational behaviour of the Condair Omega Pro in standby operation. Factory setting: Idle Drain Options: Idle Drain (the steam cylinder is drained and re- filled after a set time in standby operation)
  • Page 30 60 °C (at 20 °C ambient temperature), so that the Condair Omega Pro can produce steam as fast as possible as soon as a demand is present again. If the ambient temperature is higher or lower than 20 °C the heating power of...
  • Page 31 – Manual Capacity A: with this button you can access the settings menu for the capacity limitation. Here you determine whether the Condair Omega Pro is to be operated with a fix capacity limitation (factory setting) or whether it is to be operated with a timer controlled capacity limitation.
  • Page 32 – Operation with timer controlled capacity limitation Activate the timer function (Capacity Timers: "On"). If the capacity timer is activated, up to eight switching points (Event 1... Event 8) with different capacity limits can be defined. Each switching point is defined by a weekday or weekday range, the switching time and the capacity limitation in % of the maximum steam capacity.
  • Page 33 ("Off") the optional drain valve for the automatic draining of the scale col- lector tank in standby operation. Note: if the optional drain valve is activated, the Condair Omega Pro is completely drained in standby operation (including scale collector tank) and refilled only after a steam demand is present again.

  • Page 34: Control Settings - "Control Settings" Submenu

    5.4.3 Control settings – "Control Settings" submenu In the "Controls Settings" submenu you determine the control settings for the Condair Omega Pro steam generator. The control settings available depend on the selected signal source and the control mode. Basic Tab – Source: with this setting you determine the source of the control signal.
  • Page 35 – Setpoint Channel 1: with this button you can access the settings menu for the humidity setpoint. Here you determine whether the Condair Omega Pro is to be controlled with a fix humidity setpoint (factory setting) or whether it is to be operated timer controlled with different humidity setpoints.
  • Page 36 – 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 37 Factory setting: Setting range: 1 ... 10 % – Enable Input: With this setting you determine wether the Condair Omega Pro can be enabled and disabled via an external enable contact ("On") or not ("Off"). Factory setting: Options:...
  • Page 38 Multi Unit Operation Tab – Linkup: with this setting you determine whether the unit is part of a Linkup system and acts as master or slave unit or whether the unit is not part of a Linkup system. Note: the master unit must be set always to "Main". The further slave units in the chain must be set in ascending order to "Ext1"...

  • Page 39: Basic Settings - "General" Submenu

    Full Out B: this parameter indicates at which percentage of the demand signal cylinder B is switched off (calculated value). 5.4.4 Basic settings – "General" submenu In the "General" submenu you determine the basic settings for operating the Condair Omega Pro control software. Basic Tab –...

  • Page 40: Communication Settings - "Communication" Submenu

    – Contrast: with this setting you determine the desired value for the display contrast. Factory setting: Options: 1 (weak contrast) ... 31 (strong contrast) – Brightness: with this setting you determine the desired value for the display brightness. Factory setting: Options: 1 (dark) ...
  • Page 41 Pro assigned manually or assigned by a DHCP server. If the parameter "IP Type" is set to "Fixed", the IP address of Condair Omega Pro can be set via this field. If the parameter "IP type" is set to "DHCP", the IP address of Condair Omega Pro is assigned by a DHCP server.
  • Page 42 BACnet/IP (BACnet/IP via RJ45 interface) Important: regarding the setting of the individual BACnet parameters as well as the wiring of the Condair Omega Pro for the BACnet Ip or BACnet MS/TP communication, please observe the instructions in the separate BACnet addendum manual. This manual can be requested from your Condair representative.
  • Page 43 Remote Fault Board Tab – Indication: with this setting you determine whether only maintenance messages ("Service") or all Warning messages ("Warning") are outputted via the service relay of the remote operating and fault indication board. Factory setting: Service Options: Service or Warning –...

  • 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 and save the fault and main- tenance history and perform different diagnostic functions. General Service Tab – Small Maint. Reset A: with the "Small Maint. Reset A" function you can reset the service message or the service counter, respectively for the small maintenance of unit A.
  • Page 45 RO systems. After pressing on the "RO Service Reset" button a confirmation window appears where the resetting must be confirmed. Note: this menu item appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.

  • 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 10V External Supply: Actual voltage of the external 10 V supply. RO Tab The "RO Tab" appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.

  • 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 – Running: with this function you can activate ("On") and deactivate ("Off") the relay "Steam" on the remote operation and fault indication board. – Service: with this function you can activate ("On") and deactivate ("Off") the relay "Service"...

  • Page 49: Switching On/Off Password Protection And Software Updates Function - Submenu "Administrator

    See information in chapter 6.8. Note: this menu item appears only, if the Condair Omega Pro is connected to a Condair RO-A reverse osmosis system and if the reverse osmosis system was activated in the factory menu.

  • Page 50: Maintenance

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

  • Page 51: Maintenance Intervals

    Maintenance intervals To maintain operational safety the Condair Omega Pro steam generator must be maintained at regular in- tervals. The control software of the Condair Omega Pro features two maintenance counters one for the "Small maintenance" (Cleaning of the scale collector tank, only for units equipped with a scale collector tank) and one for the "Extended maintenance"...

  • Page 52: Maintenance List

    Maintenance list Adjacent you can find an overview of the maintenance work to be carried out on "Small maintenance" and "Extended maintenance". Components Work to be done Scale collector tank Remove and clean. Note: the scale collector tank must be replaced at the latest after 5.000 operation hours or after 3 years.

  • Page 53: Removing And Installing Components For Maintenance

    6.4.1 Preparing the Condair Omega Pro for the removal of components Before starting any removal work set the Condair Omega Pro out of operation and drain the steam cylinder and the scale collector tank (if applicable). Proceed as follows: 1. Condair Omega Pro must be switched on. Perform a draining of the steam cylinder (see chapter 4.4.3).

  • Page 54: Removal And Installation Of The Scale Collector Tank

    6.4.2 Removal and installation of the scale collector tank Removal WARNING! Danger of burning! Before removal of the scale collector tank ensure it is empty and the temperature indication adhesive on the scale collector tank indicates a temperature <122 °F (<50°C) . Snap ring O-ring Strainer...
  • Page 55 Installation Prior to the installation: • Check scale collector tank, O-ring, snap ring and strainer insert for damages and replace defective components if necessary. We recommend to replace the sealings of the scale collector tank with each maintenance. For that purpose a maintenance kit is available (see parts list). •...

  • Page 56: Removal And Installation Of The Steam Cylinder

    6.4.3 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. Loosen retaining screw on front door on the steam cylinder side of the unit using a screwdriver, then remove the front door.
  • Page 57 3. Carefully lift the steam cylinder out of steam cylinder receptacle and remove it towards the front of the unit. CAUTION! Set down the steam cylinder carefully to ensure the funnel on the bottom side of the cylinder is not damaged! 4.
  • Page 58 6. If necessary, loosen the funnel insert by lightly rotating it in either direction and lift it together with baffle from the steam cylinder. Then, remove the screen insert from the funnel insert. 7. If during maintenance one or more heating elements must be replaced: •...

  • Page 59: Removal And Installation Of The Drain Cup

    Assembly and installation of the steam cylinder Assembly of the steam cylinder takes place in reverse sequence of the removal. Please note the fol- lowing instructions: – Installation of any heating elements which have been removed should follow the figure of step 7. Please take care that the heating elements are correctly positioned and the cables are correctly connected (according to your notes).

  • Page 60: Removal And Installation Of The Filling Cup, The Level Unit And The Water Hoses

    6.4.5 Removal and installation of the filling cup, the level unit and the water hoses For removing the filling cup, the level unit and the water hoses the steam cylinder must be removed first (see chapter 6.4.3). 1. Release hose clamps, then disconnect all hoses from the corresponding connectors and remove the hoses. Note: The hoses connected to the filling cup and the level unit may also be removed together with the filling cup and the level unit (see illustration) and then disconnected from the connectors outside the unit.

  • Page 61: Removal And Installation Of The Drain Pump

    6.4.6 Removal and installation of the drain pump For removing the drain pump the steam cylinder must be removed first (see chapter 6.4.3). 1. Detach electric cables (polarity of the cables must not be observed). 2. Release hose clamps and remove the hoses from the connectors. 3.

  • Page 62: Removal And Installation Of The Inlet Valve

    6.4.7 Removal and installation of the inlet valve For removing the inlet valve the steam cylinder must be removed first (see chapter 6.4.3). 1. Detach electric cables (polarity of the cables must not be observed). Important: on multiple valves (units with increased control accuracy or units with option drain cooling) ensure to reconnect the connecting cables to same valve (note position).

  • Page 63: Removal And Installation Of The Steam Cylinder Receptacle

    6.4.8 Removal and installation of the steam cylinder receptacle For removing the steam cylinder receptacle the steam cylinder must be removed first (see chapter 6.4.3). 1. Release hose clamps and remove hoses from the connectors. 2. Undo the screw fixing cylinder receptacle to the bottom of the housing with Phillips screwdriver. 3.

  • Page 64: Notes On Cleaning The Unit Components

    Notes on cleaning the unit components Unit component What to clean and how to clean Scale collector tank • Dump any lime in scale collector tank, then carefully remove any limescale inside scale collector tank and on the strainer insert using a soft bristled brush (do not use a wire brush) using a soft bristled brush (do not use a wire brush).
  • Page 65 Unit component What to clean and how to clean Hoses • Loosen any limescale in the hoses by carefully twisting and flexing the hoses, then flsuh out the hoses thoroughly with hot water. Inlet valve • Carefully remove any limescale inside the inlet valve and on the strainer using a soft bristled brush (do not use a wire brush).

  • Page 66: Notes On Cleaning Agents

    Unit component What to clean and how to clean Drain cup • Carefully emove any limescale from the drain cup and its connectors using a soft bristled brush (do not use a wire brush). If the drain cup is heavily calcified, place it in an 8% formic acid solution (observe safety notes in chapter 6.6), until the limescale comes off.

  • Page 67: Resetting The Maintenance Counter

    Resetting the maintenance counter After completing the "Small maintenance" or the "Extended maintenance", the corresponding mainte- nance indication or maintenance counter (for module A or module B or for both), respectively must be reset. Proceed as follows to reset the maintenance counter: 1.

  • Page 68: Performing Software And Firmware Updates

    "Driver C.DB.A" update the firmware for the driver board of optional Condair RO-A re- • verse osmosis system (only possible, if Condair Omega Pro is configured for the operation with a Condair RO-A reverse osmosis system). The update starts. A progress bar is shown in the display. If the update has completed the control unit returns to the standard operating display.

  • Page 69: Fault Elimination

    General notes Only use original spare parts from your Condair representative to replace defective parts. Safety Before starting repair work on the Condair Omega Pro set the unit out of operation and disconnect it from the mains (see chapter 4.5).

  • Page 70: Malfunction List

    LED below the touch panel will lights up red. If such a malfunction occurs, the steam production of the Condair Omega Pro will be stopped automatically.
  • Page 71 The level in the steam cylinder has not dropped to the preset level within the preset time. The Condair Omega Pro carries out a level test. This procedure is repeated three times if maximum drain time is exceeded again, then a fault...
  • Page 72 Remedy ––– Invalid Level Invalid level detected, steam production is stopped! Note: As soon as the level is within the valid range again, the Condair Omega Pro continuous normal operation. Magnetic field in vicinity of level unit. Eliminate magnetic field.
  • Page 73 Connect jumper wire "J1" to terminal wire "J1" not connected to terminal block block "X12" on driver board. "X12" on driver board. These fault messages must be reset by switching the Condair Omega Pro off and on again (see chapter 7.5) Fault elimination...

  • Page 74: 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 Omega Pro can be saved to a USB memory stick for log- ging and further analysis. For this purpose proceed as follows: 1.

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

    Fig. 6: Position of the backup battery and the fuses on the driver board 5. Swivel control board assembly 90°inwards. 6. Relocate front cover on control unit and lock it with the retaining screw. 7. Reconnect Condair Omega Pro to the mains by switching on the electrical isolator.. Fault elimination...

  • Page 76: Taking Out Of Service/Disposal

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

  • Page 77: Product Specification

    Product specification Performance data 230V/1~/50...60 Hz 200V/3~/50...60 Hz 230V/3~/50...60 Hz 380V/3~/50...60 Hz 400V/3~/50...60 Hz 415V/3~/50...60 Hz Condair Omega 16,5 –– –– –– –– –– 26,0 –– –– –– –– –– 15,0 32,0 10,0 –– –– –– –– –– 18,5 10,2 10,0...

  • Page 78: Operating Data

    – Admissible Feed temperature 1...40 °C (with optional drain water cooling 1...25 °C) – Water quality Untreated drinking water, RO water, de-ionized water (for operation with softened or partly softened water please contact your Condair repre- sentative) Water drain – Drain water temperature 60...90 °C...
  • Page 80 CONSULTING, SALES AND SERVICE: CH94/0002.00 Condair Group AG Gwattstrasse 17, 8808 Pfäffikon SZ, Switzerland Phone +41 55 416 61 11, Fax +41 55 588 00 07 info@condair.com, www.condair-group.com...

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