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install, commission and service manual en pf - PDF

1. JP3 5 Vdc max 500 mA A3 JP4 24 Vdc max 150 mA J4 Driver Board 2 L L 410 Modul 413 Feedback JP4 JP3 oo J2a RS485 Boo Go o o O gup o Board 1 J19 J4 Float PMW1 PMW2 r J1 CPU Board J8 PMW3 O E J14 6 Bi Drain Fill ni 1 Li 8 J17 24VAC 24VAC 9 lgn6 24VAC COM 24VAC Hot 47 lgn5 gt bend Ld Gl 220 230V 50 60Hz l J3 A P ot La Error Service Steam Unit ON 1 1 1 l l 1 1 l 1 l l 1 1 l 1 1 1 l 1 l 1 1 1 l 1 l 1 1 l PE N Lt En i 1 l 1 1 l 1 l 1 1 l J 1 a o o a o o o a A1 A2 A3 B1 B2 B3 F1 F2 38 Control or sensor signal Y signal type set via control softvvare Control or sensor signal Z air supply limit signal signal type set via control softvvare Output 24 Vdc JP4 or 5 Vdc JP3 Safety high limit humidistat building side Flow control building side Ventilation interlock building side External Fuse 10 A slow acting building side 220 240 VAC power supply Fuse 6A fast acting 24 VAC power supply H1 J1 Remote operating and fault indication Cable bridge if no monitoring devices are connected JP3 J
2. gt 45 mm building side Manometer installation recommended building side Water supply The water supply pipe is to be connected via the filter valve accessory Z261 to the connection on the unit see foregoing illustration The filter valve should be installed as close to the humidifier as possible Note Instead of the filter valve a shut off valve and a water filter 5 um both essential can be used The following specifications must be observed Connections on unit BSP 1 2 outside thread Min inner diameter of supply line 12 mm Admissible mains pressure 3 0 to 8 0 bar hammer free system For mains pressures gt 8 bar connection must be made via pressure reducing valve adjusted to 3 0 bar For mains pressures lt 3 0 bar please contact your Condair supplier Supply rate 10 l min Admissible supply temperature 1 30 C Notes on water quality For the water supply of the Condair GS OC use exclusively untreated drinking water or fully demineralized water Note The use of fully demineralized water reduces the maintenance and the cleaning of the water tank to a minimum The use of additives such as corrosion inhibitors disinfectants etc is not allowed since these additives may endanger health and affect proper operation Ifthe Condair GS OC shall be operated with softened or partly softened water please contact your Condair supplier The connection materi
3. 80 rh 5 C 60 rh 5000 6600 8000 40 10000 13200 16000 80 15000 19800 24000 120 Example 20000 26400 32000 160 Max portion of supply air 10000 m3 h temperature rel 25000 33000 40000 200 humidity of supply air 15 C 90 rh 30000 39600 48000 240 Important notes The required maximum steam capacity depends on the specific application and the installation The calculated steam capacity based on the above formulas the h x diagram and the condition of the air to be humidified does not consider any steam loss e g due to condensation in the steam hoses and the steam distributors any heat loss of the unit as well as any absorption or release of humidity of materials located in the room being humidified In addition the calculated steam capacity does not consider any losses caused by the draining rate depending on the water quality The total amount of losses depends on the entire system and must be taken into consideration when calculating the required steam capacity If you have any questions regarding the calculation of the steam capacity please contact your Condair supplier For systems where the max required steam capacity varies extensively e g for test facilities or for systems with variable air volume flow etc please contact your Condair supplier Combustion gas The Condair GS OC can be operated with natural gas or propane The equipment is configured ex works for the respective combustion gas that is to
4. Remove hose clamps on the fill valve connections and pull off the hoses Undo the two screws fixing the fill valve to the housing then remove the fill valve Re installation is carried out in the reverse sequence Make sure the hoses are correctly secured with the hose clamps and the cables are connected correctly 57 58 Replacing the vvater level unit Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the left front panel Remove the connection cable to the level unit Remove hose clamps on the level unit connections and pull off the hoses af ux Squeeze both sides ofthe mounting bracket to release it from the slots in the support bracket behind the vvater level unit then remove the level unit Re installation is carried out in the reverse sequence Make sure the hose are correctly secured with the hose clamps and the cable is connected correctly Replacing the filling chamber Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel Remove hose clamps on the filling chamber connections and pull off the hoses Undo the tvvo nuts securing the filling chamber to the face of the tank then remove the filling cham ber Re installation is carried out in the reverse sequence Make sure the hose are correctly secured with the hose clamps 59 60 Removal of the heat exchanger see follovving illustratio
5. and to carry out maintenance work in strict accordance with the instructions Note The water supplied to the Condair GS OC contains minerals which continuously accumulate inside the water tank during the evaporation process To prevent excess accumulation the water tank must be cleaned on a regular schedule Observe all local safety regulations regarding the handling of mains powered and gas fired devices Attention The electronic parts inside the humidifier are very sensitive to electrostatic discharge To prevent damage appropriate measures against electrostatic discharge ESD protection must be taken when working on an open unit For safe operation of the Condair GS OC humidifier make sure the ambient conditions temperature humidity meet the respective specifications defined in this documentation see chapter 10 1 Safe operating ambient temperatures As long as the unit is powered and is running the heat generated internally ie that comes off of the tank is sufficient to keep the space inside the enclosure warm and will protect the electronics the electric heaters will not come on very often except during extremely cold temperatures For this reason the unit will operate safely at outdoor temperatures between 25 C 13 F and 35 C 95 F Note a thermostatically controlled cooling fan will be activated in the enclosure when the internal temperatures measured in the electronics area exceeds 25 C Safe
6. 0 7 0 16 0 9 0 22 1 2 0 30 1 5 0 41 2 1 0 58 3 2 0 96 0 5 0 10 0 8 0 17 1 0 0 25 1 4 0 36 1 9 0 52 2 9 0 88 0 5 0 11 0 8 0 20 1 2 0 30 1 7 0 45 2 7 0 79 0 5 0 13 1 0 0 24 1 5 0 38 2 4 0 69 0 7 0 16 1 2 0 30 2 1 0 58 0 8 0 20 1 7 0 45 For duct widths lt 600 mm the humidification distance for the OptiSorp system increases by approx 50 1 in rh Relative supply air humidity prior to humidification at the lowest supply air temperature 2 in rh Relative supply air humidity after the steam distribution pipe at maximum capacity Example given 1 30 rh 2 70 rh humidification distance By 1 4 m 0 36 m for steam distribution system OptiSorp Note If the humidification distance has to be reduced for technical reasons the amount of steam per steam outlet must be divided between two steam distribution pipes or the steam distribution system OptiSorp must be used If this is the case contact your Condair supplier 23 Minimum distances to be observed To prevent the vvater vapor that is emitting from the steam distribution pipe from condensing on downstream system components a minimum distance to the steam distribution pipe must be observed depends on the humidification distance B before after constriction after expansion before bend before branch before diffuser before control temperature sensor 2
7. GS OC Type 40 80 120 160 200 240 Steam output kg h 10 40 10 80 10 120 10 160 10 200 10 240 Energy consumption kW 36 5 73 0 109 5 146 0 182 5 219 0 Gasous fuel Natural gas G20 G25 G25 1 G27 GZ350 or Propane gas G31 Electric connections power supply 230V 50 60Hz 1 Phase power consumption Watt 460 690 920 1150 1380 1610 power supply fuse Ampere 10 slow acting Mechanical Connections Fill water inlet Inch BSP 1 2 Drain Inch BSP 3 4 Auxiliary drain Inch BSP 1 2 Gas line Inch BSP 1 2 BSP 3 4 BSP 1 BSP 1 BSP 1 1 4 BSP 1 1 4 Steam hose connection Inches 1 3 4 45mm 3 76 mm 3 76mm 4 101 mm 4 101 mm 4 101 mm Flue pipe connection Inches 3 76 mm 4 101mm 5 127 mm 5 1 127 mm 6 152 mm 6 152 mm Humidity control Possible control signals 0 5VDC 1 5VDC 7 0 10VDC 7 0 20mA 4 20mA Dimensions Height cm 138 with mounted flue gas venting 199 7 Width cm 126 2 Depth cm 54 5 70 8 110 4 110 4 150 150 Shipping weight kg 243 297 399 411 526 538 Operating weight filled kg 280 362 563 563 778 779 empty kg 209 251 342 353 458 470 Operating conditions Admissible water pressure bar 3 8 Water quality untreated drinking water or fully demineralized water Admissible gas supply pressure mbar G20 17 25 G25 20 30 G25 1 20 30 G27 17 5 23 62350 10 5 16 G31 25 57 5 Admissible ambient temperature CI F 25 C tot 35 C unit powered on CI F 0 C tot 25 C unit
8. The flue gas temperature during normal application and when the maintenance schedule is fulfilled is between 160 180 C If the unit is not maintained properly the flue gas temperature could increase In this case the temperature switch would shut down the unit if the temperature exceeds 200 C for safety reasons Use the supplied flue gas pipe with storm collar and rain cap exclusively The supplied flue pipe extension and the rain cap have built in mechanical locking band and gasket Simply push each component to the stop bead which provides an air and water tight seal Then tighten the integrated locking band on each component to complete the installation of the flue gas venting Make sure the rain cap is at least 60 cm above any ridge within 3 m of the unit Note if the flue gas venting needs to be longer for any reason please contact your Condair repre sentative 5 7 Installation of control and monitoring devices Install the room humidity sensor and the safety humidistat at the same height as thermostats and in a location where the measured humidity corresponds to that of the room Under no circumstances should the humidity sensors be positioned in the vicinity of the air flovv from ventilator units or air intake grids Do not mount humidity sensors on an outer wall where temperature fluctuations can affect the control behavior Install the duct humidity sensor in a position where the measured humidity corresponds to that of t
9. after siphon 10 95 Note It is not permissible to curve the drain pipe upwards because this can lead to the collection of deposits at the lowest point in the pipe and to the blockage of the pipe 31 5 5 5 5 1 32 Gas installation All installation work must be carried out in accordance with the applicable local building and installation regulations All work concerning the water installation must be performed only by adequately qualified personnel e g plumbers Ascertaining the qualifications is the customers responsibility Warning danger of electric shock For all installation work the Condair GS OC must be disconnected from the mains supply and secured against unintentional reconnection Performing the gas installation Overview Gas installation 1 Gas supply connection Model Connection GS 40 OC BSP 1 2 GS 80 OC BSP 3 4 GS 120 OC and GS 160 OC BSP 1 GS 200 OC and GS 240 OC BSP 1 1 4 2 Gas shut off valve building side 2220992262 2229222699 2229222992 3 Sediment trap Installation building side essential in the case of the use of steel gas pipes nstallation notes The gas supply pipe must be connected to the connection on the unit via a shut off valve essential requirement which is installed in the immediate vicinity of the unit When steel gas pipes are in use it is essential that a sediment separator be fitted between
10. be employed If required the equipment can be converted at a later date to work with one of the other combustion gas ua Designation Condair GS 80 OC C G20 Natural gas H E E S G20 Natural gas L ELL G25 Natural gas HS G25 1 Natural gas Lw G27 Natural gas Ls GZ350 Propane gas P Liquid gas G31 4 2 Selecting the control system The various control systems System 1 Room humidity control System 1 is suited for air conditioning systems with mainly recirculated air The humidity sensor is preferably located in the room itself or in the exhaust air duct b 4 K lap Condair A1 humidity sensor B1 B2 GS 0C B1 ventilation interlock a B2 airflow monitor B3 safety humidistat A external continuous controller e g Pl controller internal continuous controller PID controller Y input signal from A1 Ple System 2 Room humidity control with continuous limitation of the supply air humidity System 2 is suited for air conditioning systems with a large portion of supply air low supply air temperature post humidification or variable airflow volume If the supply air humidity exceeds the preset value the continuous limitation is effected prior to the room humidity control The humidity sensor A1 is preferably located in the exhaust air duct or in the roo
11. gas line must be depressurized before it is recon nected to the unit Caution Non observance of the above instruction can lead to damage to the gas pressure regulating valve Gas pressure valves overloaded due to high pressure are not covered by the manufacturer s guarantee Conversion instructions for operating the humidifier with another type of gas Ex works the appliance is equipped to operate on one type of gas To convert an appliance for operation on another type of gas follow the directions below see also illustration on the following page The conversion shall be carried out by a manufacturer s authorized representative or person trained and licenced for such activities in accordance with the requirements of the manufacturer or local authorities having jurisdiction in the area of installation 1 Disconnect the humidifier from the electrical power supply and take precautions against inadvertent switching on 2 Turn off gas supply to appliance and secure it against inadvertent opening Undo the brackets and open the right side panel s 4 Disconnect the hose from the inlet elbow note the layout Then loosen the hose clamp and remove the inlet elbow 5 Undo the coupling of the corresponding flexible gas pipe and disconnect gas pipe from the gas pressure regulating valve 6 Disconnect electrical cables to the gas pressure regulating valve and the air pressure switch note assignment before removal 7 Undo the two
12. out of service Disposal Recycling Specifications Technical Data Flue gas specifications 1 1 1 2 ntroduction At the very beginning Thank you for deciding on the outdoor version of the Condair GS OC C series gasfired steam humidifier abbreviated as Condair GS OC The Condair GS OC incorporates the latest technical advances and satisfies the requirements of the European Gas Equipment Directive 90 396 EEC and all known safety standards Nevertheless improper use may result in danger to the user or third parties and or impairment of the installation or other material assets To ensure a safe proper and economical operation of the Condair GS OC please observe and comply with all information and safety instructions contained in the present installation com missioning and service instructions If you have questions which are not or insufficiently answered in this documentation please contact your Condair supplier They will be glad to assist you Notes on the installation commissioning and service instructions The subject of these installation commissioning and service instructions is the gasfired steam humidifier Condair GS OC C series in its different versions The various accessories steam distribution pipes water filter etc are only described insofar as this is necessary for proper operation of the equipment Further information on accessories can be obtained in the respective instructions The
13. powered off Admissible ambient humidity rh 10 95 non condensing Overpressure at the flue outlet at full load Pa 80 at minimum load Pa 5 Type of protection Admissible duct air pressure Pa 800 1700 Further informations Conformity CE Patents Condair international trademark international patents 65 11 2 Flue gas specifications Natural gas G20 Natural gas G25 full load part load full load part load Condair GS 40 OC energy consumption kVV 36 5 10 5 36 5 10 5 gas consumption kg h 2 4 0 68 3 04 0 87 m3 h 3 478 0 8695 4 0443 1 0111 exhaust temperature C 180 120 180 120 exhaust mass flow kg s 0 015 0 0034 0 017 0 0058 CO content 8 9 8 8 7 8 flue gas pressure Pa 80 5 80 5 exhaust diameter mm 76 76 Condair GS 80 OC energy consumption kW 73 10 5 73 10 5 L kg h 4 72 0 68 6 08 0 87 m3 h 6 956 0 8695 8 0886 1 0111 exhaust temperature C 180 72 180 72 exhaust mass flovv kg s 0 03 0 0067 0 034 0 0113 CO content 8 9 4 4 8 7 4 3 flue gas pressure Pa 80 5 80 5 exhaust diameter mm 101 101 Condair GS 120 OC energy consumption kW 109 5 10 5 109 5 10 5 gas consumption kg h 7 08 0 68 9 12 0 87 m3 h 10 434 0 8695 12 133 1 0111 exhaust temperature C 180 57 180 57 exhaust mass flovv kg s 0 045 0 0099 0 051 0 0169 CO content 8 9 2 9 8 7 2 9 flue gas pre
14. screws that mount the venturi manifold to the combustion air blower then lift up the manifold together with the gas pressure regulating valve 8 Undo the four screws and remove the gas pipe connection of the gas pressure regulating valve 9 Undo the three screws of the air pressure switch support and remove the pressure switch assembly from the gas pressure regulating valve 10 Check the cork gasket and the O ring in the gas pipe connection for damage and replace if neces sary 11 Attach the gas pipe connection with mounted O ring and the pressure switch assembly to the gas pressure regulating valve supplied comes with venturi manifold attached Warning Make sure the gas type indicated on the label of the venturi manifold corresponds to the gas you are using Do not change the setting of sealed adjustment screw A 12 Fix the new venturi manifold don t forget the cork gasket together with the gas pressure regulating valve with the two screws to the combustion air blower 33 34 13 Reconnect the flexible gas pipe to the gas pressure regulating valve and tighten the coupling 14 Fix the inlet elbovv vvith the hose clamp to the venturi manifold 15 Reconnect the hose betvveen the air pressure svvitch and the inlet elbovv 16 Reconnect the electrical cables to the gas pressure regulating valve and the air pressure svvitch 17 On multiple burner units repeat steps 4 to 16 for each gas valve assembly pressure swit
15. the maximum steam output of the humidifier due to the heat loss involved The static pressure also increases Install the steam humidifier so that the flue gas outlet meets the following minimum distances atleast 0 6 m above any ridge located within 3 m atleast 1 m above any forced air inlet located within 3 m atleast 1 m below and 1 m horizontally away from or 0 5 m above any door window or gravity air inlet of any adjacent building atleast 1 m horizontally away from electric meters gas meters regulator and relief equipment atleast 2 5 m above grade when it is adjacent to public walkways Make sure in the place of location of the Condair GS OC the supply of clean fresh air is provided The unit must be placed at least 3 m away from any mechanical exhaust outlet Caution Operation of the humidifier with unclean air can lead to safety problems and reduce the output of the unit Impurities in the air are for example Halogens ammonia chloride excessive dust lime and dirt For questions about air quality please refer to the technical service department of your Condair distributor 19 20 The Condair GS OC gasfired steam humidifiers are designed for mounting on a curb Caution The curb and the place of installation must be built to structurally support the entire weight of the humidifier when in operation The sheet covering of the Condair GS OC heats up during operation max surface temperat
16. the shut off valve and the unit connection The following connection data must be adhered to Permissible gas operating pressure Gas Operating pressure mbar Nominal Min Max Natural gas H E E S G20 20 17 25 Natural gas L ELL G25 25 20 30 Natural gas HS G25 1 25 20 30 Natural gas Lw G27 20 17 5 23 Natural gas Ls GZ350 13 10 5 16 Propane Gas P G31 37 or 50 25 57 5 The connection material used must be pressure tested and approved for gas installations Do not use teflon tape on gas line pipe threads A flexible sealant suitable for use with Natural Gas and Propane Gas is recommended Plan gas supply piping so it will not interfere with removal of gas valves or blower assemblies and front or side service doors 5 5 2 5 5 3 Leak testing After completion of the installation work the whole gas line must be tested to a maximum pressure of 40 mbar 4 0 kPa for natural gas or 150 mbar 15 kPa for propane and checked for leaks using a commercially available soap solution The bubbles indicate leaks All leaks must be eliminated before the humidifier is put into operation Caution Never use an open flame to check for leaks The presence of any leakage is a source of danger to persons and to property due to the possibility of fire and explosion If the gas circuit must be tested to a pressure of over 150 mbar 15 kPa the gas supply pipe must be removed from the unit connection After the test the
17. 5X By before submicron particle filter 24 Installation notes and dimensions The steam distribution pipes are designed for either horizontal installation on the duct wall or with accessories for vertical installation in the duct floor The outlet orifices should always point up wards and at right angles to the airflow If possible the steam distribution pipes should be installed on the pressure side of the duct max duct pressure 1700 Pa If the steam distribution pipes are installed on the suction side of the duct the maximum vacuum must not exceed 800 Pa Select a location for the installation tailored to suit your duct see the following illustrations and position the steam distribution pipes in the duct so that a uniform distribution of steam is achieved n positioning the steam distribution pipes the follovving dimensions should be observed min H 250 mm min Hz 600 mm min Hz 720 mm min Hz 600 mm min Hz 840 mm min Hz 960 mm min H 800 mm min Hz 800 mm 25 Note VVhen locating the OptiSorp steam distribution system please note the instructions in the separate documentation for this product Guidelines for dimensioning the ventilation ducts To facilitate the installation of the steam distribution pipes and for control purposes a sufficiently sized control opening should be planned Within the range of the humidification distance the ventilation d
18. Condair GS OC C series Gasfired steam humidifier outdoor version INSTALLATION COMMISSIONING AND SERVICE INSTRUCTIONS 2511510 1112 cond ir l Contents o A 10 10 1 10 2 11 11 1 11 2 Introduction At the very beginning Notes on the installation commissioning and service instructions For your safety Product Overview Product versions Model designations Delivery Humidification system overview Construction of the gasfired steam humidifier Principle of operation Basic planning Selecting the unit Selecting the control system Options Accessories Mounting and installation works Safety instructions for mounting and installation works Unit fitting Steam installation Water installation Gas installation Flue gas installation Installation of control and monitoring devices Electrical Installation Inspecting the installations Check list Operation Safety instructions for operation Function of the display and operating elements Commissioning and notes on operation Taking out of operation Maintenance Maintenance instructions Dismantling work for maintenance and the replacement of components Notes on cleaning agents Resetting the maintenance reminder Troubleshooting Important notes on troubleshooting Error indication Resetting the error indication Replacing the backup battery on the control board of the Condair GS OC Taking out of service Disposal Taking
19. N s syiew y SSeUpseY BulyJoM jenuuy ews 1514 aw ayeq OU ajqisuodsay uohe207 UOIS A BJEMYOS 185 Jaquinu 1 adh yun p10991 BOULUD UIC a A 3epuo3 50755 TEDUO O Condair Ltd Printed in Svvitzerland Technical modifications reserved CONSULTING SALES AND SERVICE vV SGS Reg No 40002 2 Manufacturer Condair Ltd Member of the Walter Meier Group Talstrasse 35 37 8808 Pfaffikon Svvitzerland Ph 441 55 416 61 11 Fax 441 55 416 62 62 info condair com www condair com
20. YA KS 0 WY V m SRR ad pod hirii TILDE DEDEDE DEL FET V OOO DN S D W 5 Replace the backup battery CR2032 Lithium 3V 6 Reassemble the unit in reverse order 7 If necessary set date and time see operating instructions of the control The old battery must be returned to an authorised collecting pointfor correct disposal recycling in accordance with local regulations In no case the old battery must be disposed of in the domestic waste or into the environment 63 10 10 1 10 2 64 Taking out of service Disposal Taking out of service If the Condair GS OC must be replaced or if the humidification system is not needed any more pro ceed as follovvs 1 Take the unit out of operation as described in chapter 7 4 2 Have the unit and all other system components if necessary unmounted by a qualified service technician Disposal Recycling Components not used any more must not be disposed of in the domestic waste Please dispose of the unit or the individual components in accordance vvith 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 11 Specifications 11 1 Technical Data Condair
21. al must be pressure proof and certified for use in the drinking water supply Caution Fully demineralized water is aggressive When making connections to a fully dem ineralized water system use exclusively plastic or stainless steel installation materials min DIN 1 4301 Important Before connecting the water line to the unit the line must be flushed thoroughly Water drain and auxiliary water drain Both drain lines should be connected to the corresponding connection on the unit using a hose coupling Lead the drain lines via the pipe chase downwards into an open drain funnel min height 15 cm inside the building The drain funnel is then connected via a siphon to the building drain line The minimum internal diameter of 45 mm must be maintained over the full length of the building drain line Make sure that the drain line is correctly attached and easily accessible for the purpose of inspection and cleaning The following connection data should be observed Connections on unit hose connection BSP 3 4 026 mm drain connection BSP 1 2 621 mm auxiliary drain connection Warning Use only temperature resistant installation materials Caution When using fully demineralized water only stainless steel min DIN 1 4301 or chemically resistant plastic e g Polypropylene connection components must be used Drainage capacity approx 20 I min Min inner diameter of the building drain line 45 mm Min downslope
22. ambient temperature range if there is no power If there is no power supplied to the unit the unit can not run to generate any heat and the electric heat ers and the cooling fan will also not work Therefore the unit is safe to sit outdoor without any power at outdoor temperatures between 0 C 32 F and 25 C 80 F This temperature range is limited because of the electronics Warning If the unit has been exposed to temperatures outside of the above stated range do not restart the unit Before restarting the humidifier have a qualified service technician inspect the appliance and replace any defective part Warning If the outside temperature is below 5 C when reconnecting the unit to the power supply let the heaters of the unit to be on for a minimum of 30 minutes to heat the electronics before starting the unit f it is assumed that safe operation is no longer possible switch the Condair GS OC off close the gas supply and secure the unit against inadvertent power up Safe opera tion may be affected in the following events you smell gas components of the Condair GS OC humidifier are damaged the Condair GS 0C humidifier does not work correctly components of the Condair GS OC humidifier are worn or badly soiled after longtime storage under unfavorable conditions after transportation under unfavorable conditions The Condair GS OC must be installed only in locations equipped with a wat
23. ance instructions To maintain operating reliability the Condair GS OC must be serviced at regular intervals Here a distinction is made between the first service after 500 hours of operation I the minor service every time the maintenance alarm appears 1 and the annual maintenance III Important Depending on the hardness of the water and the average steam output under certain circumstances it may be necessary to reduce the service interval for the minor maintenance work If the lime residues deposited on the floor of the tank exceed a height of 5 cm the interval must be reduced If the height is less than 5 cm the interval can be extended Important Every service action must be documented in the Maintenance check sheet a copy of this document is provided in these installation commissioning and service instructions Warranty is void if the specified maintenance intervals are not observed and the maintenance work are not carried out according the instructions The following is an overview of the work to be carried out at each of the service stages Components Interval Work required l Il Ill Water tank X X X Drain the tank then open it and measure the height of the lime residues on the tank floor max 5 cm Remove the lime from the tank Check all pipe connections to the tank specially the level unit passages Clean if necessary Water outlet pipes including siphon X X X Press the drain switch and ch
24. as L ELL G25 Natural gas HS G25 1 Natural gas Lw G27 Natural gas Ls GZ350 Propane gas P G31 model designation on rating plate The Condair GS OC gasfired steam humidifiers are built into an outdoor cabinet for outdoor installa tion The humidifiers are equipped with an operating and display unit as standard by means of which the current operating parameters can be interrogated and the equipment can be configured for operation The humidifiers are controlled via the internal PID controller or an external continuous controller Delivery The standard delivery includes Gasfired steam humidifier Condair GS 0C according to the model designation complete with all flue gas components included Installation commissioning and service instructions Condair GS OC C series Operating instructions Condair GS OC C series control Spare parts list pink Accessories ordered according to chapter 4 4 steam distribution pipes steam hoses etc 3 3 Humidification system overview 1 Gasfired steam humidifier 11 Drain water line building side 2 Flue gas pipe with rain cap and storm collar 12 Shut off valve water supply building side included in the delivery 13 Auxiliary drain connection 3 Steam supply pipe building side 14 Electrical connections building side 4 Gas supply connection 15 Filter valve accessory Z261 5 Shut off valve gas supply line building side 16 Water
25. ch Flexible gas pipe Cork gasket gas pipe connection a Combustion air blower 18 Carry out a leakage test Refer to instructions in 5 5 2 19 Turn power to unit back on and initiate a test fire sequence to check for proper ignition character istics 20 If tests are acceptable affix appropriate conversion label to data plate Close door panel s and secure with the brackets Then return unit to normal operation 21 Conversion is now complete 5 6 Flue gas installation Warning Since the regulations for the installation of flueing systems differ from country to country the relevant local regulations must be adhered to without reservation All work concerning the flue pipe installation must be performed only by adequately quali fied personnel Ascertaining the qualifications is the customers responsibility 5 6 1 Performing flue gas installation Overview 2229922269 2226020007 Pag 2229292927 5 1 Flue gas connection on the unit 0940 676 mm 3 GS 80 0101 mm 4 GS 120 OC GS 160 0127 mm 5 GS 200 OC GS 240 OC 0152 6 2 Storm collar included in the delivery 3 Flue gas pipe extension included in the delivery 4 Rain cap included in the delivery 35 36 nstallation notes The following instruction notes must be observed Flue gas specifications gt see table in chapter 10 2
26. checks the function of the water level unit If the control unit has verified the proper function of the water level unit the ignition sequence starts After three attempts at ignition the auto ignition switches off The red LED lights and a corresponding error message is shown in the display Now switch the humidifier Off Check ignition safety switch off The regulator is still set to maximum humidity demand and the shut off valve in the gas line is closed Switch On the humidifier at the unit switch The combustion air blower s start s Note On multi blower units wait until all blowers have started Then 15 seconds later pre purging time the igniter is activated and the gas pressure regulat ing valve opens After 7 seconds the gas pressure regulating valve closes and the igniter is de energized due to missing ignition Note On multi burner units this process is successively completed for all burners After three ignition attempts per burner complete with pre purging the humidifier goes into safety lockout Open the shut off valve in the gas supply pipe No gas should flow to the main burner End of the test Switch off the humidifier at the unit switch Note To reset the safety switch off switch off the humidifier for at least five seconds and then switch it on again Adjust the humidity controller again to the set humidity value 45 46 Pre purge of the gas pressure regulating valve s e Disconnect all ign
27. ction during the humidification process lime deposits peel from the walls and sink to the floor of the tank An ac cumulation of lime on the floor of the tank up to a maximum height of 50 mm is permissible and does not affect the operation of the humidifier e Remove the lime deposits in the tank and combustion chamber walls with a plastic scraper Do not use metal spatulas or scrapers because these are likely to scratch the internal walls of the tank e Remove lime deposits from the floor of the tank with a spatula and or with an industrial water suc tion apparatus Rinse out residual accumulations of lime with fresh tap water via the open auxiliary water drain connection Using a bucket Never rinse away lime accumulations directly into the connected water drain outlet because there is a danger of the drain pump the drain pipe and the siphon becoming blocked Remove the hose connections to the tank and clean them internally Removal and installation of the combustion air blovver 1 Take the humidifier out of operation as described in chapter 7 4 2 Undo the brackets and open the right side panel s 3 Disconnect cables to combustion air blower gas pressure regulating valve and pressure switch note assignment of the connections Undo the coupling of the corresponding flexible gas pipe and disconnect the gas pipe Undo the two screws of the venturi manifold and lift up the ma
28. d in the supply cable and located in the compartment outside the unit above the electrical service door L Are all components correctly connected in accordance with the wiring diagram L Are all connection cables fixed L Are the connecting cables free of tension fitted through cable glands secured with cable clamps LI Is the Condair GS OC correctly configured 7 Operation 7 1 Safety instructions for operation The Condair GS OC must only be commissioned and operated by persons who are familiar with equipment and adequately qualified to undertake this work Monitoring such qualification is a matter for the customer Initial commissioning must only be undertaken by the Condair service technician or by the customer s own specially trained personnel The safety instructions in Chapter 2 must be followed and adhered to Caution Danger of electric shock With the lid of the unit open contact with current conducting components is a possibility Before switching the service switch On in the electrical supply circuit all covers on the unit must be closed and locked The following temperature ranges must be observed when operating the unit unit powered on external service switch on 25 C 13 F to 35 C 95 F unit powered off external service switch off 0 C 32 F to 25 C 80 F Warning If the unit is exposed to temperatures outside of the range for powered off condition do not restart the unit Bef
29. description Condair GS 80 OC C G20 1 Required maximum steam capacity 2 Required combustion gas Calculating the maximum required steam capacity The maximum required steam capacity is calculated from the following formulas Vep m e x2 x1 or m e x2 x1 1000 1000 mp maximum steam demand in kg h V volume of supply air portion per hour in m3 h for indirect room humidification or room volume to be humidified per hour in m3 h for direct room humidification p specific gravity of air in kg m3 specific volume of air in m3 kg desired absolute room air humidity in g kg minimum absolute supply air humidity in g kg The values for p x2 and x1 can be gathered from the h x diagram or the Carrier Diagram for moist air respectively For a rough estimate of the calculated steam capacity the following table can be used The values listed in the table are based on a desired room air temperature of 20 C and a desired relative room air humidity of 45 Yorh Note To roughly estimate the calculated maximum steam capacity for larger supply air portions or room volumes the values listed in the table can be projected accordingly 13 14 Max portion of supply air in m3 hr or room max steam volume to be humidified per hour in m3 hr capacity in kg h Condair GS 80 C G20 Temperature rel humidity of supply air 15 C 90 rh 5 C
30. dication Malfunctions during operation are indicated by a corresponding warning message operation still possible red LED flashes or a fault message operation not possible any longer red LED lights in the display of the operating and control unit Detailed information thereto can be found in the separate operating instructions for Condair GS control Resetting the error indication To reset the error indication Disconnect the Condair GS from the mains for approx 5 seconds then reconnect again Note If the fault has not been eliminated the error indication reappears after a short while 9 4 Replacing the backup battery on the control board of the Condair GS OC 1 Set the Condair GS OC out of operation as described in chapter 7 4 2 Undo the brackets and open the right front panel The electronic components inside the humidifier are very sensitive to electrostatic discharge Before carrying out the next step appropriate measures must be taken to protect the electronic components against damage caused by electrostatic discharge ESD protection 3 Undo the 2 screvvs A of the display and control unit then carefully remove the display and control unit to the front 4 Undo the 7 fastening screws B of the control board then carefully pull off the control board from the display and control unit assembly KON QO D OOTA N N NN N Q
31. e use of disinfectants is only permitted if they deposit no poisonous residues n all cases the components that have been cleaned in this vvay are to be rinsed vvith vvater Caution Do not use solvents for cleaning purposes nor aromatized or halogenized hy drocarbons or other aggressive substances Follovv local environmental protection regulations vvithout reservation Resetting the maintenance reminder After completing maintenance vvork the maintenance reminder message must be reset via the reset function in menu mode of the control see chapter 5 6 in the separate operating instructions for Condair GS control 61 9 2 9 3 62 Troubleshooting Important notes on troubleshooting Important Most operational malfunctions are not caused by faulty equipment but rather by improper installation or disregarding of planning guidelines Therefore a complete fault diagnosis always involves a thorough examination of the entire system Often the steam hose connection has not been properly executed or the fault lies with the humidity control system Service and repair work must only be carried out by qualified personnel specially trained for such activities In the case of any uncertainty please contact your local Con dair representative dealer Before commencing service and repair work the Condair GS OC must be taken out of operation as described in chapter 7 4 and prevented from being inadvertently switched on Error in
32. eam distribution pipes are selected on the basis of the duct width for horizontal installation or the duct height for vertical installation and the capacity of the steam humidifier Important Always select the longest possible steam distribution pipe optimum humidification dis tance Steam distribution pipes 1 for GS OC Duct width B Steam capacity 40 80 120 160 200 and 240 Type Length in mm L 2 inmm max in kg h 3 81 350 350 400 600 30 81 500 500 600 750 30 81 650 650 750 900 50 81 800 800 900 1100 50 81 1000 1000 1100 1300 50 81 1200 1200 1300 1600 50 81 1500 1500 1600 2000 50 81 1800 1800 2000 2400 50 81 2000 2000 2200 2600 50 81 2300 2300 2500 2900 50 81 2500 2500 2700 3100 50 1 Material CrNi steel 2 Special length on request 3 To fully exploit the overall capacity of your GS OC humidifier the output of each steam outlet may be fed to more than one distribution pipe If more than one steam distribution pipe is fed per steam outlet the steam line must be divided into multiple branches Appropriate fittings are available on request Note If the humidification distance see chapter 5 3 1 has to be reduced for technical reasons the steam output of your unit must be divided between two steam distribution pipes or the OptiSorp steam distribution system must be used If this is the case contact your Condair supplier OptiSorp steam distribution system The O
33. eam pipe must be made vvith solid piping 7 steam hose adapter Main steam pipe max length 6 m steam hoses max length 4 m S 2029202222 2222292222 x 2222020660 Qs iy The following notes must be observed The internal diameter of the steam outlet on the unit must be maintained over the entire length of the main steam piping The maximum length of the main steam pipe is 6 m Important Allowance must be made for a pressure loss of 10 mm water column approx 100 Pa per meter length or per 90 bend The minimum bend radius for solid pipes is 4 5 x internal diameter 90 bends should be avoided Wherever possible pipe bends with large radius should be used e g produced using a pipe bend ing machine or constructed from a pair of 45 bends This reduces the performance loss due to the formation of condensate and in addition the static pressure in the steam line Use Cu pipe for operation with untreated drinking water only or stainless steel pipe min DIN 1 4301 exclusively To minimize the condensate formation loss the steam pipes must be insulated over the entire length of the piping Connection of the steam pipe to the steam outlet on the unit and the connection on the steam hose adapter is effected by means of short lengths of steam hose secured with hose clamps At spots where condensate could accumulate inside the pipe a condensate drain
34. eck for free drainage Inspect all pipes for lime deposits and for correct sealing Clean or replace pipes with lime deposits Reseal replace leaking pipes Water installation X X X Check all water hoses in the unit for cracks and correct fixing replace defective hoses Check supply pipes for sealing seal if necessary Clean the filter valve or water filter Check correct function of level unit Clean or replace if neces sary Unit inner chamber X X X Check the inner chamber for dirt and deposits and clean if necessary Steam installation X X Inspect the steam and condensate hoses for cracks and correct fixing replace defective hoses Electrical installation X X 1 Check all cables in the unit for secure fixing and condition and check the insulation Components nterval ll Work required Flue gas temperature sensor Visual check that sensor is intact wired and attached to the exhaust Flue gas outlet pipe Check flue gas outlet pipe for sealing and remove all traces of condensate If specified have the flue gas system inspected by an appropriate specialist Igniter and flame sensor Every year or every 2000 hours which is reached first Remove and replace igniter and flame sensor special spares set Burner parts subject to wear Burner combustion air blower Remove burner and inspect the condition of burner mat Blow out bu
35. er into operation make sure all panels are closed and locked with the screw or the brackets respectively Do notcarry out any operations for which you are not sufficiently qualified or unfamiliar with the consequences In case of doubt contact your supervisor or Condair supplier beforehand Before carrying out working steps on particular components of the Condair GS OC humidifier set the humidifier out of service disconnect it from the power supply by setting the service switch to Off close the gas supply and secure the unit against unintentional operation Warning If the ambient temperature is below the freezing point the water tank must be drained see also chapter 7 4 Warning Before carrying out maintenance or repair works especially under extreme weather conditions e g rain snow protect the unit in a way that no electrical or other components inside the unit can get wet cover unit with a tent If parts inside the unit have become wet let them dry thoroughly and have the humidi fier checked by a qualified service technician before restarting Installation maintenance and repair of the electrical and the gas installation of the Condair GS OC humidifier must be carried out only by qualified personnel being aware of possible danger and implications Poorly maintained humidification systems may endanger health and affect proper op eration Therefore it is mandatory to observe the specified maintenance intervals
36. er drain or with sensors that safely interrupt water supply in case of leakage To prevent excess humidification the operation of the Condair GS OC must be moni tored by a high limit on off humidistat see chapters 5 8 5 9 Use only genuine accessories and spare parts available from your Condair sup plier The Condair GS OC humidifier and the optional accessories must not be modified in any way without the written consent of the manufacturer The worldwide well organized Condair distributor network provides service at all times by qualified technicians Please contact your Condair supplier in case of trouble or if you have any questions concerning the GS OC humidifier and humidification technology in general 3 2 Product Overvievv Product versions Model designations The Condair GS OC gasfired steam humidifier is available in 6 different models vvith different maximum steam output performance 40 80 120 160 200 and 240 kg h All models can be operated with natural gas or propane ex works the unit is supplied for a specific type of gas operation as stated on the rating plate Model designation GS 40 oc c G20 Product line gasfired steam humidifier with operation and display unit Steam output kg h 40 80 120 160 200 240 Housing for outdoor installation Outdoor Cabinet Equipment series Fuel Natural gas H E E S G20 Natural g
37. g PI controller Important For the control systems 2 and 3 the external controller must be equipped with two control signal inputs The Condair GS OC processes the following control signals 0 10 VDC 10 VDC 10 mADC 10 mADC 20 mADC 20 mADC 5 VDC 5 VDC l O fF ORD Further information is provided in Chapter 5 9 Output signals The Condair GS OC provides the following output signals 10VDC max 20 mA Remote operating and fault signals 4 potential free contacts Further information is provided in Chapter 5 9 Options At the moment no options are needed for the Condair GS OC Accessories Accessories overview Model Condair GS OC 40 80 120 160 200 240 Steam distribution pipe 81 see accessory details in chapter 4 4 2 number 1 2 3 4 5 6 OptiSorp System 1 System 2 System 3 System 4 System 2 System 3 steam distribution system System 3 see accessory details in chapter 4 4 2 number 1 1 1 1 1 of each 2 Steam hose adapter SA80 SA120 SA160 SA200 SA240 3 2x 13 4 3 3x 13 4 4 4x 13 4 4 6x4 3 4 4 6x 1 3 4 number 1 1 1 1 1 Steam hose meter DS80 number 1 2 3 4 5 6 Condensate hose meter KS10 number 1 2 3 4 5 6 Filter valve 2261 1 pc per system 17 4 4 2 Accessory details Steam distribution pipes The st
38. he hose connected to the pressure switch note the connection layout Then undo the three screws of the pressure switch support and remove pressure switch assembly from the gas regulating valve 8 Undo the three screws fixing the gas pressure regulating valve to the venturi manifold then remove the gas pressure regulating valve from the venturi manifold Reinstallation is achieved by following the reverse sequence Replace defective seals with new ones Make sure that all seals are inserted correctly and all cables are connected correctly Caution Danger of explosion Following maintenance work on the gas system a leakage test must always be undertaken in accordance with chapter 5 5 2 53 54 Removal and installation of the igniter and the flame sensor Cautionl VVhen replacing the igniter and the flame sensor use only the set of spares burner N spare parts subiect to vvear available from your Condair supplier since othervvise the humidifier could be damaged Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel s Disconnect the wiring connection to the igniter and to the flame sensor do Unscrevv the fixing nuts for the igniter and the flame sensor Novv carefully remove the igniter and flame sensor Caution The silicon carbide igniter is breakable Therefore handle it with great care to avoid damage Reinstallation i
39. he room that is being humidified usually in the duct return circuit Do not position humidity sensors in the immediate vicinity of steam distribution pipes nor in sections of a duct subject to air turbulence nor within the path of the humidification process itself Install the safety humidistat in the duct after the steam distribution pipes and far enough away from these that all the steam has been absorbed into the air minimum distance 3 m The safety humidistat must be positioned such that it only detects that the humidity is too high when the room humidity is in reality too high or has reached the saturation limit Install the flow monitor such that reliably detects the existence of an airflow and the absence of an airflow Connect it in such a way that the circuit is closed when airflow is present and opens when there is no airflow Before starting the humidifier check all control and monitoring devices for correct function Calibration of the control and monitoring devices On Off and continuous following the installation is recommended The accuracy of the humidity sensor and the safety humidistat must always be checked before commissioning the humidifier system 37 5 8 Electrical Installation Wiring diagram B3 B2 B1 ol 0 9 0 9 o J1 RJ45 s 45 42 Driver Board 1 Driver 0 10VDC 0 10 mADC 2 10VDC 2 20mADC 0 5VDC 0 20 mADC 1 5 VDC 4 20 mADC
40. idual condensate hoses of the main steam pipe if present the steam hose adapter if present and the steam distribution pipes must be led down with a minimum downslope of 20 via a siphon min hose bend 200 mm into a discharge funnel Important Before putting the unit into operation the siphon of the condensate hose must be filled with water 29 5 4 5 4 1 30 VVater installation All installation work must be carried out in accordance with the locally applicable water installation regulations All work concerning the water installation must be performed only by adequately qualified personnel e g plumbers Warning danger of electric shock For all installation work the Condair GS OC must be disconnected from the mains supply and secured against unintentional reconnection Performing the water installation Overview water installation iW min 15 cm Filling water connection BSP 1 2 outside thread 8 Pressure reducing valve compulsory for water Water drain connection 3 4 Shut off valve installation recommended building side Auxiliary water drain connection BSP 1 2 inside thread Filter valve accessory Z261 Filling water supply line min inner 12 mm pressures gt 8 bar building side 9 Auxiliary drain line BSP 1 2 building side 10 Drain line BSP 3 4 building side 11 Funnel building side min height 15 cm 12 Siphon min inner
41. ifier s LI Is the piping properly secured and sealed 41 42 Water drain and auxiliary water drain Has minimum inside diameter of drain pipe at least 45 mm been maintained throughout the entire length Have drain pipes been installed with a downslope of at least 10 96 Have temperature resistant materials been used up to 100 C Are the hoses and pipes correctly attached and sealed hose clamps and screwed connec tions tightened LI Is the minimum funnel height of 150 mm observed Gas installation L 15 the shut off valve fitted 15 a sediment separator installed if steel pipes are used L Is the gas circuit correctly sealed leakage check carried out LI Is the permissible gas pressure being maintained see the table in 5 5 1 Have the correct sealing materials been used Flue gas system Is the supplied flue gas pipe with storm collar and rain cap used O Are all connections of the flue gas pipe properly sealed and secured LI Does the flue gas system comply with the local regulations L Is the flue gas outlet at least 60 cm above any ridge within 3 m of the unit Electrical installation LI Does the electrical installation comply with the local regulations 1 Do the mains voltages applied correspond to the supply voltage stated on the rating plate of the unit L 15 the voltage supply correctly fused LI Is the service switch Q installe
42. igured for a 0 10 VDC control signals The control signal type can be modified via the software see menu user settings in the operating instructions for the Condair GS control The configuration whether the Condair GS is controlled via the internal or via an external controller is also done via the software 39 40 Output This output is available for custom purposes The lines are connected to terminals 6 and 7 The output signal type is configured by setting the jumper on JP3 5 Vdc max 500 mA or on JP4 24Vd3c max 150 mA Full tank blow down 24 VAC S1 This input signal can be used for remote triggering a full tank blowdown If a 24 VAC signal is pres ent for more than 60 seconds the tank blows down The signal line is connected to terminals 8 and 7 Inspecting the installations Check list Before the Condair GS OC is operated for the first time the responsible personnel must inspect all installations for correct execution observing of local regulations and check that the unit is correctly configured All deficiencies must be corrected by specialist action before commissioning takes place Use the following check list to ascertain that the installations were performed correctly Unit installation L Is the unit in the correct place see chapter 5 2 1 L 15 the unit correctly aligned vertically and horizontally Steam installation Steam distribution pipe L Steam distribution pi
43. iled information regarding the operation of the control unit and the configuration settings please observe the information given in the separate operating instructions to the Condair GS control Operating status display The unit operating status is signaled via the display and the indicator LED s on the humidifier as well as via the remote operating and fault indication as follows Operating status meaning Indication on unit Activated remote relay Warning present humidification continuing Yellow LED lights eee Awarning message alternates with the normal operating mode display Fault occurred humidification off Red LED lights K1 Error A fault message alternates with the normal operating mode display Steam production Green LED lights K2 Steam The normal operating mode display shows ENABLED Unit switched on and on standby The normal operating mode display shows K3 Power on STANDBY No humidity demand Set maintenance interval has expired Yellow LED lights K4 Service Maintenance due message is shown in the display Further note on operation If the water level falls below a fixed minimum level during operation the humidifier is automatically switched off to avoid overheating Taking out of operation If the humidifier must be taken out of operation e g for maintenance work proceed as follows 1 Close the shut off valve in the gas supply pipe 2 Close the shut
44. ing the hose The steam hose must be secured to the steam distribution pipe and humidifier steam outlet by means of hose clamps Steam line vvith fixed piping For steam lines with fixed piping the same instructions apply to the laying of the piping as already described The following additional notes should be observed The minimum internal diameter of 45 mm should be applied over the whole length of the piping Use exclusively Cu pipe for operation with untreated drinking water only or stainless steel min DIN 1 4301 To minimize the condensate formation loss the steam pipes must be insulated The minimum bend radius for solid pipes is 4 5 x internal diameter 90 bends should be avoided Wherever possible tube bends with large radii should be used e g produced using a tube bending machine or constructed from a pair of 45 bends This reduces the performance loss due to the formation of condensate and in addition the static pressure in the steam line Important Allowance must be made for a pressure loss of 10 mm water column approx 100 Pa per meter length or per 90 bend Connection of the steam pipes to the steam distribution pipe and steam humidifier is effected by means of short lengths of steam hose secured with hose clamps 5 3 4 Installing the condensate hoses Important Use original Condair condensate hose exclusively Other types of hoses can cause oper ational malfunctions The indiv
45. inimum contact opening of 3 mm is mandatory The service switch Q must be mounted in the separate compartment outside the unit above the electrical service door When installed the appliance must be electrically grounded in accordance with local codes if an external electrical source is utilized Connect ground wire to cabinet ground clamp External wiring sizes must be in accordance with existing local electrical codes and by laws Remote operation and fault indication The remote operation and fault indication board is equipped with 4 relays for remote operation and fault indication On this relay closes after the humidifier has been povvered up Steam this relay closes as soon as steam is produced Service this relay closes when the set maintenance interval has expired Error this relay closes when an error occurs External safety circuit K1 To guarantee the safety of the humidification system monitoring the operation by means of a safety circuit is an absolute requirement To accomplish this the potential free contacts 250V 2A of external monitoring devices B1 safety high limit humidistat B2 airflow monitor B3 ventilation interlock etc are connected in series to terminals 1 and 2 Control or sensor signal The signal line signal Y is connected to terminals 3 and 4 The signal line signal Z is connected to terminals 3 and 5 By default the Condair GS is conf
46. ion is achieved by following the reverse sequence Renew the flange seal and replace igniter and flame sensor if necessary Tight the nuts of the burner flange with a torque wrench torque 10 Nm Make sure all cables are connected correctly Caution Danger of explosion Following maintenance work on the gas system a leakage test must always be undertaken in accordance with chapter 5 5 2 Cleaning the burner elements Carefully blow out the burner element mats ceramic fibre material from outside with compressed air Severely soiled burner elements should be replaced Cleaning the blower burner chamber of the unit Carefully clean the blower and the burner chamber by freeing any kind of soiling and accumulations AN Caution Wet cleaning of the blower and the burner chamber is not permitted g Removal and installation of the gas pressure regulating valve Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel s Disconnect electrical wiring to the gas pressure regulating valve and the pressure switch note the connection layout 4 Undo the coupling of the corresponding flexible gas pipe and disconnect the gas pipe 5 Undo the two screws of the venturi manifold and lift up the manifold together with the gas pressure re gulating valve Undo the four screws and remove the gas pipe connection of the gas pressure regulating valve Pull off t
47. itionally observed and complied with Caution Danger from electric shock The connection of the steam humidifier to the mains electrical supply must not be made until all installation work has been completed Caution Incorrectly executed installations can result in personal injury and or damage to property through explosions fires carbon monoxide poisoning electric shock etc If you require assistance please contact a qualified installer your local gas supplier or your Condair representative In the installation itself use only materials available from your Condair representative and accessories approved by him Unit fitting Humidifier location To ensure proper functioning of the steam humidifier Condair GS OC and to obtain optimum ef ficiency the following points must be considered and observed when choosing the location for the steam humidifier The Condair GS OC must be mounted only outside of buildings where the flue gases can escape freely the local and national regulations for installation of gasfired equipment must be observed and followed The manufacturer accepts no liability for non compliance with these regulations Install the steam humidifier so that the length of the steam hose is as short as possible ideally 2 m max 4 m the minimum bend radius R 300 mm and the minimum upslope 20 and the minimum downslope 5 of the steam hose can be maintained see Chapter 5 3 2 Note Long steam lines reduce
48. itors from the ignition modules Switch On the humidifier at the unit switch The combustion air blower s start s Note On multi blower units wait until all blowers have started Then 15 seconds later pre purging time the gas pressure regulating valve opens for 7 seconds then it closes again due to missing ignition Note On multi burner units this process is successively completed for all burners After three ignition attempts per burner complete with pre purging the humidifier goes into safety lockout Note To reset the safety switch off switch off the humidifier for at least five seconds and then switch it on again Repeat this sequence minimum 2 times in order to make sure no air is left in the gas system e Switch off the humidifier at the unit switch e Reconnect all ignitors to the ignition modules Start the humidifier e Open the shut off valve in the water supply pipe Open the shut off valve in the gas supply pipe e Switch on the external service switch e Switch the humidifier On at the unit switch Condair GS 240 START UP Condair GS 240 Standby 03 03 2009 12 00 00 mem nE Ee eee Condair GS 240 Demand 250 03 03 2009 12 05 00 CW nE EE eee The Condair GS OC carries out a system and level test during which all the LEDs light up f a failure occurs on the system test a corresponding error message is shovvn in the display Afte
49. key the draining is controlled via the display and control unit Unit switch Function Switches the unit on and off The switch is illuminated when the unit is running 7 3 Commissioning and notes on operation Caution Before the Condair GS OC is operated for the first time the responsible per sonnel must inspect all installations for correct execution and check that the unit is correctly configured see check list in chapter 6 All deficiencies must be corrected by specialist action before commissioning takes place The humidifier is operated as follows Examine the humidifier and all installations for possible damage Caution Damaged units and units with damaged installations must not be operated Check the cleanliness of the outer cabinet The panels may be cleaned with a damp cloth and warm soapy water Caution Make sure no water is dripping into the cabinet through the ventilation openings in panels of the unit housing Fill the water tank Close the shut off valve in the gas supply line Open the shut off valve in the water supply pipe Set the internal or the external regulator to maximum humidity demand Switch on the service switch in the electrical supply circuit Switch on the humidifier at the unit switch The filling valve opens and the water tank fills filling time approx 30 minutes for the largest model for smaller units the filling time is shorter At the end of the filling cycle the control unit
50. l Pl controller with the option to connect a second humidity sensor k bb 0 l K p K Eu A1 2 humidity sensor A2 Condair Al B1 ventilation interlock B1 B2 GS 0C B3 B2 airflow monitor B3 safety humidistat 2 Pl external Pl controller internal continuous controller PID controller Y input signal from A1 2 input signal from A2 Which humidity control system for which application Application Location of the humidity sensor Room or exhaust air duct supply air duct Air conditioning systems with Supply air portion up to 33 System 1 System 1 Supply air portion up to 66 System 1 or 2 System 2 or 3 Supply air portion up to 100 System 2 System 3 Supply air humidity control System 3 Please contact your Condair supplier if your application meets the following conditions Humidification of small rooms up to 200 m3 Air conditioning systems with a high number of air exchanges Systems with variable air volume flow Test facilities with extreme control accuracy requirements Rooms with a high variation in max steam capacity Systems with temperature fluctuations Cold rooms and systems with dehumidification 4 3 4 4 4 4 1 Control input signals The Condair GS OC is regulated via the internal PID controller or an external continuous controllrt e
51. l be interrupted until the water level reaches C again To ensure safe operation the control system constantly monitors the proper function of the level unit in regular intervals Steam generation control The steam is generated in the water tank via the heat exchanger s The steam production is regulated continuously by the internal PID controller or an external continuous controller Flushing The concentration of minerals in the water in the tank increases due to the evaporation process In order that this concentration does not exceed a specified value an appropriate quantity of water is pumped off from the tank at a fixed time interval and replaced by fresh water These flushing cycles are based on steam production to increase the efficiency of the humidifier When a flushing cycle is initiated the drain pump is activated and the inlet valve opens In the mixing pipe below the filling chamber the hot drain water is mixed with the cold cooling water and leaves the unit with a temperature approx around 60 70 C If the lowest operating level is reached in the tank during the flushing process the inlet valve remains open until the water level in the tank has again reached the normal operating level 4 4 1 Basic planning All the data necessary for the selection and layout of a Condair GS OC humidifier system are provided in the following chapters Selecting the unit The selection of the unit is reflected in the type
52. l the fire department Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Warning Improper installation adjustment alteration service maintenance or use can cause carbon monoxide poisoning an explosion fire electrical shock or other conditions which may cause personal injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency local gas supplier or your distributor or branch Warning Should overheating occur or the gas fail to shut off shut off the manual gas valve to the appliance before shutting off the electrical supply Warning Do not use this appliance if any part has been exposed to excess humidity Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water The Condair GS OC humidifier must only be installed operated and serviced by persons familiar with the product and sufficiently qualified for the respective task It is the customer s responsibility to ensure that the present Installation commissioning and service instructions is supplemented by internal instructions with respect to supervisory and notification liability working methods personnel qualifications etc An open unit must not be operated Before putting the Condair GS OC humidifi
53. m itself The hu midity sensor A2 for the limitation of the supply air humidity is located in the supply air duct after the steam distribution pipe This control system requires the internal PID controller or an external continuous controller with the option to connect a second humidity sensor Attention The continuous limitation of the supply air humidity is no substitute for the safety humidistat b CH K Ap A2 B3 1 1 Condair A1 2 humidity sensor B1 B2 GS 0C B1 ventilation interlock B2 airflow monitor m 17 B3 safety humidistat Pl external continuous controller e g Pl controller AN PID internal continuous controller PID controller Y 1 Y input signal from A1 Ple lt Z input signal from A2 15 16 System 3 Supply air humidity control with continuous output limitation Supply air humidity control humidity sensor installed in supply air duct should be used only where room humidity control is impracticable for technical reasons Such systems always require a Pl controller The humidity sensor A1 is located in the supply air duct after the steam distribution pipe The humidity sensor A2 for the continuous output limitation is located in the supply air duct before the steam distribution pipe Such asystem requires the internal PID controller or an externa
54. me of dimensioning the air conditioning system Please note the follovving instructions to ensure proper humidification of the duct air Calculating the humidification distance The water vapor emitting from the steam distribution pipes requires a certain distance to be absorbed by the ambient air so that it is no longer visible as steam This distance is referred to as humidifica tion distance and serves as a basis for the determination of the minimum distances from the upstream components in the system Humidification distance By Expansion and mixing zone g l s l 91 q 1 Incoming air humidity before humidification q 2 Air humidity after humidification 1x Bn 4 5 x Bn The calculation of the humidification distance is dependent on several factors For a rough estima tion of the humidification distance BA the following table is useful Recommended standard values listed in this table are based on a supply air temperature range of 15 C to 30 C The values given in bold print only apply to steam distribution pipes 81 the values in brackets apply to the Opti Sorp steam distribution system Input humidity Length of humidification distance Bu in m 1 in rh Output humidity 2 in rh 40 50 60 70 80 90 5 0 9 0 22 1 1 0 28 1 4 0 36 1 8 0 48 2 3 0 66 3 5 1 08 0 8 0 20 1 0 0 26 1 3 0 34 1 7 0 45 2 2 0 64 3 4 1 04
55. n 1 2 3 4 5 8 9 Take the humidifier out of operation as described in chapter 7 4 Disconnect the gas supply pipe from the connection on the humidifier and close off the pipe Undo the brackets and open the right side panel s Dismount flue gas pipe extension at the connection of the flue gas manifold Free all cable connections to the components combustion blower ignition module air pressure switch etc of the respective heat exchanger Important Note the connector assignment Undo the coupling of the respective flexible gas pipe and remove the flexible gas pipe Dismount the burner with the air blower and the gas pressure regulating valve of the respective heat exchanger Unscrew the nuts and remove the flue gas manifold from the heat exchanger Unscrew the nuts on the heat exchanger and pull out the heat exchanger from the tank Re installation is carried out in the reverse sequence Replace all seals with new ones Make sure all cables are connected correctly Caution Danger of explosion Following maintenance work on the gas system a leakage test must always be undertaken in accordance with chapter 5 5 2 8 3 8 4 Notes on cleaning agents The information and specifications relating to the cleaning agents to be used must be strictly observed n particular Information on personal protection environmental protection and all restrictions in the use of cleaning agents N Th
56. n according to the following drawing Make sure the top of the curb is level in either direction Caution Make sure the curb and the place of installation are solid enough to structur ally support the entire weight of the humidifier when in operation A B C D E F GS400C 866 220 19 127 27 101 GS 8006 6866 382 20 127 28 101 GS 12006 866 779 20 127 18 101 GS 160 866 779 20 127 18 101 5 200 866 1175 32 127 18 101 5 240 866 1175 32 127 18 101 Dimensions in mm ini A l ol g k 2 2 2 ai m E s o Lo g 4 mn Electrical side F E Gmin 500 mm above surface where snovv and ice could accumulate 2 Cut out the hole in the roof for routing the vvater piping and the electrical vviring into the unit dimen sions see above 3 Lift the unit on the curb using a crane AN Caution Please observe the safety instructions for transporting the unit see above Caution To make sure positive or negative pressure of the building does not affect the operation of the Condair GS OC the pipe chase in the unit base must be sealed after completion of the installation of the water piping and the electrical wiring 22 5 3 5 3 1 Steam installation Positioning and mounting of the steam distribution pipes The location for the steam distribution pipes should be determined at the ti
57. nifold together with the gas pressure re gulating valve 6 Undo the two screws of the electronic board if present and remove electronic board 7 Undo the nuts on the outlet side of the blower and remove the blower unit Reinstallation is achieved by following the reverse sequence Replace defective seals with new ones Make sure that all seals are inserted correctly and all cables are connected correctly Caution Danger of explosion Following maintenance work on the gas system a leakage test must always be undertaken in accordance with chapter 5 5 2 51 52 Removal and installation of the burner O 9 o 2 1 2 0 Hold burner only on metal pipe ES N A OL Se Ceramic matting do not touch Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel s Remove the combustion air blower see the section Removal and installation of the combustion air blower above 4 Disconnect the cables to the igniter and to the flame monitoring unit and remove the components see the section on Removal and installation of the igniter and the flame sensor 5 Unscrew the four nuts in the burner flange and carefully remove the burner unit Make sure that the burner is not damaged Note Grease dirt and dust at the ceramic matting can affect the performance of the burner Re installat
58. off valve in the water supply pipe 3 Press the drain switch The gas pressure regulation valve s close s and the tank empties Important If drain pump is defective drain tank manually via the auxiliary drain 4 Wait until the water tank empties Now switch off the humidifier at the unit switch 5 Isolate the humidifier from the electrical power supply Switch off the external service switch in the power supply circuit and secure the switch in the Off position to safeguard against unintentional switch on Important Make sure the ambient temperature is within the admissible range of 0 C 32 F to 25 C 80 F when the humidifier is isolated from the power 47 8 1 48 Maintenance All maintenance work must only be carried out by experienced and trained person nel who are familiar with the procedures required The instructions and data relating to the maintenance work must be followed explicitly The only maintenance work permitted is that described in this chapter Use only original Condair spares to replace defective components Before commencing the maintenance work the Condair GS OC has to be taken out of operation as described in chapter 7 4 and secured against inadvertent start up Warning Before carrying out maintenance or repair work under extreme weather conditions e g rain snow protect the unit in a way that no electrical or other components inside the unit can get wet cover unit with a tent Mainten
59. ore restarting the humidifier have a qualified service technician inspect the appliance and replace any defective part 43 7 2 44 Function of the display and operating elements SY QOD N ms Display and control unit Function Configuration of the Condair GS ndication of operating parameters Reset of maintenance counter r red LED Fault Function The LED flashes in case of a temporary mal function of the unit Warning status Further operation ofthe unitis still possible The warning message is shown in the display The LED lights in case of a severe malfunction of the unit Fault status Further operation is not possible any longer The fault message is CS o condair 170 shown in the display The LED flashes alternately vvith the green LED if the external safety chain ventilation interlock has triggered is open As soon as the safety chain is closed again the indication disappears L yellovv LED Maintenance Function The LED lights if the maintenance is due L green LED Humidification Function The LED lights if the unit produces steam The LED flashes alternately vvith the red LED if the external safety chain ventilation inter lock has triggered is open As soon as the safety chain is closed again the indication disappears Drain key Function Manual draining of the water tank After having pressed the drain
60. our safety ntended use Gas fired steam humidifiers Condair GS OC are intended exclusively for humidifica tion in ventilation systems vvithin the specified operating conditions Any other type of application vvithout the vvritten consent of your Condair supplier is considered as not conforming vvith the intended purpose The manufacturer supplier cannot be made liable for any damages resulting from improper use The user bears full responsibility Operation of the equipment in the intended manner requires that all the information in these instructions is observed in particular the safety instructions General safety instructions The local guidelines and regulations for the installation and operation of gasfired equipment steam humidifiers must be adhered to without reservation All persons working with the Condair GS OC humidifier must observe and comply with all information and safety instructions contained in the present Installation commissioning and service instructions If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life Caution What to do if you smell gas Do not try to light any appliance Do not touch any electrical switch do not use any telephone in your building Immediately call your gas supplier from a neighbor s tele phone Follow the gas supplier s instructions If you can not reach your gas supplier cal
61. pe correctly positioned and secured screws tightened L Are the outlet orifices at right angles to the air flow direction Steam pipe between steam outlet on unit and steam hose adapter main steam pipe Maximum length of 6 m L1 Minimum bend radius of 4 5 x internal diameter of solid steam pipe Is the pipe properly insulated O Is the correct installation material used O Is the minimum internal diameter maintained over the entire pipe length Steam hose between steam hose adapter and steam distributor LI Maximum length of 4 m Minimum bend radius of 300 mm 4 5 x internal diameter with fixed piping Have the instructions for hose positioning been followed Steam hose no sagging condensate pocket Rigid steam lines properly insulated Correct installation material used Minimum internal diameter maintained Steam hose securely attached vvith clamps L Heat expansion during operation and shortening of the hose with ageing taken into consid eration Condensate hoses 1 Downslope of at least 20 96 Siphons existing and filled with water LI Condensate hoses correctly fixed Water installation Filling water supply Has filter valve accessory Z261 or shut off valve and filter 5 um respectively been installed in supply line LI Have admissible water pressure 3 0 8 bar and temperature 1 30 C been observed LI Does supply capacity match the humid
62. ptiSorp steam distribution system is used in ventilation ducts with a short humidification distance for the calculation of the humidification distance refer to chapter 5 3 1 When ordering an OptiSorp system the duct dimension must be specified Please consult the data in the following table OptiSorp Number of steam Max steam capacity Duct dimensions connections in kg h 1 Width in mm Height mm System 1 1 45 30 450 4000 450 1650 System 2 2 90 60 450 4000 450 2200 System 3 3 135 90 450 4000 800 3200 System 4 4 180 120 450 4000 800 3200 1 For duct widths 600 mm the values in brackets apply 18 5 5 1 5 2 5 2 1 Mounting and installation vvorks Safety instructions for mounting and installation vvorks The local directives and regulations for the installation of gasfired equipment Steam humidifiers must be unconditionaliy observed and complied vvith All local regulations relating to the execution of gas flue gas water steam and electrical installations must be observed and complied with All mounting and installation work must be performed only by adequately qualified per sonnel Ascertaining the qualifications is the customer s responsibility All the information contained in these installation commissioning and service instructions relating to equipment assembly and to gas flue gas water steam and electrical installa tion must be uncond
63. r 3 5 Principle of operation Combustion System The combustion system is based on a fully modulating forced draft combustion air blovver a nega tive pressure regulator gas valve and a 10096 premix burner On a call for humidity the combustion air blower starts and creates a negative pressure across an orifice located at the air inlet The blower starts fora moment to purge the system then the hot surface ignitor is activated During this time the electronic ignition module does a diagnostic check of safety systems including the air proving switch which senses the negative pressure at the air inlet After the function of the safety systems has been verified the gas valve will open and the gas air mixture is ignited by the hot surface ignitor If flame is sensed by the flame sensor within 7 seconds the gas valve remains open and combustion continues If flame is not sensed the above sequence is repeated a maximum of three times after which the ignition module will lock out and a respective error message will appear in the display The gas valve maintains a constant ratio of air to Natural Gas or Propane independent of blower speed or external conditions This air and fuel is thoroughly mixed in the blower and then forced through the burner ports where ignition occurs Hot products of combustion are forced through a baffle inside the heat exchanger and then vented outside The heat exchanger has large vertical surfaces to minimize scale build
64. rner mat with compressed air or replace burner if neces sary Replace all burner seals with new ones special spares set Burner parts subject to wear Clean combustion air blower if necessary The electric motors of the blowers are provided with permanent lubrication and do not require maintenance 49 8 2 50 Dismantling vvork for maintenance and the replacement of components Prepare vvater tank for cleaning 2299229292 2242022 200220022 Torque 5 7 Nm 50 in Lb Take the humidifier out of operation as described in chapter 7 4 2 Undo the brackets and open the left front panel Then unscrew the nuts of the side tank cover and remove the cover 3 On GS OC 120 240 only unlock and remove the left top panel Then unscrevv the nuts of the top tank cover and remove the cover The re assembly of the water tank takes place in the reverse sequence Make sure that the seals of the tank covers are not damaged replace if necessary Important Tighten the nuts of the tank cover s with a torque wrench torque 5 7 Nm Do not over tighten the nuts Cleaning the water tank Caution Danger of combustion The water and all lime deposits in the tank can be extremely hot and may lead to burning on contact Therefore allow the humidifier to cool before commencing cleaning work The combustion chamber walls are usually self cleaning Due to the expansion and contra
65. rthe system testthe unitisin normal operation mode The display shovvs the standard operating display first page of the indication level Note The contents of the standard operating display depends on the actual operating status and on the configuration of the Condair GS and can differ from the opposite display As soon as the humidity controller demands humidity the combustion air blovver s start s Then 15 seconds later pre purging time the ignition proc ess for the burner s is started The burner s ignite s and steam is generated in the tank via the heat exchanger s The green LED lights and the adjacent display is shown If no flame is detected by the flame sensor within 7 seconds after the ignition of a burner the gas pressure regulation valve closes again The ignition se quence is repeated a maximum of three times per burner If no burner could be ignited the humidifier goes into system lockout The red LED lights and an appropriate fault message appears in the display At the same time the operating and remote fault alarm potential free contact Error closes Note The system lockout is reset by switching the humidifier off briefly 5 sec onds and then on again If only individual burners of a multi burner unit could not be ignited the humidi fier remains operational In the display a corresponding warning message appears in the display indicating which burner s has have failed to ignite 7 4 Note for deta
66. s achieved by following the reverse sequence Inspect gaskets and replace if defective Make sure that all gaskets are inserted correctly and all cables are connected correctly Replacement of the ignition module Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right front panel Note the cable assignment then remove all connection cables to the ignition module e ON gt Unscrew the two fixing screws securing the ignition module and then remove ignition module Re installation follows in the reverse sequence Make sure the connecting cables are connected cor rectly Replacement of the air pressure switch 5 Sep ey Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel s 1 2 3 Pull off the hose connected to the pressure switch note the connection layout 4 Remove the connection cable to the pressure switch note assignment before removal 5 Unscrew the two fixing screws and remove the air pressure switch Re installation follows in the reverse sequence Make sure the cables and the hose are connected correctly 55 56 Replacing the transformer 1 2 3 4 Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right front panel Remove the connection cables to the transformer if necessary labeling the cable
67. s before removal Unscrew the two nuts and remove he transformer Re installation is carried out in the reverse sequence Make sure the cables are connected correctly Replacing the drain pump Take the humidifier out of operation as described in chapter 7 4 Important If drain pump is defective drain tank manually via the auxiliary drain Undo the brackets and open the right side panel Remove the connection cables to the drain pump note assignment before removal Remove hose clamps on the drain pump connections and pull off the hoses then remove the drain pump Re installation is carried out in the reverse sequence Make sure the hoses are correctly secured with the hose clamps and the cables are connected correctly Replacing the auxiliary drain valve Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel Remove the connection cables to the auxiliary drain valve note assignment before removal Disconnect the auxiliary drain valve from the tank connection and remove Re installation is carried out in the reverse sequence Make sure the cables are connected correctly Replacing the fill valve 1 2 3 4 5 Take the humidifier out of operation as described in chapter 7 4 Undo the brackets and open the right side panel Remove the connection cables to the fill valve note assignment before removal
68. se installation commissioning and service instructions are restricted to the planning of a humidifying system that is to be equipped with a gasfired steam humidifier Cond air GS OC the installation commissioning operation and servicing of the gasfired steam humidifier Condair GS OC These installation commissioning and service instructions are supplemented by various separate items of documentation system dravvings technical specifications etc VVhere necessary appropri ate cross references are made to these publications in the present installation commissioning and service instructions Note Under certain circumstances your installation may differ from the data in this documentation In this case please make contact with your local Condair representative Conventions This symbol draws attention to safety instructions and warnings of potential danger which if unheeded could result in injury to persons and or damage to property Safekeeping Please safeguard these installation commissioning and service instructions in a safe place where it can be immediately accessed If the equipment changes hands the documentation should be passed on to the new operator If the documentation gets mislaid please contact your Condair supplier Language versions These installation commissioning and service instructions are available in various languages Please contact your Condair supplier for information 2 For y
69. ssure Pa 80 5 80 5 exhaust diameter mm 127 127 Condair GS 160 OC energy consumption kW 146 10 5 146 10 5 gas consumption kg h 9 44 0 68 12 16 0 87 m3 h 13 9121 0 8695 16 1773 1 0111 exhaust temperature C 180 49 180 49 exhaust mass flow kg s 0 06 0 0131 0 068 0 0224 CO content 8 9 2 2 8 7 2 2 flue gas pressure Pa 80 5 80 5 exhaust diameter mm 127 127 Condair GS 200 OC energy consumption kW 182 5 10 5 182 5 10 5 gas consumption kg h 11 8 0 68 15 2 0 87 m3 h 17 3902 0 8695 20 2216 1 0111 exhaust temperature C 180 44 180 44 exhaust mass flow kg s 0 075 0 0164 0 085 0 0279 CO content 8 9 1 8 8 7 1 7 flue gas pressure Pa 80 5 80 5 exhaust diameter mm 152 152 Condair GS 240 OC energy consumption kW 219 10 5 219 10 5 gas consumption kg h 14 16 0 68 18 24 0 87 m3 h 20 8682 0 8695 24 2659 1 0111 exhaust temperature C 180 41 180 41 exhaust mass flow kg s 0 09 0 0196 0 102 0 0335 CO content 8 9 1 5 8 7 1 5 flue gas pressure Pa 80 5 80 5 exhaust diameter mm 152 152 When operating with natural gas G25 1 G27 GZ350 or propane gas G31 please contact your Condair supplier for the correspond ing flue gas specifications 66 abeg amp y Seunseaw 0982 6w 10 lul III Il sued p sejd yuez y Ul SaNpisas lili v Jo 3 bl u 5 wdd Jo p ul sinoy SUeUa UIEIY BOUeUAJUIEW avueu zue
70. supply line building side 6 Gas supply line building side 17 Funnel with trap building side 7 Sediment trap building side 18 Steam hose adapter accessory SA 8 Fill water connection 19 Condensate hose accessory KS10 9 Check valve 20 Steam hose accessory DS80 10 Drain vvater connection 21 Steam distribution pipe accessory 81 3 4 10 Construction of the gasfired steam humidifier NOJA co 10 11 12 14 2020026002 200220220 220200220 OOO WE n Vis SL Water tank Steam outlet connection Heat exchanger 1 to 3 Burner 1 to 6 Level unit Key pad and display unit ndication LED s green Steam production yellovv Maintenance red Error Drain key manual draining Unit svvitch Tansformer Control board Driver board Remote operating and fault indication board gnition modules SA a WAS AN YAA XAVZ SE Burner electronic Combustion air blower 1 to 6 Flame sensor Igniter Drain pump Air pressure switch Gas pressure control valve 1 to 6 Auxiliary drain connection Drain connection Double inlet valve filling water Connection filling water Connection gas supply line Vacuum break Filling chamber Compartment for external service switch Flue gas pipe with rain cap and storm colla
71. uct should be waterproofed Low temperature ducts below 15 C shallow ducts or branch ducts might require the use of a field supplied condensate drain pan below the steam distributor see figure below Drain pan p Branch duct un ES Lo 2 Shallow duct a Drain pan to drain _ Ceiling to drain gt Air ducts passing through cold rooms should be insulated to prevent the humidified air from con densing along the duct vvall Poor airflovv conditions vvithin the air duct e g caused by obstacles tight bends etc can lead to condensation of the humidified air Steam distribution pipes must not be mounted to round ducts Exercise extreme caution vvhen installing in fiberglass or internally lined ducts f necessary remove 10 15 cm of the lining where the steam is being introduced fyou have questions relating to the dimensioning of ventilation ducts in combination vvith Condair steam humidifiers contact your Condair supplier Installing the steam distribution pipes OptiSorp steam distribution system Detailed information on the installation of steam distribution pipes and OptiSorp steam distribution system can be found in the separate Mounting Instructions for this products 26 5 3 2 nstalling the main steam pipe The steam pipe betvveen the steam outlet of the unit and the steam hose adapter main st
72. ue gas outlet with storm collar and rain cap Steam outlet Gas supply zi I 1262 Connections and weights Model Connections Net Operating Flue gas Steam Filling water Gas Water drain Aux Water 7 drain GS OC 40 3 76 mm 1 1 3 4 45 mm BSP 1 2 BSP 1 2 BSP 3 4 BSP 1 2 209 280 GS OC 80 4 101 mm 3 76 mm BSP 1 2 BSP 3 4 BSP 3 4 BSP 1 2 251 362 GS OC 120 5 127 mm 3 76 mm BSP 1 2 BSP 1 BSP 3 4 BSP 1 2 342 563 GS OC 160 5 127 mm 4 101 mm BSP 1 2 BSP 1 BSP 3 4 BSP 1 2 353 563 GS OC 200 6 152 mm 4 101 mm BSP 1 2 BSP 1 1 4 BSP 3 4 BSP 1 2 458 778 GS OC 240 6 152 mm 4 101 mm BSP 1 2 BSP 1 1 4 BSP 3 4 BSP 1 2 470 779 21 5 2 2 Mounting the humidifier Transporting the unit The Condair GS OC can be transported and lifted either with a forklift via the two cutouts in the base of the unit or with a crane via the four removable lifting lugs Please observe the following safety notes Caution When lifting the unit with a forklift make sure the forks extend across the entire base of the unit to prevent tipping or damage to the unit Caution When lifting the unit with a crane all four lifting lugs must be used When lifting the unit make sure the unit is not damaged by the lifting cables chains Mounting instructions 1 Atthe place of installation make a curb foundatio
73. umper to set output A3 to 5 Vdc max 500 mA JP4 Jumper to set output A3 to 24 Vdc max 150 mA K1 Q External safety loop 24 Vac External service switch or plug type connector RJ45 Communication interface for detailed informations S1 refer to the separate documentation Full tank blow down 24 Vac Notes on electrical installation All work concerning the electric installation must be performed only by adequately qualified personnel electrician or workman with equivalent training Ascertaining the qualifications is the customer s responsibility Observe all local regulations concerning the electric installation Warning danger of electric shock The steam humidifier may be connected to electric mains only after all installation work has been completed Attention The electronic parts inside the humidifier are very sensitive to electrostatic discharge To prevent damage appropriate measures against electrostatic discharge ESD protection must be taken when carrying out installation work Please observe the following installation notes regarding the electrical installation Primary wiring Humidifiers require field wiring to primary voltage terminal blocks Power requirementis 220 240V 50 60Hz 10 Aslow acting fused F1 circuit single phase Wiring is fed through a 22 mm hole in the bottom of the control compartment Installation of external service switch Q all pole disconnecting device with a m
74. up and promote scale shedding to the bottom of the tank This self cleaning action helps to maintain the efficiency of the heat exchanger while the smooth surfaces allow for easy cleaning when necessary The GS 40 OC has a single combustion chamber heat exchanger The combustion system is duplicated on larger units with multiple chambers inside a common tank Regulation of the water level in the tank Filling chamber Vacuum break Double fill valve Pressure equalizer Main fill line Level unit Drain outlet Mixing pipe Drain pump Auxiliary drain 11 12 The level in the water tank is continuously monitored by the level unit On initial start up the control unit checks the function of the level unit During this test the tank is filled up first to level A then drained to level C and filled up again to level A As soon as level B is reached and the test of the level unit vvas successful the humidifier is ready for operation if a humidification demand is present the combustion process starts VVhen the vvater level due to the evaporation process reaches level B the level unit sends a signal to the control system vvhich opens the double inlet valve and the vvater tank is filled up On reaching level A the level unit again sends a signal to the control system and the double inlet valve is closed If the water level goes below level C the combustion wil
75. ure approx 60 70 C Therefore make sure that no heat sensitive materials are placed in the immediate vicinity of the humidifier No combustible materials must be placed in the immediate vicinity of the Condair GS OC hu midifier Insulation materials wooden floor coverings etc Observe local regulations Do not mount the humidifier on a base that is subject to vibration If necessary please contact your Condair representative Do not cover the air openings louvers in the panels of the unit otherwise the air flow may be insuf ficient Do not place the unit in a narrow niche or a closed compartment Place the humidifier so that the unit is easily accessible and there is sufficient space for maintenance work The minimum distances shown in the following illustration must be maintained min 3000 mm min 3000 mm min 3000 mm min 3000 mm Pa r mi kadin teal Ee 1 E bl m D z m ip A min 1000 mm min 1000 mm l da mn am min 1000mm 1 min 500 mm Tn an z pz Cell m o 5 o E ssa BAS Dimensions in mm Steam outlet A B 5 40 545 589 5 80 708 617 GS 120 1104 632 GS 160 1104 632 5 200 1500 647 GS 240 1500 647 Fl
76. with siphon min hose bend 2200 mm must be mounted 2 5 3 3 Installing the steam hoses between steam hose adapter and steam distributors Important Use original Condair steam hose exclusively Other types of steam hoses can cause un desired operational malfunctions min 20 min 5 The following notes must be observed Lead the steam hose with an upslope of at least 20 or with a minimum downslope of 5 to the steam distribution pipe The steam hose should be kept as short as possible ideally 2 m max 4 m while observing the minimum bend radius of 300 mm Important Allowance must be made for a pressure loss of 10 mm water column approx 100 Pa per meter steam hose Reductions in the cross section such as kinks should be avoided throughout the entire length of the hose The installation of a stop cock in the steam hose is not permissible Steam hoses must be prevented from sagging condensate pockets if necessary support with pipe clamps rails or wall brackets If sagging can not be prevented e g when passing by obstacles a condensate drain with siphon min hose bend 200 mm must be mounted at the lowest point of the steam hose see following illustration min 5 min 20 1 Important When deciding on the length and layout of the hose it should be noted that the steam 28 hose may become somewhat shorter with progressive ageing Secur

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