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Condair Dual 2 Installation And Operating Instructions Manual

Hybrid humidifier
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Condair Dual 2
Hybrid Humidifier
INSTALLATION AND OPERATING INSTRUCTIONS

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  • Page 1 Condair Dual 2 Hybrid Humidifier INSTALLATION AND OPERATING INSTRUCTIONS...

  • Page 3: Table Of Contents

    Notes on the installation and operating instructions Special tools Important notes Correct use for intended purpose Safety instructions Overview of the Condair Dual Hybrid Humidifier Basic design of the Condair Dual Hybrid Humidifier Function Scope of versions Options Installation and first-time commissioning Safety notes for installation and commissioning Installation of the humidification unit 4.2.1...

  • Page 4: Introduction

    All persons working with the Condair Dual Hybrid Humidifier must observe and comply with all information and safety instructions contained in the present installation and operating instructions. Please contact your Condair supplier in case of trouble or if you have any questions concerning humi dification technology in general. 1.2...

  • Page 5: Special Tools

    Language versions The installation and operating instructions for the Condair Dual Hybrid Humidi- fier are avail able in several languages. Please contact your Condair supplier if you re quire another language version of the present documentation. Special tools...

  • Page 6: Important Notes

    Important notes Please read this chapter carefully. It contains important information, which must be observed for safe, correct and economic application of the Condair Dual Hybrid Humidifier. Correct use for intended purpose The Condair Dual Hybrid Humidifier is intended exclusively for humidi- fication in ventilation systems.
  • Page 7 (minimum requirements according to DIN 1.4301) or plastic. – If it can be assumed that safe operation is no longer possible, the Condair Dual must be taken out of service and secured against un intentional operation. Safe operation may be affected in the following events: –...

  • Page 8: Overview Of The Condair Dual Hybrid Humidifier

    Overview of the Condair Dual Hybrid Humidifier Basic design of the Condair Dual Hybrid Humidifier 13 Drain with siphon trap (by customers) 1 Control unit 14 Drain valve 2 Power supply 15 Conductance sensor 3 Control or sensor signal input 16 Connector box with 2 spray valves (3-step) 4 Connector for external safety circuit...

  • Page 9: Function

    Function From the reversing osmosis system (RO system) the fully demineralized water (also called permeate) is fed to the booster pump (9) via a shut-off valve (7) and a filter (8). Depending on the current output re quirements the booster pump increases the water pressure to the required operating pressure of approximately 7 bars (yield load).
  • Page 10 Spray circle discharge (only with option Z409) (18) (19) (17) (16) Water jet pump On systems having a central unit with spray circle discharge (option Z409) the spray circle drain valve Y5 opens after no humidification demand has occurred for 12 hours. Then, the valves Y9, Y10 and Y11 open one after the other for approximately 60 seconds to discharge each spray circle via the water jet pump.

  • Page 11: Scope Of Versions

    Scope of versions The Condair Dual Hybrid Humidifier is available in two versions: either as “centralized system” (type: CD ZE ...) or as “decentralized system” (type: CD DZ ...). In the centralized system the control unit, the booster pump, the silver ion- ization unit and the connector box are assembled and wired in the form of a so-called “central unit”...
  • Page 12 Decentralized system (CD DZ ...) Humidification unit Electrical connectors (power supply, control or sensor signal Control unit input, connector for external safety circuit) Permeate minimum pressure switch Shut-off valve (by customers) Excess temperature switch of pump Filter (by customers, max. mesh width 0.005 Booster pump Connector (G 1/2") for fully demineralized water Silver ionization unit Permeate conductance sensor...

  • Page 13: Options

    Serial interfaces RS232 “Z404” or RS485 “Z405” The serial interface (RS232 or RS485) is used to transmit operational data from the Condair Dual Hybrid Humidifier to a PC or a building control system. Note: It is up to the customer to develop installation­specific software. In for­...
  • Page 14 “C” (fastened to the floor) monitor the water system and report possible leaks to the leakage signal transmitter “D” which issues an alarm and interrupts the water supply to the Condair Dual via the safety valve “E”. The transformer “F” built into the control unit of the Condair Dual supplies...

  • Page 15: Installation And First-Time Commissioning

    Hybrid Humidifier. It is the customer’s responsibility to ensure suit able quali­ fi cation. – Prior to installation work, the ventilation system (into which the Condair Dual is to be incorporated) must be taken out of operation and secured against unintentional start-up.
  • Page 16 – For control and maintenance purposes we recommend to provide the duct/monobloc with an additional inspection door after the post-evapo- ration unit. – The section of the duct holding the humidification unit must be equipped with a sloping tub having drains before and after the post-evaporation unit (pass-through tub), or with a drain before the separation as well as drains before and after the post-evaporation unit (separated tubs). Each drain must be connected separately to the waste water system via a siphon. For hygienic reasons connect the drain pipes with an open outlet to the waste water system of the building.

  • Page 17: Installation Of The Nozzle System

    4.2.1 Installation of the nozzle system The components of the nozzle system are supplied separately and must be assembled at the installation site. The following sections explain the general installation of the nozzle system. Detailed information (dimensions, fastening points, etc.) can be found in the “installation drawing”...
  • Page 18 First fix the two vertical mounting rails on both sides in the duct (see instal- lation drawing for positioning and fixing). Important! Use exclusively the fixing materials provided. If this is not pos- sible in your case, make absolutely sure that the fixing holes are correctly sealed from the inside of the duct with suitable components.
  • Page 19 5. Fix the grid bearings to the prescribed positions on the horizontal mount- ing rails, using the screws and sliding nuts provided. 6. Mount bearing sleeve “A” and the three or five bearing bushes “B” on the nozzle grid. 7. Insert the nozzle grid/s in the frames at the appropriate position/s (note numbering on the installation drawing).

  • Page 20: Installation Of The Post-Evaporation Unit

    4.2.2 Installation of the post-evaporation unit The components of the post-evaporation unit are supplied separately and must be assembled at the installation site. The following sections explain the general installation of the post-evaporation unit. Detailed information (dimensions, fastening points, etc.) can be found in the “installation drawing” supplied with your particular system. Important! The dimensions listed in the installation drawing are manda- tory.
  • Page 21 First attach the upper cross arm: ø3.3 mm 1. Stick the provided self-adhesive sealing plates to all wall supports. 2. Stick the drilling template provided for the left and right wall supports on the wall of the duct at the correct location (see installation drawing) and drill the ø3.3 mm holes (6 holes per wall support).
  • Page 22 Mount the base plate (only systems equipped with a “Booster”): ø3.3 mm 5. If your system is equipped with a “Booster”, now mount the base plate in the tub. The base plate is attached to the tub ledge using self-tap- ping screws (drill holes ø3.3 mm before), behind the post evaporation unit.
  • Page 23 7. Fix each vertical section, left and right, to the upper cross arm, using the clamping brackets, the M6x20 hexagon socket screws and the washers supplied. The two vertical sections serve as spacers when mounting the lower cross arm. Important! Before tightening the screws, push the vertical sections to the very stop towards the duct roof and align the supports parallel to the duct wall and at a right angle to the duct roof.
  • Page 24 9. Fix the lower cross arm (lowest arm on systems with three cross arms) to the two vertical sections using the clamping brackets, the M6x20 hexagon socket screws and the washers supplied. Important! Before tightening the screws, align the two vertical sec- tions parallel to the duct wall and the lower cross arm parallel to the upper cross arm.
  • Page 25 Mounting and alignment of the vertical sections: Use the brackets for the upper flow sheets as spacers (the bracket with system-specific 5 0 m width is marked with a “V”) 5 0 m Drain-off sheet left Drain-off sheet with system-specific width (marked with a ”V”) Drain-off sheet right 11. Use the clamping brackets to fix all vertical sections to the cross arms and temporarily align them according to the installation drawing pro- vided.
  • Page 26 Starting from the (already fixed) vertical section to the very left, align and fix the remaining vertical sections one after the other. Proceed as follows: push the corresponding vertical section towards the duct roof until it comes to a stop. Then, align the section parallel to the preced- ing section on the left by means of a bracket for the upper flow sheets.
  • Page 27 ø3.3 mm 13. Mounting the brackets for the upper flow sheets: Starting with the narrow vertical section (left or right), align the front edge of the first bracket with the front edge of the topmost opening in the vertical section (see figure above), then fix the bracket to the duct roof using 2 (or 3, as required) self­tapping screws (drill holes ø3.3 mm before).
  • Page 28 Install the tub seal: 15. Cut the whole length of the tub sealing to the appropriate width (width = distance between upper edge of lower cross arm and bottom of duct plus 30 mm). Then, starting on one side of the duct fix the tub seal to the lower cross arm using the supplied fastening sheets, M6x12 hexagon socket screws and washers.
  • Page 29 Install the booster elements (only on systems with “Booster”) If your system is equipped with a “Booster”, the booster elements must now be mounted. Note: If the post-evaporation unit is accessible from the back via a service door the “Booster” may be installed at the end of the installation procedure. The connector pieces and the short snap lashes are then mounted from the back.
  • Page 30 6 5 m 17. From the back, hang all booster elements to the upper cross arm. Use the thread plates and the M6x12 mm hexagon socket screws to fix the remaining brackets (2 or 4) to the booster elements (tighten the screws by hand only to allow later adjustment of the brackets).
  • Page 31 Install the ceramic plates Note: The installation of the ceramic plates takes place from the bottom to the top and always starts with the two rear rows to the very left and right (viewed in flow direction). Then all other rear rows (if present) are installed and finally all front rows are mounted.
  • Page 32 Duct, top view Air flow direction 21. Only the rear rows of ceramic plates require the installation of anti-drip sheets. However, the anti-drip sheets must be installed only on the sides of the ceramic plates which overlap with the plates of a front row (see figure above). The ceramic plates at the very bottom require the installation of plate sealings instead of anti-drip sheets. Insert the anti-drip sheet on the corresponding side between the vertical section and the overlapping ceramic plate until it comes to a stop.
  • Page 33 Install the ceramic angle L = 300 mm L = 400 mm L = 100 mm L = 300 mm L = 500 mm L = 300 mm L = 300 mm L = 700 mm 24. Place the ceramic angle (one or two angles) on top of the ceramic plate.
  • Page 34 Install the lateral flow sheets: ø3.3 mm 26. Fix the two­part lateral flow sheets to the duct wall using the self­tapping screws provided (drill holes ø3.3 mm before). First mount the lower part of the lateral flow sheets, then the upper one (the upper part must overlap the lower one).

  • Page 35: Installation Of The Central Unit

    Installation of the central unit Location of the central unit – The central unit is designed for wall mounting. Make sure the construc- tion (wall, pillar, etc.) to which the central unit is to be mounted, offers a sufficiently high load­bearing capacity and is suitable for the installa- tion.

  • Page 36: Installation Of The Components Of The Decentralized System

    5 0 0 Mounting profiles for direct fastening to the monobloc Z409 4 0 0 Important! Mount the small cabinet (spray circle discharge) in a way that the hoses (building side) between the housing lead- throughs on the duct, and the corresponding connectors on the small cabinet can be installed with a constant downslope.
  • Page 37 Installation of the connector box 1 2 5 Upon delivery the box is ready to be connected. Use the provided fasten- ing material (4 pan head screws M5x55 mm, 4 spring washers M5, and M5x55 4 blind nuts M5) to mount the connector box directly to the ventilation duct/ monobloc or to a frame.

  • Page 38: Water Installation

    Water installation Water installation of the centralized system The following illustration shows the water installation of the centralized system. Installations to be carried out are highlighted in grey. Important! Read and observe the notes on water installation at the end of the current chapter. G 1/2") G 1/2") Z409...
  • Page 39 Water installation of the decentralized system The following illustration shows the water installation of the decentralized system. Installations to be carried out are highlighted in grey. Important! Read and observe the notes on water installation at the end of the current chapter. ø10 mm Lmax= 10 m Min.
  • Page 40 If the water pressure is >10 bar, install a pressure reducing valve (set to 10 bar) in the supply conduit. – If the conduit length between the water conditioning unit and the Condair Dual exceeds 20 m, the supply conduit must be equipped with a suit- able pressure damper (overflow valve, surge tank, etc.).
  • Page 41 – Working pressure at maximum humidification capacity: min. 2 bar – Maximum admissible inlet temperature: 45 °C – No additives (such as chlorine, disinfecting agents, ozone, etc.) – Max. germ count at the water inlet on the Condair Dual: 100 cfu/ml...

  • Page 42: Electrical Installation

    Electrical installation All work concerning the electrical installation must be performed only by adequately qualified personnel (electrician or specialist with equi valent training). Please observe all local regulations concerning the electrical instal- lation. Wiring diagram (also found on the cover of the control unit) The following wiring diagram provides an overview of the electrical installa­...
  • Page 43 Notes on electrical installation – The terminals accept the following maximum cable cross sections: stranded wire 1.5 mm , solid copper wire 2.5 mm – All connecting cables and strands must be led mandatory through the two snap ferrites SF located directly before the control unit. Please observe the instructions provided with the snap ferrites.

  • Page 44: First-Time Commissioning

    Since first-time commissioning is always done by a service technician of your Condair supplier the current manual does not provide de tail ed infor- ma tion on this procedure. The commissioning protocol with the system configuration data can be...

  • Page 45: Operation

    Ascertaining the qualification is the customer’s responsibil- ity. Introduction The Condair Dual Hybrid Humidifier is operated via the control unit. The control unit provides the following display and control elements: 1 Display (5x7 dot matrix, 2x16 characters) 2 <M >...
  • Page 46 –­ The­Condair­Dual­is­in­standby­mode­(no­humidification). Condair Dual ready –­ The­ Condair­ Dual­ humidifies­ (in­ addition,­ the­ “Humidification­ on”­ Condair Dual indicator lights). humidific. on – Drain valve open, the permeate is led directly to the drain conduit Condair Dual (cause:­preset­flushing­cycle­is­in­progress­(every­24­hrs.)­or­the­...

  • Page 47: Taking The Humidifier Out Of Operation

    5.3 Taking the humidifier out of operation To take the Condair Dual Hybrid Humidifier out of operation, e.g. for main- ten ance pur poses, proceed as follows: • Set the power switch to “O”. • Disconnect the control unit from the mains: Set the service switch of the mains supply line to “Off”.

  • Page 48: Inquiring Operating Parameters

    The Condair Dual provides a so-called display level used for inquiring various operating parameters. However, the display level does not let you change the parameters. Accessing the display level The Condair Dual is in standard operation mode (the display of the control Condair Dual unit shows the current state of operation). ready •...
  • Page 49 Overview of the display level Standard operation Condair Dual ready Display level perform. [kg/h] perform. [kg/h] controller funct appliance: valve Y8: perform. [kg/h] contr.val.p-punp nom. value rF act.value: 95 % 45 % Demand p-pump w.fl. P-band 25 % 10 % p-pump.
  • Page 50 Description of display level parameters The following description explains the parameters that may be accessed via the <▼> and <▲> keys once the display level has been launched (with the <M > or <E> key). – Maximum humidification output perform. [kg/h] Maximum spraying capacity in kg/h.
  • Page 51 7 Ah Note: This parameter is available only if the silver ionization is ac- tive. – Working hour meter elapsed time Working hours elapsed since first­time commissioning of the Condair 180 h Dual. – Remaining time until maintenance is due maintenance due Hours remaining until next maintenance is to be carried out.

  • Page 52: Setting Up Operating Parameters

    Condair Dual Hybrid Humidifier. Accessing the setup level The Condair Dual is in standard operation mode (the display of the control Condair Dual unit shows the current operating status). ready Simultaneously press the <▼>...
  • Page 53 Following entry of the last digit the opposite message is displayed briefly Condair Dual to confirm access to the setup level. setup level Note: If you entered an erroneous code the message “incorrect code” briefly appears on the display, and subsequently you are asked to re­enter the access code.
  • Page 54 Overview of the setup level Standard operation Condair Dual ready entry code 8808 Condair Dual Setup level Setup level language mainten. interv. nom. value rh english 2000 h 45 % analog signal perform. limit P-band 0-10 Vdc ( 81%) 100 % 10 % integr.
  • Page 55 – Analog signal analog signal Selection of the analog signal range. 0-10 Vdc ( 81%) Factory setting: 0-10 Vdc Optional settings: 0-20 Vpa (phase-control), 0-10Vdc, 2-10Vdc, 0-5Vdc (step control board), 1-5Vdc, 0-1Vdc, 0-20mA, 4-20mA and 0-8.2Vdc Note: The value in brackets is the current value in % of the maximum signal or the current ambient humidity in %rh, respectively.
  • Page 56 – Proportional range (P-range) of the internal PI controller P-band Sets the proportional range of the internal PI controller in %. 10 % Note: This parameter is available only if the internal PI controller is active. Factory setting: 10 % Setting range: 4 - 100 % Note: The proportional range is used to smoothen the control char- acteristic.

  • Page 57: Maintenance And Replacement Of Parts

    Certificate following long-term tests at the Fresenius Institute. To ensure operational safety and to guarantee hygiene in long-term opera- tion, the maintenance concept for the Condair Dual has been structured in two stages. This differentiates between periodical checking and the implementation of a total hygiene service of the Hybrid Humidifier.
  • Page 58 Periodical checking Periodical checking should be carried out monthly and include the follow- ing steps: Item Work to be carried out Nozzle system – Check the spray pattern of the spray nozzles (spray cone: optimum 90°, 60° acceptable). If necessary, clean the spray nozzles (see total hygiene service).

  • Page 59: Notes On Cleaning Agents

    (please contact your Condair dealer). Bacterial count concentrations in the upper area of the permitted range may be an indication of the onset of bacterial problems in the ventilation system.

  • Page 60: Removal And Installation Of Components

    Removal and installation of components 6.3.1 Removal and installation of ceramic plates Removal of ceramic plates Note: If the ceramic plates of a rear row (viewed in flow direction) must be removed, the ceramic plates of the adjacent front rows must be dismantled first.
  • Page 61 5. Carefully pull the ceramic plate out of one vertical section, slightly tilt the plate forward, then withdraw it from the other vertical section. 6. Remove the ceramic angle(s) located on top of the next ceramic ele- ment. Repeat steps 2 to 6 until all ceramic plates of a row are removed. Installation of the ceramic plates Before installation, check all ceramic plates and ceramic angles for pos- sible damage.

  • Page 62: Removal And Installation Of The Spray Nozzles

    6.3.2 Removal and installation of the spray nozzles Removal of the spray nozzles • Remove the hose(s) from the spray nozzle (press the locking ring towards screw, then pull hose off). • Squeeze the catch locks of the nozzle support and remove the sup- port.

  • Page 63: Replacement Of Silver Ionization "Hygieneplus

    LED goes off and then comes on again briefly (approx. 1 second). Replacing the silver ionization cartridge • Set the hybrid humidifier Condair Dual out of operation as per chapter 5.3 and depressurize the water system. • Remove the two electrical connectors from the connections on the silver ionization cartridge.

  • Page 64: Replacement Of The Control Unit Fuses

    Replacement of the control unit fuses The fuses of the control unit must be replaced by authorized personnel only (e.g. electrician). Caution! Electronic components are sensitive to electrostatic discharge. Protective measures (ESD protection) must be taken before replacing the fuse(s) of the control unit. Replace fuses F1 and F3 of the control unit only with fuses matching the specifications below: –...

  • Page 65: What If

    What if ...? 7.1 Error messages Faults detected during operation trigger the fault indicator (red LED) and a corresponding event message appears on the display. The Cond air Dual makes a distinction between alarms and errors. Alarms An alarm indicates a temporary fault that was detected during operation (short-time interruption of the water supply) or faults that do not cause damage to the system.
  • Page 66 Replace silver ionization cartridge (see chapter 6.4). Errors An error message indicates a fault detected during operation that may cause damage to the system. If such a fault occurs, the Condair Dual is switched off automatically. Indication: red LED lights constantly...
  • Page 67 Error message Cause/Remedy Cause: Conductance limit exceeded (>100 µS/cm). error 05 Remedy: Check reverse osmosis system (max. conductance µS/cm), conduct. perm. check conductance sensor and clean, if required. Cause: Permeate conductance out of admissible range of tolerance (con- error 06 ductance sensor disconnected or short-circuited). cond.meas perm.

  • Page 68: Failures

    Maximum humidification capacity Output limitation active. Deactivate output limitation (see is not reached chapter 5.5). System incorrectly dimensioned (in- Contact your Condair supplier. sufficient capacity). Booster pump defective (insufficient Replace booster pump. permeate pressure). Booster pump starts too late or Output limitation active and/or se-...

  • Page 69: Instructions For Fault Elimination

    – Caution! Electronic components are very susceptible to electrostatic discharge. When carrying out repairs to the control unit, appropriate measures (ESD-protection) must be taken to prevent damage to elec- tronic components. – Malfunction of the booster pump must be remedied by your Condair supplier only.

  • Page 70: Specifications/Ambient Conditions

    Specifications/ambient conditions Type Capacity in l/h Type Capacity in l/h at 7 bar at 7 bar water pressure water pressure Scope of versions in terms of capacity CD ZE / DZ 20 CD ZE / DZ 300 CD ZE / DZ 40 CD ZE / DZ 400 CD ZE / DZ 60 CD ZE / DZ 500...

  • Page 71: Appendix

    Notes on humidity control with the internal PI controller The internal PI controller of the Condair Dual Hybrid Humidifier The controller built into the Condair Dual Hybrid Humidifier is a so­called PI controller (proportional-integral controller). The PI controller interprets the analog signal as the actual humidity value captured by a sensor and controls the humidification capacity via the “proportional range”...

  • Page 72: Enthalpy Control For Condair Dual

    In simple terms, enthalpy is the amount of energy of the air in kJ/kg. With an enthalpy control the air temperature and the air humidity are used to control the preheater in a way, that the Condair Dual can be exactly and continuously regulated along the adiabatic line to the respec- tive outlet conditions (rF2 and T2).
  • Page 73 When adapting, make sure the calculated efficiency factor of the humidifier system “η” is not exceeded according the following formula. Preheater Hybrid humidifier Condair Dual Incoming air Mixed air Position encoder enthalpie control...

  • Page 74: Commissioning Protocol/Maintenance Record

    9.2 Commissioning protocol/Maintenance record On the following two page you will find: – the “Commissioning protocol” holding the current operating param- eters – the “Maintenance record” specimen (to be copied)

  • Page 77: Setup Table Silver Ionization "Hygieneplus

    9.3 Setup table silver ionization “Hygieneplus” Setup of ionization current and capacity counter Capacity of unit [l/h] Type of silver ionization cartridge “Hygieneplus” Ionization current [mA] 14.6 14.6 14.6 14.6 29.2 29.2 29.2 29.2 29.2 Capacity counter [Ah] Capacity of unit [l/h] Type of silver ionization cartridge “Hygieneplus”...
  • Page 78 Notes...
  • Page 79 © condair ltd., printed in switzerland technical modifications reserved...
  • Page 80 40002-2 Manufacturer: condair ltd. Member of the Walter Meier group talstrasse 35-37, 8808 pfäffikon, switzerland ph. +41 55 416 61 11, Fax +41 55 416 62 62 info@condair.com, www.condair.com...

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