Condair Omega Pro Service Manual
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Condair Omega Pro Service Manual

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SERVICE MANUAL
Steam generator
Condair Omega Pro
Humidification and Evaporative Cooling

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Summary of Contents for Condair Condair Omega Pro

  • Page 1 SERVICE 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 authorized by Condair Group AG. Copyright Notice ©...

  • Page 3: Table Of Contents

    Determining unit settings 3.1.2 Determining unit settings 3.1.3 Reset unit to factory default 3.1.4 Determining the countdown function for the blocking of the Condair Omega Pro Factory functions in the "Service" submenu 3.2.1 Reset fault and service history 3.2.2 Output diagnostic functions...
  • Page 4 Replacing the integrated controller board and using the existing SIM card Appendix Condair Omega Pro 400 V standard unit wiring Connection of the Condair RO-A pure water system to the Condair Omega Pro (Condair Omega Pro integrated systems) 6.2.1 Wiring diagram Condair RO-A - Condair Omega Pro 6.2.2...

  • Page 5: Introduction

    The present service manual is meant for the trained Condair service technician and assumes a profound knowledge on the Condair Omega Pro. It is also assumed that the Service technician has notice of the installation manual and operation manual of the Condair Omega Pro and that he is familiar with the dangers when working on the unit.

  • Page 6: For Your Safety

    General The service technician working with the Condair Omega Pro must have read and understood the present service manual as well as the installation manual and the operation manual of the Condair Omega Pro before carrying out any work. Knowing and understanding the contents of the service manual as well as the installation manual and the operation manual of the Condair Omega Pro is a basic requirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the unit safely and correctly.
  • Page 7 DANGER! Danger of electric hazard! The Condair Omega Pro is mains powered. Live parts may be exposed when the unit is open. Touching live parts may cause severe injury or danger to life. Prevention: Before carrying out any work set the Condair Omega Pro out of operation (switch off the unit, disconnect it from the mains and stop the water supply) and secure the unit against inadvertent power-up.

  • Page 8: Factory Settings

    Factory settings With the factory password "1055" you may access the factory settings in the "Factory" submenu as well as the factory functions in the "Service" submenu. Factory settings in "Factory" submenu • Select the "Factory" submenu as shown below. Password: 1055 Factory settings...

  • Page 9: Determining Unit Settings

    – Mode: With this setting you determine whether the controller is configured to control the Condair Omega Pro only ("RS"), the Condair Omega Pro with optional reverse osmosis system ("RS+RO") or the optional reverse osmosis system only ("RO").

  • Page 10: Determining Unit Settings

    – Drain Cool: With this setting you can activate ("On") or deactivate ("Off") the software function for the optional drain cooling if the Condair Omega Pro is equipped with the optional drain cooling. Factory setting: Options:...
  • Page 11 – Hygiene Flush: With this setting you can activate ("On") or deactivate ("Off") the water supply line flushing function. Factory setting: Options: On (water supply line flushing function activated) or Off (water supply line flushing function deactivated) Int.-/Ext. Valve: With this setting you determine whether the flushing of –...

  • Page 12: Reset Unit To Factory Default

    All settings and operating hours are retained ( ATTENTION, only valid from software version 5.6.x.xx). 3.1.4 Determining the countdown function for the blocking of the Condair Omega Pro • In the "Factory" submenu press on the <Factory Default> button, and select the "Countdown" tab.

  • Page 13: Factory Functions In The "Service" Submenu

    Factory functions in the "Service" submenu • In the main menu press on the <Service> button as shown below. Password: 1055 3.2.1 Reset fault and service history • Select in the "Service" submenu the "Fault/Service History" tab. Note: the functions "Reset Fault History" and "Reset Service History" are shown only, if the menu has been accessed with the factory password "1055".

  • Page 14: Output Diagnostic Functions

    3.2.2 Output diagnostic functions • Select in the "Service" submenu the "Diagnostic" tab. Note: the menu item "Output Diagnostics" is shown only, if the menu has been accessed with the factory password "1055". The following output diagnostic functions for "Cylinder A" (and "Cylinder B", if applicable) are avail- able after accessing the "Output Diagnostics"...
  • Page 15 – Inlet 2: With this function you can open and close the second inlet valve on Option P units. Note: On standard units this parameter has not function. – Drain 1: With this function you can open and close the optional drain cooling valve.

  • Page 16: Operational Malfunctions

    Operational malfunctions W5 - Extension unit missing Function: indicates that there is no connection between the main unit and the extension unit. Procedure: if the connection between the main unit and the extension unit is lost, the system will be blocked and the warning "W5"...

  • Page 17: W6 - Main Unit Missing

    W6 - Main unit missing Function: indicates that there is no connection between the extension unit and the main unit. Procedure: if the connection between the extension unit and the main unit is lost, the system will be blocked and the warning "W6" will be displayed. The warning display is automatically reset as soon as a connection is available again.

  • Page 18: E10 - Reset Integrated Controller

    E10 – Reset Integrated controller Function: indicates that the Integrated Controller of the Condair Omega Pro has carried out an automatic restart due to a software problem. Procedure: If the Integrated Controller of the Condair Omega Pro detects a software problem that makes continued operation impossible, the controller carries out an automatic restart.

  • Page 19: W20/E20 - External Safety Loop Open Or Interrupted

    W20/E20 - External safety loop open or interrupted Function: indicates that the safety loop is open. Procedure: if the external safety loop is open the system is blocked and the warning message "W20" is triggered. As soon as the safety loop is closed again the warning or error message is automatically reset. Note: By setting the parameter "Safety Loop"...

  • Page 20: E22 - Maximum Filling Time Exceeded

    180 s 180 s Procedure: the Condair Omega Pro monitors the filling process with different levels. If a level is not reached within the preset time (see table above) warning message "W22" is triggered and the heating is blocked as soon as the level drops below level 1 (level red). However the filling process is not stopped.

  • Page 21: E26 - Main Contactor Jammed

    Function: indicates that the level in the steam cylinder has dropped, although there is no humidity demand. Procedure: if the Condair Omega Pro detects a level change without a request being present, the error message "E26" immediately appears and the system is blocked. The reason for this may be a leak or a jammed main contactor.

  • Page 22: W28 - Small Maintenance Due

    Time delay: – – Reset: Perform small maintenance, then – reset maintenance counter. Diagnostic actions: • Perform small maintenance in accordance with the instructions in the operation manual of the Condair Omega Pro, then reset maintenance counter. Operational malfunctions...

  • Page 23: W29 - Extended Maintenance Due

    Time delay: – – Reset: Perform extended maintenance, – then reset maintenance counter. Diagnostic actions: • Perform extended maintenance in accordance with the instructions in the operation manual of the Condair Omega Pro, then reset maintenance counter. Operational malfunctions...

  • Page 24: W32 - Humidity Sensor Signal Interrupted

    W32 - Humidity sensor signal interrupted Function: indicates that the humidity sensor signal is out of range. Unit is blocked. Procedure: the monitoring of the humidity sensor signal is active only, if the internal controller is activated. If the humidity sensor signal drops below the threshold of 5 %, warning message "W32" is triggered and the unit is blocked.

  • Page 25: E34 - Maximum Drain Time Exceeded

    Function: indicates that the maximum drain time has exceeded. Procedure: the Condair Omega Pro monitors the draining process with different levels. If the next lower level is not reached within the preset time of 20 seconds the warning message "W34" is triggered. The unit starts a level test and continuous the draining process.

  • Page 26: W35 - Bms Timeout

    4.11 W35 - BMS Timeout Function: indicates that no control signal has been transmitted via the BACnet or Modbus bus system for longer than the time specified with the "BMS Timeout" parameter (factory setting: 300 s). Procedure: As soon as the control signal (demand or humidity signal) is sent via the BACnet or Modbus bus system, communication of the bus system is also monitored.

  • Page 27: E47 - Invalid Level Detected

    Procedure: if a wrong level is detected the "W47" is triggered and the unit stops humidifying and starts a level test. If the level test has passed, the Condair Omega Pro restarts steam production. If the level test can not be passed for five times, the error message "E47" is triggered and the unit is blocked.

  • Page 28: E52 - Unstable Level

    Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check the hose connections between the level unit and Steam cylinder receptacle and between the level unit and steam output. •...

  • Page 29: E54 - Leak Sensor

    4.14 E54 – Leak sensor Function: Indicates that the optional leak sensor connected to contact J8 has detected leaking water. Procedure: If the optional leak sensor detects leaking water, the error message "E54" appears imme- diately and the system is blocked. The reason for this can be a leak in the water supply or drain line or a leak in the device.

  • Page 30: E56 - Internal Safety Loop Interrupted

    Check the cylinder and the thermostat (Klixon) on it. • Check the connection between the power board and the driver board. 4.16 E58, E60, E61, E62 and E73 See malfunction list in the installation and operating instructions of the reverse-osmosis system Condair RO-A. Operational malfunctions...

  • Page 31: E74 - Keep Alive Signal Missing

    Entry error history: – System: – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check connecting cable between control board and driver board. • Replace driver board. Operational malfunctions...

  • Page 32: E80 - Usb Logger Fault

    Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check whether the logger mode is activated, without using it • Check whether a FAT32 formatted USB memory stick is connected to the USB port on the control board.

  • Page 33: E82 - Driver Missing

    System: – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check cable and plugs between the control and driver board. • Change the driver board. • Change the control board.

  • Page 34: E83 - Driver Board Address Of Extension Unit Wrong

    Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check whether the rotary switch on the driver board of the extension unit is set to 1. 4.21 E84 - Driver board unspecific Function: indicates that the driver board is defective.

  • Page 35: E85 - Product Id Of Driver Board Wrong

    E85 - Product ID of driver board wrong Function: indicates that the product ID of the driver board does not match. Procedure: if a wrong driver board is installed (e.g. driver board of Condair EL), error "E85" is triggered and the unit is blocked.

  • Page 36: E87 / E88 / E89 - Driver Local Supply Voltage

    Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Go to "Main Menu > Service > Input diagnostic" and check the 24 V value. • Adjust the voltage with the potentiometer on the power supply. If it is not possible to bring the 24 V voltage to the admissible range, change the power supply.

  • Page 37: E95 - Heating Voltage Missing

    4.26 E95 - Heating voltage missing Function: indicates that the heating voltage is missing although a demand is present. Procedure: if a humidity demand is present the control check every two minutes, whether or not heating voltage is present. If no heating voltage is present the error message "E95" is triggered and the system is blocked.

  • Page 38: E97 / E98 - 24 V/10 V Output Of Driver Board Out Of Admissible Range

    Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check voltage on 24 V (JP2 set) or 10V (JP1 set) output of the driver board between the terminals Vout and GND.

  • Page 39: E100 - Fault State On Output Driver Of Inlet Valve

    E100A(B) System: – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check wiring to inlet valve 1. • Check coil of inlet valve 1 for short circuit. Operational malfunctions...

  • Page 40: E101 - Fault State On Output Driver Of Inlet Valve

    E101A(B) System: – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check wiring to inlet valve 2. • Check coil of inlet valve 2 for short circuit. Operational malfunctions...

  • Page 41: E111 - Fault State On Output Driver Of Optional Drain Water Cooling Valve

    – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check wiring to drain water cooling valve. • Check coil of drain water cooling valve for short circuit. Operational malfunctions...

  • Page 42: E112 - Fault State On Output Driver Of Optional Scale Collector Drain Valve

    – Unit blocked Time delay: – – Reset: – Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check wiring to optional scale collector drain valve. • Check coil of optional scale collector drain valve for short circuit.

  • Page 43: E120 - Fill Time Minimum

    Unit blocked Time delay: – – Reset: self healing Switch Condair Omega Pro Off and On again. Diagnostic actions: • Check the level unit for calcification and clean if necessary. • Check the hose connections from the level to the cylinder and clean if necessary.

  • Page 44: E121 - Maximum Vaporization Time Exceeded

    E121 - Maximum vaporization time exceeded Function: indicates that the maximum vaporization time has exceeded. Procedure: the Condair Omega Pro monitors the vaporization time to reach the requested demand. If the maximum vaporization time has exceeded the warning message "W121" is triggered and the unit starts a level test.

  • Page 45: E124, E200, E201 And E210

    Threshold 20% * Evaporation Gradient = Actual threshold for monitoring. CAUTION! With evaporation Gradient set to 5, the monitoring function is disabled 4.34 E124, E200, E201 and E210 See malfunction list in the installation and operating instructions of the reverse-osmosis system Condair RO-A. Operational malfunctions...

  • Page 46: W300 - Safety Loop Blower Pack Open

    4.35 W300 - Safety loop blower pack open Function: indicates that the blower pack safety loop is open. Procedure: If the safety loop of the blower pack is interrupted, the system is blocked and the warning "W300" is displayed. As soon as the safety loop safety loop of the blower pack is closed again the warn- ing or error message is automatically reset.

  • Page 47: Notes On Unit Components And Functions

    Power electronic board to control the heating elements according to the demand. • Power supply Generates the internal supply voltage. Unit versions The Condair Omega Pro is distinguished by a basic version and additional options. Type Characteristics Basic • Power board and heating contactors Option P •...

  • Page 48: Control Signals

    Control signals The control signal input unit is capable of handling a variety of signals. A suitable signal range can be selected in the menu "control settings" (Main Menu -> Configuration -> Control Settings). Control signals Jumper JP2 on driver board Remarks 24V (ON/OFF) 0 –...

  • Page 49: Heating Control Condair Omega Pro

    Heating control Condair Omega Pro 5.4.1 Steam demand and heating assemblies Condair Omega Pro 230 V 5 kg, 8 kg, 10 kg Steam Heating assembly module A (Steam cylinder A) demand [%] A1/1 A1/2 A1/3 200 V 16 kg / 230 V 16 kg, 20 kg...
  • Page 50 380-415 V 16 kg, 20kg / 440-500V 16, 30kg / 550-600V 20kg Steam Heating assembly module A (Steam cylinder A) demand [%] A1/1 A1/2 A1/3 380-415V 24, 30kg, 40kg / 440-500V 20, 40kg / 550-600V 30, 40kg Steam Heating assembly module A (Steam cylinder A) demand [%] A1/1 A1/2...

  • Page 51: Level Unit

    Max. level The level unit is the most important part of the steam generator. Without the level unit the Condair Omega Pro is not able to produce steam in a secure and precise manner. Due to the importance, the level unit is checked by a level tests after certain states and times.

  • Page 52: Fill And Drain States On The Basic Unit With Option P

    5.6.2 Fill and drain states on the Basic unit with option P State Procedure Condition Condition NO Condition YES Next procedure – Start up Level test Level ≤1 Steam cylinder Drain from N to – Stand still will be filled until level test ≥...

  • Page 53: Idle Drain

    Idle Drain If the unit is a certain time in standby the cylinder with the standing water would be the perfect environ- ment for legionella and bacteria. Because of that, the idle drain is used to change the cylinder water after a defined time of 1-100h.

  • Page 54: Service Interval Times And Reduction Time

    5.10 Service interval times and reduction time The service interval times and reduction time can be configured in two different ways. 5.10.1 Manual input of the service interval times and reduction time With this type of configuration the interval times for the small and the extended maintenance as well as the reduction time are manually inputted in the control software.

  • Page 55: Calculated Service Interval And Reduction Time

    5.10.2 Calculated service interval and reduction time If the water supply quality is well known, it’s also possible to set the water mode in such a way, that the interval times for the small and the extended maintenance as well as the reduction time are automatically calculated based on the water quality.

  • Page 56: Definitions

    5.10.2.2 Definitions Water type: Water type Description Tap water Untreated tap water RO water with low conductivity < 5uS RO water with high conductivity > 5uS Equation parameter: Equation parameter Tap water RO water RO water < 5uS > 5uS Equation parameter Reduction (are used to calculate the reduction time) Factor...

  • Page 57: Equations For The Calculation Of The Maintenance And Reduction Intervals

    5.10.2.3 Equations for the calculation of the maintenance and reduction intervals Equation 1: (Ref. Water hardness − Water hardness) = Factor * (t * Gradient Interval IntervalNom IntervalNom Water hardness gradient range Equation 1 is used to calculate the interval time for the small and the extended maintenance as well as the reduction interval time when using tap water.
  • Page 58 Example 3: 20kg unit, Small maintenance: Small maintenance interval according to small maintenance table (see chapter 5.10.2.1): 600 h Water quality: Tap water, 18 °dH Used equation: Equation 1 (12 °dH − 18 °dH) = 1 * (600 h + * 600 h * 0.4 = 456 h Interval 10 °dH...

  • Page 59: Sim Card

    5.11 SIM card The main memory for the settings is in the flash memory of the integrated controller; the SIM card serves as a backup of all settings. When starting the integrated controller, the serial number of the SIM card is compared to that of the integrated controller.

  • Page 60: Replacing The Integrated Controller Board And Using The Existing Sim Card

    If an Integrated Controller without software is used, proceed as follows: 1. Switch off the power to the Condair Omega Pro and insert the USB stick with the requested software into the USB port at the back of the Integrated Controller.
  • Page 61 7. Open menu "Factory > Factory Default" and select <Reset Serial Number>, then confirm with <Yes>. 8. Disconnect the Condair Omega Pro from the mains and after 3 seconds switch it back on. Confirm the message "First Power Up" during the starting sequence with <Proceed>.
  • Page 62 Transferring the original settings from the SIM card is not possible when: – A completely new control unit with a new serial number is delivered (see case 10.3). The serial number has been loaded into the integrated controller during production. It does not match the serial number of the existing SIM card.

  • Page 63: Appendix

    Appendix Condair Omega Pro 400 V standard unit wiring HEAT GR. CON- PUMP SWITCH TACTOR PWR IC RS485 RS485 REMOTE BOARD RS485 RS485 ACCESSORY BOARD Appendix...

  • Page 64: Connection Of The Condair Ro-A Pure Water System To The Condair Omega Pro (Condair Omega Pro Integrated Systems)

    Connection of the Condair RO-A pure water system to the Condair Omega Pro (Condair Omega Pro integrated systems) 6.2.1 Wiring diagram Condair RO-A - Condair Omega Pro brown/green braun white white IC Omega Pro yellow green Option Softener Rotary switch...
  • Page 65 Connection of the driver boards of the Condair RO-A pure water system and the Condair Omega Pro Connect RS485 control cable to terminal X14 (RS485-1) Driver board on the driver board inside the Condair RO-A pure water unit and to the terminal X14 (RS485-1) on the driver board inside the Condair Omega Pro steam generator according to the opposite wiring diagram.

  • Page 66: Connecting Condair Omega Pro Type Units To The Condair Ro-A

    6.2.2 Connecting Condair Omega Pro type units to the Condair RO-A RS485-1 RS485-2 Condair RO-A 40...300 l/h Condair Omega Pro 5...40 – Single units "S" et "M" Driver board RO-A Driver board Omega Pro Condair Omega Pro Rotary switch = 0...
  • Page 68 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.condairgroup.com...

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