Condair ME Series Operation Manual
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Condair ME Series Operation Manual

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READ AND SAVE THESE INSTRUCTIONS
OPERATION MANUAL
Surface evaporator
Condair ME Control
Humidification and Evaporative Cooling

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  • Page 1 READ AND SAVE THESE INSTRUCTIONS OPERATION MANUAL Surface evaporator Condair ME Control 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

    3.4.1 Typical system Condair ME Control, internal install 3.4.2 Typical system Condair ME Control, external install with centre drain tank 3.4.3 Typical system Condair ME Control, external install with side drain tank (evaporative modules up to 3000 mm wide only) 3.4.4...
  • Page 4 Dismantling and installation of the evaporative module Consumables guide Routine water sampling and hygiene checks Cleaning and disinfection Cleaning and disinfection procedure Resetting the maintenance indication on Condair ME Control 6.10 Performing software and firmware updates Fault elimination Fault indication on Condair ME Control control unit...

  • Page 5: Introduction

    Improper use of the Condair ME Control may result in danger to the user or third parties and/or impairment of material assets. If you have questions after reading this documentation, please contact your Condair representative.
  • Page 6 If the operation manual gets mislaid, please contact your Condair representative. Language versions This operation manual is available in various 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 only be carried out by personnel with appropriate industry recognised qualifications or training. It is assumed that all persons working with the Condair ME Control are familiar and comply with the appropriate local regulations on work safety and the prevention of accidents.
  • Page 8 Inadequately operated and/or poorly maintained surface evaporator may endanger health. When inadequately operated and/or poorly maintained micro-organisms may grow in the evaporative module, the water tank and the water system of the Condair ME Control and may affect the air in the AHU/air duct.
  • Page 9 Preventing unsafe operation If it is suspected that safe and hygienic operation is no longer possible, then the Condair ME Control should immediately be shut down and secured against accidental power-up according to chapter 4.6. This can be the case under the following circumstances: –...

  • Page 10: Product Overview

    One hydraulic module which is mounted internal or external to the AHU/air duct. – Control unit with integrated controller with touch panel According to your order the Condair ME Control can be equipped with the following options: – Droplet separator –...

  • Page 11: Product Designation / Which Model Do You Have

    Product designation / Which model do you have The product designation and the most important unit data (e.g. serial number, evaporative module product key, etc.) are found on the rating plates toward the end of the evaporative module and on the right side of the control unit.

  • Page 12: Construction Of The System Components

    Construction of the system components 3.3.1 Construction of the evaporative module air flow direction Upstands Distribution heads Tank connector ø50 mm Blanking plates (option, may differ in the look from Rating plate the drawing shown above) Droplet separator, mandatory for high face veloci- Mounting frame for evaporative cassettes ties up to 4.5 m/s Water tank...

  • Page 13: Construction Of The Hydraulic Module

    3.3.2 Construction of the hydraulic module Drain valve (normally open) 11 Push-fit connector (ø15 mm) for pressure equalisa- Drain pump tion (only used when mounted outside of AHU) Stage pump 5 with push-fit connector ø15 mm 12 Water supply push-fit connector ø15 mm (module is Stage pump 3 with push-fit connector ø15 mm supplied with a connecting hose that inserts here) Stage pump 1 with push-fit connector ø15 mm...

  • Page 14: System Overviews / Functional Description

    Wall feed through stage pumps) Water supply line Vent drain pipe Air flow direction Inter connecting cable hydraulic module Drain pipe AHU drain with trap with trap Fig. 4: Typical system Condair ME Control, internal install Product Overview...

  • Page 15: Typical System Condair Me Control, External Install With Centre Drain Tank

    Air flow direction Hydraulic module (with supply Vent drain valve, drain valve, drain pump pipe and stage pumps) AHU drain Drain pipe with trap with trap Fig. 5: Typical system Condair ME Control, external install with centre drain tank Product Overview...

  • Page 16: Typical System Condair Me Control, External Install With Side Drain Tank (Evaporative Modules Up To 3000 Mm Wide Only)

    Vent drain pipe AHU drain Drain pipe with trap with trap Fig. 6: Typical system Condair ME Control, external install with side drain tank (evaporative modules up to 3000 mm wide only) Product Overview...

  • Page 17: Schematic Flow Diagrams

    Stage pumps 2... max. 5 sensor pump Gravity solenoid drain valve (NO) Drain trap (building side) Tundish (building side) Fig. 7: Schematic flow diagram Condair ME Control (internally mounted) Hydraulic module Shut-off valve with Inlet solenoid Pressure strainer) valve (NC) equalisation...
  • Page 18 The Condair ME Control provides On/Off or stage control by means of the Condair ME Control control unit and the stage pumps. The Condair ME Control control unit processes analog sensor/control signals and uses them to control the stage pumps.

  • Page 19: Operation

    Important notes on operation Qualification of personnel The Condair ME Control must be commissioned and op erated only by personnel familiar with the sys- tem and adequately qualified for the respective tasks. It is the owner’s responsibility to verify proper qualification of the operating personnel.

  • Page 20: Initial Commissioning

    The initial commissioning of the Condair ME Control requires appropriately trained technical personnel. We strongly recommend that your Condair representative commissions your system. Inspections Prior to initial commissioning ensure Condair ME Control is correctly installed, connected and tight in accordance with the installation manual supplied. Commissioning After the system has been inspected and found correct proceed with the initial commissioning: 1.
  • Page 21 17. Power cycle the Condair ME Control to remove the forced disinfection demand (allowing normal control to be resumed) and check correct control operations (signals, fault outputs, Modbus/BACnet). 18. Raise any installation concerns. 19. Record the commissioning and preserve commissioning documentation.

  • Page 22: Display And Operating Elements

    If the control unit is switched off all func- tions (including hygiene functions) of the Condair ME Control are deactivated. Fig. 9: Display and operating elements Condair ME Control DANGER! Risk of electric shock! There is still mains voltage inside the control unit even when you switch off the <Control unit On/ Off>...

  • Page 23: Start Up For Normal Operation

    It is assumed that initial commissioning has been carried out properly by the service technician of your Condair representative. If the Condair ME Control has been out of operation for a prolonged period of time, the system must be examined for any damage or contamination. If doubts exist about the hygienic status of the system, the system must be cleaned and disinfected prior to the start up.

  • Page 24: Notes On Operation

    Demand present/system is cooling "Unit on" The Condair ME Control is switched on and under voltage 4.5.3 Recommended regular checks during operation During operation the Condair ME Control has to be checked periodically in accordance with the table below. Operations Checks Daily Weekly...

  • Page 25: Draining Of The Water Tank

     not in drain cycle) If the checks reveal any irregularities (e.g. leakage, error indication) or any damaged components take the Condair ME Control out of operation as described in 4.6. Then, have the malfunction elimi- chapter nated or the damaged component replaced by a well trained specialist or a service technician from your Condair representative.

  • Page 26: Performing A Matrix Wash Over

    Password: 8808 Condair ME Control is in normal operation mode. 1. Select the "Service" submenu (displays 1-3) 2. Select "Matrix Wash Over" function in the "Service" submenu. The matrix wash over confirmation dialogue appears.

  • Page 27: Decommissioning The System

    If the Condair ME Control is in working order, then for hygiene reasons we recommend that the system should be left powered on, even if the Condair ME Control is not going to be used for a prolonged period of time. To prevent the Condair ME from cooling set the "Operation" function in the service menu to "Off".

  • Page 28: Operating The Condair Me Control Software

    Operating the Condair ME control software Standard operating display After switching on the control unit and the automatic system test the control unit 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 29: Operating Status Indication

    After the demand has dropped to zero, the system drains a small amount of water to give space to the water running out of the matrix. The Condair ME Control is draining the tank and uses the first section of the drain procedure to check whether the drain valve is working properly.

  • Page 30: Maintenance And Malfunction Indications

    This message appears after switching on, if the control unit has been isolated from the mains supply for more than 48 hours. The Condair ME Control is blocked for 5 minutes. Before operation the water supply line to the hydraulic module must be flushed. The commissioning warning is reset automatically after 5 minutes or you can reset the warning in the "Service"...

  • Page 31: Navigating/Operating The Condair Me Control Software

    Navigating/operating the Condair ME control software Navigation element Action Accessing main menu Accessing system information Performing a tank drain Accessing Help screen If you press on a field with a blue arrow symbol a new screen with additional information or settings appears.

  • Page 32: Information Functions

    Operating Tab – Actual Stage: Actual number of currently operating stages of the system. – Max Stage: Number of maximum stages set to operate. Max. Capacity: Maximum evaporating capacity in kg/h or lb/hr. – Operating the Condair ME control software...
  • Page 33 Incoming Air Temperature: Actual temperature of the air before the evaporative cassettes. Note: This information field appears only if optional freeze protection sen- sor is installed and the optional freeze protection function is activated in the engineering menu. Operating the Condair ME control software...
  • Page 34 Incoming Air Temperature: Actual temperature of the air before the evaporative cassettes. Note: This information field appears only if the optional freeze protection sensor is installed and the optional freeze protection function is activated in the engineering menu. Operating the Condair ME control software...
  • Page 35 Note: This field appears only if "BACnet MSTP" is enabled. BACnet IP Network – Node ID: shows the actual BACnet node ID for the Condair ME Control. Note: This field appears only if "BACnet IP" is enabled. – Online Status: shows the connection status of the Condair ME Control to Condair Online("Connected"...

  • Page 36: Configuration

    General Tab Within the "General" tab various unit data is shown. Additionally you can access a graphical display of the Condair ME Control performance data, and you can save the performance data to a USB memory stick as a .csv file.

  • Page 37: Control Settings - "Control Settings" Submenu

    5.4.2 Control settings – "Control Settings" submenu In the "Control Settings" submenu you determine the control settings for the Condair ME Control. The control settings available depend on the selected signal source and the control mode. Basic Tab – Source: with this setting you determine whether the control signal comes from an analogue source (signal of a temperature sensor or demand signal from an external temperature controller) or via Modbus or BACnet.
  • Page 38 ITime Channel 2: with this setting you set the integral time of channel 2 ("Cooling") in minutes. Note: this setting appears only if the "Control Mode" is set to "RH PI". Factory setting: 5 minutes Setting range: 1 ... 60 minutes Operating the Condair ME control software...
  • Page 39 Threshold 5: With this setting you determine the set point at which the pump of stage 5 will switch on or off in % of the demand signal. Factory setting: Varies with number of stages Setting range: 2 ... 99 % Operating the Condair ME control software...

  • Page 40: Basic Settings - "General" Submenu

    5.4.3 Basic settings – "General" submenu In the "General" submenu you determine the basic settings for operating the Condair ME Control control unit. Basic Tab – Date: With this setting you determine the current date in the set format ("MM/DD/YYYY" or "DD/MM/YYYY").

  • Page 41: Communication Settings - "Communication" Submenu

    Network Parameters Tab The following network settings are used for the communication via the inte- grated interface of the integrated controller of the Condair ME Control. – IP Type: with this setting you determine whether you want to assign the IP...
  • 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 ME Control 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 Service or Warning – Safety Chain Indication: With this setting you determine whether a Fault ("On") or a Warning ("Off") is triggered when the external safety chain is open. Factory setting: Options: Off or On Operating the Condair ME control software...

  • Page 44: Service Functions

    General Service Tab – Operation: with this function you can turn on or off the Condair ME Control cooling operation. The System remains energized and all hygiene func- tions will still be carried out.
  • Page 45 Detailed information on the individual relay diagnostic functions can be found in chapter 5.5.2.2. Note: By accessing the "Relay Diagnostics" submenu the cooling system is automatically switched to standby operation. Operating the Condair ME control software...

  • Page 46: 5.5.2.1 Input Diagnostic Functions - "Input Diagnostics" Submenu

    – Dosing Pump Level Float: Actual level ("Empty"= Tank is empty or "OK"=Level in the tank is OK) in the liquid tank of the optional system for enhancing polyester media water absorption. Operating the Condair ME control software...
  • Page 47 Speed Pump 4: Actual speed of stage pump 4 in % of the maximum speed. – – Speed Pump 5: Actual speed of stage pump 5 in % of the maximum speed. – Speed Pump 6: No function. – Speed Pump 7: No function. Operating the Condair ME control software...

  • Page 48: 5.5.2.2 Relay Diagnostic Functions - "Relay Diagnostics" Submenu

    – Fault: with this function you can activate ("On") and deactivate ("Off") the relay "Fault" on the remote operating and fault indication board, which indicates that a fault is present. Operating the Condair ME control software...

  • Page 49: Administration Settings

    ("Yes") or not ("No"). Main Menu Password: with the function "Main Menu Password" you – can protect the access to the main menu with the user password "8808" against unauthorised access ("Yes") or not ("No"). Operating the Condair ME control software...
  • Page 50 USB memory stick connected to the USB port on the control board. – Manually Load Contact Info: this function allows you to manually change/ enter contact information data (which are displayed when pressing the <Help> button). Operating the Condair ME control software...

  • Page 51: Maintenance

    The instructions and details for maintenance work must be followed and upheld. Only carry out the maintenance work described in this documentation. The Condair ME Control must be maintained in the prescribed intervals, the cleaning work must be carried out correctly.

  • Page 52: Maintenance Intervals

    Depending on the encountered hygiene status when performing a system service the interval time must be decreased or increased. In any case the Condair ME Control system should receive a complete service at least once annually. Note: We recommend to perform a minor service between two system services.

  • Page 53: Maintenance Guide

    Maintenance guide Please note that the information given in the table below is only to act as a guide which shows the work to be carried out on "Minor Service" and "System service". Correct maintenance is vital to ensure optimum output, reliability and safety. Operations Minor System...

  • Page 54: Dismantling And Installation Of Components For Maintenance

    Prevention: before carrying out any work on the evaporative module dry all wet surfaces in the AHU/ duct. 1. Take the Condair ME Control out of operation as described in chapter 4.6 and allow to drain and dry.

  • Page 55: Consumables Guide

    Note: Start disinfection process always with the “Start Disinfection” function in the service menu (see chapter 5.5.2), to prevent the Condair ME Control draining the water tank during the disinfection process. For systems in operation or where the water quality or air quality is poor, it is recommended to disman- tle and scrub the system clean first, then to carry out a disinfection.

  • Page 56: Cleaning And Disinfection Procedure

    Step 1 - Preparatory work • If the Condair ME Control is already in operation, check for correct operation. • Ensure the Condair ME system and the AHU are OFF and isolated.
  • Page 57 • Start disinfection process always with the “Start Disinfection” function in the service menu (see chapter 5.5.2), to prevent the Condair ME Control draining the water tank during the disinfection process. • Check that the evaporative cassettes become fully saturated, and the system is operating cor- rectly.

  • Page 58: Resetting The Maintenance Indication On Condair Me Control

    Resetting the maintenance indication on Condair ME Control After completing maintenance work, the maintenance indication or the maintenance counter, respectively must be reset. Proceed as follows to reset the maintenance counter: 1. Select in the "Service" submenu the function "System Service Reset"...

  • Page 59: Performing Software And Firmware Updates

    6.10 Performing software and firmware updates To update the control software of the Condair ME Control or the firmware of one of its electronic boards, proceed as follows: 1. Set the <Control unit On/Off> switch on the right side of the control unit to the Off position, then switch off the voltage supply to the control unit via the external electrical isolator and secure switch in the Off position to prevent it from inadvertent power up.

  • Page 60: Fault Elimination

    LED below the touch panel will indicate an active fault on the Condair ME Control. If such a malfunction occurs, the operation of the system is limited only or the Condair ME Control will be stopped automatically.

  • Page 61: Malfunction List

    ––– Freeze Prot The Condair ME stopped operating as the temperature of the incoming air fell below the preset limit of the optional freeze detection. Note: If – at any time – the air temperature of the incoming air rises above the limit value again, the system will continue with normal operation.
  • Page 62 Water Inlet Tank (re)fill timeout. The Condair ME Control stopped operation as the tank could not be (re)filled within a preset time. The Condair ME Control periodically tries to fill the tank. Note: If – at any time – the required water level is reached, the system will continue with normal operation.
  • Page 63 Remedy No UV lamp The Condair ME Control indicates fault as no UV lamp has been detected. Depend- ing on the configuration of the "Shut Down" function (factory level) the Condair ME Control stops or continues operation. The fault message must be reset after elimination of malfunction.
  • Page 64 Replace level sensor. ––– Water Temp Snsr Water temperature sensor signal failed, Condair ME Control changed to "Fill Cycle" mode dilution. The fault message must be reset after elimination of malfunction. Water temperature sensor not connected. Correctly connect water temperature sensor.
  • Page 65 Contact your Condair representative. ––– Local 24V Supply Local 24V supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Fuses on driver board defective. Check fuses on driver board and replace.
  • Page 66 Correctly connect drain pump. E129 Pump Error The controller was not able to activate one or more stage pumps. The Condair ME (Pump 1) Control will continue to attempt normal operation. The fault message must be reset after elimination of malfunction.

  • Page 67: 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 ME Control can be saved to a USB memory stick for log- ging and further analysis. For this purpose proceed as follows: 1.

  • Page 68: Notes On Fault Elimination

    (ESD-protection) must be taken to prevent damage to electronic components. – Repair work and the replacement of faulty components must be carried out by your Condair repre- sentative’s service technician only! Resetting the fault status on Condair ME Control To reset the error indication: 1.

  • Page 69: Replacing The Fuses And Backup Battery In The Control Unit

    Replacing the fuses and backup battery in the control unit The fuses of the control unit must be replaced by authorized personnel only (e.g. electrician). Replace fuses of the control unit only with fuses matching the specifications below with the appropriate nominal current capacity. Never use refurbished fuses. Do not bridge the fuse holder. To replace the fuses or the backup battery proceed as follows: 1.

  • Page 70: Taking Out Of Service/Disposal

    Taking out of service/Disposal Taking out of service If the Condair ME Control must be replaced or if the Condair ME Control is not needed any more, pro- ceed as follows: 1. Take the Condair ME Control out of operation as described in chapter 4.6.

  • Page 71: Product Specifications

    Product specifications Technical data Condair ME Control Supply voltage control unit 100...240 VAC/50...60 Hz Supply voltage circulation pumps 24 VDC (supplied by control unit) Power consumption < 278 W (5 stages, no options fitted) Control signals 0...5 VDC 1...5 VDC 0..10 VDC 2...10 VDC...

  • Page 72: Appendix

    Appendix 10.1 Wiring diagram Condair ME Control Appendix...
  • Page 73 Notes...
  • Page 74 Notes...
  • Page 76 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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