condair mk5 · 7 3 product overview 3.1 unit types the steam humidifiers condair mk5 are available...
TRANSCRIPT
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INSTALLATION AND OPERATING INSTRUCTIONS
Resistive Humidifiers
2562
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EN
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Condair Mk5
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Contents
1 Introduction 41.1 To the very beginning 41.2 Notes on the installation and operating instructions 42 For your safety 53 Product overview 73.1 Unit types 73.2 Identificationoftheunit 83.3 Standarddelivery 83.4 Humidificationsystemoverview 93.5 Steamhumidifierconstruction 93.6 Functional description 104 Basic planning 114.1 Selecting the unit 114.2 Selecting the control system 144.3 Options 164.4 Accessories 174.4.1 Accessoriesoverview 174.4.2 Accessorydetails 184.5 Additional planning instructions 205 Mounting and installation works 215.1 Safetyinstructionsformountingandinstallationworks 215.2 Unitfitting 215.2.1 Humidifierlocation 215.2.2 Mountingthehumidifier 235.2.3 Inspecting the installed unit 235.3 Steam installation 245.3.1 Positioningandmountingofthesteamdistributionpipes 245.3.2 Positioningandmountingofthefanunit 275.3.3 Installingthesteamandcondensatelines 285.3.4 Inspecting the steam installation 305.4 Water installation 315.4.1 Performingthewaterinstallation 315.4.2 Inspectingthewaterinstallation 335.5 Electric installation 345.5.1 Electricinstallationoverview 345.5.2 Wiring diagram 355.5.3 Notes on component installation 375.5.4 Inspecting the electrical installation 406 Operation 416.1 Unitconfiguration 416.2 Putting into operation 436.3 Takingoutofoperation 456.4 Interrogationoftheoperatingstatus 466.5 Setting the operating parameters 506.6 Maintenance 556.6.1 Notes on maintenance 556.6.2 Dismantlingandre-assemblywork 566.6.3 Notesoncleaning 596.6.4 Toresetthemaintenanceindication 596.7 Fault elimination 606.7.1 Fault indication 606.7.2 What,if..? 616.7.3 Replacingunitfuses 636.7.4 Resettingfaultindication“Error” 637 Technical data 64
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Limitation
ThesubjectoftheseinstallationandoperatinginstructionsarethesteamhumidifierCondair Mk5 in theversions:“Visual”and“Process”.Thevariousaccessories(humidistats,waterfilter,etc.)areonlydescribedinsofarasthisisnecessaryforproperoperationoftheequipment.Furtherinformationonaccessories can be obtained in the respective instructions.
These installation and operating instructions are restricted to:
– the planningofahumidifyingsystemthatistobeequippedwithasteamhumidifierCondairMk5
– the installation, commissioning, operation and servicing ofthesteamhumidifierCondairMk5
Theseinstallationandoperatinginstructionsaresupplementedbyvariousseparateitemsofdocumenta-tion(sparepartslist,installationinstructionsforelectricalinstallation,etc.).Wherenecessary,appropri-atecross-referencesaremadetothesepublicationsintheseinstallationandoperatinginstructions.
Conventions
Thissymboldrawsattentiontosafety instructions and warningsofpotentialdangerwhich,ifunheeded,couldresultininjurytopersonsand/ordamagetoproperty.
Safekeeping
Pleasesafeguardtheseinstallationandoperatinginstructionsinasafeplace,whereitcanbeimmedi-atelyaccessed.Iftheequipmentchangeshands,thedocumentationshouldbepassedontothenewoperator.Ifthedocumentationgetsmislaid,pleasecontactyourSupplier.
Language versions
These installation and operating instructions are available in various languages. Please contact your supplierforinformation.
1 Introduction
1.1 To the very beginning
Wethankyouforhavingpurchasedthesteam humidifier Condair Mk5.
ThesteamhumidifierCondairMk5incorporatesthelatesttechnicaladvancesandmeetsallrecognizedsafetystandards.Nevertheless,improperusemayresultindangertotheuserorthirdpartiesand/orimpairmentofmaterialassets.
Toensureasafe,proper,andeconomicaloperationofthesteamhumidifierCondairMk5,pleaseob-serveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallationandoperating instructions.
Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyourSupplier.Theywillbegladtoassistyou.
1.2 Notes on the installation and operating instructions
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2 For your safety
Intended use
SteamhumidifiersCondairMk5areintendedexclusivelyfordirect or indirect room hu-midification or for humidification in laboratory and process applications withinthespecifiedoperatingconditions.Anyothertypeofapplication,withoutthewrittenconsentofyoursupplier,isconsideredasnotconformingwiththeintendedpurpose.Themanu-facturer/suppliercannotbemadeliableforanydamagesresultingfromimproperuse.Theuserbearsfullresponsibility.Operationoftheequipmentintheintendedmannerrequiresthat all the information in these instructions is observed (in particular the safety instructions).
General safety instructions
– ThesteamhumidifierCondairMk5mustonlybeinstalled,operatedservicedandinall cases repaired only by persons who are adequately qualifiedtoundertakesuchworkandarewellacquaintedwiththeproduct.Ascertainingthequalificationsisthecustomer‘s responsibility.Thisunitmaynotbeusedbypersons(includingchildren)withreducedphysical,sensoryormentalabilitiesorpersonswithlackingexperienceand/orknowledge,unlesstheyaresupervisedbyapersonresponsiblefortheirsafetyortheyreceivedinstructionsonhowtooperatetheunit.Childrenmustbesupervisedtomakesurethattheydonotplaywithunit.
– Caution Hot water vapour - Danger of scalding! The Defensor Mk5 produces hot water vapour. There is danger of scalding when getting in touch with hot water vapour or the hot water inside the steam cylinder and the lime collector tank. Prevention:Donotcarryoutanyworkonthesteamsystemduringoperation(steamlines,steamdistributor,fanunit,etc.).IfthesteamsystemisleakysettheDefensorMk5immediatelyoutofoperationasdescribedinchapter6.3.Correctlysealthesteamsystembeforeputtingtheunitintooperationagain.
– Caution Danger of burning! During operation the components of the steam sys-tem (steam cylinder, steam distributor, etc.) get very hot (up to 100 °C). There is danger of burning when touching the hot components. Prevention: BeforecarryingoutanyworkonthesteamsystemsettheDefensorMk5outofoperationasdescribedinchapter6.3,thenwaituntilthecomponentshavecooleddownsufficientlythuspreventingdangerofburning.
– Caution, danger of electric shock! The Condair Mk5 is operated with mains voltage. Before commencing workontheCondairMk5,theunitistoberendered inopera-tiveinaccordancewithsection6.3andpreventedfromfurtherinadvertentoperation(isolateunitfromtheelectricalpowersupply,isolatewatersupply).
– Observe all local safety regulations.– relatingtotheoperationofmains-operatedelectrical and electronic equipment– and the provision of water, steam and electrical installations
– Poorlymaintainedhumidificationsystemscanendangerhealth.The servicing inter-vals should therefore be adhered to without reservation and the servicing work carried out correctly.
– Ifitissuspectedthatsafe operation is no longer possible,thentheCondairMk5should immediately be shut down and secured against accidental power-up. This canbethecaseunderthefollowingcircumstances:– iftheCondairMk5isdamaged– iftheCondairMk5isnolongeroperatingcorrectly– ifconnectionsand/orpipingarenotsealedorcablesareloose
– TheCondairMk5mustonly be operated under the specified operating conditions (seesection7).
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– Thecustomer is responsible for theregular inspection,cleaninganddisinfectionoftheductsectioninwhichthesteamdistributorisinstalled.Thismustbeperformedinaccordancewiththehygieneregulationsinforceforoperatingair handling units.
– TheCondairMk5isprotectedaccordingtoIP21.Makesuretheunitsareinstalledinadrip-prooflocation
– Caution! IftheCondairMk5isinstalledinanareawithoutawaterdrain,watersensorsmustbefittedinthearea,suchthatintheeventofleakageinthewatersystem,thewaterfeedissafelyshutoff.
– Caution, danger of corrosion! In order to avoid damage, no corrosion-sensitive componentsshouldbelocatedintheareaoftheaerosolstreams.
– No work/repairshouldbecarriedoutontheCondairMk5otherthanthatdescribedinthese instructions.
– Useexclusivelyoriginal accessories and spare partsavailablefromyoursupplier.
– No modifications must be undertakenontheCondairMk5withouttheexpresswrit-tenconsentofthemanufacturer.
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3 Product overview
3.1 Unit types
ThesteamhumidifiersCondair Mk5 are available in 2 different type series:
– Visual Fordirectorindirectroomairhumidificationwithstandard requirements for control precision.
– ProcessFordirectorindirectroomairhumidificationinlaboratory and process appli cationswherethereare increased requirements for control precision.
Basically,thedevicesofbothtypeseriesareofthesameconstructionexceptforthelevelcontrolandelectronics.TheVisualunits>10kg/hareequippedwithacombinedcontactor/electroniccontrolandalevelunitwithasinglefloat.ToachieveahigherlevelofaccuracytheProcessunitsincludeadedicatedelectroniccontrolwithspecialcontrolsoftwareandareequippedwithalevelunitcomprisingtwofloats.
Theyareavailableinversionssuitableforoperationwithuntreated drinking water(with lime collec-tor tank)orwithfully demineralized water(without lime collector tank).Allversionsareequipped,asstandard,withanoperating and display unit,bymeansofwhichthecurrentoperatingparameterscanbereadandtheequipmentconfiguredforoperation,andanintegrated PI controller.Theequip-mentcanbesuppliedwithvariousotheroptions.
Type overview and type designation
Theunitsofbothtypeseriesareavailableinvariousversionswithdifferent steam capacities and layout of the power section(heatingvoltage).Thefollowingtableprovidesanoverviewofthevariousmodels and their capacity ranges.
Condair Mk5 Visual ..-../Process..-.. Heating voltage
small large double unit large5 8 10 16 20 24 30 40 50 1) 60 1) 80 1)
max. steam capacity in kg/h5.0 8.0 10.0 16.0 20.0 24.0 30.0 40.0 50.0 60.0 80.0 400V/3~/50...60Hz4.6 7.3 9.0 14.6 18.0 21.9 27.0 36.2 45.0 54.0 72.4 220V/3~/50...60Hz5.1 8.4 10.3 16.7 20.6 25.1 30.6 41.5 51.2 61.2 83.0 415V/3~/50...60Hz5.1 8.7 10.3 ––– ––– ––– ––– ––– ––– ––– ––– 240V/1N~/50...60Hz5.1 8.0 10.0 ––– ––– ––– ––– ––– ––– ––– ––– 230V/1N~/50...60Hz3.9 5.8 7.1 11.6 14.3 17.4 21.5 28.8 35.6 43.0 57.6 200V/3~/50...60Hz
1) Mk5 ... 50 ... Mk5 ... 60 ... Mk5 ... 80 ... Unit A: 20 kg/h 30 kg/h 40 kg/h Unit B: 30 kg/h 30 kg/h 40 kg/h
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Thetypedesignationisstructuredasfollow:
Designation Code
Brand name Condair
Product line Mk5
Type series –Directorindirectroomhumidification –Humidificationforlaboratoryandprocessapplications
VisualProcess
Operating mode – Operation with untreated drinking water (with lime collector tank) –Operationwithfullydemineralizedwater(withoutlimecollectortank)
–VE
Steam capacity in kg/h – 5, 8, 10, 16, 20, 24, 30, 40, 50, 60 or 80 ..
Heating voltage – 400V/3~/50...60Hz – 220V/3~/50...60Hz – 415V/3~/50...60Hz – 240V/1N~/50...60Hz – 230V/1N~/50...60Hz – 200V/3~/50...60Hz
400V/3~220V/3~415V/3~
240V/1N~230V/1N~200V/3~
3.3 Standard delivery
The standard delivery includes:
– SteamhumidifierCondairMk5compl.(accordingtotypedesignation)equippedwiththedesiredoptions(remoteoperatingandfaultindication,pressurecompensationkit,etc.)accordingtochap-ter 4.3
– Fixingsetincludingdowelsandfixingscrews(forsingleunitsupto40kg/h),mountingprofilewithdowelsandfixingscrews(fordoubleunits50...80kg/h)
– Installation and operating instructions
– Sparepartslist(red)
– Orderedaccessories(steamdistributionpipe,steamhose,etc.)accordingtochapter4.4
CondairAG/CH-8808PfäffikonMk5 Visual 30 XXXXXXX 02.13400V 3~ / 50...60Hz 22.3 kWDampf/Steam/Vapeur=30.0kg/hWasser/Water/Eau=1...10bar
MadeinSwitzerland
3.2 Identification of the unit
Theidentificationoftheunitisfoundonthetypeplate:
Type designation Serialnumber(7digits) Month/Year
Heating voltage
Maximumsteamcapacity
Admissiblewatersupplypressure
Powerconsumption
Fieldwithcertificationsymbols
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3.4 Humidification system overview
1 Steamhumidifier 2 Electrical connections 3 Water drainage 4 Limecollectortank(onlyonunitsforoperation
with untreated drinking water) 5 Filter valve (accessory “Z261”) 6 Water supply (building side) 7 Fanunit(accessory“FAN3S..”) 8 Condensatehose(accessory“KS10”) 9 Steamhose(accessory“Z10”)10 Steamdistributionpipe(accessory“81–...”)
3.5 Steam humidifier construction 1 Housing (500 or 600) 2 Power board 3 Heating contactor (Visual >10 kg/h only) 4 Mains contactor 5 Supplymodule 6 Control board 7 Cable openings 8 LC-Display 9 Control keys 10 Unit switch 11 Drain switch12 Statusindicator(LED)13 Limecollectortank(onlyonunitsforoperation
with untreated drinking water) 14 Drain 15 Water connection16 Steamcylinder 17 Drain pump 18 Resistance heating element19 Inletvalvewithfilter 20 Water supply 21 Filling pipe22 Overflowpipe23 Steamoutletconnector 24 Water cup 25 Pressure equalizing pipe 26 Level unit 27 Type plate
5
6
4
3
7
1
2
10
8
9
23
1
26
2
3
4
5
6
27
7
8
9
10 11 12 13
15 14
17
16
18
19 20
21 22
24 25
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3.6 Functional description
TheCondairMk5steamhumidifierisanunpressurizedsteamgenerator.Itoperatesontheresistanceheatingprincipleandisdesignedfordirect(withfanunit)andindirect(withsteamdistributionpipe)roomair humidification in ventilatingandair-conditioning systems. In conjunctionwitha “Process”steamdistributionpipetheunitmaybeusedforhumidificationinlaboratoryandprocessapplications.
Water supply
Thewateristakenviaafiltervalve(accessory“Z261”)tothesteamhumidifier.Itreachesthesteamcylinderviatheinletvalve(levelcontrolled)andtheopenwatercup.
Level regulation
Thewaterlevelinthesteamcylinderiscontinuouslymonitoredwiththelevelunit.Ifthewaterlevelreachesapresetlevel(owingtotheevaporationprocess)thelevelunitsuppliesasignaltothecon-troller.Thisopenstheinletvalveandthesteamcylinderisfilledup.Whenthepresetoperatinglevelisreached, the level unit supplies another signal to the controller to close the inlet valve.Thepressureequalizingpipebetweenthesteamconnectionandthelevelunitensuresthatthewaterlevels are the same in the steam cylinder and the level unit.
Steam generation regulation
Thesteamisproducedinthesteamcylinderbyseveralresistanceheatingelements.Anexternalortheinternalregulatorforconnectionasrequiredcontrolthesteamproductionfullyvariablyfrom0to100%.
Flushing
Theevaporationprocessincreasestheconcentrationofmineralsinthewaterofthesteamcylinder.Asuitablevolumeofwatermustbeflushedthroughthesteamcylinderfromtimetotimeandreplacedbyfreshwatertoensurethatthisconcentrationdoesnotexceedaspecificvalueunsuitableforoperation.TheMk5steamhumidifierperformsanauto-adaptiveflushing.Thisconsistsofthefollowingtwoformsofflushing:
– Automatic flushing takesplaceassoonasthewater inthesteamcylinderexceedstheupperoperatinglevel(e.g.byfoamingofthewater).
– Flushing dependent on time performstheflushingprocessatpreselectedtimeintervals(seesec-tion6.1“Adjustments”).
Automaticortime-dependentflushingtakesplacedependingonthewaterqualityandtheoperatingdata.Ifthelowestoperatinglevelisreachedduringtheflushingprocess,theinletvalveremainsopenuntilthewaterlevelinthesteamcylinderhasreachedthenormalworkinglevelagain.Ifthelowestoperating level is not reached, the inlet valve is closed.
Lime collector tank
Themineralsprecipitatedbytheevaporationprocessaccumulateatthebottomofthesteamcylinder.Unitsdesignedforoperationwithuntreateddrinkingwaterareequippedwithanadditionallimecol-lectortanklocateddirectlyunderneaththesteamcylinder.Thiswaythemineralsdonotaccumulateinthesteamcylinderbutmainlyinthecollectortankthusextendingtheserviceintervalsandreducingthe maintenance costs.
Unitsdesignedforoperationwithfullydemineralizedwaterdonothavealimecollectortankasfullydemineralizedwatercontainsonlysmallamountsofminerals.
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4 Basic planning
AllthedatanecessaryfortheselectionandlayoutofaCondairMk5humidifiersystemareprovidedinthefollowingchapters.
4.1 Selecting the unit
Theselectionoftheunitisreflectedinthetypedescription:
1. Application
2. Supplywaterquality
3. Requiredmaximumsteamcapacity
4. Requiredheatingvoltage
1. Application
Thetypeseriescanbeselectedonthebasisofthefollowingtable:
Scopeofuse Type series
For direct or indirect room air humidification with standard requirements for control precision.
Visual
For direct or indirect room air humidification in labora-tory and process applications where there are increased requirements for control precision.
Process
Achievable control precisionNote:Thecontrolprecisionmaydependonthelocationofthehumiditysensor.– Visual: ±5 %rh(PI-controlanduseofuntreateddrinkingwater)
±2 %rh(PI-controlanduseoffully demineralized water) Note:Duringthedraincycle(operationwithdrinkingwater)orduringtherefillcycle(operationwithfullydemineralizedwater)thecontrolprecisioncandeviatefromtheabovestatedvalues.
– Process: ±2 %rh(PI-controlanduseofuntreateddrinkingwater) ±1 %rh(PI-controlanduseoffully demineralized water)
Note:WhenoperatingtheMk5Processwithdrinkingwaterthecontrolprecisioncandeviatefromtheabovestatedvaluesduringthedraincycle.ForprocessairhumidificationwithconstantcontrolprecisiontheMk5ProcessmustbeoperatedwithfullydemineralizedwaterandthedraincyclemustbesettoPos.0(seechapter6.1).
2. Supply water quality Description Version
Unit withalimecollectortankforoperationwithuntreated drinking water and partially softened water (see also notes on water quality in chapter 5.4.1).
–
Unit withoutalimecollectortankforoperationwithfullydemineralizedwaterwithaconductivityvalue
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3. Calculating the maximum required steam capacity
Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:
V • ρmD = • (x2 - x1) 1000
V mD = • (x2 - x1) 1000 • ε
mD: maximumsteamdemandinkg/hV: volumeofsupplyairportionperhourinm3/h(forindirectroomhumidification)orroomvolumeto
behumidifiedperhourinm3/h(fordirectroomhumidification)ρ: specificgravityofairinkg/m3ε: specificvolumeofairinm3/kgx2: desired absolute room air humidity in g/kgx1: minimum absolute supply air humidity in g/kg
Thevaluesforρ, ε, x2 and x1canbegatheredfromtheh,x-diagram or the Carrier-Diagramformoistair respectively.
Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalueslistedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroomairhumidityof45%rh.
Max.portionofsupplyairinm3/hr or roomvolumetobehumidifiedperhourinm3/hr
max. steamcapacity in kg/hTemperature/rel.humidityofsupplyair
-15 °C/90 %rh -5 °C/80 %rh 5 °C/60 %rh6501000200025003000375050006250750010000
8501350265033004000500066008250990013200
1000160032004000480060008000100001200016000
5816202430
40
50
60
80
Example: Max.portionofsupplyair3000m3/h, temperature/rel. humidityofsupplyair-15°C/90%rh
or
Important notes:
– Therequiredmaximumsteamcapacitydependson thespecificapplicationand the installation.Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionoftheairtobehumidifieddoesnotconsideranysteamloss(e.g.duetocondensationinthesteamhosesandthesteamdistributors),anyheatlossoftheunitaswellasanyabsorptionorreleaseofhumidityofmaterialslocatedintheroombeinghumidified.In addition, the calculated steam capacity does not consider any losses caused by the draining rate dependingonthewaterquality.
Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsiderationwhencalculatingtherequiredsteamcapacity.Ifyouhaveanyquestionsregardingthecalculationofthesteam capacity please contact your supplier.
– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesorforsystemswithvariableairvolumeflow,etc.),pleasecontactyoursupplier.
Mk5 Visual VE 24-400V/3~
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4. Heating voltage/control voltage Heating voltage
TheCondairMk5steamhumidifiersareavailablewithvariousheatingvoltages.Themaximumachievable steamcapacity and the power consumption are directly dependent on the selectedheatingvoltage(seetable).
400 V/3~ 220 V/3~ 415 V/3~ 240 V/1N~ 230 V/1N~ 200 V/3~
50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz
Condair Mk5Visual.../Process...
kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A
...5-.. 5.0 3.8 5.5 4.6 3.4 9.0 5.1 4.0 6.0 5.1 4.0 17.0 5.1 4.0 16.5 3.9 3.0 8.2
...8-.. 8.0 6.0 8.7 7.3 5.5 14.4 8.4 6.5 9.0 8.7 6.5 27.2 8.0 6.0 26.0 5.8 4.5 13.1
...10-.. 10.0 7.5 11.0 9.0 6.7 17.7 10.3 8.0 11.5 10.3 8.0 33.0 10.0 7.4 32.0 7.1 5.5 16.1
...16-.. 16.0 12.0 17.4 14.6 10.9 28.7 16.7 13.0 18.1 –– –– –– –– –– –– 11.6 9.0 26.1
...20-.. 20.0 14.9 21.5 18.0 13.5 35.4 20.6 16.0 22.3 –– –– –– –– –– –– 14.3 11.1 32.2
...24-.. 24.0 18.1 26.2 21.9 16.4 43.1 25.1 19.5 27.2 –– –– –– –– –– –– 17.4 13.5 39.2
...30-.. 30.0 22.3 32.3 27.0 20.2 53.1 30.6 24.0 33.5 –– –– –– –– –– –– 21.5 16.7 48.3
...40-.. 40.0 30.0 43.3 36.2 27.2 71.4 41.5 32.3 45.0 –– –– –– –– –– –– 28.8 22.4 64.9
...50-..A 20.0
+30.0
14.9+
22.3
21.5+
32.3
18.0+
27.0
13.5+
20.2
35.4+
53.1
20.6+
30.6
16.0+
24.0
22.3+
33.5–– –– –– –– –– ––
14.3+
21.5
11.1+
16.7
32.2+
48.3B
...60-..A 30.0
+30.0
22.3+
22.3
32.3+
32.3
27.0+
27.0
20.2+
20.2
53.1+
53.1
30.6+
30.6
24.0+
24.0
33.5+
33.5–– –– –– –– –– ––
21.5+
21.5
16.7+
16.7
48.3+
48.3B
...80-..A 40.0
+40.0
30.0+
30.0
43.3+
43.3
36.2+
36.2
27.2+
27.2
71.4+
71.4
41.5+
41.5
32.3+
32.3
45.0+
45.0–– –– –– –– –– ––
28.8+
28.8
22.4+
22.4
64.9+
64.9B
Shouldyourequireaunitwithadifferentheatingvoltage,pleasecontactyoursupplier.
Control voltage
CondairMk5steamhumidifiersaredesignedforastandardcontrolvoltageof220...240V/50...60Hz.
Ifusedinsystemswithoutseparatecontrolvoltagesupply,theCondairMk5maybeequippedwithanoptionaltransformer400-500V/230V(seechapter4.4).
Mk5 Visual VE 24-400V/3~
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4.2 Selecting the control system
The various control systems
– System 1: Room humidity control
System1issuitedfordirect room humidification and air conditioning systems with mainly recirculated air.Thehumiditysensororhumidistatrespectivelyispreferablylocatedintheroomitselforintheexhaustairduct.
A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatB4 humidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1
– System 2: Room humidity control with continuous limitation of the supply air humidity
System2issuitedforairconditioningsystemswithalarge portion of supply air, low supply air temperature, post-humidification, or variable airflow volume.Ifthesupplyairhumidityexceedsthepresetvalue,thecontinuouslimitationiseffectedpriortotheroomhumiditycontrol.Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.Thehu-miditysensor(A2)forthelimitationofthesupplyairhumidityislocatedinthesupplyairductafterthesteamdistributionpipe.Thiscontrolsystemrequiresaexternal continuous controllerwiththeoption to connect a second humidity sensor.Attention!Thecontinuouslimitationofthesupplyairhumidityisnosubstituteforthesafetyhumidistat.
A1/2 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1Z inputsignalfromA2
CondairMk5
CondairMk5
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– System 3: Supply air humidity control
Supply air humidity control (humidity sensor installed in supply air duct) should be used only where room humidity control is impracticable for technical reasons.SuchsystemsalwaysrequireaPI-controller.Thehumiditysensor(A1)islocatedinthesupplyairductafterthesteamdistribution pipe.
A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller) Y inputsignalfromA1
Which humidity control system for which application?
Application Location of the humidity sensor
Room or exhaust air duct supply air ductAir conditioning systems with: supply air portion up to 33% System1 System1 supply air portion up to 66% System1or2 System2or3 supply air portion up to 100% System2 System3 supply air humidity control — System3Directroomhumidification System1 —
Pleasecontactyoursupplier,ifyourapplicationmeetsthefollowingconditions:
– Humidificationofsmallroomsupto200m3
– Airconditioningsystemswithahighnumberofairexchanges
– Systemswithvariableairvolumeflow
– Testfacilitieswithextremecontrolaccuracyrequirements
– Roomswithahighvariationinmax.steamcapacity
– Systemswithtemperaturefluctuations
– Coldroomsandsystemswithdehumidification
CondairMk5
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4.3 Options
ThefollowingtablepresentsanoverviewofalloptionswhichareavailableforthesteamhumidifierCondairMk5.
Condair Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Interface RS232/RS485(InterfacePCBRS232/RS485fordataex-changewithabuildingcontrolsystem)
RS
number 1 1 1 1 1 1
Remote operating and fault indication(PCBwithrelaycontactsfortheconnectionofremotedisplaysfor“Operation”,“Steam”,“Fault”and“Service”)
RFS
number 1 1 1 1 1 1
Pressure compensation kit up to 10’000 Pa(Assemblykitfortheinstallationofthefillingbowlontheequipmentcover,fortheopera-tionofthesteamhumidifierininstallationswithductairpressuresupto10’000Pa)
OVP
number 1 1 2 1 1 2
Transformer 400-500V/230V(Transformerforsystemswithoutaseparatecontrolvoltagesupply)
TRAF 1)
number 1 1 1 1
Connection terminal 400-415 V/3~(Separate terminals for systems wheredirectconnectionofheatingvoltagetomaincontactor(standardversion)isnotpermittedbylocalregulations)
KLK KLG KLK KLG
number 1 1 2 1 1 2
Unit housing stainless steel S-Inox L-Inox S-Inox L-Inox
number 1 1 2 1 1 2
1) Whenorderingindicatethetypeofunit
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4.4 Accessories
4.4.1 Accessories overview
Thefollowingtablepresentsanoverviewofallaccessorieswhichareavailableforthesteamhumidi-fierCondairMk5.
Condair Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Steam distribution pipe(seeaccessorydetailsinchapter4.4.2)
81-...
number 1 2 1 2
Steam distribution pipe Process(seeaccessorydetailsinchapter4.4.2)
Z..
number 1 2 1 2
OptiSorp steam distribution system(seeaccessorydetailsinchapter4.4.2)
System 1 System 2 System 1 System 2
number 1 1 1 1
Fan unit(seeaccessorydetailsinchapter4.4.2)
FAN3S Mk M
orFAN3S
Mk M FC
FAN3S Mk L FAN3S Mk M
orFAN3S
Mk M FC
FAN3S Mk L
number 1 1 2 1 1 2
Steam hose / meter Z10 (ø54/42)
number 1 2 1 2
Condensate hose / meter KS10
number 1 2 1 2
Filter valve Z261
number 1(persystem)
Mounting profile BS4 BS5 BS6 1) BS4 BS5 BS6 1)
number 2 2 2 2 2 2
Humidity sensor, room CRC
number 1(persystem)
Humidity sensor, duct CDC
number 1(persystem)
1) FordoubleunitsthemountingprofilesBS6areincludedinthestandarddelivery
-
18
Steam distribution pipes 81-... for indirect room humidification
Thesteamdistributionpipesareselectedonthebasisoftheduct width(forhorizontalinstallation)orthe duct height(forverticalinstallation)andthecapacityofthesteamhumidifier.Important!Alwaysselectthelongestpossiblesteamdistributionpipe(optimumhumidificationdistance).
4.4.2 Accessory details
Steam distribution pipes 81-... for Condair Mk5 (CrNi steel)
Duct width (B) Steam output
Type Length in mm (L) 3) in mm max. in kg/h81-200 1) 200 210...400 1081-350 2) 350 400...600 3081-500 2) 500 600...750 3081-650 650 750...900 5081-800 800 900...1100 5081-1000 1000 1100...1300 5081-1200 1200 1300...1600 5081-1500 1500 1600...2000 5081-1800 1800 2000...2400 5081-2000 2000 2200...2600 5081-2300 2300 2500...2900 5081-2500 2500 2700...3100 50
1) Onlyforunitswithamax.steamcapacityof10kg/h2) Onlyforunitswithamax.steamcapacityof30kg/h3) Speciallengthavailableonrequest
Note:Ifthehumidificationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,theamountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesorthe OptiSorp steam distribution system mustbeused.Ifthisisthecase,contactyoursupplier.
Steam distribution pipe “Process” (accessory “Z...”)
Thesteamdistributionpipe“Process”isusedfordirect humidification of materialinmanufacturingprocesses (processhumidification),or inventilationductswithacritical saturation distance (thesteamdistributionpipe“Process”reducesthesaturationdistancebyapproximately30%).Thedesiredlengthmustbespecifiedwhenordering.
Pleasecontactyoursupplier,theywillassistyouincustomizingthesteamdistributionhead“Process”.Pleasehavethefollowinginformationreadilyavailable:
– steamquantityinkg/h
– dimensionsofventilationduct(widthxheight)
Important! Thetableforthedeterminationofthehumidificationdistanceprovidedinchapter5.3.1doesnot apply to the Process steam distribution pipe.
-
19
OptiSorp steam distribution system
TheOptiSorpsteamdistributionsystemisusedinventilationductswhereonlyashorthumidificationdistance isavailable(seechapter5.3.1forcalculationofhumidificationdistance).Ductdimensionsshouldbegivenwhenordering.Pleasenotethefollowingdataforthis:
OptiSorp Number of steam connections
max. steam capacity in kg/h 1)
Duct dimension
Width in mm Height in mm
System 1 1 45 (30) 450...2700 450...1650
System 2 2 90 (60) 450...2700 450...2200
1) For duct width
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20
4.5 Additional planning instructions
Inadditiontotheselectionofthesteamhumidifier,theaccessoriesandtheoptions,otherpointsshouldbeconsideredduringplanning.Pleasenotetheinformationinthefollowingchapters:– Unitfitting(seechapter5.2)– Steaminstallation(seechapter5.3)– Waterinstallation(seechapter5.4)– Electricinstallation(seechapter5.5)
Ifyouhaveotherquestionsrelatingtoplanningthatarenotadequatelycoveredbytheseinstallationandoperatinginstructions,pleasecontactyoursupplier.Hewillbehappytoprovidefurtherassistance.
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21
5 Mounting and installation works
5.1 Safety instructions for mounting and installation works
– Allmountingandinstallationworkmustbeperformedonly by adequately qualified personnel.Ascertainingthequalificationsisthecustomer‘sresponsibility.
– Alllocalregulationsrelatingtotheexecutionoftherespectiveinstallationwork(Water,steamandelectricalinstallation)mustbenotedandcompliedwith.
– Alltheinformationcontainedintheseinstallationandoperatinginstructionsrelatingtoequipmentassemblyandtowater,steamandelectricalinstallationmustbeuncondi-tionallyobservedandcompliedwith.
– 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.
– Electronic components are very sensitive to electrostatic discharges. In order to protect thesecomponents,duringallinstallationworkwiththeequipmentopened,precautionsmustbetakenagainstdamageduetoelectricaldischarge(ESDprotection).
5.2 Unit fitting
5.2.1 Humidifier location
Theinstallationsiteofthesteamhumidifierdependslargelyonthelocationofthesteamdistributionpipeorfanunit(seechapter5.3.1and5.3.2),respectively.Toensureproperfunctioningofthesteamhumidifierandtoobtainanoptimalefficiency,thefollowingpointsmustbeconsideredandobservedwhenchoosingthelocationforthesteamhumidifier:
– Installthesteamhumidifiersothatthelength of the steam hose is kept as short as possible (max. 4 m) and that the minimum bend radius (R= 300 mm) and up-slope (20 %) or down-slope (5 %)ofthesteamhoseisobserved(seechapter5.3.3).
– ThesteamhumidifiersCondairMk5aredesignedforwall-mounting.Makesurethattheconstruc-tion(wall,pillar,floor-mountedconsole,etc.)towhichthehumidifiersaretobemounted,offersasufficientlyhighload-bearingcapacity(takenoticeoftheweightinformationfoundinthischapter),andissuitablefortheinstallation.
Warning!Donotmountthesteamhumidifierdirectlytotheventilationduct(insufficientstability).
– ThebackpaneloftheCondairMk5isretainingheatduringoperation(max.surfacetemperatureofthemetalhousingapprox.60-70°C).Makesure,therefore,thattheconstruction(wall,pillar,etc.)towhichtheunitsaretobemounted,doesnotconsistofheat-sensitivematerial.
– Foroperationinvolvingafanunit,thesteamhumidifiermustalwaysbeinstalledlowerthanthefanunit.
– Installthesteamhumidifierinsuchamannerthatitisfreelyaccessiblewithsufficientspaceavail-ableformaintenancepurposes(refertothefollowingillustrationforminimumdistances).
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22
Dimensions and Weights
Minimum distances to observe
437 mm 500 mm
1087
mm
1087
mm
392 mm 594 mm
160 mm257 mm 194 mm212 mm30
0 mm
300 m
m
69 mm 132 mm 103 mm45 mm
min.
400 m
m
min. 600 mm min. 50 mm min. 400 mm
min.
600 m
m
50 mm
min.
600 m
m
Mk5 ...50.. Mk5 ...60.. Mk5 ...80..Unit A: 20 kg/h 30 kg/h 40 kg/hUnit B: 30 kg/h 40 kg/h 40 kg/h
Unit AUnit B
Housing size small large double unit largeSteamcapacity in kg/h 5 8 10 16 20 24 30 40 50 60 80
Netweightin kg 36 36 37 38 41 43 43 44
1x411x43 2x43 2x44
Grossweight in kg 51 51 52 53 71 73 73 74
1x711x73 2x73 2x74
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23
5.2.2 Mounting the humidifier
• Usethedrillingtemplate(printedonthepacking)tomarkattachmentpoint“A”onthewall.Important! Observe location notes.
• Drillholeø10mm,insertthesuppliedplasticplug,andtightenthescrewuntilthedistancebetweenthewallandthescrewheadis5mm.
• Unlockleftfrontpanelandremovebothfrontpanels.Hanguptheunitonthescrew,andusethespiritleveltoadjustithorizontallyandvertically.
• Markattachmentpoints“B”.Whenfinished,removetheunitagain.
• Drillholesø10mmandinsertthesuppliedplasticplugs.
• Hangtheunituponthescrewagainbeforeattachingitwiththeremainingtwoscrews.Beforetight-eningthescrews,readjusttheunitwiththespiritlevel.
• Reattachthefrontpanelsandlockthem.
5.2.3 Inspecting the installed unit
Usethefollowingchecklisttoascertainthattheinstallationwasperformedcorrectly:
Is/aretheunit(s)inthecorrectplace?(seechapter5.2.1)
Is/aretheunit(s)correctlyalignedverticallyandhorizontally?
Issteamhumidifierproperlysecured?(stabilityofthecarryingstructure)
Caution!WhenfixingtheCondairMk5,useonly the fixing materials supplied with the unit.Iffixingwiththematerialssuppliedisnotpossibleinyourparticularcase,selectamethodoffixingthatisofsimilarstability.Incaseofdoubt,pleasecontactyoursupplier.
Note:Thefollowingexplainshowtofixtheunitwithoutoptionalmountingprofiles.Toinstalltheunitwithmountingprofiles,pleasenotethespecialinstructionsprintedonthepackaging.
View from the front
Measure Housing sizesmall large
a 232,0 mm 237,0 mmb 175,0 mm 181,0 mmc 166,5 mm 166,5 mmd 460,0 mm 460,0 mm
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24
5.3 Steam installation
5.3.1 Positioning and mounting of the steam distribution pipes
Thelocationforthesteamdistributionpipesshouldbedeterminedatthetimeofdimensioningtheairconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidificationoftheductair.
Calculating the humidification distance
Thewatervapor,emittingfromthesteamdistributionpipes,requiresacertaindistancetobeabsorbedbytheambientairsothatitisnolongervisibleassteam.Thisdistanceisreferredtoashumidifica-tion distance “BN”andservesasabasisforthedeterminationoftheminimumdistancesfromtheupstream components in the system.
Humidificationdistance BN Expansionandmixingzone
φ1: Incoming air humidity beforehumidificationφ2: Air humidity afterhumidification
Thecalculationofthehumidificationdistance“BN”isdependentonseveralfactors.Foraroughestima-tionofthehumidificationdistance“BN”,thefollowingtableisuseful.Recommendedstandardvalueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevaluesgiveninbold type only apply to steam distribution pipes 81-..., the values in brackets apply to the OptiSorp steam distribution system.
Humidity at inlet φ1 in %rh
Humidification distance BN in mHumidity at outlet φ2 in %rh
40 50 60 70 80 905 0,9 (0,22) 1,1 (0,28) 1,4 (0,36) 1,8 (0,48) 2,3 (0,66) 3,5 (1,08)
10 0,8 (0,20) 1,0 (0,26) 1,3 (0,34) 1,7 (0,45) 2,2 (0,64) 3,4 (1,04)20 0,7 (0,16) 0,9 (0,22) 1,2 (0,30) 1,5 (0,41) 2,1 (0,58) 3,2 (0,96)30 0,5 (0,10) 0,8 (0,17) 1,0 (0,25) 1,4 (0,36) 1,9 (0,52) 2,9 (0,88)40 − 0,5 (0,11) 0,8 (0,20) 1,2 (0,30) 1,7 (0,45) 2,7 (0,79)50 − − 0,5 (0,13) 1,0 (0,24) 1,5 (0,38) 2,4 (0,69)60 − − − 0,7 (0,16) 1,2 (0,30) 2,1 (0,58)70 − − − − 0,8 (0,20) 1,7 (0,45)
Forductwidths
-
25
Minimum distances to be observed
To prevent thewater vapor, that is emitting from the steam distributionpipe, from condensing ondownstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeobserved(dependsonthehumidificationdistance“BN”).
before/after filter/register before/after fan, zone exit
Caution!Thehumidificationdistanceandderivedfromittheminimumdistancebetweenthesteamdistributorandsystemcomponents locateddownstreamintheductaredeterminedonthebasisoftheexpectedoperatingparameters(e.g.airspeed,supplyairtemperature,etc.)whenplanningthesystem.Analterationoftheseoperatingparametersatalatertimemayinducethatthedeterminedhumidificationdistanceisnotcorrectanylongerandsteamiscondensatingduringoperationonsys-temcomponentslocateddownstreamintheduct.Thismayleadtodamageofthesystemand/oranexcessivegrowingofgerms.
Installation notes and dimensions
Thesteamdistributionpipesaredesignedforeitherhorizontalinstallation(ontheductwall)or,withaccessories,forverticalinstallation(intheductfloor).Theoutlet orifices should always point up-wards and at right angles to the airflow.
Ifpossible,thesteamdistributionpipesshouldbeinstalledonthepressure sideoftheduct(max. duct pressure 1500 Pa).Ifthesteamdistributionpipesareinstalledonthesuctionsideoftheduct,the maximum vacuum must not exceed 1000 Pa.
Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)andpositionthesteamdistributionpipesintheductsothatauniformdistributionofsteamisachieved.
before/after constriction after expansion before bend
before branch before diffuser before control sensor
2,5xBNbeforesubmicronparticlefilter
0.5 x BN BN0.5 x BN
BN BN 5 x BN
1.5 x BN * 5 cm BN BN
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26
Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved.
Note:PleasenotetheinstructionsintheseparatedocumentationforthisproductwhenlocatingtheOptiSorp steam distribution system.
Guidelines for dimensioning the ventilation ducts
– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufficientlysizedcontrolopeningshouldbeplanned.
– Withintherangeofthehumidificationdistance,theventilationductshouldbewater-proofed.
– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidifiedairfromcon-densingalongtheductwall.
– Poorairflowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canleadtocondensationofthehumidifiedair.
– Steam distribution pipes must not be mounted to round ducts.
Ifyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithsteamhu-midifiers,contactyoursupplier.
Installing the steam pipes/the OptiSorp steam distribution system
Detailedinformationontheinstallationofsteamdistributionpipes/OptiSorpsteamdistributionsystemcanbefoundintheseparate“MountingInstructions”forthisproducts.
gmin= 150mmhmin= 85mm
min.H=250mm H≥400mm min.H=200mm
min.H=400mm min.H=350mm min.H=300mm
min.H=600mm min.H=500mm min.H=400mm
min.H=720mm min.H=600mm min.H=500mm
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27
Thefanunitismountedon the wall separately above the unit.Toallowthesteamcomingfromthefanunittospreadoutevenly,withoutcondensingonobstacles(ceilings,joists,pillars,etc.),thefollow-ingminimumdimensionsmustbeobservedwhenselectingthelocationforthefanunit.
FAN3SMkM/FAN3SMkMFC FAN3SMkL
mDmax. 8kg/h 16kg/h 30kg/h 40kg/h
A mín. 4.0 m 6.0 m 8.0 m 10.0 m
B mín. 1.0 m 1.0 m 1.0 m 1.5 m
C ca. 2.2 m 2.2 m 2.2 m 2.2 m
D ca. 0.5 m 0.7 m 1.0 m 1.5 m
E mín. 0.15 m
E max. (max.lengthofsteamhose) 4.0 m (recommended: 2.0 m)
Note:Theminimumspacesinthetableapplyforaroomatmosphereof15°Candmax.60%rh.Forlowertemperaturesand/orhigherhumiditythevaluesmustbeincreasedaccordingly
Note:Inordertoachieveauniformdistributionofthehumiditywithintheroom,additionalfactorssuchastheroomsize,theroomheight,etc.,mustbetakenintoconsiderationbesidesobservingtheminimumdistances.Ifyouhavequestionsconcerningthedirectroomhumidification,pleasecontactyoursupplier.
Furtherinformationisprovidedintheseparateinstallationandoperatinginstructionsforthefanunit.
5.3.2 Positioning and mounting of the fan unit
-
28
Important! Useoriginalsteamandcondensatehosefromyourunitsupplierexclusively.Othertypesofhosescancauseundesiredoperationalmalfunctions.Important! After installation the protective plastic tube around the steam hose must be removed.
Instructions for the hose layout
Thehoselayoutdependsonthepositionofthesteamdistributionpipe:
– Steam distribution pipe is mounted more than 500 mm above the top edge of the humidifier:
Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thenleadthehosewithaminimum upslope of 20%and/oraminimum downslope of 5% to the steam distribution pipe.
Thecondensatehoseisleddowntothehumidifierwithaminimum slope of 20 %,intheformofa siphon (min. hose bend radius Ø200 mm ),andinsertedabout2cmintothespecifiedopening.Note:Ifyourunitfeedsanumberofsteamdistributionpipes,theindividualcondensatehosesaretobeledintothedischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
Note: forsteamcapacities≤20kg/htheseparatereturnofthecondensateviathecondensatehosecanbedispensedwithifthesteamhoseisinstalledinsuchawaythatthecondensatecanflowbackintothesteamcylinderunhinderedwithaconstantdownslope.
5.3.3 Installing the steam and condensate lines
5.3.3.1 Steam line with flexible hose
min.
300 m
m
Rmin.
300 m
m
min. 5 % min. 20 %
max.
4m
min.
300 m
m
Rmin.
300 mm
min. 20 %
max.
4m
min. 20 %
Ømin.
200 mm
min.
300 m
m min. 20 %
Ømin.
200 mm
-
29
– Steam distribution pipe is mounted less than 500 mm above the top edge of the humidifier:
Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thendowntothesteamdistributionpipewithaminimum slope of 5 %.
Thecondensatehoseisleddownwithaminimum slope of 20 %,intheformofasiphon (min. hose bend diameter Ø200 mm),directlyintoadischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
– Thesteamhoseshouldbekeptasshortaspossible(max. 4 m)whileobservingtheminimum bend radius of 300 mm. Important!Allowancemustbemadeforapressure loss of 10 mm water column (approx. 100 Pa) per meter steam hose.Note:Ifyourparticularinstallationexceedsthemaximumsteamhoselengthof4mcontactyoursupplier. In any case, steam hoses longer than 4 m must be insulated in their entire length.
– Caution! Reducing the cross section or the complete closure of the steam pipe will cause an excessive increase in pressure in the steam cylinder when the unit is operat-ing and could lead to the risk of scalding accidents. Therefore you must comply with the following instructions:
– Wheninstallingmakesurethesteampipeisopenovertheentirelengthandthroughthewholecrosssection.Anysealingplugs,adhesivesealingsheetsetc.mustberemovedbeforeconnectingthesteampipeandreductionsincrosssectionbykinking,forexample,must be avoided.
– Steamhosesmustbepreventedfromsagging(condensatepockets);ifnecessary,sup-portsteamhosewithpipeclamps,trough,orwallbrackets,orinstallacondensatedrainatlowestpointinthesteamhose.
– It is not permitted to install a stop valve(e.g.amanuallycontrolledstopvalve,solenoidvalve,etc.)inthesteampipe.
– Important!Whendecidingonthelengthandlayoutofthehose,itshouldbenotedthatthesteamhosemaybecomesomewhatshorterwithprogressiveageing.
Securing the steam hose
Thesteamhosemustbesecuredtothesteamdistributionpipeandhumidifiersteamoutletbymeansofhose clamps.
max.
4m
min. 5 %
Rmin.
300 m
m
max.
4m
min.
300 m
m
min. 20 %
min.
300 m
m
min. 20 %min. 5 %
Rmin. 300 m
m
min. 20%
min.
300 m
m
min. 20 %
Ømin.
200 m
m
min.
300 m
m
min. 20 %
Ømin.
200 m
m
-
30
Usethefollowingchecklisttoascertainthatthesteaminstallationwasperformedcorrectly:
– Steam distribution pipe
Steamdistributionpipecorrectlypositionedandsecured(screwstightened)?
Aretheoutletorificesatrightanglestotheairflowdirection?
– Steam hose
Maximumlengthof4m?
Minimumbendradiusof300mm(100mmwithfixedpiping)?
Havetheinstructionsforhosepositioningbeenfollowed?
Isthesteampipeopenovertheentirelengthandthroughthewholecrosssection?
Steamhose:nosagging(condensatepocket)?
Rigidsteamlines:properlyinsulated?Correctinstallationmaterialused?Minimalinternaldiametermaintained?
Steamhosesecurelyattachedwithclamps?
Heatexpansionduringoperationandshorteningofthehosewithageingtakenintoconsidera-tion?
Hastheprotectiveplastictubearoundthesteamhosebeenremoved?
– Condensatehose
Downslopeofatleast20%?
Siphonexistingandfilledwithwater?
Condensatehosecorrectlyfixed?
Forsteamlineswithrigidpiping, thesameinstructionsapply to the layingof thepipingasalreadydescribed.Thefollowingadditionalnotesshouldbeobserved:
– The minimum internal diameter of 42 mm mustbeappliedoverthewholelengthofthepiping.
– Useexclusivelycopperpipe(operationwithuntreateddrinkingwater)orstainlesssteel(min.DIN1.4301,operationwithfullydemineralisedwater.
– Tominimizethecondensateformation(=loss),thesteampipesmustbeinsulated.
– The minimum bend radiusforsolidpipesis100 mm.
– Connectionofthesteampipestothesteamdistributionpipeandsteamhumidifieriseffectedbymeansofshortlengthsofsteamhosesecuredwithhoseclamps.Connectiontothesteamhumidi-fierissecuredviaaG11/4”coupling..
– Important! Allowancemustbemadeforapressure loss of approx. 100 Pa per meter length or per90°bend.
5.3.4 Inspecting the steam installation
5.3.3.2 Steam line with rigid piping
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31
5.4 Water installation
Allworkconcerningthewaterinstallationmustbeperformedonly by adequately qualified personnel(e.g.plumbers).Ascertainingthequalificationsisthecustomer’sresponsibility.
Please observe all local regulationsconcerningtheinstallationofappliancestothemainsandwastewatersystems.
Warning - danger of electric shock!Forallinstallationwork,thesteamhumidifiermust be disconnected from the mains supply and secured against unintentional re-connection.
5.4.1 Performing the water installation
Overview water installation
1 Waterconnection,unionnutG1/2" 2 Watersupplypipe(min.innerØ:8mm) 3 WaterdrainØ40mm 4 Drainpipe(min.innerØ:40mm,min.30cmdirectedverticallydownwards) 5 Pressurereducingvalve(compulsoryforwaterpressures>10bar,buildingside) 6 Manometer(installationrecommended,buildingside) 7 Filtervalve(accessory“Z261”) 8 Funnel(buildingside) 9 Siphon(min.innerØ:40mm,buildingside)10 Drainline,buildingside(min.innerØ:40mm)
H2O (1...10 bar)
1
3
2
4
5 6 7
8 9 108 9
min
. 30 c
m
-
32
Water supply
Thewaterfeedpipe(min.internalØ:8mm)istobeconnectedviathefilter valve that is available as anaccessory,totheconnectionontheunit(seedetailedillustration).Alternatively,ashut-off valve and a water filter maybeinstalled.Theinstallationofthefiltervalveshouldbemadeascloseaspossibletothesteamhumidifier.
Warning - danger of damage! Union nutatthehumidifierconnectionmustbehand-tightened only.
Thefollowingconnectionspecificationsmustbeobserved:
– Connectiononunit:G 1/2" (Union nut)
– Min.innerØofsupplyline:8 mm
– Admissible mains pressure 1.0 to 10.0 bar(hammer-freesystem)Formainspressures>10bar,connectionmustbemadeviapressurereducingvalve(adjustedto2.0bar).Formainspressures
-
33
5.4.2 Inspecting the water installation
Usethefollowingchecklisttoascertainthattheinstallationhasbeenperformedcorrectly:
– Water supply
Hasfiltervalveorshut-offvalveandfilter125µmrespectivelybeeninstalledinsupplyline?
Haveadmissiblewaterpressure(1.0–10bar)andtemperature(1–40°C)beenobserved?
Doessupplycapacitymatchthehumidifier(s)?
Areallpipesproperlysecured(threadedconnectionstightened)?
Isthefeedpipeproperlysealed?
– Water drain
Hasminimuminsidediameterofdrainpipesbeenmaintainedatleast40mmthroughouttheentirelength?
Hasdrainpipebeeninstalledwithadownslopeofatleast10%?
Hastheheatresistanceofthematerialusedbeenverifiedtobeatleast100°C?
Arehosesandlinesproperlysecured(hoseclampsandthreadedconnectionstightened)?
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34
5.5 Electric installation
– Allworkconcerning theelectric installationmustbeperformedonlybyadequately qualified personnel (electrician or workman with equivalent training). Ascertaining thequalificationsisthecustomer‘sresponsibility.
– Warning - danger of electric shock!The steamhumidifiermaybe connected toelectricmainsonlyafterallinstallationworkhasbeencompleted.
– Please observe all local regulations concerning the electric installation.
– Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protec-tion)
5.5.1 Electric installation overview
1 Supply heating voltage Up 2 Supply control voltage Uc 3 InterfaceRS232/RS485 4 Remoteoperatingandfaultindications(option“RFS”) 5 Externalcontinuouscontroller 6 Humiditysensor(supplyair/room/exhaust) 7 Safetyhumidistat 8 Airflowmonitor
9 Ventilationinterlock10 Externalsafetycircuit11 Steamhumidifier 12 Internal continuous controller13 Controlvoltagesupplytosecondunit14 Controllinetosecondunit15 Secondunit(from50kg/h)
CondairMk5(A)
CondairMk5(B)
-
35
Theelectricalinstallationistobecarriedoutinaccordancewiththefollowingwiringdiagram.
Caution! Observetheinstallationnotesinthefollowingsection.
5.5.2 Wiring diagram
1 2
3 4
5 6
7 8
9 10
F2 (1
AF)
F1 (6
.3 AT
)
JP1
JP2
JP1
JP2
J7
X1
K1 Q3
A1
M
K3 B3 B2 B1
A2 A3
F3
X6
L1
N SK
1 P
N P1
SK
2
L1
L2
L3
L1L2
L3PE
Q4
F4
L1N
Q4T1
F4
L1N
PE
F2 (1
AF)
F1 (6
.3 AT
)
X1
K1
Q3
F3
X6
L1
N SK
1P
N P1
SK
2
L1
L2
L3
L1L2
L3PE
+–
P / P
I
V+IN
GND
V+
IN G
ND
V+IN
GND
ON-O
FF
140..
.10kΩ
S1
S2
S3
S4
J3
J6
JP2 F5
(2
00 m
AF)
ON 1
2 3
4
Com
-Por
t
200-240V / 50...60Hz
200-
240V
/ 50..
.60Hz
J K1
St
eam
K2
Erro
r K3
Se
rvice
K4
Un
it On
H1
INPU
T 44
0-50
0VΔ
p
max.ϕ
Q3
F3
L1N
PE
Q3
F3
L1N
PE
Unit
BUn
it ASu
pplymo
dule
Supplymo
dule
Contr
ol bo
ard
(Opti
on)
Switches (
K1...K
4) sh
own i
n idle
posit
ion
SetJP2
to
5V
SetJP2
to
24V
(Opti
on)
Unit B
Unit A
LC di
splay
-
36
Legend to wiring diagram
A1 Controller(active)orhumiditysensorA2 Controller(passive),setjumperJP2to5VA3 On/Offcontrol,setjumperJP2to24VB1 VentilationinterlockB2 AirflowmonitorB3 SafetyhumidistatF1 Internalfusesupplymodule(6.3A,slowacting)F2 Internalfusesupplymodule(1A,quickacting)F3 Externalfuseheatingvoltagesupply(seetableinthefollowingchapter)F4 Externalfusecontrolvoltage(max.10A,slowacting)F5 Internalfusecontrolmodule(200mA,quickacting)H1 Remoteoperatingandfaultindication(option“RFS”)J Shortcircuited,ifnoexternalmonitoringdevicesareconnectedJ3 ConnectionterminalforremoteoperatingandfaultindicationJ6 ConnectionterminalforcontrollinetounitB(forunitswith50...80kg/hsteamcapacityonly)J7 ConnectionterminalforcontrollinefromunitAJP2 Jumper(controlsignal)oncontrolboardunitAK1 Mainscontactor(heatingvoltage)unitA/unitBK3 Externalsafetycircuit(safetyhumidistat,airflowmonitor,etc.)M Fanunit(accessory“FAN3S..”)Q3 ExternalmainswitchheatingvoltagesupplyQ4 ExternalmainswitchcontrolvoltagesupplyT1 Auto-transformercontrolvoltagesupply(option“TRAF”)S1 Rotaryswitch"draininterval”S2 Rotaryswitch“maintenanceinterval”S3 Rotaryswitch“controlsignal”S4 DIP-switch“unitsettings”X1 ConnectionterminalforcontrolvoltagetosupplymoduleX6 ConnectionterminalforvoltagesupplyfromunitAtounitB
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37
400 V/3~50…60 Hz
220 V/3~50…60 Hz
415 V/3P~50…60 Hz
240 V/1N~50…60 Hz
230 V/1N~50…60 Hz
200 V/3~50…60 Hz
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
P N m
ax. in
kW
I N ma
x. in
A
A L m
in. in
mm2
F3 in
A, q
uick a
cting
Mk5 Visual 5-..Mk5 Process 5-.. 3,8 5,5 1,5 10 3,4 9,0 2,5 16 4,0 6,0 1,5 10 4,0 17,0 2,5 20 4,0 16,5 4,0 20 3,0 8,2 1,5 10
Mk5 Visual 8-..Mk5 Process 8-.. 6,0 8,7 1,5 10 5,5 14,4 2,5 16 6,5 9,0 1,5 10 6,5 27,2 6,0 32 6,0 26,0 6,0 32 4,5 13,1 1,5 16
Mk5 Visual 10-..Mk5 Process 10-.. 7,5 11,0 1,5 16 6,7 17,7 2,5 20 8,0 11,5 1,5 16 8,0 33,0 10,0 40 7,4 32,0 10,0 40 5,5 16,1 2,5 20
Mk5 Visual 16-..Mk5 Process 16-.. 12,0 17,4 2,5 20 10,9 28,7 6,0 32 13,0 18,1 2,5 20 ––– ––– ––– ––– ––– ––– ––– ––– 9,0 26,1 6,0 32
Mk5 Visual 20-..Mk5 Process 20-.. 14,9 21,5 6,0 25 13,5 35,4 10,0 40 16,0 22,3 4,0 25 ––– ––– ––– ––– ––– ––– ––– ––– 11,1 32,2 10,0 40
Mk5 Visual 24-..Mk5 Process 24-.. 18,1 26,2 6,0 32 16,4 43,1 16,0 63 19,5 27,2 6,0 32 ––– ––– ––– ––– ––– ––– ––– ––– 13,5 39,2 16,0 63
Mk5 Visual 30-..Mk5 Process 30-.. 22,3 32,3 10,0 40 20,2 53,1 16,0 63 24,0 33,5 10,0 40 ––– ––– ––– ––– ––– ––– ––– ––– 16,7 48,3 16,0 63
Mk5 Visual 40-..Mk5 Process 40-.. 30,0 43,3 16,0 63 27,2 71,4 25,0 80 32,3 45,0 16,0 63 ––– ––– ––– ––– ––– ––– ––– ––– 22,4 64,9 25,0 80
Mk5 Visual 50-..Mk5 Process 50-..
A 14,9+
22,3
21,5+
32,3
6,0+
10,0
25,0+
40,0
13,5+
20,2
35,4+
53,1
10,0+
16,0
40+63
16,0+
24,0
22,3+
33,5
4,0+
10,0
25+40
––– ––– ––– ––– ––– ––– ––– –––11,1
+16,7
32,2+
48,3
10,0+
16,0
40+63B
Mk5 Visual 60-..Mk5 Process 60-..
A 22,3+
22,3
32,3+
32,3
10,0+
10,0
40,0+
40,0
20,2+
20,2
53,1+
53,1
16,0+
16,0
63+63
24,0+
24,0
33,5+
33,5
10,0+
10,0
40+40
––– ––– ––– ––– ––– ––– ––– –––16,7
+16,7
48,3+
48,3
16,0+
16,0
63+63B
Mk5 Visual 80-..Mk5 Process 80-..
A 30,0+
30,0
43,3+
43,3
16,0+
16,0
63,0+
63,0
27,2+
27,2
71,4+
71,4
25,0+
25,0
80+80
32,3+
32,3
45,0+
45,0
16,0+
16,0
63+63
––– ––– ––– ––– ––– ––– ––– –––22,4
+22,4
64,9+
64,9
25,0+
25,0
80+80B
5.5.3 Notes on component installation
Important note:
– Allconnectingcablesintheelectricalinstallationaretobefedinviathecableglandsonthebaseoftheunit(theexceptiontothisistheheatingvoltageconnectioncable,forwhichthespecialclampisprovided).
– Thedetailsrelatingtoindividualcomponentsaretobenotedandfollowed.
Heating voltage supply Up
Caution!Beforeconnecting,ensurethatthemainsvoltagecorrespondswiththeheating volt-age for the unit (see mains code on the type label).Note:Onequipmentversionscombiningtwobasicunits,eachunithasatypelabel
Thehumidifier(inthecaseoftwinnedunits,eachseparateunit)istobeconnectedtothemainssupplyinaccordancewiththeconnectionschematic,viaaservice switch “Q3”(anallpoledisconnectingdevicewithaminimumcontactopeningof3mmisanessentialrequirement)andan“F3” fuse group (essentialrequirement:fusesaretobeasdetailedinthefollowingtable).Thesupplywiringistobefedintotheunitviathetension-relievingdevice(cableclamp)andconnectedtotheterminalsofthe“K1” mains contactor.
LC displayAB
Note:Dependingonthesteamcapacitytheloadofthephasesmaybeasymmetric.
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38
Control voltage supply Uc
Caution!Beforeconnecting,makesurethatthemainsvoltagecorrespondswiththecontrol voltage of the unit (200…240 V, 50…60 Hz).
Caution!Thehumidifiermustonlybeconnectedtoamains supply with a protective conductor.
TheconnectiontothecontrolvoltageUcismadeinaccordancewiththeconnectionschematic,totheterminal “X1” on the supply module. The customer is to install a service switch Q4 in the supply line (allpoledisconnectingdevicewithaminimumcontactopeningof3mm)andanF4 fuse (max. 10 A slow acting) (thesearebothessentialrequirements).Note:Onversionsinwhichtwounitsareincorporated,thecontrolvoltageconnectionismadetotheunitfittedwiththedisplayandoperatingfacility(unitA).Theterminal“X1”ofthesecondunit(unitB)remainsunused.TosupplythecontrolvoltagetounitB,theterminals“X6”onthesupplymodulesofboth units must be connected using the supplied cable.
Thecross-sectionofthemainscablemustcomplywiththeapplicablelocalregulations(minimumof1.5 mm2).
External safety circuit
Toensurethesafetyofthehumidifiersystem,itisessentialthataso-calledexternalsafetycircuitbeprovided to monitor the operation.
To this end, the potential-free contacts (max. contact loading 250V/5A) oftheexternalmonitoringdevices(e.g.maximumhumidistat,flowmonitor,ventilationinterlock,etc.)areconnectedin series with the corresponding contacts on the terminal “X1”,inaccordancewiththeconnectionschematic.
Caution, danger of electric shock!Themainsvoltage isconnected to terminal “X1”(up to240V).Thesteamhumidifiermustthereforebeisolatedfromthemainssupply(powerandcontrolcomponents),beforestartingtheconnectionwork.
If,forwhateverreason,noexternalmonitoringdevicesareconnected,aconnectingbridge“J”mustbeinstalledontheappropriatecontactsontheterminalstrip“X1”.
Do not apply any extraneous voltage to the terminals.
Thecross-sectionofthecablemustcomplywiththeapplicablelocalregulations(minimumof1mm2).
Remote operating and fault indication H1 (Option “RFS”)
TheoptionalremoteoperatingandfaultindicationPCBistobeconnectedviatheconnectionsocket“J3”onthecontrolboard.TheremoteoperatingandfaultindicationPCBcontainsthepotential-freerelaycontactsK1…K4fortheconnectionofthefollowingoperatingandfaultindications:
– K1“Steamproduction”: Thisrelayclosesassoonastheunitproducessteam.
– K2“Fault”: Thisrelayisactivatedifthereisafault.
– K3“Maintenance”: Thisrelayisactivatedwhenthesetserviceintervalhasexpired.
– K4“UnitOn”: Thisrelayclosesassoonastheunitisswitchedonviathemainswitch.
The maximum contact loading is 250V/5A.
Appropriatesuppressormodulesaretobeusedfortheswitchingofrelaysandminiaturecontactors.
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39
Control signal / Humidity sensor signal
Theconnectionofanexternalactivecontroller“A1”,apassivecontroller“A2”,anOn/OffHumidistat“A3”orahumiditysensor(forcontrolviatheinternalcontroller),isaccomplishedontheappropriatecontactsontheterminalstripinaccordancewiththeconnectionschematic.Notethefollowingcon-nectioninformation:
External controller
Internal controller
Connection active controller “A1”
passive controller “A2”
On/Off controller “A3”
Humidity sensor
Pos. Jumper JP2
– neutral X X
– 5 V 140Ω...10kΩ
– 24 V X
Rotary switch S3
Pos. Signal0 No signal selected1 On/Off24V X2 0...5 V DC (Potentiometer) X3 0...10 V DC X X4 0...1 V DC X X5 1...5 V DC X X6 2...10 V DC X X7 0...20 V Phase intersect X X8 4...20 mA X X9 0...20 mA X X
Note:Thecontrollerhumiditysensoristobemountedatasuitablepositionintheductafterthesteamdistributionpipe,withaminimumseparationof5timesthehumidificationdistanceBN(butnotclosetotheheatingorcoolingunitsoftheventilationsystem).Please refer to theseparate installation instructions for thecontroller/sensorwhenpositioningandconnecting these components.
Control cable for versions with two units
Thesuppliedcontrolcable(flatribboncable)isconnectedtoterminal“J6”onthecontrolboardofunitAandtoterminal“J7”onthesupplymoduleofunitB.
Connecting the fan unit
Seeseparatedocumentation“Fanunit”.
RS232/RS485 connection
Seeseparatedocumentation“InterfaceRS232/485”
5V24VJP2
5V24VJP2
5V24VJP2
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40
5.5.4 Inspecting the electrical installation
Inspectforcorrectinstallationinaccordancewiththefollowingchecklist:
Dothemainsvoltagesappliedcorrespondtotherespectivedetailsstatedontheratingplate/sforthepowerandcontrolcomponents?
Arethevoltagesupplies(Powerandcontrolcomponents)correctlyfused?
Istheserviceswitch“Q”installedinthesupplycabletothepowerandcontrolcomponents?
Areallcomponentscorrectlyconnectedinaccordancewiththeconnectionschematic?
Areallconnectioncablesfixed?
Aretheconnectingcablesfreeoftension(fittedthroughcableglands/securedwithcableclamps?)
Istherotaryswitch“S3”settocorrespondwiththecontroller(active,passive,On/Off)orhumiditysensor?
Isjumper“JP2”onthecontrolboardcorrectlysetforthecontrollerused?
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41
6 Operation
6.1 Unit configuration
Warning - danger of electric shock! Disconnect the steam humidifier from the mains supply(heatingandcontrolvoltage)beforeopeningtheunit.
Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protection).
All adjusting elements are situated on the control board:– Rotaryswitch“S1”: draininterval– Rotaryswitch“S2”: maintenanceinterval– Rotaryswitch“S3”: controlsignal(seechapter5.5.3)– Rotaryswitch“S4”: unitsettings
Setting the drain interval (“S1”)
Theevaporationprocessincreasestheconcentrationofmineralsaltsinthesteamcylinder.Periodicflushingfollowedbyrefillingoffreshwatercankeeptheconcentrationofmineralsaltsatalowlevel.
Theintervaltimetobeselecteddependsonthequalityofthewaterandthetypeofunit.Itmayhavetobeadaptedtotheactualcircumstancesduringoperation.Thefollowingmaintenanceintervalscanbe selected.
Position “S1” drain interval at 100% steam capacity
Unit type Condair Mk5 Visual/Process
5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 ∞1 720 min.2 360 min. VE VE VE VE VE VE VE VE VE VE VE3 180 min.4 120 min. X5 60 min. X X6 30 min. X7 20 min. X X8 10 min. X X X X X9 5 min.
VE= SettingforfullydemineralizedwaterX= Standardsetting
Notes:
– Thestandardsettings(seeprecedingtable)refertoawaterhardnessof210ppm(12°dHor21°fH,respectively).
– IftheCondairMk5isoperatedwithfullydemineralizedwater,theswitchcanbesetto“2”.
– IftheCondairMk5shallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyoursupplier.
– Ifnohumidificationtakesplaceformorethan4hours,theunitwillproceedtoaflushingcycleandafloattestuponthenexthumidificationrequest.
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42
Setting the maintenance interval (“S2”)
Themaintenanceintervalforthesmallandtheextendedmaintenanceissetwithswitch“S2”.Whenthesettimehasexpired,amaintenancemessageindicatesthattheunitshouldbeserviced.
Theintervalstobeselecteddependonthequalityofthewaterandthetypeofunit.Itmayhavetobeadaptedtotheactualcircumstancesduringoperation.Thefollowingmaintenanceintervalscanbeselected:
Position “S2”
Interval for Unit type Condair Mk5 Visual/Process
small maintenance extend. maintenance 5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 200 h 600 h1 300 h 600 h2 300 h 900 h3 450 h 900 h4 400 h 1200 h X X5 600 h 1200 h X X X X X6 500 h 1500 h X X X7 750 h 1500 h X8 3000 h 3000 h VE VE VE VE VE VE VE VE VE VE VE9 6000 h 6000 h
VE= SettingforfullydemineralizedwaterX= Standardsettingforwaterwithmediumhardness(12°dH,21°fH,210ppm)
Note:Themaintenanceintervaltimesrefertoasteamoutputof100%.Iflessoutputisrequiredinoperation,themaintenanceintervalsarecorrespondinglyincreased.However,werecommendtocarryoutanextendedmaintenanceatleastonceayear.
Setting the control signal (“S3”)
Seeinformationsinchapter5.5.3
Unit settings (“S4”)
VariousunitparameterscanbesetattheDIPswitch“S4”.Theunitparametersarepresetatthefactoryandmustonlybechangedbythecustomerinconsultationwiththesupplier.
Switch Standard setting Description1 OFF Automatic temperature stabilization ON/OFF
When the automatic temperature stabilization is switched on, the water in the steamcylinderismaintainedataspecifictemperaturewhenthereisabreakin steam production, so that steam can be immediately generated again on renewed demand.
2 OFF SwitchpausecontrolON/OFFIn the “OFF” position the switching element’s pause (Triac and Contactors) is controlled normally (maintaining “Flicker”-regulations). In the “ON” position the pauseisreducedtooptimizetheprecisionofcontrol.
3 OFF On/offswitchdelayheatingcontactorON/OFFInthe“OFF”positiontheon/offswitchdelayissetforoptimallifeofthecon-tactors.Inthe“ON”positiontheon/offswitchdelayisreducedtooptimizetheprecisionofcontrol(reducedlifeofheatingcontactors).
4 OFF Spare
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43
6.2 Putting into operation
Thefollowingprocedureiscarriedoutinordertooperatethesteamhumidifier:
• Whenputtingthesteamhumidifierintooperationthefirsttimeorwhenput-tingthesteamhumidifierintooperationafterworkhasbeencarriedoutonthesteamsystem,thecommissioningpersonnelmustmandatorycheckwhetherthesteampipeisopenovertheentirelength.Todothisproceedasfollows:• Removethefrontdoor(s)oftheDefensorMk5.• Undotheupperhoseclampofthesteamhoseintheunitwithascrewdriver
andpullthehosedowntoremoveitfromthesteamconnection.• Startuptheventilationsystemandcheckwhetheracleardraughtthatcor-
respondsapproximatelytothepressureintheventilationsystem(positiveornegativepressure)canbedetectedattheopensteamoutletinsidetheunit.
Caution! A steam pipe that is reduced in cross section or com-pletely closed will cause an excessive increase in pressure in the steam cylinder when the unit is operating and could lead to the risk of scalding accidents. Therefore: Ifnodraughtoronlyaslightonecanbedetectedthesteampipemustbecheckedforblockagesandreductionsincrosssectionbeforecontinuingwithcommissioningandyoumustensurethat the steam pipe is open across the entire length and through the wholecrosssection.
• Examine the steam humidifier and installation for possible damage.Caution! Damaged unitsandunitswithdamagedordefectiveinstalla-tionfeaturesmust not be operated.
• Mountfrontdooroftheunitandlockit.
• Openthefilter valve/shut-off valveinthewaterfeedline.
• Switchontheserviceswitchforthemainssupply(Heatingandcontrolvoltage).
• Switchonthesteamhumidifiermainswitch.
Thesteamhumidifiercarriesoutasystem test. The adjacent display appears andthethreeLEDslightforapprox.3seconds.Ifafaultisdetectedduringthesystemtest,acorrespondingfaultmessageistriggered(seechapter6.7).
If the system test is successful,thesteamcylinderfillsupandafloattestiscarriedout(functioncheckonthelevelunit).Theadjacentdisplayappears.Note:Ifafaultisdetectedduringthefloattest,anappropriatefaultmessageistriggered(seechapter6.7).
Ifthefloattestissuccessful,theCondairMk5willbeinnormal operating mode. The adjacent display appears and the green LED lights.
filling
Mk5 Visual
ready
test
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44
• The following procedure should be carried out only on the first occasion that the unit is operated:
• Carryoutthesoftware-dependentequipmentsettings(Condairservicetechnician).Note:Informationonthesettingsthatcanbemadebythecustomerisprovidedinchapter6.5).
• Checkforcorrectfunctioningofthemonitoringequipment(externalsafetycircuit).
• Checkthefunctionofthesteamhumidifier:Switch on the humidification by raising the set humidity value on the humidity controller/humidistat.Switch off the humidification byloweringthesethumidityvalueonthehumiditycontroller/humidistat.
• Setthedesiredhumidityvalueonthehumiditycontroller/humidistat.
Theheatingcurrentswitchesonassoonasthehumiditycontroller/humidistatdemands humidity. The greenLEDlightsandsteamisproducedafterashortdelay(approx.5minutes).
Operating status display on the unit
TheoperatingstatusisdisplayedintheLEDontheunitasfollows:
– Green LED lit: Unit producing steam
– Yellow LED flashing:Majororminorservicingdue.Therelevantnoticeisshowninthedisplay(seechapter6.6).
– Red LED flashing: There is a problem. The unit is trying to solve the problem. The relevant warn-ing message appearsinthedisplay(seechapter6.7).
– Red LED lit: Insoluble problem. The relevant error message appearsinthedisplay(seechapter6.7).
Remote operating and fault indication
Ifyoursteamhumidifierisequippedwiththeoptionalremoteoperatingandfaultindication(option“RFS”),theoperatingstatuswillbeshownasfollows:
Display on unit Meaning Activated remote display relay
Green LED lit Steamproduction K1 “Steam production”
Red LED lit Insoluble problem K2 “Error”
RedLEDflashing Fault elimination No message
Yellow LED flashing Steamcylinderservicedue K3 “Maintenance”
Unit switched on Unitreadyforoperation K4 “Unit on”
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45
6.3 Taking out of operation
The followingprocedure is followedwhen it is required toshutdown thesteamhumidifier,e.g. formaintenancework:
• Closethefiltervalve/shut-offvalveinthewaterfeedline.
• Brieflydepressthedrainswitchformorethan7seconds.Theheatingvoltageisisolatedandthesteam cylinder empties.
• Waituntilthesteamcylinderisempty(approx.5-10minutes),thenoperatetheoff-switchonthesteamhumidifier.
• Emptythelimecollectortankviathedrainvalve.
Caution: Danger of scalding!Thewaterinthelimecollectortankmaybehot.
• Isolatethesteamhumidifierfromthemainssupply:Switchoffallserviceswitchesinthemainssup-plylines(heatingandcontrolvoltage)andsecurethemintheoffposition.
Caution: Danger of burning! Ifsteamwasproducedjustbeforetheunitistakenoutofoperation,waitbeforeopeningtheunitandletthesteamcylindercooldowntopreventdangerofburning.
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46
6.4 Interrogation of the operating status
TheCondairMk5operatinganddisplayunithasaso-called“displaylevel”fromwhichvariousoperat-ing parameters can be interrogated. Note: It is not possible to change the values on the display level.
Overview of the display level and operation
Operation: Call up the display level with or next operating parameter previous operating parameter Exit the display level with Note: 1)appearsonlyif“controllerfunct”isactive(“on”) 2)appearsonlyif“softstart”isactive(“on”) 3)appearsonlyif“demineral.mode”isactive(“on”) 4) appears only on Mk5 Process units
Menu
Mk5 Visual
ready
steam-prod[kg/h]
ref.=50/act=25
analog input [%]
25
controller funct
on
ref.value rh[%]
45
P-band [%]
30
integr.time[min]
10
elapsed time
623
time to mainten.
600/1200
drain cycle 4: 120
stand-by heating
on
power limit [%]
100
softstart
on
softstart time
30 Min
softst. power
50 %
demineral. mode
on
demineral. delay
3
inlet valve cor.
100
Modbus address 01
analog signal
0 - 5V (poti)
software version
V 01.20
machine type
20kg/400V
1)
2)
4)
2)
1)
1)
3)
Normal service mode
Display levelor
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47
steam-prod[kg/h]
ref.=50/act=25
– Steam production
Currentactualandnominalvalueofsteamproductioninkg/h.– Nominalvalue:max.unitcapacityxinputsignalvalue
Note:ifacapacitylimitationissetthenominalvalueisgiveninbrackets– Actualvalue:max.unitcapacityxinputsignalvaluexcapacitylimitation
Note:iftheinternalcontrollerisactivatedonlytheactualvalueisshown.
Underthefollowingconditionstheactualvaluemaydiffer fromthenominalvalue:uponactivationoftheheatingpower,ifcapacitylimitationisactive,dur-ingthefillingcycleofthesteamcylinder.
– Analog input (humidity demand)
Currentvalueofthesignalappliedtotheanaloginputin%ofitsmax.value.Note:Iftheinternalcontrollerisactivethedisplayedvaluecorrespondstothecurrentairhumidity(%rh).
– Internal controller
Internalcontrolleractivated(“on”)/deactivated(“off”).Note:Theinternalcontrollercanbeactivatedonthesettinglevel(seechapter6.5).
– Nominal value of relative humidity
Selectedvalueofrelativehumidityin%rh.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Proportional range of the internal controller
Selectedproportionalrange(P-Range)oftheinternalcontrollerin%.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Integral time of the internal controller
Selectedintegraltimeoftheinternalcontrollerinminutes.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Working hours
Totalofworkinghourselapsedsinceinitialcommissioningofthesteamhumidifier.
– Time remaining to small/extended maintenance
Thetimeremaining(inhours)beforethenextsmall/extendedmaintenance.Note:Thestatedtimesarebasedon100%steamcapacity.Iftheoperationisatalessercapacity,thetimeshouldbeextendedaccordingly.Themaintenanceintervalsaresetusingtherotaryswitch“S2”onthecontrolboard.Pleasepayattention to the notes in chapter 6.1.
Description of the operating parameters on the display level
Thefollowingdescribestheindividualoperatingparametersthatcanbeselectedusingthekeys and ,afterthedisplaylevelhasbeencalled-up.
analog input [%]
25
controller funct
on
ref.value rh [%]
45
P-band [%]
30
Integr.time[min]
10
elapsed time
623
time to mainten.
600/1200
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48
power limit [%]
100
– Flushing cycle
Thefollowingindicationsareprovidedforthesetflushinginterval:Left: Switchsettingonrotaryswitch“S1”Right: Setflushinginterval
Note:Theflushingintervalissetonswitch“S1”onthecontrolboard.Pleaseobserve the notes in chapter 6.1.
– Stand-by heating
Stand-byheatingactivated(“on”)/deactivated(“off”).Note:Ifstand-byheatingisactivethewatertemperatureinthesteamcylinderisconstantlykeptatapprox.70°C.Stand-byheatingmaybeactivated/deac-tivatedwiththeDIPswitch“S4-1”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.
– Capacity limitation
Thesetcapacitylimitationasapercentageofthemaximumcapacity.
– Soft start
Softstartenabled(“on”)/disabled(“off”).Note:Afterrestartoraftertheunithasbeenidlefor4hours(stand-by)theSoftstartfunctionreducesthehumidificationcapacitytoapresetvalueforaselect-ableperiod(valuesettingsseeparametersbelow).
– Time limit for Soft start
SelectedtimelimitforSoftstartfunctioninminutes.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.
– Capacity limit for Soft start
SelectedcapacitylimitforSoftstartfunctionin%ofmaximumcapacity.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.
– Demineralization mode
Demineralizationmodeenabled(“on”)/disabled(“off”).Note:TheDemineralizationmodeflushesthesteamcylinderwithinanhourafterapresetnumberofscumdetectionshastakenplace(seeDemineraliza-tiondelay).Thispreventstheformationofscum.
– Demineralization delay
Selectedthedelayfordemineralization.Note:ThismenuitemisavailableonlyiftheDemineralizationmodeisenabled.
Note:Thisvaluedeterminesthenumberofscumdetectionsallowed(maxi-mumlevelinsteamcylinderisreached)beforethesteamcylinderisflushedforapresettime.
stand-by heating
on
drain cycle
4: 120
softstart
on
softstart time
30 Min
softst. power
50 %
demineral. mode
on
demineral. delay
3
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49
– Inlet valve correction
Setinletvalvecorrection(cycleratio)in%ofstandardsettingvaluetobalanceoutwaterpressurevariations.Note:ThismenupointisavailableonlywithMk5Processunits.
– Modbus address
Actualmodbusaddressoftheunit.Note:Themodbusaddressisneededonlyforunitswithbuilt-intelemonitoringinterfaceorbuilt-inRS232/RS485serialinterface.Detailedinformationaboutthetelemonitoringinterfaceandtheserialinterfacecanbefoundintheseparatemanualsthataresuppliedwiththeseoptions.
– Analog signal
RangeoftheactiveanalogsignalinVormA,respectively.Note:Therangeoftheanalogsignalmaybeadjustedusingtherotaryswitch“S3”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.
– Software version
Currentsoftwareversionforthesteamhumidifier.
– Unit type
valueleft: Max.steamcapacityinkg/hvalueright: HeatingvoltageinVAC
Modbus address
01
analog signal
0 - 5V (poti)
software version
V 1.00
inlet valve cor.
100
machine type
20kg/400V
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50
6.5 Setting the operating parameters
YoucanadaptvariousCondairMk5steam-airhumidifieroperatingparameterstotheoperatingrequire-mentsonthesettinglevelofthecontrolanddisplayunit.Thesettinglevelisprotectedbyanaccesscodetoguardagainstunauthorizedaccess.
Caution!Thesettingsonthesettinglevelhaveadirectinfluenceontheoperatingbehaviorofthesteam-airhumidifier.Thesettingsmustthereforeonlybemadebypersonnelwhoarefamil-iarwiththetechniquesofhumidificationandclimaticcontrolandwiththeCondairMk5system.
Overview of the setting level and operation
Operation: – Forcall-upofthesettinglevelseethefollowing“Call-upofthesettinglevel” – Next menu item – Previous menu item – For change to set values see the section “Changing the set values” – Exit the setting level with Note: 1) appears only on Mk5 Process units 2) appearsonlyif“controllerfunct”isactivate(“on”) 3) appearsonlyif“softstart”isactivate(“on”) 4) appearsonlyif“demineral.mode”isactivate(“on”)
Menu
Modbus address
(Enter=Entry)
diagnose pgm
(Enter=Entry)
faulthistory
. /. /6.B/6.A
erase history
(Enter=Entry)
integr.time[min]
(Enter=Entry)
softstart
(Enter=Entry)
softstart time
(Enter=Entry)
softst. power
(Enter=Entry)
demineral. mode
(Enter=Entry)
demineral. delay
(Enter=Entry)
language
(Enter=Entry)
power limit [%]
(Enter=Entry)
inlet valve cor.
(Enter=Entry)
controller funct
(Enter=Entry)
ref.value rh[%]
(Enter=Entry)
P-band [%]
(Enter=Entry)
adjust level
entry code
8808
Mk5 Visual
ready
1)
2)
3)
3)
2)
4)
2)
Normal service mode
and
Settinglevel
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51
Mk5 Visual
ready
entry code
9999
entry code
8999
adjust level
language
English
Sprache
Deutsch
new data
entered
unchanged
ref.value rh [%]
045
ref.value rh [%]
045
XXXXXXXX
(Enter=Entry)
new data
not valid
Call-up of the setting level
WiththeCondairMk5innormaloperation:
• Simultaneouslydepressthekeys and .
Youarenowpromptedtoenterthefourdigitaccesscode“8808”. The digit on thefarleftflashes.
• Entertheaccesscode“8808”asfollows:
Changethefirstdigitwiththekeys and .Acceptyourinputwiththekey.Thenextdigitstartstoflash.Repeatthisstepfortheremainingdigits.
Afteracceptanceofthelastdigit,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouareonthesettinglevel.Thefirstmenuitemthenap-pears on the display.Note:Ifyouhaveenteredanincorrectcodethemessage“Incorrect Code”ap-pearsbrieflyonthedisplay.Theunitthenreturnstothenormalservicemode.
To change the set values
The unit is on the setting level.
• Pressthekey,ifyouwishtochangethecurrentsetting.
– Menu items with selected values
• Pressthekey or ,inordertoselectthedesiredsettingfromthelist.
• Acceptyourinputwiththe key.
– Menu item with numerical set value
Thedigitonthefarleftstartstoflash.
• Pressthekey,inordertoreducethevalueoftheselecteddigitorthekey,inordertoincreasethevalueofthedigit.
• Acceptyourentrywiththe key.Note:Ifthevaluetobeenteredisamulti-digitvalue,thenextdigitstartstoflash.Youcanchangethisdigitasdescribedabove.
Afterconfirmingthelastdigit(numericalsetvalue)andtheselectedsetvalue,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouhaveenteredanewvalue.Thentheselectedmenuitemappearsagain.Note:Ifaninvalidvaluehasbeenenteredinanumericalinput,theadjacentmessage appears.
Ifyouhaveexitedtheinputfieldwiththekey,withouthavingchangedthesetvalue,theadjacentmessageappearsbrieflyonthedisplay.Thenthedis-playforalteringthesetvalueappearsagain.
Theprocessofchangingthevaluecanbeinterruptedatanypointbypressingthe key.Thelaststoredsetvaluethenremainsunchanged.
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Description of the menu items on the setting level
Thefollowinglistsallthemenuitemsthatcanbeselectedandchangedafteractivationofthesettinglevel.
– Language
Dialoguelanguageofthedisplayunit.Factory setting: depends on the countryOptions: german, english, french
Note:Thedisplayunitswitchestotheselectedlanguageimmediatelyafterthesuitablelanguageoptionhasbeenconfirmed.
– Capacity limitation
Limitationof thesteamcapacity(in%) inreferenceto themaximumsteamcapacity.Factory setting: 100 %Setting range: 10…100 %
Note:Thisparameterisusedtolimitthemaximumperformanceincasethesteamcapacityexceedsthehumidificationrequiredbyyourinstallation.
– Inlet valve correction
Settingthecyclefrequencyoftheinletvalvein%ofthestandardsetting.Note:ThismenupointisonlygiveninMk5Processunit.Factory setting: 100 %Setting range: 70-130 %
Comment:Thewaterfeedquantitycanbereduced(value100)withthisparameter inorder tobalanceoutvariations inwaterpressure.
– Controller setup
Activation(“on”)/Deactivation(“off”)oftheinternalPIcontroller.Factory setting: offOptions: on(PIcontrolleractivated),off(PIcontrollerdeactivated)
Note:Theinternalcontrollermustnotbeactivatedifanexternalcontrollerisconnectedtothehumidifierbecausetheinternalcontrollerwouldinterprettheanalogsignaloftheexternalcontrollerastheactualhumidityvaluedetectedbyahumiditysensor.Thiswouldcausethe internalcontroller toswitchthehumidifier to100%steamcapacity if the inputsignaldropsto0%which, inturn,wouldleadtoover-humidification.
– Nominal humidity value
Nominalhumidityvaluein%rh.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.Factory setting: 45 %rhSetting range: 10…100 %rh
language
English
power limit [%]
100
controller funct
off
ref.value rh [%]
045
inlet valve cor.
100
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53
– Proportional range(P-band)oftheinternalPIcontroller
ProportionalrangeoftheinternalPIcontrollerin%.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.
Factory setting: 30 %Setting range: 4…100 %
Note: The P-Range is