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Condair DL Series Operation Manual

Adiabatic humidification system
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OPERATION MANUAL
Adiabatic humidification system
Condair DL
Humidification and Evaporative Cooling

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  • Page 1 OPERATION MANUAL Adiabatic humidification system Condair DL Humidification and Evaporative Cooling...
  • Page 2 Condair Ltd., except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Ltd. does not accept any liability due to incorrect installation or operation of the equipment or due to the use of parts/components/equipment that are not authorized by Condair Ltd.

  • Page 3: Table Of Contents

    Notes on the operation manual For your safety Product Overview Models overview Product designation / Which model do you have Basic design the adiabatic air humidification system Condair DL Functional description Hydraulic diagram System overview Condair DL Overview humidification unit Condair DL...
  • Page 4 Replacing the fuses and backup battery in the control unit Resetting the fault indication Taking out of service/Disposal Taking out of service Disposal/Recycling Product specification Technical data Options Appendix 10.1 CE declaration of conformity 10.2 Wiring diagram Condair DL 10.3 Wiring plan Condair DL Contents...

  • Page 5: Introduction

    Nevertheless, improper use of the adiabatic air humidification system Condair DL may result in danger to the user or third parties and/or impairment of material assets. To ensure a safe, proper, and economical operation of the adiabatic air humidification system Condair...
  • Page 6 If the documentation 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

    Every person working with the adiabatic air humidification system Condair DL must have read and under- stood the installation manual and the operation manual of the Condair DL before carrying out any work. Knowing and understanding the contents of the installation manual and the operation manual 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 8 One may get in touch with live parts when the control unit is open. Touching live parts may cause severe injury or danger to life. Prevention: Before carrying out any work on the adiabatic air humidification system Condair DL switch off the control unit, disconnect it from the mains via the electrical isolator and secure electrical isolator in Off position against inadvertent power-up.

  • Page 9: Product Overview

    Product Overview Models overview The adiabatic air humidification system Condair DL is available in two base models (Type A: with booster pump, Type B: without booster pump) for different duct/AHU sizes. Condair DL . Type A Type B (with booster pump) (without booster pump) Duct inside width “W”...
  • Page 10 Product key Example: Condair DL A 1800 2000 100 R 7 75 0 5 21 Unit series Type: A: Standard version with booster pump B: Version without booster pump AHU/duct inside width in mm AHU/Duct min. inside height in mm...

  • Page 11: Basic Design The Adiabatic Air Humidification System Condair Dl

    13 Inlet valve Y1 31 External continuous controller (by client, e.g. Enthalpy controller) 14 Pressure sensor inlet pressure PS4 32 Air duct/AHU 15 Silver ionisation A3 16 Conductivity sensor Lf1 Abb. 1: Basic design the adiabatic air humidification system Condair DL Product Overview...

  • Page 12: Functional Description

    Functional description From the reverse-osmosis system (RO system) the fully demineralised water (also called RO water or permeate) is fed via a shut-off valve (18, by client) and a water filter (19, by client) to the central unit (17). In the central unit the RO water is fed via the inlet valve Y1 (13), the conductivity measurement Lf1 (16), and the silver ionisation (15) which degerminates the water and the sterile filter (10) to the valve mani- fold (21) with the spray valves Y5-Y7 (7 control steps), Y5-Y7+Y9 (7 control steps with double stage), Y5-Y8 (15 control steps) or Y5-Y8+Y9 (15 control steps with double stage) and the drain valve Y10.
  • Page 13 Hygiene function/Flushing In order to prevent standing water, each spray circuit which is not active is emptied via the corresponding spray valve (the spray valves are connected to the drain in currentless status). If the conductivity in the water supply line exceeds a preset value or if the humidification system has been without demand for more than 23 hours, the drain valve Y10 opens and the water supply line and the water lines in the central unit are flushed for a certain time with fresh RO water.

  • Page 14: Hydraulic Diagram

    3 spray circuits double stage: Y5, Y6, Y7 and Y9 (7-steps) 4 spray circuits: Y5, Y6, Y7 and Y8 (15-steps) 4 spray circuits with double stage: Y5, Y6, Y7, Y8 and Y9 (15-steps, from 500 kg/h) Abb. 2: Hydraulic diagram humidification system Condair DL Product Overview...

  • Page 15: System Overview Condair Dl

    G 1/2" male thread adapter (supplied) 12 Post-evaporation unit Test valve, flame treatable (recommended, by client) 13 Humidity controller (e.g. enthalpy controller) or Water filter (recommended, by client) humidity sensor Shut-off valve water supply (mandatory, by client) Abb. 3: System overview Condair DL Product Overview...

  • Page 16: Overview Humidification Unit Condair Dl

    Overview humidification unit Condair DL Support frame Nozzle unit Support frame post-evaporation unit Spray nozzles Ceramic plates Lateral sealing plates Rubber sealing duct floor Upper sealing plates Wall feed throughs spray circuits (ø8/10 mm) Abb. 4: Overview Humidification unit Condair DL Product Overview...

  • Page 17: Overview Control Unit Condair Dl

    Switch <Humidification On/Off> Ag-Ionisation board 12 Terminals mains voltage supply Conductivity monitoring board 13 Snap ferrite mains voltage supply BMS interface board (option LonWorks or BACnet) 14 Switch <Control unit On/Off> Abb. 5: Overview control unit Condair DL (without internal cabling) Product Overview...

  • Page 18: Overview Central Unit Condair Dl

    18 Spray valve Y8 Silver ionisation cartridge 19 Water jet pump Booster pump (Type A only) 20 Manometer inlet pressure 10 Pressure switch PS2 (Type A with Sterile filter only) 21 Pressure sensor PS4 Abb. 6: Overview central unit Condair DL Product Overview...

  • Page 19: Operation

    Operation The adiabatic air humidification system Condair DL may be commissioned and operated only by persons familiar with the adiabatic air humidification system Condair DL and adequately qualified. It is the owner’s responsibility to verify proper qualification of the personnel.

  • Page 20: Display And Operating Elements

    (including hygiene functions) of the adiabatic air humidification system Condair DL are deactivated. Abb. 7: Display and operating elements Condair DL DANGER! Risk of electric shock! Since mains supply to the control unit is not interrupted by switching off the <Humidification On/Off>...

  • Page 21: Recommissioning After Interruption Of Operation

    6. If the adiabatic air humidification system Condair DL has been disconnected from the mains for more than 48 hours the message “Commissioning” appears. If this is the case proceed as follows: •...

  • Page 22: Notes On Operation

    If the inspection reveals any irregularities (e.g. leakage, error indication) or any damaged components take the adiabatic air humidification system Condair DL out of operation as described in chapter 4.5 – Decommissioning the system. Then, have the malfunction be eliminated or the damaged component be replaced by a well trained specialist or a service technician from your Condair representative.

  • Page 23: Manual Flushing Of The Water System

    Manual flushing of the water system 4.4.4 Note: if an error message is active manual flushing is not possible. To perform a manual flushing of the water system proceed as follows: 1. Press on the <Drain> button in the standard operating display. The “Manual” submenu appears. 2.

  • Page 24: Perform A Pressure Release Of The Water System

    The pressure release cycle is stopped and the unit returns to the “Manual” submenu. Decommissioning the system In order to take the adiabatic air humidification system Condair DL out of operation (e.g. to perform maintenance works) perform the following steps: 1.
  • Page 25 With the system switched on, the water circuit is flushed at regular intervals and hence the build-up of germs is opposed. If the adiabatic air humidification system Condair DL is not be used for a longer period of time observe the following points: –...

  • Page 26: Operating The Condair Dl Control Software

    Operating the Condair DL 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 humidity regulation of the system and can deviate from the display shown below.

  • Page 27: Operating Status Indication

    The hygiene functions (regular flushing of the water system) remain still active. The humidification system is stopped due to a malfunction which obviates further operation. Additionally “Warning” or “Fault” is displayed in the maintenance and malfunction field. Operating the Condair DL control software...

  • Page 28: Maintenance And Malfunction Indications

    A malfunction with status “Fault” is active. Additionally the red LED lights. Depending on the malfunction the humidification system is either be stopped or stays operable for a certain period of time. Operating the Condair DL control software...

  • Page 29: Navigating/Operating The Condair Dl Control Software

    Navigating/Operating the Condair DL control software Navigation element Action Accessing main menu Accessing system information Performing manual drain/pressure release Accessing help screen If you press on a field with a blue arrow symbol a new screen with additional information or settings appears.

  • Page 30: Information Functions

    Hours of Operating: Operating hours since initial commissioning of the system. – Next Service: Remaining time until next maintenance of the system must be performed. – Remaining AgIon Capacity: Remaining capacity of the silver ionisation cartridge in Ah. Operating the Condair DL control software...
  • Page 31 Manual Capacity A: Set capacity limitation in % of the maximum capacity. – PS2: Actual status of the optional pressure switch PS2 when operating the humidification system Condair DL type A with sterile filter (“On”= pressure present, “Off”= no pressure present). –...
  • Page 32 (conductivity supply water). – Ext. A.DB.A 2 Version: Actual software version of the Ag ionisation board. – Ext. A.DB.A 3 Version: No function – Serial Number: Serial number of the humidification system. Operating the Condair DL control software...

  • Page 33: Configuration

    Note: if at the point in time, on which the timer controlled flushing is to be carried out, a humidity demand is present, the flushing is omitted. Operating the Condair DL control software...

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

    Factory setting: Analog Options: Analog or Modbus – Control Mode: with this setting you determine the type of controller used with the adiabatic air humidification system Condair DL. Factory setting: Demand Options: On/Off (external On/Off humidistat) Demand (external continuous controller)

  • Page 35: Basic Settings - "General" Submenu

    Options: 1 ... 60 minutes Basic settings – “General” submenu 5.4.4 In the “General” submenu you determine the basic settings for operating the Condair DL control unit. Basic – Date: With this setting you determine the current date in the set format (”MM/DD/YYYY” or “DD/MM/YYYY”).

  • Page 36: Communication Settings - "Communication" Submenu

    The following parameters appear only if the Modbus function is activated. – Modbus Address: With this setting you determine the Modbus ad- dress for the adiabatic air humidification system Condair DL for the communication via a Modbus network. Factory setting: Setting range: 1 ...
  • Page 37 Service or Warning – Safety Loop: With this setting you determine whether an Fault (“On”) or a Warning (“Off”) is triggered when the external safety chain is open. Factory setting: Options: Off or On Operating the Condair DL control software...

  • Page 38: Maintenance Functions

    System Service Reset: with the“System Service Reset“ function you can reset the system service message or the system service counter, respec- tively. After pressing on the “System Service Reset” button a confirmation window appears where the resetting must be confirmed. Operating the Condair DL control software...
  • Page 39 Detailed information on the individual relay diagnostic functions can be found in chapter 5.5.2.3 – Relay diagnostic functions – “Relay Diagnostics” submenu. Note: By accessing the “Relay Diagnostics” submenu the humidification system is automatically switched to standby operation. Operating the Condair DL control software...

  • Page 40: 5.5.2.1 Input Diagnostic Functions - "Input Diagnostics" Submenu

    PS2: Actual pressure status after sterile filter (“Off”= no pressure present, “On”= pressure present). – PS4: Actual water inlet pressure in bar. – PS5: Actual nozzle pressure in bar. – Pump Current: Actual current of the booster pump motor. Operating the Condair DL control software...
  • Page 41 24V External Supply: Actual voltage of the external 24 V supply. – 10V External Supply: Actual voltage of the external 10 V supply. – 5V Peripheral Supply: Actual voltage of the external 5 V supply. Operating the Condair DL control software...

  • Page 42: 5.5.2.2 Output Diagnostic Functions - "Output Diagnostics" Submenu

    “Service” on the remote operating and fault indication board. – Fault: with this function you can activate (“On”) and deactivate (“Off”) the relay “Fault” on the remote operating and fault indication board. Operating the Condair DL control software...

  • Page 43: 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 DL control software...

  • Page 44: Maintenance And Replacement Of Components

    The adiabatic air humidification system Condair DL must be maintained in the prescribed intervals, the cleaning work must be carried out correctly. Only use original spare parts from your Condair representative to replace defective parts or parts which have elapsed their lifetime.

  • Page 45: Hygiene And Maintenance According To Vdi 6022

    Condair DL has been structured in two stages. This differentiates between periodical check- ing and the implementation of a total system service of the Condair DL. In order to operate the system according to the regulations “optimised air humidification DGUV” the maintenance must be carried out in accordance with the information given in chapter 6 –...

  • Page 46: Periodical Checking

    Note: a master of the maintenance record sheet is included in the delivery or can be ordered from your Condair representative. Maintenance and Replacement of components...

  • Page 47: Total System Service

    6.2.2 Total system service The frequency of the implementation of a total system service depends on the operating conditions. The state of the humidifier‘s hygiene and its components mostly depends on the quality of the humidifier water, the performance (and the frequency of replacement) of the filter installed before the unit, the air velocity, the air temperature, and the microbiological and chemical composition of the inlet air.
  • Page 48 In the event of bacterial count concentrations above the limit of 100 cfu/ml, the water supply/water pipes must be subject to a microbiological inspection and appropriate action must be taken immediately (please contact your Condair representative). Bacterial count concentrations in the upper area of the permitted range may be an indication of the onset of bacterial problems in the water supply.

  • Page 49: Notes On Cleaning And Cleaning Agents

    Notes on cleaning and cleaning agents For the cleaning of the individual system components of the Condair DL and the cleaning agents which should be used a separate cleaning instruction is available. Condair recommends to use “Condair Clean” as cleaning agent. Please contact your Condair representative for this purpose.

  • Page 50: Removal And Installation Of Components

    Removal and installation of components 6.4.1 Removal and installation of the ceramic plates Removal of the ceramic plates Start point of removal Abb. 9: Removal of the ceramic plates Proceed as follows to remove the ceramic plates: 1. Remove upper sealing plates. 2.
  • Page 51 Installation of the ceramic plates Start point of installation Abb. 10: Installation of the ceramic plates Before installation, check all ceramic plates for possible damage. Damaged ceramic plates and ceramic angles must not be reinstalled. For installation of the ceramic plates proceed in the reverse order of removal (also see section “Install ceramic plates”...

  • Page 52: Removal And Installation Of The Spray Nozzles

    Removal and installation of the spray nozzles 6.4.2 Abb. 11: Removal and installation of the spray nozzles Removal of the spray nozzles 1. Loosen nozzle “A” by hand and remove it together with the O-ring“B”. Note: prior to the removal note the position and the colour identification of the nozzle. 2.

  • Page 53: Removal And Installation Of The Nozzle Holder

    Removal and installation of the nozzle holder 6.4.3 Abb. 12: Removal and installation of the nozzle holder Removal of the nozzle holder 1. Remove nozzle“A” together with the O-ring “B” as described in chapter 6.4.2. 2. Remove coloured ring “D” from the nozzle holder. 3. Remove the hose(s) from the nozzle holder (press the locking ring towards screw, then pull hose off).

  • Page 54: Replacement Of The Silver Ionisation Cartridge "Hygieneplus

    Replacing the silver ionisation cartridge 1. Set the adiabatic air humidification system Condair DL out of operation as described in chapter 4.5 – Decommissioning the system, and release the pressure in the water system.

  • Page 55: Replacement Of The Sterile Filter And De-Aeration Of The Filter Housing

    If error “E66” is shown or before any commissioning for a new humidification season the sterile filter must be replaced. 1. Set the adiabatic air humidification system Condair DL out of operation as described in chapter 4.5 – Decommissioning the system, and release the pressure in the water system.

  • Page 56: Resetting The Maintenance Counter

    Resetting the maintenance counter After completing the total system maintenance or after replacement of the Ag ionisation cartridge, the corresponding maintenance indication or maintenance counter, respectively must be reset. Proceed as follows to reset the maintenance counter: 1. Select in the “Service” submenu the corresponding reset function (“System Service Reset” or “Ag Reset”).

  • Page 57: Fault Elimination

    Fault elimination Fault indication Malfunctions during operation detected by the control software are indicated by a corresponding Warning message (operation still possible) or Fault message (operation not longer possible) in the maintenance and fault indication field in the standard display of the control unit. Warning Temporary problems (e.g.

  • Page 58: Malfunction List

    Water inlet pressure too low or not present! Water Missing! Note: as soon as the water pressure rises again above the set minimum value the humidification system Condair DL to work normally. Shut-off valve in the water supply line Open shut-off valve.
  • Page 59 ––– Activation code has not been entered yet. Activation Activation code has not been entered Enter activation code (code available from your Condair representative). yet. ––– Invalid signal from inlet water pressure sensor PS4! Pr.Sens.Inlet Check/correctly connect pressure sen- Pressure sensor PS4 not or not cor- rectly connected.
  • Page 60 Wrong type of nozzle installed. Install correct type of nozzle. Nozzles clogged. Clean/Replace nozzles. Max. nozzle pressure set too high. Contact your Condair representative. Wrong order of spray circuits or spray Correctly connect spray circuits. valves. Pressure relief valve on booster Contact your Condair representative.
  • Page 61 Permeate membrane of the reverse Check/repair reverse osmosis system. osmosis system defective or service due. Conductivity board wrong configured Contact your Condair representative. or defective. Conductivity sensor soiled or defec- Replace conductivity sensor. tive (short circuit). ––– Communication between control board and driver board interrupted.
  • Page 62 ––– Monitoring of the frequency converter has triggered. FC Error Frequency converter overloaded, too Contact your Condair representative. hot or over current monitoring has triggered. Error code can be checked on frequency converter. Fuse “F1” on the driver board defec- Replace fuse “F1”...

  • Page 63: Malfunctions Without Indication

    Maximum humidification Capacity limitation active. Deactivate capacity limitation (set to: 100%). capacity is not reached System incorrectly dimensioned (insuf- Contact your Condair representative. ficient capacity). Booster pump defective (insufficient Replace booster pump. permeate pressure) Pressure relief valve of booster pump Contact your Condair representative.

  • Page 64: Notes On Fault Elimination

    Electronic components are very sensitive to electrostatic discharge. When carrying out repairs to the control unit, appropriate measures (ESD-protection) must be taken to prevent damage to electronic components. – Repair work on the booster pump must be carried only by your Condair representative. Fault elimination...

  • Page 65: 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.

  • Page 66: Resetting The Fault Indication

    Resetting the fault indication To reset the error indication (red LED light, operating status indication shows “Stop”): 1. Disconnect the control unit from the mains via the <Control unit On/Off> switch (located on the bottom side of the control unit). 2. Wait approx. 5 seconds, then reconnect the control unit to the mains by switching the <Control unit On/Off>...

  • Page 67: Taking Out Of Service/Disposal

    Components not used any more must not be disposed of in the domestic waste. Please dispose of 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 68: Product Specification

    Product specification Technical data Condair DL Type A Type B (with booster pump) (without booster pump) Dimensions/Weight Installation length in AHU/duct (Min-Max) 600 - 900 mm Width AHU/duct (Min-Max) 450 - 4200 mm Height AHU/duct (Min-Max) 450 - 4000 mm Dimensions central unit HxWxD...

  • Page 69: Options

    The nominal control accuracy may not always be available, because various factors (temperature control, water recycling, flap valve systems, etc.) may affect the accuracy. Higher temperature on demand Options Condair DL Type A Type B (with booster pump) (without booster pump)

  • Page 70: Appendix

    Appendix 10.1 CE declaration of conformity Appendix...

  • Page 71: Wiring Diagram Condair Dl

    Appendix...

  • Page 72: Wiring Plan Condair Dl

    Appendix...
  • Page 73 Notes...
  • Page 74 Notes...
  • Page 76 © 01.2016 Condair GmbH. Technical modifications reserved. Condair GmbH Parkring3, 85748 Garching-Hochbrück Tel. (0) 89 207 008 -0, Fax (0) 89 207 008 -140, www.condair.de...

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