InstallatIon, commIssIonIng and servIce InstructIons

gasfired steam humidifier

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123

en

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condair gs... c series

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Contents

1 Introduction 41.1 At the very beginning 41.2 Notes on the installation, commissioning and service instructions 4

2 For your safety 6

3 Product Overview 83.1 Product versions/Model designations 83.2 Delivery 83.3 Humidificationsystemoverview 93.4 Constructionofthegasfiredsteamhumidifier 103.5 Principle of operation 11

4 Basic planning 134.1 Selecting the unit 134.2 Selecting the control system 154.3 Options 174.4 Accessories 17

5 Mounting and installation works 195.1 Importantnotesonmountingandinstallationworks 195.2 Unitfitting 205.3 Steam installation 245.4 Water installation 315.5 Gas installation 345.6 Flue gas installation 375.7 Installation of the air inlet line for room air-independent units (RS units) 425.8 Installation of control and monitoring devices 445.9 ElectricalInstallation 45

6 Inspecting the installations (Check list) 47

7 Operation 497.1 Importantnotesonoperation 497.2 Functionofthedisplayandoperatingelements 507.3 Commissioning 517.4 Notes on operation 537.5 Takingtheunitoutofoperation 54

8 Maintenance 558.1 Important notes on maintenance 558.2 Maintenance instructions 558.3 Dismantlingworkformaintenanceandthereplacementofcomponents 578.4 Notes on cleaning agents 678.5 Resetting the maintenance reminder 67

9 Troubleshooting 689.1 Importantnotesontroubleshooting 689.2 Errorindication 689.3 Resettingtheerrorindication 689.4 ReplacingthebackupbatteryonthecontrolboardoftheCondairGS 69

10 Taking out of service/Disposal 7010.1 Takingoutofservice 7010.2 Disposal/Recycling 70

11 Specifications 7111.1 Technical Data 7111.2 Fluegasspecifications 72

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1.1 At the very beginning

ThankyoufordecidingontheCondairGSCseriesGasfiredSteamHumidifier (abbreviated as “Condair GS”).

The Condair GS incorporates the latest technical ad van ces and satisfiestherequirementsoftheEuropeanGasEquipmentDirective(90/396/EEC)andallknownsafetystandards.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, please observe and comply withallinformationandsafetyinstructionscontainedinthepresentinstallation,commissioningandserviceinstructionsaswellastheinstructionsgiveninthemanualsforthecomponentsusedinthehumidificationsystem.

Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyourCondairsupplier.Theywillbegladtoassistyou.

1.2 Notesontheinstallation,commissioningandserviceinstructions

LimitationThe subject of these installation, commissioning and service instructions is the Condair GS C series GasfiredSteamHumidifier in its different versions. The various accessories are only described in-sofar as this is necessary for proper operation of the equipment. Further information on accessories can be obtained in the respective instructions.

These installation, commissioning and service instructions is restricted to the planning, installation, commissioning,operation, servicing and trouble shootingofthegasfiredsteamhumidifierCondairGS and is meant for welltrainedpersonnelbeingsufficientlyqualifiedfortheirrespectivework.

These installation, commissioning and service instructions are supplemented by various separate items of documentation (operating instructions for Condair GS/GS...OC - C series control, spare parts list, etc.). Where necessary, appropriate cross-references are made to these publications in the installation, commissioning and service instructions.

1 Introduction

5

Symbolsusedinthisdocumentation

CAUTION!Thecatchword“CAUTION”designatesnotesinthisdocumentationthat,ifneglected,maycausedamageand/ormalfunctionoftheunitorothermaterialassets.

WARNING!Thecatchword“WARNING”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyand danger notes in this this documentation that, if neglected, may cause to injury to persons.

DANGER!Thecatchword“DANGER”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyand danger notes in this this documentation that, if neglected, may lead to severe injury or even death of persons.

SafekeepingPleasesafeguardtheseinstallation,commissioningandserviceinstructionsinasafeplace,wherethey can be immediately accessed. If the equipment changes hands, the installation, commissioning andserviceinstructionsshouldbepassedontothenewoperator.

If the installation, commissioning and service instructions get mislaid, please contact your Condair supplier.

Language versionsThese installation, commissioning and service instructions are available in various languages. Please contact your Condair supplier for information.

Copyright protectionThe present installation, commissioning and service instructions are protected under the Copyright Act. Passing-on and reproduction of the installation, commissioning and service instructions (or part thereof)aswellasexploitationandcommunicationof thecontentsareprohibitedwithoutwrittenpermission by the manufacturer. Violation of copyright terms is subject to legal prosecution and arisesliabilityforindemnification.

Themanufacturerreservestherighttofullyexploitcommercialpatentrights.

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GeneralEverypersonworkingwiththeCondairGSmusthavereadandunderstoodtheinstallation,commis-sioningandserviceinstructionsbeforecarryingoutanywork.Knowingandunderstandingthecontentsoftheinstallation,commissioningandserviceinstructionsisabasic requirement forprotecting thepersonnelagainstanykindofdanger, toprevent faultyoperation, and to operate the unit safely and correctly.Iftheinformationintheseinstallation,commissioningandserviceinstructionsisnotfollowedexactly,afireorexplosionmayresultcausingpropertydamage,personalinjuryorlossoflife.

Allideograms,signsandmarkingsappliedtotheunitmustbeobservedandkeptinreadablestate.

QualificationofpersonnelAll actions described in the present Installation, commissioning and service instructions (commis-sioning, operation, maintenance, etc.) must be carried out only by welltrainedandsufficientlyqualifiedpersonnelauthorisedbytheowner.ForsafetyandwarrantyreasonsanyactionbeyondthescopeofthismanualsmustbecarriedoutonlybyqualifiedpersonnelauthorisedbytheConairrepresentative.

ItisassumedthatallpersonsworkingwiththeCondairGSarefamiliarandcomplywiththeappro-priateregulationsonworksafetyandthepreventionofaccidents.

Intended useThegasfiredsteamhumidifierCondairGSisintendedexclusivelyforhumidificationinventila-tionsystemswithinthespecifiedoperatingconditions.Anyothertypeofapplicationwithouttheexpresswrittenconsentofthemanufacturerisconsideredasnotconformingwiththeintendedpurpose and may lead to the Condair GS becoming dangerous.Operation of the equipment in the intended manner requires thatall the information in theseinstallation, commissioningandservice instructions isobserved (inparticular the safetyinstructions).

Dangerthatmayarisefromtheunit

DANGER! Danger of electric shockTheCondairGSismainspowered.Onemaygetintouchwithlivepartswhentheunitisopen.Touchinglivepartsmaycausesevereinjuryordangertolife.

Prevention:beforecarryingoutanyworksettheCondairGSoutofoperationasdescribedinchapter6.3(switchofftheunit,disconnectitfromthemainsandstopthewaterandgassupply)andsecuretheunitagainstinadvertentpower-up.

2 For your safety

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DANGER! Danger of explosionTheCondairGSisworkingwithgas.Improperinstallation,adjustment,alteration,service,maintenance,orusecancausecarbonmonoxidepoisoning,anexplosion,fire,orotherconditionswhichmaycausepersonalinjuryorpropertydamage. Prevention:anyworkonthegassystemmustbecarriedoutonlybywelltrainedandsufficientlyqualifiedpersonnelauthorisedbytheowner.BeforecarryingoutanyworkonthegassystemsettheCondairGSoutofoperationasdescribedinchapter6.3.(switchofftheunit,disconnectitfromthemainsandstopthewaterandgassupply)andsecuretheunitagainstinadvertentpower-up.

Donotstoreorusegasolineorotherflammablevaporsandliquidsinthevicinityofthisoranyother appliance

Whattodoifyousmellgas: do not try to light any appliance. Do nottouchanyelectricalswitch;do not use any telephone in your building. Immediately call your gas supplier from a neighbor’s telephone.Followthegassupplier’sinstructions.Ifyoucannotreachyourgassupplier,callthefiredepartment.

DANGER! Danger of burningThewatertank,thesteamlineandtheexhaustsystemgetveryhotduringoperation.Thereisdangerofburningwhentouchingthesecomponentsduringorshortlyafteropera-tion. Prevention:Donottouchthewatertank,thesteamlineandtheexhaustsystemduringoperation.BeforecarryingoutanyworksettheCondairGSoutofoperationasdescribedinchapter6.3,thenwaituntilthecomponentshascooleddownsufficientlythuspreventingdangerofburnin.

Behaviour in case of dangerIf it is suspected that safe operation is no longer possible, then the Condair GS should immediately be shut down and secured against accidental power-up according to chapter 6.3. This can be thecaseunderthefollowingcircumstances:– if you smell gas– if the Condair GS or its mains cable is damaged– if the Condair GS is no longer operating correctly– if connections and/or piping are not sealed– ifcomponentsoftheCondairGShumidifierarewornorbadlysoiled.– iftheCondairGSoranycomponentshasbeenexposedtoexcesshumidity.– after longtime storage under unfavorable conditions.– after transportation under unfavorable conditions.

AllpersonsworkingwiththeCondairGSmustreportanyalterationstotheunitthatmayaffectsafetytotheownerwithoutdelay.

ProhibitedmodificationstotheunitNomodificationsmustbeundertakenontheCondairGSwithouttheexpresswrittenconsentofthe manufacturer.

Forthereplacementofdefectivecomponentsuseexclusivelyoriginal accessories and spare parts available from your Condair supplier.

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3 Product Overview

TheCondairGSgasfiredsteamhumidifierisavailablein6differentmodelswithdifferentmaxi-mumsteamoutputperformance(40,80,120,160,200and240kg/h). All models can be supplied in a version suitable for operation independent of the room air conditions (Withaseparateairinlet)andcanbeoperatedwithnaturalgasorpropane(theunitissuppliedEx--worksforaspecifictypeofgasoperation).

Model designation

GS 40 C G20 RS

Product line (gasfired steam humidifier with operation and display unit)

Steam output (kg/h)4080120160200240

Equipment series

FuelNatural gas H, E, E(S): G20Natural gas L, ELL: G25Natural gas HS: G25.1Natural gas Lw: G27Natural gas Ls: GZ350Propane gas P: G31

Room air-independent unit (with separate air intake)

Thehumidifiersareequippedwithanoperating and display unit,asstandard,bymeansofwhichthecurrentoperatingparameterscanbeinterrogatedandtheequipmentcanbeconfiguredforoperation.Thehumidifiersarecontrolledviatheinternal PID controlleroranexternalcontinuous controller.

3.2 Delivery

The standard delivery includes:

– GasfiredsteamhumidifierCondairGScompl.withunitstand(accordingtothemodeldesignation)– Installation, commissioning and service instructions Condair GS C series– Operating instructions Condair GS control– Spare parts list– Accessories ordered according to chapter 4.4 (steam distribution pipes, steam hoses, etc.).

3.1 Product versions/Model designations

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3.3 Humidificationsystemoverview

1 Gasfiredsteamhumidifier 2 Electricalconnections 3 Gas supply connection 4 Shut-off valve gas supply line (building side) 5 Gas supply line (building side) 6 Sediment trap (building side) 7 Fillwaterconnection 8 Filter valve (accessory “Z261”) 9 Watersupplyline(buildingside)10 Drainwaterconnection11 Drainwaterline12 Funnelwithtrap

13 Auxiliarydrainconnection14 Shut-offvalveauxiliarydrain(buildingside) 15 Flue gas pipe16 Fluegasadapterwithcondensatedrain

(accessory “FA...”)17 Airintakepipe(RS-unitsonly) 18 Main steam pipe (building side)19 Steamhoseadapter(accessory“SA...”)20 Steamhose(accessory“DS80”) 21 Steam distribution pipe (accessory “81–...”)22 Condensatehose(accessory“KS10”)

1

10

5

89

15

16

12

14

13

17

2

43

76

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12

21

19

18

2220

22

10

3

4

2

1

16

23

20

21

24

25

26

27

28

22

2930

15 18

19

17

5 6

11

7 108

913

1412

1 Watertank 2 Steam outlet(s) (1 to 6) 3 Heatexchanger(1to3) 4 Burner(1to6) 5 Level unit 6 Key pad and display unit 7 IndicationLED’s green: “Steam production” yellow:“Maintenance” red:“Error” 8 Drainkey(manualdraining) 9 Drainoverrideswitch(manualdraining)10 Unitswitch 11 Tansformer 12 Control board 13 Driver board 14 Remote operating and fault indication board

3.4 Constructionofthegasfiredsteamhumidifier

15 Ignition modules16 Burnerelectronic17 Combustionairblower(1to6) 18 Flame sensor19 Igniter20 Drainpump21 Airpressureswitch 22 Gas pressure control valve (1 to 6)23 Auxiliarydrainline 24 Drain connection25 Doubleinletvalvefillingwater26 Connectionfillingwater 27 Connection gas supply line28 Vacuumbreak29 Fillingchamber30 Pressureequalizerline(levelunit)

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CBA

3.5 Principle of operation

CombustionSystemThecombustionsystemisbasedonafullymodulatingforceddraftcombustionairblower,anegativepressureregulatorgasvalveanda100%premixburner.Onacallforhumidity,thecombustionairblowerstartsandcreatesanegativepressureacrossanorificelocatedattheairinlet.Theblowerstarts for a moment to purge the system, then the hot surface ignitor is activated. During this time theelectronicignitionmoduledoesadiagnosticcheckofsafetysystemsincludingtheairprovingswitchwhichsensesthenegativepressureattheairinlet.Afterthefunctionofthesafetysystemshasbeenverified,thegasvalvewillopenandthegas/airmixtureisignitedbythehotsurfaceignitor.Ifflameissensedbytheflamesensorwithin7 seconds thegasvalveremainsopenandcombustioncontinues.Ifflameisnotsensed,theabovesequenceisrepeatedamaximumofthreetimesafterwhichtheignitionmodulewilllockoutandarespectiveerrormessagewillappearinthedisplay.ThegasvalvemaintainsaconstantratioofairtoNaturalGasorPropaneindependentofblowerspeedorexternalconditions.Thisairandfuelisthoroughlymixedintheblowerandthenforcedthroughtheburnerportswhereignitionoccurs.

Hotproductsofcombustionareforcedthroughabaffleinsidetheheatexchangerandthenventedoutside.Theheatexchangerhaslargeverticalsurfacestominimizescalebuild-upandpromotescalesheddingtothebottomofthetank.Thisself-cleaningactionhelpstomaintaintheefficiencyoftheheatexchangerwhilethesmoothsurfacesallowforeasycleaningwhennecessary.

TheGS40hasasinglecombustionchamber/heatexchanger.Thecombustionsystemisduplicatedonlargerunitswithmultiplechambersinsideacommontank.

Regulation of the water level in the tank

Thelevelinthewatertankiscontinuouslymonitoredbythelevelunit.Oninitialstart-up,thecontrolunitchecksthefunctionofthelevelunit.Duringthistestthetankisfilledupfirsttolevel“A”,thendrainedtolevel“C”andfilledupagaintolevel“A”.Assoonaslevel“B”isreachedandthetestofthelevelunitwassuccessfulthehumidifierisreadyforoperation,ifahumidificationdemandispresentthe combustion process starts.

Level unit

Pressureequalizer

Filling chamber

Vacuumbreak

MainfilllineDoublefillvalve

Drain outlet

Drain pumpAuxiliarydrain

Mixingpipe

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Whenthewaterlevelduetotheevaporationprocessreacheslevel“B”,thelevelunitsendsasignaltothecontrolsystem,whichopensthedoubleinletvalveandthewatertankisfilledup.Onreachinglevel “A”, the level unit again sends a signal to the control system and the double inlet valve is closed.Ifthewaterlevelgoesbelowlevel“C”,thecombustionwillbeinterrupteduntilthewaterlevelreaches“C” again.To ensure safe operation, the control system constantly monitors the proper function of the level unit in regular intervals.

Steamgeneration/controlThesteamisgeneratedinthewatertankviatheheatexchanger/s.ThesteamproductionisregulatedcontinuouslybytheinternalPIDcontrolleroranexternalcontinuouscontroller.

FlushingTheconcentrationofmineralsinthewaterinthetankincreasesduetotheevaporationprocess.Inorderthatthisconcentrationdoesnotexceedaspecifiedvalue,anappropriatequantityofwaterispumpedofffromthetankatafixedtimeintervalandreplacedbyfreshwater.Theseflushingcyclesarebasedonsteamproductiontoincreasetheefficiencyofthehumidifier.

Whenaflushingcycleisinitiatedthedrainpumpisactivatedandtheinletvalveopens.Inthemixingpipebelowthefillingchamberthehotdrainwaterismixedwiththecoldcoolingwaterandleavestheunitwithatemperatureapprox.around60-70°C.

Ifthelowestoperatinglevelisreachedinthetankduringtheflushingprocess,theinletvalveremainsopenuntilthewaterlevelinthetankhasagainreachedthenormaloperatinglevel.

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4 Basic planning

Condair GS 80 C G20 RS 1. Requiredmaximumsteamcapacity

2. Required combustion gas

3. Combustion air supply

4.1 Selecting the unit

Theselectionoftheunitisreflectedinthetypedescription:

4.1.1 Calculatingthemaximumrequiredsteamcapacity

Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:

V•ρ mD= •(x2-x1) 1000

or V mD= •(x2-x1) 1000•ε

mD: maximumsteamdemandinkg/hV: volume of supply air portion per hour in m3/h(forindirectroomhumidification)orroomvolume

tobehumidifiedperhourinm3/h(fordirectroomhumidification)ρ: specificgravityofairinkg/m3

ε: specificvolumeofairinm3/kgx2: desired absolute room air humidity in g/kgx1: minimum absolute supply air humidity in g/kgThevaluesforρ,ε,x2andx1canbegatheredfromtheh,x-diagramortheCarrier-Diagramformoistair respectively.

Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalueslistedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroomairhumidityof45%rh.Note:Toroughlyestimatethecalculatedmaximumsteamcapacityforlargersupplyairportionsorroom volumes, the values listed in the table can be projected accordingly.

Max.portionofsupplyairinm3/hrorroomvol-umetobehumidifiedperhourinm3/hr

max.steam capacity in kg/hTemperature / rel. humidity of supply air

-15°C/90%rh -5°C/80%rh 5°C/60%rh

5000 6600 8000 4010000 13200 16000 8015000 19800 24000 12020000 26400 32000 16025000 33000 40000 20030000 39600 48000 240

Example:Max.portionofsupplyair10000m3/h, temperature/rel. humidity of supply air -15°C/90%rh

Condair GS 80 C G20 RS

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Importantnotes:– Therequiredmaximumsteamcapacitydependsonthespecificapplicationandtheinstallation.

Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionoftheairtobehumidifieddoesnotconsideranysteamloss(e.g.duetocondensationinthesteamhosesandthesteamdistributors),anyheatlossoftheunitaswellasanyabsorptionorreleaseofhumidityofmaterialslocatedintheroombeinghumidified.In addition, the calculated steam capacity does not consider any losses caused by the draining ratedependingonthewaterquality.

Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsiderationwhencalculatingtherequiredsteamcapacity.Ifyouhaveanyquestionsregardingthecalculationof the steam capacity please contact your Condair supplier.

– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesorforsystemswithvariableairvolumeflow,etc.),pleasecontactyourCondairsupplier.

4.1.2 Combustiongas

TheCondairGScanbeoperatedwithnatural gas or propane.Theequipmentisconfiguredex--worksfortherespectivecombustiongasthatistobeemployed.Ifrequired,theequipmentcanbeconvertedatalaterdatetoworkwithoneoftheothercombustiongas.

Combustion gas Designation

NaturalgasH,E,E(S) G20

NaturalgasL,ELL G25

Natural gas HS G25.1

NaturalgasLw G27

Natural gas Ls GZ350

Propane gas P (Liquid gas) G31

Condair GS 80 C G20 RS

4.1.3 Combustionairsupply

Toensurecorrectcombustion,caremustbetakentoprovideeitheraventilation opening in the roomwheretheequipment is installed(roomair-dependentdevice) or a separate air inlet pipe(roomair-independentdevice) so that an adequate supply of clean, fresh air, is available.

Equipmentversion Designation

Roomair-dependentdeviceFor roomswithasufficiently largeventilationopeningandasourceofcleanintakeair.Caution! Local building regulations must be observed.

___

Roomair-independentdevice(RSequipment)Air supply through a separate pipe from outside the building.Forclosedrooms,roomswithlowairpressureandroomswithdirtyintakeair.

RS

Condair GS 80 C G20 RS

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4.2 Selectingthecontrolsystem

Thevariouscontrolsystems– System1:Roomhumiditycontrol

System1issuitedforairconditioningsystemswithmainlyrecirculatedair.Thehumiditysensorispreferablylocatedintheroomitselforintheexhaustairduct.

A1/2 humidity sensorB1 ventilationinterlockB2 airflowmonitorB3 safetyhumidistatPIE externalcontinuouscontroller(e.g.PIcontroller)PIDI internal continuous controller (PID controller)Y input signal from A1Z input signal from A2

A1 humidity sensorB1 ventilationinterlockB2 airflowmonitorB3 safetyhumidistatPIE externalcontinuouscontroller(e.g.PIcontroller)PIDI internal continuous controller (PID controller)Y input signal from A1

– System2:RoomhumiditycontrolwithcontinuouslimitationofthesupplyairhumiditySystem2issuitedforairconditioningsystemswithalargeportionofsupplyair,lowsupplyairtemperature,post-humidification,orvariableairflowvolume.Ifthesupplyairhumidityexceedsthe preset value, the continuous limitation is effected prior to the room hum idity control.Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.Thehumidity 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 externalcontinuouscontrollerwiththeoptiontoconnectasecondhumiditysensor.Attention! The continuous limitation of the supply air humidity is no substitute for the safe-ty humidistat.

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– System3:SupplyairhumiditycontrolwithcontinuousoutputlimitationSupply air humidity control (humidity sensor installed in supply air duct) should be used only whereroomhumiditycontrolisimpracticablefortechnicalreasons.Suchsystemsalwaysrequirea PI-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 thesteamdistributionpipe.SuchasystemrequirestheinternalPIDcontrolleroranexternalPI--controllerwiththeoptiontoconnectasecondhumiditysensor.

A1/2 humidity sensorB1 ventilationinterlockB2 airflowmonitorB3 safetyhumidistatPIE externalPI-controllerPIDI internal continuous controller (PID controller)Y input signal from A1Z input signal from A2

Whichhumiditycontrolsystemforwhichapplication?

Application Locationofthehumiditysensor

Roomorexhaustairduct supply air duct

Airconditioningsystemswith:

Supplyairportionupto33% System 1 System 1

Supplyairportionupto66% System 1 or 2 System 2 or 3

Supplyairportionupto100% System 2 System 3

Supply air humidity control ––– System 3

PleasecontactyourCondairsupplier,ifyourapplicationmeetsthefollowingconditions:

– Humidificationofsmallroomsupto200m3

– Airconditioningsystemswithahighnumberofairexchanges

– Systemswithvariableairvolumeflow

– Testfacilitieswithextremecontrolaccuracyrequirements

– Roomswithahighvariationinmax.steamcapacity

– Systemswithtemperaturefluctuations

– Coldroomsandsystemswithdehumidification

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4.3 Options

At the moment no options are needed for the Condair GS.

4.4 Accessories

4.4.1 Accessories overview

Model Condair GS 40 ... 80 ... 120 ... 160 ... 200 ... 240 ...

Steamdistributionpipe(see accessory details in chapter 4.4.2)

81-...

number 1 2 3 4 5 6

OptiSorpsteamdistributionsystem(see accessory details in chapter 4.4.2)

System1 System2 System3 System4 System2System3

System3

number 1 1 1 1 1 of each 2

Steamhoseadapter ––– SA80(3"/2x13/4")

SA120(3"/3x13/4")

SA160(4"/4x13/4")

SA200(4"/6x13/4")

SA240(4"/6x13/4")

number ––– 1 1 1 1 1

Steamhose/meter DS80

number 1 2 3 4 5 6

Condensatehose/meter KS10

number 1 2 3 4 5 6

Filter valve Z261 (1 pc. per system)

Flue gas adapter with condensate drain

FA40 FA80 FA120/160 FA200/240

number 1 1 1 1

Control/input signalsTheCondairGSisregulatedviatheinternalPIDcontrolleroranexternalcontinuouscontroller(e.g.PI controller). Important!Forthecontrolsystems2and3theexternalcontrollermustbeequippedwithtwocontrolsignal inputs.

TheCondairGSprocessesthefollowingcontrolsignals:

– 0...10VDC– 2...10VDC– 0...10mADC– 2...10mADC– 0...20mADC– 4...20mADC– 0...5VDC– 1 ... 5 VDC

FurtherinformationisprovidedinChapter5.9.

Output signalsTheCondairGSprovidesthefollowingoutputsignals:

– 10VDC(max.20mA)– Remote operating and fault signals (4 potential-free contacts)

FurtherinformationisprovidedinChapter5.9.

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OptiSorp Numberofsteam connections

Max.steamcapacity in kg/h 1)

DuctdimensionsWidthinmm Heightinmm

System1 1 45(30) 450...4000 450...1650

System2 2 90(60) 450...4000 450...2200

System3 3 135(90) 450...4000 800...3200

System4 4 180(120) 450...4000 800...3200

1) Forductwidths<600mmthevaluesinbracketsapply

4.4.2 Accessory details

SteamdistributionpipesThesteamdistributionpipesareselectedonthebasisoftheductwidth(forhorizontalinstallation)ortheductheight(forverticalinstallation)andthecapacityofthesteamhumidifier.Important!Alwaysselectthelongestpossiblesteamdistributionpipe(optimumhumidificationdistance).

Steam distribution pipes 1) for GS40,80,120,160,200and240

Ductwidth(B) Steam capacity

Type Length in mm (L) 2) in mm max.inkg/h 3)

81-350 350 400…600 3081-500 500 600…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) Material: CrNi steel2) Special length on request3) TofullyexploittheoverallcapacityofyourGShumidifier,theoutputofeach

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 intomultiplebranches.Appropriatefittingsareavailableonrequest.

Note:Ifthehumidificationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,thesteamoutputofyourunitmustbedividedbetweentwosteamdistributionpipes or the OptiSorp steamdistributionsystem must be used. If this is the case, contact your Condair supplier.

OptiSorpsteamdistributionsystemTheOptiSorpsteamdistributionsystemisusedinventilationductswithashorthumidificationdistance(forthecalculationofthehumidificationdistancerefertochapter5.3.1).WhenorderinganOptiSorpsystemtheductdimensionmustbespecified.Pleaseconsultthedatainthefollowingtable.

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5 Mounting and installation works

QualificationofpersonnelAllmountingandinstallationworkmustbeperformedonlybyadequatelyqualifiedpersonnelfamiliarwiththeCondairGS.Ascertainingthequalificationsisthecustomer‘sresponsibility.

General notes All the information contained in these installation, commissioning and service instructions relating to equipmentassemblyandtogas,fluegas,water,steamandelectricalinstallationmustbeuncondi-tionallyobservedandcompliedwith.

Thelocaldirectivesandregulationsfortheinstallationofgasfiredequipment(Steamhumidifiers)mustbeunconditionallyobservedandcompliedwith.

Alllocalregulationsrelatingtotheexecutionofgas,fluegas,water,steamandelectricalinstallationsmustbeobservedandcompliedwith.

SafetyThe connection of the Condair GS to the mains electrical supply must not be made until all installation workhasbeencompleted.

Incorrectlyexecutedinstallationscanresultinpersonalinjuryand/ordamagetopropertythroughexplosions,fires,carbonmonoxidepoisoning,electricshock,etc.Ifyourequireassistance,pleasecontactaqualifiedinstaller,yourlocalgassupplieroryourCondairrepresentative.Intheinstallationitself, use only materials available from your Condair representative and accessories approved by him.

5.1 Importantnotesonmountingandinstallationworks

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5.2 Unitfitting

5.2.1 Humidifierlocation

The positioning of the Condair GS is largely dependent on the location of installation of the steam distributionpipe(seeChapter5.3.1)andonthedetailsofthefluegaspipe(seeChapter5.6)andthe air supply line (RS units only, see Chapter 5.7). To ensure proper functioning of the steam humi-difierandtoobtainoptimumefficiency,thefollowingpointsmustbeconsideredandobservedwhenchoosingthelocationforthesteamhumidifier:

– thelocalandnationalregulationsforinstallationofgasfiredequipmentmustbeobservedandfollowed.Themanufactureracceptsnoliabilityfornon-compliancewiththeseregulations.

– Installthesteamhumidifiersothat:

– thelengthofthesteamhoseisasshortaspossible(ideally2m,max.4m),theminimumbendradius(R=300mm)andtheminimumupslope(20%)andtheminimumdownslope(5%)ofthesteamhosecanbemaintained(seeChapter5.3.2).Note:Longsteamlinesreducethemaximumsteamoutputofthehumidifier,duetotheheatloss involved. The static pressure also increases.

– thefluegaspipecanbeinstalledinaccordancewiththeapplicablelocalbuildingandinstal-lation regulations.

– in the case of room air-independent units (RS units) the installation location can be reached withanairsupplylineandgoodaccessibilityisassured.

– Inthecaseofroomair-dependentunitscaremustbetakentoprovideanadequateintakeofair(inaccordancewithlocalbuildingregulations).

ForUKonly:PleaserefertoBS5440:PartIIorBS6644wheninstallingunits.Wedrawyourattention especially to combustion an ventilation air supply requirements for plant rooms. Perma-nentlowandhighlevelopeningscommunicatingdirectlywiththeoutsideairshallbefittedwithgrilleshavingatotalminimumfreeareaasfollows.

Freeareagrillesizes

Lowlevel High level

GS40 14,400mm2 14,400mm2

GS80 55,800mm2 27,900mm2

GS120 70,200mm2 35,100mm2

GS160 84,600mm2 43,300mm2

GS200 89,000mm2 50,500mm2

GS240 113,400mm2 57,700mm2

Theroomair-independenthumidifiers(RSunits)donotrequireaseparateventilationopening,sincethecombustionairrequiredisprovidedbyanairintakepipefromoutsidethebuilding.

CAUTION!Operationofthehumidifierwithuncleanaircanleadtosafetyproblemsandreducetheoutputoftheunit.Impuritiesintheairare,forexample:Halogens,ammonia,chloride,excessivedust,lime and dirt. For questions about air quality, please refer to the technical service department of your Condair distributor

– TheCondairGSgasfiredsteamhumidifiersaredesignedforfloormountingontheunitstand(includedinthedelivery)fixedtothefloor.

– ThesheetcoveringoftheCondairGSheatsupduringoperation(max.surfacetemperatureapprox.60-70°C).Thereforemakesurethatnoheat-sensitivematerialsareplacedintheimmediatevicinityofthehumidifier.

21

min.1000mmmin.1000mm min.1000mm

769mm

769mm

min.1000mm

– NocombustiblematerialsmustbeplacedintheimmediatevicinityoftheCondairGShumidifier(Insulationmaterials,woodenfloorcoverings,etc.).Observelocalregulations!

– Donotmountthehumidifierinalocationthatisendangeredbyheatorfrost!Ifthehumidifiermustbemountedoutside,itmustbehousedinaweatherproofandthermostaticallyventilatedcabinet.If necessary, please contact your Condair representative.

– Donotmountthehumidifieronabasethatissubjecttovibration.Ifnecessary,pleasecontactyour Condair representative.

– TheCondairGSmustbeinstalledonlyinlocationsequippedwithawaterdrainorwithsensorsthatsafelyinterruptwatersupplyincaseofleakage.

– Donotcovertheairopeningsinthetopandbottomcoversofthehumidifierhousingotherwisetheairflowmaybeinsufficient.Furthermore,donotplacetheunitinanarrownicheoraclosedcompartment (observe minimum distances).

– Positionthehumidifiersothattheunitiseasilyaccessibleandthereissufficientspaceformain-tenancework.Theminimumdistancesshowninthefollowingillustrationmustbemaintained.

22

D

27

26

64

465

26

538

48

633

15 1094

12

E F

974780

353

1133

844

727

72

802

769

25 43

A

B

C

4"

353

139 GS 160

353

139 GS 40

1 3/4"

907

3"

353

139 GS 120

3"

353

139 GS 80

4"

353

139 GS 200

4"

250 203

139 GS 240

139

Dimensions (in mm)

Connections and weights

Model Connections Net weight

kg

Operating weight

kgFlue gas SteamNo. x ø

FillingWater

Gas WaterDrain

AuxiliaryWater Drain

GS 40 3" (76 mm) 1 x 1 3/4" (45 mm) BSP 3/4" BSP 1/2" 3/4" (19 mm) NPT 1/2" 140 211GS 80 4" (101 mm) 1 x 3" (76 mm) BSP 3/4" BSP 3/4" 3/4" (19 mm) NPT 1/2" 162 273

GS 120 5" (127 mm) 1 x 3" (76 mm) BSP 3/4" BSP 1" 3/4" (19 mm) NPT 1/2" 238 459GS 160 5" (127 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1" 3/4" (19 mm) NPT 1/2" 261 471GS 200 6" (152 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1 1/4" 3/4" (19 mm) NPT 1/2" 290 610GS 240 6" (152 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1 1/4" 3/4" (19 mm) NPT 1/2" 314 623

Steam outlet

Flue gas outlet

Air intake(RS units only)

Control signal

Gas supply

Water supply

Water drain

Auxiliarywater drain

Power supply

A B C D E FGS 40 528 271 377 421 236 160GS 80 689 431 537 588 372 295GS 120 1086 827 933 984 371 278GS 160 1086 827 933 984 371 278GS 200 1482 1224 1330 1381 366 187GS 240 1482 1224 1330 1381 366 187

23

TheCondairGShumidifiersmustbemountedontheunitstand supplied with the unit. If mounting on the unit stand supplied is not possible in your particular case, select a method of mounting that is of similar stability. In case of doubt, please contact your Condair supplier.

5.2.2 Mountingthehumidifier

Mounting instructions1. Assembletheunitstandasshownintheseparateinstallationinstructions.Handtightenallbolts

only.

2. Liftuphumidifierwithaliftingdeviceapprox.900mmabovethefloor.

3. Positionunitstandbelowthehumidifier.

4. Lowerthehumidifierandalignwiththeholesoftheunitstand.

5. Fastenthehumidifiertotheunitstandusingthebolts,cupwashersandnutsprovided.

6. Tightenallnutandboltpairsto22.6Nm(200lb-in)oruntilsecure.

7. Positiontheentireassemblytothedesiredlocation.Makesurethehumidifierisstable,shimmingofthefloorbelowthesupportlegsoftheunitstandmaybenecessary.

8. Fixtheunitstandtothefloor(mandatory)viathefourholesinthesupportplatesoftheunitstand.

24

5.3 Steaminstallation

5.3.1 Positioningandmountingofthesteamdistributionpipes

The location for the steam distribution pipes should be determined at the time of dimensioning the airconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidificationoftheduct air.

CalculatingthehumidificationdistanceThewatervapor,emittingfromthesteamdistributionpipes,requiresacertaindistancetobeabsorbedbytheambientairsothatitisnolongervisibleassteam.Thisdistanceisreferredtoashumidifica-tiondistance“BN” and serves as a basis for the determination of the minimum distances from the upstream components in the system.

Thecalculationofthehumidificationdistance“BN” is dependent on several factors. For a rough es-timationofthehumidificationdistance“BN”,thefollowingtableisuseful.Recommendedstandard valueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevaluesgiven inboldprintonlyapplytosteamdistributionpipes81-.., the values in brackets apply to theOptiSorpsteamdistributionsystem.

Input humidity φ1in%rh

LengthofhumidificationdistanceBN in mOutputhumidityφ2in%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<600mmthehumidificationdistancefortheOptiSorpsystemincreasesbyapprox.50%

φ1in%rh: Relativesupplyairhumiditypriortohumidificationatthelowestsupplyairtemperatureφ2in%rh: Relativesupplyairhumidityafterthesteamdistributionpipeatmaximumcapacity

Examplegiven:φ1=30%rh,φ2=70%rhhumidificationdistanceBN: 1.4m(0.36mforsteamdistributionsystemOptiSorp)

Note:Ifthehumidificationdistancehastobereducedfortechnicalreasons,theamountofsteampersteamoutletmustbedividedbetweentwosteamdistributionpipesorthesteamdistributionsystemOptiSorp must be used. If this is the case, contact your Condair supplier.

HumidificationdistanceBN Expansion-andmixingzone

φ1:Incomingairhumiditybeforehumidificationφ2:Airhumidityafterhumidification

25

MinimumdistancestobeobservedTopreventthewatervapor,thatisemittingfromthesteamdistributionpipe,fromcondensingondo-wnstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeobserved(dependsonthehumidificationdistance“BN”).

before/after constriction after expansion before bend

beforebranch beforediffuser beforecontrol/temperaturesensor

before/afterfilter/register before/afterfan,zoneexit

* 2,5xBNbeforesubmicronparticlefilter

InstallationnotesanddimensionsThesteamdistributionpipesaredesignedforeitherhorizontalinstallation(ontheductwall)or,withaccessories,forverticalinstallation(intheductfloor).Theoutletorificesshouldalwayspointupwardsandatrightanglestotheairflow.

Ifpossible,thesteamdistributionpipesshouldbeinstalledonthepressuresideoftheduct(max.ductpressure1700Pa).Ifthesteamdistributionpipesareinstalledonthesuctionsideoftheduct,themaximumvacuummustnotexceed800Pa.

Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)andposition the steam distribution pipes in the duct so that a uniform distribution of steam is achieved.

0.5 x BN BN 0.5 x BN

BN BN 5 x BN

BN BN 1.5 x BN * 5 cm

26

Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved:

H

H

gmin

hmin

gmin gmin

gmin

gmin gmin

gmin

gmin gmin

gmingmin

gmin gmin

gmingmin

gmin.= 100mmh min.= 85 mm

Hmin.=250mm H≥400mm Hmin.=200mm

Hmin.=400mm Hmin.=350mm Hmin.=300mm

Hmin.=600mm Hmin.=500mm Hmin.=400mm

Hmin.=720mm Hmin.=600mm Hmin.=500mm

Hmin.=840mm Hmin.=700mm Hmin.=600mm

Hmin.=960mm Hmin.=800mm Hmin.=700mm

27

Drain panto drain

Shallowduct

Drain panCeiling to drain

Branchduct

Note: When locating the OptiSorp steam distribution system please note the instructions in the se-parate documentation for this product.

Guidelinesfordimensioningtheventilationducts– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufficiently

sizedcontrolopeningshouldbeplanned.

– Withintherangeofthehumidificationdistance,theventilationductshouldbewaterproofed.

– Lowtemperatureductsbelow15°C,shallowducts,orbranchductsmightrequiretheuseofafieldsuppliedcondensatedrainpanbelowthesteamdistributor(seefigurebelow).

– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidifiedairfromcon-densingalongtheductwall.

– Poorairflowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canleadtocondensationofthehumidifiedair.

– Steam distribution pipes must not be mounted to round ducts.

– Exerciseextremecautionwheninstallinginfiberglassorinternallylinedducts.Ifnecessary,re-move10-15cmoftheliningwherethesteamisbeingintroduced.

IfyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithCondairsteamhumidifiers,contactyourCondairsupplier.

Installingthesteamdistributionpipes/OptiSorpsteamdistributionsystemDetailed information on the installation of steam distribution pipes and OptiSorp steam distribution system can be found in the separate “Mounting Instructions” for this products.

28

5.3.2 Installing the main steam pipe

The steam pipe between the steam outlet of the unit and the steam hose adapter (main steam pipe) must be made with solid piping.

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 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.

– 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 with siphon (min. hose bend Ø200 mm) must be mounted.

min

. 1 m

steam hose adapter (accessory “SA..”)

steam hoses (max. length 4 m) Main steam pipe

(max. length 6 m)

29

Important!UseoriginalCondairsteamhoseexclusively.Othertypesofsteamhosescancauseundesired operational malfunctions.

Thefollowingnotesmustbeobserved:

– Leadthesteamhosewithanupslope of at least 20%orwithaminimumdownslopeof5% to the steam distribution pipe.

– Thesteamhoseshouldbekeptasshortaspossible(ideally2m,max.4m)whileobservingtheminimumbendradiusof300mm. Important!Allowancemustbemadeforapressure loss of10mmwatercolumn(approx.100Pa) per meter steam hose.

– Reductionsinthecrosssectionsuchaskinksshouldbeavoidedthroughouttheentirelengthofthehose.Theinstallationofastopcockinthesteamhoseisnotpermissible.

– Steamhosesmustbepreventedfromsagging(condensatepockets);ifnecessary,supportwithpipeclamps,railsorwallbrackets.Ifsaggingcannotbeprevented(e.g.whenpassingbyobstac-les)acondensatedrainwithsiphon(min.hosebendØ200mm)mustbemountedatthelowestpointofthesteamhose(seefollowingillustration).

min. 5 % min. 20 %

min. 20 %

max.

4 m Rmin. 300 m

m

5.3.3 Installingthesteamhosesbetweensteamhoseadapter andsteamdistributors

– Important! When deciding on the length and layout of the hose, it should be noted that the steam hosemaybecomesomewhatshorterwithprogressiveageing.

R min. 300 mm

min. 20 %

min. 5 %

max. 4

m

30

min. 20 %

min.

300 m

m

Ø min. 200 mm

Securing the hoseThesteamhosemustbesecuredtothesteamdistributionpipeandhumidifiersteamoutletbymeansof hoseclamps.

SteamlinewithfixedpipingForsteamlineswithfixedpiping,thesameinstructionsapplytothelayingofthepipingasalreadydescribed.Thefollowingadditionalnotesshouldbeobserved:

– The minimuminternaldiameterof45mmshouldbeappliedoverthewholelengthofthepiping.– UseexclusivelyCupipe(foroperationwithuntreateddrinkingwateronly)orstainlesssteel(min.

DIN1.4301).– Tominimizethecondensateformation(=loss),thesteampipesmustbeinsulated.– The minimumbendradius for solid pipes is 4-5xinternaldiameter.

90°bendsshouldbeavoided.Whereverpossible,tubebendswithlargeradiishouldbeused(e.g.producedusingatubebendingmachine,orconstructedfromapairof45°bends).Thisreducesthe performance loss due to the formation of condensate, and in addition, the static pressure in the steam line.

– Important!Allowancemustbemadeforapressurelossof10mmwatercolumn(approx.100 Pa)permeterlengthorper90°bend.

– Connectionofthesteampipestothesteamdistributionpipeandsteamhumidifieriseffectedbymeansofshortlengthsofsteamhosesecuredwithhoseclamps.

5.3.4 Installing the condensate hoses

The individual condensate hoses of the main steam pipe (if present), the steam hose adapter (if present)andthesteamdistributionpipesmustbeleddownwithaminimumdownslopeof20% viaasiphon(min.hosebendø200mm)intoadischargefunnel.

Important!Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.

Important!UseoriginalCondaircondensatehoseexclusively.Othertypesofhosescancauseoper-ational malfunctions.

31

5.4 Water installation

5.4.1 Performingthewaterinstallation

Overview water installation

1 FillingwaterconnectionBSP3/4"(outsidethread) 2 Filter valve (accessory “Z261”) 3 Fillingwatersupplyline(min.innerØ:12mm) 4 Manometer (installation recommended, building side) 5 Pressurereducingvalve(compulsoryforwaterpressures>8bar,buildingside) 6 Waterdrainconnection3/4"(Ø19mm) 7 Drainline,buildingside(min.innerØ:45mm,min.50cmdirectedverticallydownwards) 8 Funnel (building side, min. height 15 cm) 9 Siphon(min.innerØ:>45mm,buildingside)10 AuxiliarywaterdrainconnectionNPT 1/2" (inside thread) 11 Shut-off valve (installation recommended, building side)

9

6

7

8

1011

1

23 4 5

min.50cm

min. 15 cm

32

Water supplyThewatersupplypipeistobeconnectedviathefiltervalve(accessory“Z261”),totheconnectionontheunit(seeforegoingillustration).Thefiltervalveshouldbeinstalledasclosetothehumidifieras possible.Note:Insteadofthefiltervalve,ashut-off valve and a waterfilter5µm ( (both essential) can be used.

Thefollowingspecificationsmustbeobserved:

– Connections on unit: BSP 3/4" (outside thread)

– Min. inner diameter of supply line: 12mm– Admissible mains pressure 3.0 to 8.0 bar (hammer-free system)

Formainspressures>8bar,connectionmustbemadeviapressurereducingvalve(adjustedto3.0bar).Formainspressures<3.0barpleasecontactyourCondairsupplier.

– Supply rate: 10l/min– Admissible supply temperature: 1…30 °C– Notesonwaterquality:

– ForthewatersupplyoftheCondairGS,useexclusivelyuntreated drinking water or fully demineralizedwater.Note:Theuseoffullydemineralizedwaterreducesthemaintenanceandthecleaningofthewatertanktoaminimum.

– The use of additives such as corrosion inhibitors, disinfectants, etc. is not allowed, since these additives may endanger health and affect proper operation.

– IftheCondairGSshallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyourCondair supplier.

– Theconnectionmaterialmustbepressure-proofandcertifiedforuseindrinkingwatersupplysystems.

CAUTION!Fullydemineralizedwaterisaggressive.Whenmakingconnectionstoafullydemineralizedwatersystem,useexclusivelyplasticorstainlesssteelinstallationmaterials(min.DIN1.4301).

– Important!Beforeconnectingthewaterlinetotheunit,thelinemustbeflushedthoroughly.

33

Water drainThe drain line should be connected to the unit drain connection using a hose coupling. The drain lineshoulddropverticallydownforaminimumof50cmandintoanopendrainfunnel(min.height15 cm). The drain line is then connected via a siphon to the building drain line. The minimum internal diameterof45mmmustbemaintainedoverthefulllengthofthebuildingdrainline.Makesurethatthe drain line is correctly attached and easily accessible for the purpose of inspection and cleaning. Thefollowingconnectiondatashouldbeobserved:

– Connection on unit (hose connection): 3/4"(Ø19mm)

CAUTION!Use only temperature-resistantinstallation materials!

Whenusingfullydemineralizedwater,onlystainlesssteel(min.DIN1.4301)orchemically-re-sistant plastic (e.g. Polypropylene) connection components must be used.

– Drainage capacity: approx.20l/min– Min. inner diameter of the building drain line: 45mm– Min.downslopeaftersiphon:10 %

Note:Itisnotpermissibletocurvethedrainpipeupwards,becausethiscanleadtothecollectionofdepositsatthelowestpointinthepipeandtotheblockageofthepipe.

34

5.5 Gas installation

Installation notesThe gas supply pipe must be connected to the connection on the unit via a shut-off valve (essential requirement),whichisinstalledintheimmediatevicinityoftheunit.Whensteelgaspipesareinuse,itisessentialthatasedimentseparatorbefittedbetweentheshut-offvalveandtheunitconnection.Thefollowingconnectiondatamustbeadheredto:

– Permissible gas operating pressure:

Gas Operatingpressure(mbar)Nominal Min Max

NaturalgasH,E,E(S) G20 20 17 25NaturalgasL,ELL G25 25 20 30Natural gas HS G25.1 25 20 30NaturalgasLw G27 20 17.5 23Natural gas Ls GZ350 13 10.5 16Propane gas P G31 37or50 25 57.5

– The connection material used must be pressure tested and approved for gas installations.

– Donotuseteflontapeongaslinepipethreads.AflexiblesealantsuitableforusewithNaturalGas and Propane Gas is recommended.

– Plangassupplypipingsoitwillnotinterferewithremovalofgasvalvesorblowerassembliesandfront or side service doors.

Allinstallationworkmustbecarriedoutinaccordancewiththe applicable local building and in-stallation regulations.

5.5.1 Performingthegasinstallation

Overview Gas installation

1 Gas supply connection

Model Connection GS40 BSP1/2"GS80 BSP3/4"GS120andGS160 BSP1"GS200andGS240 BSP11/4"

2 Gas shut-off valve (building side)

3 Sediment trap (Installation - building side - essential in the case of the use of steel gas pipes)

3

1 2

35

5.5.2 Leak testing

Aftercompletionoftheinstallationwork,thewholegaslinemustbetestedtoamaximumpressureof40mbar(4.0kPa)fornaturalgasor150mbar(15kPa)forpropaneandcheckedforleaksusingacommerciallyavailablesoapsolution.Thebubblesindicateleaks.Allleaksmustbeeliminatedbeforethehumidifierisputintooperation.

DANGER!Neveruseanopenflametocheckforleaks.Thepresenceofanyleakageisasourceofdangertopersonsandtoproperty,duetothepossibilityoffireandexplosion.

Ifthegascircuitmustbetestedtoapressureofover150mbar(15kPa),thegassupplypipemustberemovedfromtheunitconnection.Afterthetest,thegaslinemustbedepressurizedbeforeitisreconnected to the unit.

CAUTION!Non-observance of the above instruction can lead to damage to the gas pressure regulating valve. Gaspressure valvesoverloadeddue to highpressurearenot coveredby themanufacturer‘sguarantee.

5.5.3 Conversioninstructionsforoperatingthehumidifierwithanothertypeofgas

Exworkstheapplianceisequippedtooperateononetypeofgas.Toconvertanapplianceforope-rationonanothertypeofgas,followthedirectionsbelow(seealsoillustrationonthefollowingpage).

Important:Theconversionshallbecarriedoutbyamanufacturer’sauthorizedrepresentativeorpersontrainedandlicencedforsuchactivities,inaccordancewiththerequirementsofthemanufacturerorlocalauthoritieshavingjurisdictionintheareaofinstallation.

1. Disconnectthehumidifierfromtheelectricalpowersupplyandtakeprecautionsagainstinadver-tentswitchingon.

2. Turn off gas supply to appliance and secure it against inadvertent open ing.

3. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

4. Disconnectthehose(s)fromtheinletelbow(notethelayout).Then,loosenthehoseclampandremovetheinletelbow.

5. Undothecouplingofthecorrespondingflexiblegaspipeanddisconnectgaspipefromthegaspressure regulating valve.

6. Disconnectelectricalcablestothegaspressureregulatingvalveandtheairpressureswitch(note assignment before removal).

7. Undothetwoscrewsthatmounttheventurimanifoldtothecombustionairblower,thenliftupthemanifoldtogetherwiththegaspressureregulatingvalve.

8. Undothefourscrewsandremovethegaspipeconnectionofthegaspressureregulatingvalve.

9. Undothethreescrewsoftheairpressureswitchsupportandremovethepressureswitchas-sembly from the gas pressure regulating valve.

10.CheckthecorkgasketandtheO-ringinthegaspipeconnectionfordamageandreplaceifne-cessary.

36

11.Attachthegaspipeconnection(withmountedO-ring)andthepressureswitchassemblytothegaspressureregulatingvalvesupplied(comeswithventurimanifoldattached).Warning!Makesurethegastypeindicatedonthelabeloftheventurimanifoldcorrespondstothe gas you are using. Donotchangethesettingofsealedadjustmentscrew“A”.

12.Fixthenewventurimanifold(don’tforgetthecorkgasket)togetherwiththegaspressureregulat-ingvalvewiththetwoscrewstothecombustionairblower.

13.Reconnecttheflexiblegaspipetothegaspressureregulatingvalveandtightenthecoupling.

14.Fixtheinletelbowwiththehoseclamptotheventurimanifold.

15.Reconnectthehosefromtheairpressureswitchandifpresentfromtheairinletmanifold(onRSunitsonly)totheinletelbow.

16.Reconnecttheelectricalcablestothegaspressureregulatingvalveandtheairpressureswitch.

17. On multiple burner units repeat steps 4 to 16 for each gas valve assembly.

18.Carryoutaleakagetest(Refertoinstructionsin5.5.2).

19.Turnpowertounitbackonandinitiateatestfiresequencetocheckforproperignitioncharac-teristics.

20.Iftestsareacceptable,affixappropriateconversionlabeltodataplate.Replacedoorpanelandfixitwithscrew.Then,returnunittonormaloperation.

21.Conversionisnowcomplete.

Hose to air inlet manifold(RS units only)

Corkgasket

Inletelbow

Hose clamp

Gas pressure regulating valve

Flexiblegaspipe

Combustionairblower

Hose to pressureswitch

Pressureswitch

Venturi manifold

gas pipe connection

O-ring

37

5.6 Flue gas installation

Important:Since the regulations fortheinstallationofflueingsystemsdifferfromcountrytocountry,therelevantlocalregulationsmustbeadheredtowithoutreservation. In any case, please consult your Condair representative. Thisappliesinparticulartotheroomair-independentsteamairhumidifiers(RSunits).Pleasenotethatflueingmustbedesignedforoverpressureorunderpressure,dependingonlocalregulations.

Allworkconcerningthefluepipeinstallationmustbeperformedonlybyadequatelyqualifiedper-sonnel.Ascertainingthequalificationsisthecustomersresponsibility.

5.6.1 Performingfluegasinstallation

Overview

1 Flue gas connection on the unit– GS40: ø76mm(3")– GS80: ø101mm(4")– GS120/GS160: ø127mm(5")– GS200/GS240: ø152mm(6")

2 Fluegasadapterwithcondensatedrain(accessory“FA...”)– GS40: FA40(DA=80mm)– GS80: FA80(DA=100mm)– GS120/GS160: FA120/160(DA=130mm)– GS200/GS240: FA200/240(DA=160mm)

3 Flue gas pipe (building side)

4 Condensate drain (building side)

5 Siphon(min.diameter300mm,buildingside)

DA

3

2

1

5

4max.40mm

ø15 mm

DA

GS40 ø80mmGS80 ø100mmGS120/GS160 ø130mmGS200/GS240 ø160mm

38

Applicablefluesystemsforroomair-dependentunits

Type B23

FluearrangementTherearedifferenttypesofapplicablefluesystemsfortheCondairGSdependingontheunittype(roomair-dependentorroomairindependentunits).Thefollowingfluegasdiagramsareforguidanceonly,andmustbereadinaccordancewiththelocalcountrycodesforfluegassystems.

min. 1.5m

≥ 1m

≥ 1mmin.

1m

≤ 2.5m> 2.5m

Rain cap (by client)

FluelengthfortypeB23fluesystems:min.2.1m,max.30m (see installation notes)

fluegasterminal(according local regulations)

Applicablefluesystemsforroomair-independentunits–RSunits

Type C33

min. 1.5m Rain cap (by client)

min.

1m

FluelengthfortypeC33fluesystems: min.2.1m,max.21m (see installation notes)

correct

not correct

39

air inlet terminal(according local regulations)

Rain cap (by client)

fluegasand air inlet terminals(according local regulations)

Type C53

min. 1.5m

min.

1m

> 2.5 m ≤ 2.5 m

≥ 1m ≥

1m

min. 1.2

m

FluelengthfortypeC53fluesystems:min.2.1m,max.21m (see installation notes)

Note:Wherelocalregulationspermit,theRSunitscanbeinstalledasC63xappliances.AsaC63xappliance,theCondairGScanbeconnectedtoaseparatelyapprovedandmaketedsystemforthesupplyofcombustionairanddischargeoffluegases.Forsuchapplications,refertotheapplicablelocal regulations and the separate Installation Instructions “Installation as a C6 appliance” available from your Condair dealer.

Type C63x

40

General installation notesThefollowinginstructionnotesmustbeobserved:

– Fluegasspecifications:--->seetableinchapter10.2

– The flue gas temperature during normal application andwhen themaintenance schedule isfulfilledisbetween160-180°C.Iftheunitisnotmaintainedproperlythefluegastemperaturecouldincrease.Inthiscasethetemperatureswitchwouldshutdowntheunitifthetemperatureexceeds200°Cforsafetyreasons.

– Useexclusivelycorrosionfreeinstallationandsealingmaterialstestedandapprovedforfluegassystems.

– AllconnectionsofthefluegaspipemustbesealedwithhightemperatureRTVsiliconeratedforatleast250°C.

– Selectasuitablepipingarrangementforthedischargeoffluegasesfromthebuilding.

– Theminimuminternaldiametermustbeobservedovertheentirelengthofthefluegaspipe.– GS40: ø76mm(3")– GS80: ø101mm(4")– GS120/GS160: ø127mm(5")– GS200/GS240: ø152mm(6")

– Horizontalpipesectionsshouldhaveaminimumupwardslopeof21mm/mandshouldbesup-ported every 1.5 m and additionally supported at every pipe bend.

– Foranyfluelengthsover7mlong,useinsulatedpipes.

– WhenthefluepipeisleadthroughnearbyroomsthepipemustbeequippedwithanF90-typeinsulation.

– Provideafire-proofscreenorbarrier(ataminimumdistanceof50mmtofluegaspipe)topreventpersonalinjuryinareaswhereinadvertentpersonnelcontactwithfluepipecanoccurorwhereheat-sensitive products are stored.

– Securethefluepipe(e.g.bymeansofbeadingthepipe,seeoverview)topreventitfromslippingintotheflueconnectoroftheunit.

– AcondensatedischargepointshouldbeinstalledatanappropriatepositionintheGShumidifierfluegassystem(seeoverview).Asiphonwithaminimum300mmheadofwatermustbeinstalledinthecondensatedischargeline,sothatnofluegasescanescapeviathedischargepipe.

Beforeoperatingthehumidifier,makesurethatthesiphoninthecondensatedischargeisfilledwithwaterandthecondensateoutletisinaccordancewiththeapplicablelocalregulationsforsanitary installations.

Flueing with overpressureWhenflueingwithoverpressurethemaximumadmissiblelengthofthefluepipeequals30metersforroom air-dependent units and 21 meters for room air-independent RS unit (assuming same diameter asconnectoronCondairGS)whereeach90°elbowisequalto3mandeach45°elbowisequalto1.5mofstraightpipe.Threeelbowsoutsidethehumidifiercasingisarecommendedmaximumforflueingsystems.

Werecommend30mor21mrespectivelyfluelengthmaximumtoensurethatoutputismaintained.Forlengthsover30mor21mrespectively,pleaseconsultyourCondairsupplier.

41

Flueing with underpressureIflocalregulationsrequireflueingwithunderpressure,theunderpressuremustbewithin-0.2and-0.62mbar.Theapplicablelocalregulationsforthelayoutoffluegaspipesforunderpressuremustbeobservedandcompliedwith.

AdditionalrequirementswhenflueingthroughasidewallAttention!Somecountriesprohibitleadingthefluepipethroughasidewall.Observelocalregulationsandcontactthelocalauthoritiesand/orthechimney-sweep.

Positionthehumidifierasnearaspossibletothewallthroughwhichthefluepipeistobetaken.

Locatetheflueterminalatleast1maboveanyforcedairinletlocatedwithin3m;oratleast1mbelow,1mhorizontallyfrom,or0.5maboveanydoor,window,orgravityairinletintoanybuilding.

Aminimumhorizontalclearanceof1mfromelectricmeters,gasmeters,regulatorandreliefequ-ipment is required.

Locatetheflueterminalatleast2.5mabovegradewhenitisadjacenttopublicwalkways.

Locatethebottomoftheflueterminalatleast45cmabovegradeorground,ornormallyexpectedsnowaccumulationlevel.Thesnowlevelmaybehigheronwallsexposedtoprevailingwinds.

Avoidareaswherelocalexperienceindicatesthatcondensatedrippagemaycauseproblemssuchasaboveplanters,patios,oroverpublicwalkways,oroveranareawherecondensateorvaporcouldcreateanuisanceorhazard,orcouldbedetrimentaltotheoperationofregulators,reliefvalves,orother equipment.

Refertothefluemanufacturer’sinstallationinstructions.

AdditionalrequirementsforfluegassystemsofRSunitsTheRSunitsarecertifiedasC33andC53appliances.Wherelocalregulationspermit,theRSunitscan be installed as C6 appliances. For such applications, refer to the separate Installation Instructions “Installation as a C6 appliance” available from your Condair dealer.

PleaseobservethefollowingadditionalrequirementsforthefluegasinstallationofRSunits:

– Onlyuseinstallationmaterialinaccordancewiththelocalregulations.

– Thefluegaspipeandtheairinletpipemusthavethesamelength(min.2.1m,max.21m).

– Observe the requirements regarding terminal locations in section 5.7.

42

5.7 Installationoftheairinletlineforroomair-independentunits(RSunits)

Important:Since the regulations fortheinstallationofairsupplysystemsforgasfiredappliancesdifferfrom country to country, therelevantlocalregulationsmustbeadheredtowithoutreservation. In any case, please consult your Condair representative.

Installationoftheairsupplylinemustonlybecarriedoutbyadequatelyqualifiedpersonnel.

Overview

5.7.1 Performingairsupplyinstallation

1 Air supply connection on RS units– GS40: ø76mm(3")– GS80: ø101mm(4")– GS120/GS160: ø127mm(5")– GS200/GS240: ø152mm(6")

2 Connection hose (building side)

3 Hose clamps (building side)

4 Air supply line, hose or rigid pipe (building side)

1 2

3

4

43

Airsupplyarrangement

Installation notes– Max.admissiblesupplyairtemperatureis30°C.Makesuretheairsupplylineisnotheatedup

bythefluegasline.

– Themaximumpipelengthfortheairsupplylineisequivalentto21meters.Theminimumdiameter(seeabove)mustbemaintainedovertheentirelengthoftheline.Inthisestimate,each90°bendisequalto3mofstraightpipelengthandeach45°bendisequalto1.5mofstraightpipelength.Not more than 3 pipe bends must be built into the air supply line.Theairsupplylineshouldbeapproximatelyaslongasthefluegaslineandmustbesupportedat least every 1.5 m of its length and additionally supported at every pipe bend.

– Theairsupplylinecanbeprovidedeitherasafixedtubeorasahose.Theminimuminternaldiameter must be observed over the entire length.– GS40: ø76mm(3")– GS80: ø101mm(4")– GS120/GS160: ø127mm(5")– GS200/GS240: ø152mm(6")

– Allconnectionsontheairsupplylinemustbepositivelysealedwithasiliconesealanttoensureproper sealing of the air supply line.

– Theairsupplylinemustbeinstalledwiththesuppliedair intakewall terminal(seeillustrationabove and refer to section “Terminal locations”).

– At lowtemperatures(under18°C),waterofcondensationcan formon theoutsideof theairsupplyline.Topreventthis,werecommendthatairsupplylinesthataresituatedincoldroomsare insulated.

min. 1.2

m

44

5.8 Installationofcontrolandmonitoringdevices

– Install the roomhumiditysensorand the safetyhumidistatat the same height as thermostats andinalocationwherethemeasuredhumiditycorrespondstothatoftheroom.Undernocir-cumstancesshouldthehumiditysensorsbepositionedinthevicinityoftheairflowfromventilatorunitsorair intakegrids.Donotmounthumiditysensorsonanouterwall,wheretemperaturefluctuationscanaffectthecontrolbehavior.

– Installtheducthumiditysensorinapositionwherethemeasuredhumiditycorrespondstothatoftheroomthatisbeinghumidified(usuallyintheductreturncircuit).Donotpositionhumiditysensors in the immediate vicinity of steam distribution pipes, nor in sections of a duct subject to airturbulence,norwithinthepathofthehumidificationprocessitself.

– Installthesafetyhumidistatintheduct,afterthesteamdistributionpipesandfarenoughawayfrom these, that all the steam has been absorbed into the air (minimum distance 3 m). The safety humidistatmustbepositionedsuchthatitonlydetectsthatthehumidityistoohighwhentheroomhumidity is in reality too high or has reached the saturation limit.

– Installtheflowmonitorsuchthatreliablydetectstheexistenceofanairflowandtheabsenceofanairflow.Connectitinsuchaway,thatthecircuitisclosedwhenairflowispresentandopenswhenthereisnoairflow.

– Beforestartingthehumidifier,checkallcontrolandmonitoringdevicesforcorrectfunction.

– Calibrationofthecontrolandmonitoringdevices(On/Offandcontinuous)followingtheinstallationisrecommended.Theaccuracyofthehumiditysensorandthesafetyhumidistatmustalwaysbecheckedbeforecommissioningthehumidifiersystem.

TerminallocationsWhenlocatingtheairintakeandthefluegasterminalsthefollowingrequirementsmustbeobserved:

– All terminal must terminate at an outside location.

– Locationofairintakeandfluegasterminalmustcomplywithalllocalandnationalregulations.

– Airintakeandfluegasterminalcanbeinstalledindifferentpressurezones.

– Airintakeandfluegasterminalcannotbeinstalledonoppositewallsofthebuilding.

– Aminimumdistanceof1.2mmustbemaintainedbetweentheairintakeandthefluegasterminaltopreventrecirculationoffluegases(seefigureabove).

– Whenthefluegasorairintaketerminalislocatedlessthan2.75mfromthegroundorcanbeaccessedbypersonnelaguardmustbeinstalledataminimumdistanceof50mmtotheterminalto prevent personal injury.

45

5.9 Electrical Installation

A1 control or sensor signal Y (signaltypesetviacontrolsoftware)

A2 control or sensor signal Z (air supply limit signal) (signaltypesetviacontrolsoftware)

A3 Output 24 Vdc (JP4) or 5 Vdc (JP3) B1 Safety high limit humidistat (building side)B2 Flowcontrol(buildingside)B3 Ventilationinterlock(buildingside)F1 ExternalFuse(10A,slow-acting,buildingside)

220...240VACpowersupply

F2 Fuse(6A,fast-acting)24VACpowersupplyH1 Remote operating and fault indicationJ1 Cable bridge (if no monitoring devices are connect ed)JP3 Jumper(tosetoutputA3to5Vdcmax.500mA)JP4 Jumper(tosetoutputA3to24Vdcmax.150mA)K1 Externalsafetyloop(24Vac)Q Externalserviceswitchorplug-typeconnectorRJ45 Communication interface (for detailed informations

refer to the separate documentation)S1 Fulltankblowdown(24Vac)

Wiringdiagram

1 2 3 4 5 6 7 8

J1

A2Z A1 Y

K1B1B2B3

F2

0…10 mADC2…20 mADC0…20 mADC4…20 mADC

0…10 VDC2…10 VDC0…5 VDC1…5 VDC

24VA

C “H

ot”

24VA

C “C

OM”

F1 100mA

Unit ONSteamServiceError

1 2 3 4 5 6 7 8 9 10

H1 L1NPE

220...230V/50...60Hz

L1 N PE

A3

S1

JP3: 5 Vdc, max. 500 mAJP4: 24 Vdc, max.150 mA

24 Va

cSL CH

1CH

2+5

Vdc

FTBDGN

D

GND

J13-FeedbackJP4JP3

J10-Modul

J1-RJ45

J2-Driver Board 1

J3J4

-Driv

er B

oard

2

J4PMW1

J19Float

J6PMW2

J8PMW3 J16

DrainJ15Fill

DriverBoard 1

ControlBoard

J1824VAC

J1724VAC

J5-Ig

n4J3

-A/P

J7-Ig

n5J9

-Ign6

J2a-

RS48

5J1

-CPU

Boa

rd

J14Blower

J13-FeedbackJ10-Modul

DriverBoard 2

J2a-

RS48

5J1

-CPU

Boa

rd

F1

Q

RJ45

46

Installation notesAllworkconcerningtheelectricinstallationmustbeperformedonlybyadequatelyqualifiedpersonnel(electricianorworkmanwithequivalenttraining).Ascertainingthequalificationsisthecustomer‘sresponsibility.

Observe all local regulations concerning the electric installation.

DANGER! Danger of electric shock!Thesteamhumidifiermaybeconnectedtoelectricmainsonlyafterallinstallationworkhasbeencompleted.

CAUTION!Theelectronicpartsinsidethehumidifierareverysensitivetoelectrostaticdischarge.Topreventdamage,appropriatemeasuresagainstelectrostaticdischarge(ESDprotection)mustbetakenwhencarryingoutinstallationwork

Primarywiring

Humidifiersrequirefieldwiringtoprimaryvoltageterminalblocks.Powerrequirementis220…240V/50…60Hz,10Aslow-actingfused(“F1”)circuit,singlephase.Wiringisfedthrougha22mmholeinthebottomofthecontrolcompartment.Installationofexternalserviceswitch“Q”(allpoledisconnectingdevicewithaminimumcontact opening of 3 mm) is mandatory.

Wheninstalled,theappliancemustbeelectricallygroundedinaccordancewithlocalcodes,ifanexternalelectricalsourceisutilized.Connectgroundwiretocabinetgroundclamp.

Externalwiringsizesmustbeinaccordancewithexistinglocalelectricalcodesandby-laws.

Remoteoperationandfaultindication(H1)

TheRemoteoperationandfault indicationboardisequippedwith4relaysforremoteoperationandfaultindication.– “On”:thisrelayclosesafterthehumidifierhasbeenpoweredup– “Steam”: this relay closes as soon as steam is produced– “Service”: thisrelaycloseswhenthesetmaintenanceintervalhasexpired– “Error”: thisrelaycloseswhenanerroroccurs

External safety circuit (K1)

Toguaranteethesafetyofthehumidificationsystem,monitoringtheoperationbymeansofasafetycircuitisanabsoluterequirement.Toaccomplishthis,thepotential-freecontacts(250V/2A)ofexternalmonitoringdevices(B1:safetyhighlimithumidistat,B2:airflowmonitor,B3:ventilationinterlock,etc.)areconnectedinseries to terminals 1 and 2.

Control or sensor signal

The control signal (signal Y) is connected to terminals 3 and 4. The air supply limit signal (signal Z) is con-nectedtoterminals3and5.BydefaulttheCondairGSisconfiguredfora0…10VDCcontrolsignals.Thecontrolsignaltypecanbemodifiedviathesoftware(seemenu“usersettings”,intheoperatinginstructionsfortheCondairGScontrol).TheconfigurationwhethertheCondairGSiscontrolledviatheinternalorviaanexternalcontrollerisalsodoneviathesoftware.

Output A3

This output is available for custom purposes. The lines are connected to terminals 6 and 7. The output signal typeisconfiguredbysettingthejumperonJP3(5Vdcmax.500mA)oronJP4(24Vdcmax.150mA).

Full tank blow down 24 VAC (S1)

Thisinputsignalcanbeusedforremotetriggeringafulltankblowdown.Ifa24VACsignalispresentformorethan60secondsthetankblowsdown.Thesignallineisconnectedtoterminals8and7.

47

6 Inspecting the installations (Check list)

BeforetheCondairGSisoperatedfor thefirst time,theresponsiblepersonnelmust inspect all installations for correct execution (observing of local regulations)andcheckthattheunit is correctlyconfigured.Alldeficienciesmustbecorrectedbyspecialistactionbeforecommissioningtakesplace.

Usethefollowingchecklisttoascertainthattheinstallationswereperformedcorrectly:

– Unit installation Is the unit in the correct place (see chapter 5.2.1)? Istheunitcorrectlyalignedverticallyandhorizontally? Issteamhumidifierproperlysecured(unitstandfixedtothefloor)?

– Steaminstallation– Steam distribution pipe

Steamdistributionpipecorrectlypositionedandsecured(screwstightened)? Aretheoutletorificesatrightanglestotheairflowdirection?

– Steampipebetweensteamoutletonunitandsteamhoseadapter(mainsteampipe) Maximumlengthof6m? Minimumbendradiusof4-5xinternaldiameterofsolidsteampipe? Is the pipe properly insulated? Is the correct installation material used? Is the minimum internal diameter maintained over the entire pipe length?

– Steamhosebetweensteamhoseadapterandsteamdistributor Maximumlengthof4m? Minimumbendradiusof300mm(4-5xinternaldiameterwithfixedpiping)? Havetheinstructionsforhosepositioningbeenfollowed? Steamhose:nosagging(condensatepocket)? Rigid steam lines: properly insulated? Correct installation material used? Minimum internal

diameter maintained? Steamhosesecurelyattachedwithclamps? Heatexpansionduringoperationandshorteningofthehosewithageingtakenintoconsi-

deration?

– Condensate hoses Downslopeofatleast20%? Siphonsexistingandfilledwithwater? Condensatehosescorrectlyfixed?

– Water installation

– Fillingwatersupply Hasfiltervalve(accessory“Z261”)orshut-offvalveandfilter5µmrespectivelybeenin-

stalled in supply line? Haveadmissiblewaterpressure(3.0–8bar)andtemperature(1–30°C)beenobserved? Doessupplycapacitymatchthehumidifier(s)? Is the piping properly secured and sealed?

48

– Water drain Has minimum inside diameter of drain pipe (at least 45 mm) been maintained throughout

the entire length? Hasdrainpipebeeninstalledwithadownslopeofatleast10%? Havetemperature-resistantmaterialsbeenused(upto100°C)? Arethehosesandpipescorrectlyattachedandsealed(hoseclampsandscrewedcon-

nections tightened)? Istheminimumfunnelheightof150mmobserved?

– Gas installation Istheshut-offvalvefitted? Is a sediment separator installed, if steel pipes are used? Isthegascircuitcorrectlysealed(leakagecheckcarriedout)? Is the permissible gas pressure being maintained (see the table in 5.5.1)? Have the correct sealing materials been used?

– Flue gas system Doesthefluegassystemcomplywiththelocalregulations? Doesfluegaspipelengthcomplywiththemaximumrecommended(see5.6.1)? Is the minimum pipe cross-section (corresponding to the internal diameter at the unit connec-

tion) maintained over the entire length of the pipe? Havecondensatedischargeoutletsbeenincorporatedwherenecessaryandprovidedwithasiphonandisthesiphonfilledwithwater?

Isthefluegaspipesealedandhasthepermittedsealingmaterialbeenused? Haveallheat-sensitiveandeasilyflammablematerialsbeenremovedfromthevicinityofthefluegaspipe?

Isthefluegaspipeinsulatedatallthenecessarypositions? Isthefluegasoutletterminaloutsidethebuildingcorrectlylocated? Have the permitted sealing materials been used?

– Air supply system for room air-independent units (RS units) Doestheairsupplysystemcomplywiththelocalregulations? Doesairsupplylinelengthcomplywiththemaximumrecommended(see5.7)? Is the minimum pipe cross-section (corresponding to the internal diameter at the unit connec-

tion) maintained over the entire length of the air supply line? Is the air supply line correctly sealed and has the permitted sealing material been used? Is the inlet terminal outside the building correctly located?

– Electricalinstallation Doestheelectricalinstallationcomplywiththelocalregulations? Do the mains voltages applied correspond to the supply voltage stated on the rating plate of

the unit? Is the voltage supply correctly fused? Istheserviceswitch“Q”installedinthesupplycable? Areallcomponentscorrectlyconnectedinaccordancewiththewiringdiagram? Areallconnectioncablesfixed? Are the connecting cables freeof tension (fitted through cableglands/securedwith cable

clamps?) IstheCondairGScorrectlyconfigured?

49

7 Operation

QualificationofpersonnelTheCondairGSmustonlybecommissionedandoperatedbypersonswhoarefamiliarwithequip-mentandadequatelyqualifiedtoundertakethiswork.Monitoringsuchqualificationisamatterforthe customer.

InitialcommissioningmustonlybeundertakenbytheCondairservicetechnicianorbythecustomer‘sownspeciallytrainedpersonnel.

SafetyDonotstoreorusegasolineorotherflammablevaporsandliquidsinthevicinityofthisoranyotherappliance.

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.

Donotoperatethisapplianceifanyparthasbeenexposedtoexcesshumidity.Immediatelycallaqualifiedservicetechniciantoinspecttheapplianceandtoreplaceanypartofthecontrolsystemandanygascontrolwhichhasbeenunderwater.

Anopenunitmustnotbeoperated.BeforeputtingtheCondairGShumidifierintooperationmakesurealldoorsareclosedandlockedwiththescrew.

ForsafeoperationoftheCondairGShumidifier,makesuretheambientconditionsmeettherespec-tivespecificationsdefinedinthisdocumentation.

TopreventexcesshumidificationtheoperationoftheCondairGSmustbemonitoredbyahighlimiton/off humidistat (see chapter 5).

7.1 Importantnotesonoperation

50

Display and control unitFunction: Configuration of the Condair GS. Indication of operating parameters. Reset of maintenance counter. red LED “Fault”Function: The LED lights in case of a severe malfunction

of the unit (Fault status). Further operation is not possible any longer. A corresponding fault message is shown in the display.

yellow LED “Maintenance”/“Warning”Function: The LED lights in case of a temporary mal-

function of the unit (Warning status) or if the maintenance is due. A corresponding warning message is shown in the display

If he LED lights and simultaneously the gre-en LED flashes, the external safety chain is open (ventilation interlock has triggered). As soon as the safety chain is closed again, the indication disappears.

greenLED“Humidification”Function: The LED lights if the unit produces steam.

If the LED flashes and simultaneously the yellow LED lights, the external safety chain is open (ventilation interlock has triggered). As soon as the safety chain is closed again, the indication disappears.

Drain keyFunction: Manual draining of the water tank. After

having pressed the drain key, the draining is controlled via the display and control unit.

Unit switchFunction: Switches the unit on and off. The switch is

illuminated when the unit is running.

7.2 Functionofthedisplayandoperatingelements

51

BeforetheCondairGSisoperatedforthefirsttime,theresponsiblepersonnelmustinspect all in-stallations for correct executionandcheckthattheunitiscorrectlyconfigured(seechecklistinchapter 6).Alldeficienciesmustbecorrectedbyspecialistactionbeforecommissioningtakesplace.

Thehumidifierisoperatedasfollows:

1. Examinethehumidifierandallinstallationsforpossibledamage.

CAUTION!

Damagedunitsandunitswithdamagedinstallationsmustnotbeoperated!

2. Checkthecleanlinessoftheoutercabinet:Thepanelsmaybecleanedwithadampclothandwarmsoapywater.

CAUTION!Makesurenowaterisdrippingintothecabinetthroughtheventilationopeningsintheunithousing.

3. Fillthewatertank:

• Closetheshut-offvalveinthegassupplyline.

• Opentheshut-offvalveinthewatersupplypipe.

• Sethumiditycontrollertomaximumhumiditydemand.

• Switch-ontheserviceswitchintheelectricalsupplycircuit.

• Switch-onthehumidifierattheunitswitch.

• Thefillingvalveopensandthewatertankfills(fillingtime:approx.30minutesforthelargestmodel,forsmallerunitsthefillingtimeisshorter).Attheendofthefillingcyclethecontrolunitchecksthefunctionofthewaterlevelunit.Ifthecontrolunithasverifiedtheproperfunctionofthewaterlevelunittheignitionsequencestarts.Afterthreeattemptsatignitiontheautoignitionswitchesoff.TheredLEDlightsandacorrespondingerrormessageisshowninthedisplay.NowswitchthehumidifierOff.

4. Checkignition:

Theregulatorisstillsettomaximumhumiditydemandandtheshut-offvalveinthegaslineisclosed.

• Switch-Onthehumidifierattheunitswitch.

Thecombustionairblower(s)start(s).Note:Onmulti-blowerunits,waituntilallblowershavestarted. Then, 15 seconds later (pre-purging time) the igniter is activated and the gas pressure regu-lating valve opens. After 7 seconds the gas pressure regulating valve closes and the igniter isde-energized(duetomissingignition).Note: On multi-burner units, this process is successively completed for all burners.Afterthreeignitionattemptsperburner(completewithpre-purging),thehumidifiergoesintosafetylockout.

• Opentheshut-offvalveinthegassupplypipe.Nogasshouldflowtothemainburner.Endofthetest.

• Switch-offthehumidifierattheunitswitch.Note:Toresetthesafetyswitch-off,switch-offthehumidifierforatleastfivesecondsandthenswitchitonagain.

• Adjustthehumiditycontrolleragaintothesethumidityvalue.

7.3 Commissioning

52

5. Pre-purge of the gas pressure regulating valve(s):

• Disconnectallignitorsfromtheignitionmodules.

• Switch-Onthehumidifierattheunitswitch.

Thecombustionairblower(s)start(s).Note:Onmulti-blowerunits,waituntilallblowershavestarted. Then, 15 seconds later (pre-purging time) the gas pressure regulating valve opens for 7 se-conds, then it closes again (due to missing ignition). Note: On multi-burner units, this process is successively completed for all burners.

Afterthreeignitionattemptsperburner(completewithpre-purging),thehumidifiergoesintosafetylockout.Note:Toresetthesafetyswitch-off,switch-offthehumidifierforatleastfivesecondsandthenswitchitonagain.

Repeatthissequenceminimum2timesinordertomakesurenoairisleftinthegassystem.

• Switch-offthehumidifierattheunitswitch.

• Reconnectallignitorstotheignitionmodules.

6. Startthehumidifier:

• Opentheshut-offvalveinthewatersupplypipe.

• Opentheshut-offvalveinthegassupplypipe.

• Switchontheexternalserviceswitch.

• SwitchthehumidifierOnattheunitswitch.

The Condair GS carries out a systemandleveltest,duringwhichalltheLEDslightup.

If a failure occurs on the system test, a corresponding error message is showninthedisplay.

After the system test the unit is in normaloperationmode. The display showsthestandard operating display(firstpageoftheindicationlevel).Note: The contents of the standard operating display depends on the actual operatingstatusandontheconfigurationoftheCondairGSandcandifferfrom the opposite display.

As soon as the humidity controller demands humidity, the combustion air blower(s)start(s).Then,15secondslater(pre-purgingtime)theignitionprocess for the burner(s) is started. The burner(s) ignite(s) and steam is generatedinthetankviatheheatexchanger(s).ThegreenLEDlightsandtheadjacentdisplayisshown.

If no flame is detectedby the flamesensorwithin7 secondsafter theignition of a burner, the gas pressure regulation valve closes again. The ignitionsequenceisrepeatedamaximumofthreetimesperburner.Ifnoburnercouldbeignited,thehumidifiergoesintosystemlockout.The red LEDlightsandanappropriate faultmessageappears in thedisplay.Atthe same time, the operating and remote fault alarm potential-free contact (“Error”)closes.Note:Thesystemlockout isresetbyswitchingthehumidifieroffbriefly(5 seconds) and then on again. If only individual burners of a multi-burner unit could not be ignited the humi-difierremainsoperational.Inthedisplayacorrespondingwarningmessageappearsinthedisplayindicatingwhichburner(s)has/havefailedtoignite.

Condair GS 240START UP

Menu

Condair GS 240Standby

03.03.2009 12.00.00

Menu

Condair GS 240Demand :50%

03.03.2009 12.05.00

53

Note:fordetailedinformationregardingtheoperationofthecontrolunitandtheconfigurationset-tings please observe the information given in the separate operating instructions to the Condair GS control.

7.4 Notes on operation

7.4.1 Remoteoperatingandfaultindication

Viatheoperatingandfaultindicationthefollowingoperatingstatusareshownremotely:

Activatedremoteindication relay

When? Display on unit

“Error” A malfunction (fault status) is present, further operation is not pos-sible.

RedLEDlightsA corresponding fault message is showninthedisplay

“Service” Maintenance is due. The unit re-mains operational for a certain time.

YellowLEDlightsTheservicewarningmessageisshowninthedisplay

“Steamdemand” Steam demand/Steam production

GreenLEDlights.The standard operating display is shown.

“Uniton” Unitswitchedon Unitswitchlights.The standard operating display is shown.

7.4.2 Inspections during operation

DuringoperationtheCondairGSandthehumidificationsystemhavetobeinspectedweekly.Onthisoccasioncheckthefollowing:

• thewater,gasandsteaminstallationforanyleakage.

• thehumidifierandtheothersystemcomponentsforcorrectfixingandanydamage.

• theelectricinstallationforanydamage.

Iftheinspectionrevealsanyirregularities(e.g.leakage,errorindication)oranydamagedcompo-nentstaketheCondairGSoutofoperationasdescribedinchapter7.5.Then,contactyourCondairrepresentative.

54

7.5 Taking the unit out of operation

Ifthehumidifiermustbetakenoutofoperation,e.g.formaintenancework,proceedasfollows:

1. Close the shut-off valve in the gas supply pipe.

2. Closetheshut-offvalveinthewatersupplypipe.

3. Pressthedrainswitch.Thegaspressureregulationvalve/sclose/sandthetankempties.Important!Ifdrainpumpisdefective,draintankmanuallyviatheauxiliarydrain.

4. Waituntilthewatertankempties.Nowswitchoffthehumidifierattheunitswitch.

5. Isolatethehumidifierfromtheelectricalpowersupply:SwitchofftheexternalserviceswitchinthepowersupplycircuitandsecuretheswitchintheOffpositiontosafeguardagainstunintentionalswitch-on.

55

8 Maintenance

QualificationofpersonnelAllmaintenanceworkmustbecarriedoutonlybywellqualifiedandtrainedpersonnelauthorisedby the owner. Maintenance and repair of the electrical installation of the Cond air GS must be carried out only by qualifiedpersonnel(e.g.electrician)beingawareofpossibledangerandimplications.

Itistheowner’sresponsibilitytoverifyproperqualificationofthepersonnel.

General notes Theinstructionsanddetailsformaintenanceworkmustbefollowedandupheld.

Onlythemaintenanceworkdescribedinthisdocumentationmaybecarriedout.

Only use original Condair spare parts to replace faulty parts.

SafetyBeforemaintenanceisinitiated,theCondairGSmustbetakenoutofoperationinaccordancewith instructions in chapter 7.5 and protected against unintentional switching on.

8.2 Maintenance instructions

To maintain operating reliability, the Condair GS mustbeservicedatregular intervals. Here, a distinctionismadebetweenthefirstserviceafter500hoursofoperation(I), theminorserviceeverytimethemaintenancealarmappears(II) and the annualmaintenance(III).Important!Dependingonthehardnessofthewaterandtheaveragesteamoutput,undercertaincircumstancesitmaybenecessarytoreducetheserviceintervalfortheminormaintenancework.If the limeresiduesdepositedonthefloorofthetankexceedaheightof5cm the interval must bereduced.Iftheheightislessthan5cmtheintervalcanbeextended.

Important:Everyserviceactionmustbedocumentedinthe“Maintenance”reportsheet(acopyofthis document is provided in these installation, commissioning and service instructions). Warranty isvoidifthespecifiedmaintenanceintervalsarenotobservedandthemaintenanceworkarenotcarried out according the instructions.

Thefollowingisanoverviewoftheworktobecarriedoutateachoftheservicestages.

Components Interval WorkrequiredI II III

Watertank X X X Drainthetank,thenopenitandmeasuretheheightofthelimeresiduesonthetankfloor(max.5cm).Removethelimefromthetank.Checkallpipeconnectionstothetank(speciallythelevelunit passages). Clean if necessary.

Water outlet pipes, including siphon

X X X Pressthedrainswitchandcheckforfreedrainage.Inspect all pipes for lime deposits and for correct sealing. Cleanorreplacepipeswithlimedeposits.Reseal/replaceleakingpipes.

8.1 Importantnotesonmaintenance

56

Components Interval WorkrequiredI II III

Water installation X X X Checkallwaterhosesintheunitforcracksandcorrectfixing,replacedefectivehoses.Checksupplypipesforsealing,sealifnecessary.Cleanthefiltervalve(orwaterfilter).Checkcorrect functionof levelunit.Cleanor replace ifnecessary.

Unit inner chamber X X X Checktheinnerchamberfordirtanddepositsandcleanif necessary.

Steam installation X X Inspectthesteamandcondensatehosesforcracksandcorrectfixing,replacedefectivehoses.

Electricalinstallation X X Checkallcablesintheunitforsecurefixingandconditionandchecktheinsulation.

Air supply pipe (RS units) X X Checkforsealing,sealifnecessary.Checkscreeninairintaketerminal,cleanifnecessary.

Flue gas temperature sensor X X Visualcheckthatsensorisintact,wiredandattachedtotheexhaust.

Flue gas system X X Checkfluegassystemforsealingandremovealltracesofcondensate.Checkscreeninfluegasterminal,cleanifnecessary.Ifspecified,havethefluegassysteminspectedby an appropriate specialist.

Igniterandflamesensor X Everyyearorevery2000hours(whichisreachedfirst).Removeand replace igniter and flamesensor (specialsparesset“Burnerpartssubjecttowear”).

Burner/combustionairblower X Remove burner and inspect the condition of burner mat. Blowoutburnermatwithcompressedairorreplaceburnerifnecessary.Replaceallburnersealswithnewones(specialsparesset“Burnerpartssubjecttowear”).Cleancombustionairblowerifnecessary.Theelectricmo-torsoftheblowersareprovidedwithpermanentlubricationand do not require maintenance.

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8.3 Dismantlingworkformaintenanceandthereplacementofcomponents

Prepare water tank for cleaning

Torque: 5.7 Nm (50 in-Lb)

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Unlockandremovetheleftfrontpanel.Then,unscrewthenutsofthesidetankcoverandremovethe cover.

3. OnGS120...240only:unlockandremovethelefttoppanel.Then,unscrewthenutsofthetoptankcoverandremovethecover.

There-assemblyofthewatertanktakesplaceinthereversesequence.Makesurethatthesealsofthetankcoversarenotdamaged(replaceifnecessary).Important!Tighten thenutsof the tankcover(s)witha torquewrench(torque:5.7Nm).Donotovertighten the nuts.

Cleaning the water tank

WARNING! Dangerofcombustion!Thewaterandalllimedepositsinthetankcanbeextremelyhotandmayleadtoburningoncontact.Therefore,allowthehumidifiertocoolbeforecommencingcleaningwork.

Thecombustionchamberwallsareusuallyself-cleaning.Duetotheexpansionandcontractiondu-ringthehumidificationprocess,limedepositspeelfromthewallsandsinktothefloorofthetank.Anaccumulationoflimeonthefloorofthetankuptoamaximumheightof50mmispermissibleanddoesnotaffecttheoperationofthehumidifier.• Removethelimedepositsinthetankandcombustionchamberwallswithaplasticscraper.Do

notusemetalspatulasorscrapers,becausethesearelikelytoscratchtheinternalwallsofthetank.

• Removelimedepositsfromthefloorofthetankwithaspatulaand/orwithanindustrialwatersuctionapparatus.Rinseoutresidualaccumulationsoflimewithfreshtapwaterviatheopenauxiliarywaterdrainconnection(Usingabucket).Neverrinseawaylimeaccumulationsdirectlyintotheconnectedwaterdrainoutlet,becausethereisadangerofthedrainpump,thedrainpipeandthesiphonbecomingblocked.

• Removethehoseconnectionstothetankandcleantheminternally.

Gasket

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1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Disconnectcablestocombustionairblower,gaspressureregulatingvalveandpressureswitch(note assign ment of the connections).

4. On RS units only:Undothehoseclampandremovetheairsupplyhosefromtheinletelbow.Alsodisconnectthesmallairhosefromtheinletelbow.

5. Undothecouplingofthecorrespondingflexiblegaspipeanddisconnectthegaspipe.

6. Undothetwoscrewsoftheventurimanifoldandliftupthemanifoldtogetherwiththegaspres-sure re gulat ing valve.

7. Undothetwoscrewsoftheelectronicboard(ifpresent)andremoveelectronicboard.

8. Undothenutsontheoutletsideoftheblowerandremovetheblowerunit.

Reinstallationisachievedbyfollowingthereversesequence.Replacedefectivesealswithnewones.Makesurethatallsealsareinsertedcorrectlyandallcablesareconnectedcorrectly.

DANGER! Danger of explosion!Followingmaintenanceworkonthegassystem,a leakagetestmustalwaysbeundertaken inaccordancewithchapter5.5.2.

Removalandinstallationofthecombustionairblower

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Removalandinstallationoftheburner

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Removethecombustionairblower(seethesection“Removalandinstallationofthecombustionairblower”above).

4. Disconnectthecablestotheigniterandtotheflamemonitoringunitandremovethecomponents(seethesectionon“Removalandinstallationoftheigniterandtheflamesensor”).

5. Unscrewthefournutsintheburnerflangeandcarefully removetheburnerunit.Makesurethatthe burner is not damaged.Note: Grease, dirt and dust at the ceramic matting can affect the performance of the burner.

Re-installationisachievedbyfollowingthereversesequence.Renewtheflangesealandreplaceigniterandflamesensorifnecessary.Tightthenutsoftheburnerflangewithatorquewrench(torque:10Nm).Makesureallcablesareconnectedcorrectly.

DANGER! Danger of explosion!Followingmaintenanceworkonthegassystem,a leakagetestmustalwaysbeundertaken inaccordancewithchapter5.5.2.

CleaningtheburnerelementsCarefullyblowouttheburnerelementmats(ceramicfibrematerial)fromoutsidewithcompressedair. Severely soiled burner elements should be replaced.

Cleaningtheblower/burnerchamberoftheunitCarefullycleantheblowerandtheburnerchamberbyfreeinganykindofsoilingandaccumulations.

CAUTION!Wetcleaningoftheblowerandtheburnerchamberisnotpermitted!

Ceramic matting, do not touch!

Hold burner only on metal pipe

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Removalandinstallationofthegaspressureregulatingvalve

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. On RS units only:Undothehoseclampandremovetheairsupplyhosefromtheinletelbow.Alsodisconnectthesmallairhosefromtheinletelbow.

4. Disconnectelectricalwiringtothegaspressureregulatingvalveandthepressureswitch(notethe connection layout).

5. Undothecouplingofthecorrespondingflexiblegaspipeanddisconnectthegaspipe.

6. Undothetwoscrewsoftheventurimanifoldandliftupthemanifoldtogetherwiththegaspres-sure re gulat ing valve.

7. Undothefourscrewsandremovethegaspipeconnectionofthegaspressureregulatingvalve.

8. Pulloffthehoseconnectedtothepressureswitch(notetheconnectionlayout).Then,undothethreescrewsofthepressureswitchsupportandremovepressureswitchassemblyfromthegasregulating valve.

9. Undo the threescrewsfixing thegaspressure regulatingvalve to theventurimanifold then,remove the gas pressure regulating valve from the venturi manifold.

Reinstallationisachievedbyfollowingthereversesequence.Replacedefectivesealswithnewones.Makesurethatallsealsareinsertedcorrectlyandallcablesareconnectedcorrectly.

DANGER! Danger of explosion!Followingmaintenanceworkonthegassystem,a leakagetestmustalwaysbeundertaken inaccordancewithchapter5.5.2.

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Removalandinstallationoftheigniterandtheflamesensor

CAUTION!Whenreplacingtheigniterandtheflamesensor,useonlythesetofspares“burnersparepartssubject towear”available fromyourCondair supplier, sinceotherwise thehumidifiercouldbedamaged.

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Disconnectthewiringconnectiontotheigniterandtotheflamesensor.

4. Unscrewthefixingnutsfortheigniterandtheflamesensor.Nowcarefullyremovetheigniterandflamesensor.

CAUTION!Thesiliconcarbideigniterisbreakable.Thereforehandleitwithgreatcaretoavoiddamage.

Reinstallationisachievedbyfollowingthereversesequence.Inspectgasketsandreplaceifdefective.Makesurethatallgasketsareinsertedcorrectlyandallcablesareconnectedcorrectly.

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1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Pulloffthehoseconnectedtothepressureswitch(notetheconnectionlayout).

4. Removetheconnectioncabletothepressureswitch(noteassignmentbeforeremoval).

5. Unscrewthetwofixingscrewsandremovetheairpressureswitch.

Re-installationfollowsinthereversesequence.Makesurethecablesandthehoseareconnectedcorrectly.

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

3. Note the cable assignment, then remove all connection cables to the ignition module.

4. Unscrewthetwofixingscrewssecuringtheignitionmoduleandthenremoveignitionmodule.

Re-installationfollowsinthereversesequence.Makesuretheconnectingcablesareconnectedcorrectly.

Replacementoftheairpressureswitch

Replacementoftheignitionmodule

63

Replacingthetransformer

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

3. Remove the connection cables to the transformer, if necessary labeling the cables before removal.

4. Unscrewthetwonutsandremovehetransformer.

Re-installationiscarriedoutinthereversesequence.Makesurethecablesareconnectedcorrectly.

Replacingthedrainpump

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.Important!Ifdrainpumpisdefective,draintankmanuallyviatheauxiliarydrain.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Remove the connection cables to the drain pump (note assignment before removal).

4. Remove hose clamps on the drain pump connections and pull off the hoses, then remove the drain pump.

Re-installationiscarriedoutinthereversesequence.Makesurethehosesarecorrectlysecuredwiththehoseclampsandthecablesareconnectedcorrectly.

64

Replacingthefillvalve

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Removetheconnectioncablestothefillvalve(noteassignmentbeforeremoval).

4. Removehoseclampsonthefillvalveconnectionsandpulloffthehoses.

5. Undothetwoscrewsfixingthefillvalvetothehousing,thenremovethefillvalve.

Re-installationiscarriedoutinthereversesequence.Makesurethehosesarecorrectlysecuredwiththehoseclampsandthecablesareconnectedcorrectly.

Replacing the water level unit

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetheleftfrontpanel.

3. Remove the connection cable to the level unit.

4. Remove hose clamps on the level unit connections and pull off the hoses.

5 Squeezebothsidesofthemountingbrackettoreleaseitfromtheslotsinthesupportbracketbehindthewaterlevelunit,thenremovethelevelunit.

Re-installationiscarriedoutinthereversesequence.Makesurethehosearecorrectlysecuredwiththe hose clamps and the cable is connected correctly.

65

Replacingthefillingchamber

1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Removehoseclampsonthefillingchamberconnectionsandpulloffthehoses.

4 Undothetwonutssecuringthefillingchambertothefaceofthetank,thenremovethefillingchamber.

Re-installation iscarriedout inthereversesequence.Makesurethehosearecorrectlysecuredwiththehoseclamps.

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Removaloftheheatexchanger(seefollowingillustration)1. Takethehumidifieroutofoperation,asdescribedinchapter7.5.

2. Disconnectthegassupplypipefromtheconnectiononthehumidifierandcloseoffthepipe.

3. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

4. On RS units only:Removethehosesfromairintakemanifoldandairinletelbows.Then,di-smount air supply pipe at the air supply connection.

5. Dismountfluegaspipeatthefluegasoutletconnection.

6. Undothescrew(s)(phillipsscrewdriver)andremovetheleftandtherighttoppanels.

7. Freeallcableconnectionstothecomponents(combustionblower,ignitionmodule,airpressureswitch,etc.)oftherespectiveheatexchanger.Important!Notetheconnectorassignment.

8. Undothecouplingoftherespectiveflexiblegaspipeandremovetheflexiblegaspipe.

9. Dismounttheburnerwiththeairblowerandthegaspressureregulatingvalveoftherespectiveheatexchanger.

10.Unscrewthenutsandremovethefluegasmanifoldfromtheheatexchanger.

11.Unscrewthenutsontheheatexchangerandpullouttheheatexchangerfromthetank.

Re-installationiscarriedoutinthereversesequence.Replaceallsealswithnewones.Makesureall cables are connected correctly.

DANGER! Danger of explosion!Followingmaintenanceworkonthegassystem,a leakagetestmustalwaysbeundertaken inaccordancewithchapter5.5.2.

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Theinformationandspecificationsrelatingtothecleaningagentstobeusedmustbestrictlyobse-rved. In particular: Information on personal protection, environmental protection and all restrictions in the use of cleaning agents.

The use of disinfectants is only permitted if they deposit no poisonous residues. In all cases, the componentsthathavebeencleanedinthiswayaretoberinsedwithwater.

CAUTION!Donotusesolventsforcleaningpurposes,noraromatizedorhalogenizedhydrocarbonsor other aggressive substances.

Followlocalenvironmentalprotectionregulationswithoutreservation.

8.4 Notes on cleaning agents

8.5 Resettingthemaintenancereminder

Aftercompletingmaintenancework,themaintenanceremindermessagemustberesetviathere-set function in menu mode of the control (see chapter 5.6 in the separate operating instructions for Condair GS control).

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9 Troubleshooting

9.2 Error indication

Malfunctions during operation are indicated by a corresponding warning message (operation still possible, yellow LED lights) 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.

9.1 Important notes on troubleshooting

Qualification of personnelHave faults eliminated by adequately qualified and trained personnel only. Malfunctions caused by the electrical installation must be repaired by authorized personnel (e.g. electrician) only.

SafetyWhen eliminating faults, the Condair GS must be taken out of operation, as described in chapter 7.5, and prevented from further inadvertent operation.Make sure the power supply to the unit is cut off (test with voltage tester) and that the stop valves in the water and gas supply line are closed.

General noteMost operational malfunctions are not caused by faulty equipment but rather by improper installa-tion 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.

9.3 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.

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9.4 Replacing the backup battery on the control board of the Condair GS

1. Set the Condair GS out of operation as described in chapter 7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

CAUTION!The electroniccomponentsinsidethehumidifierarevery sensitive to electrostatic discharge.Beforecarryingoutthenextstep,appropriatemeasuresmustbetakentoprotecttheelectroniccomponentsagainstdamagecausedbyelectrostaticdischarge(ESDprotection).

3. Undothe2screws“A”ofthedisplayandcontrolunit,thencarefullyremovethedisplayandcontrolunit to the front.

4. Undothe7fasteningscrews“B”ofthecontrolboard,thencarefullypull-offthecontrolboardfromthe display and control unit assembly.

5. Replacethebackupbattery(CR2032,Lithium3V).

6. Reassemble the unit in reverse order.

7. If necessary set date and time (see operating instructions of the control).

WARNING! Environmentalhazard!

The old battery must be returned to an authorised collecting point for correct disposal/recyclinginaccordancewithlocalregulations.Innocasetheoldbatterymustbedisposedofinthedomesticwasteorintotheenvironment.

A

B

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10 Taking out of service/Disposal

10.1 Taking out of service

IftheCondairGSmustbereplacedorifthehumidificationsystemisnotneededanymore,proceedasfollows:

1. Taketheunitoutofoperationasdescribedinchapter7.5.

2. Havetheunit(andallothersystemcomponents,ifnecessary)unmountedbyaqualifiedservicetechnician.

10.2 Disposal/Recycling

Componentsnotusedanymoremustnotbedisposedofinthedomesticwaste.Pleasedisposeoftheunitortheindividualcomponentsinaccordancewithlocalregulationsat the authorised collecting point.

If you have any questions, please contact the responsible authority or your local Condair representative.

Thankyouforyourcontributiontoenvironmentalprotection.

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11 Specifications

11.1 Technical Data

Condair GS 40 80 120 160 200 240

Steamoutput

room air-dependent kg/h 10…40 10…80 10…120 10…160 10…200 10…240

room air-independent (RS units) kg/h 10…40 10…80 10…120 10…160 10…200 10…240

Energyconsumption kw 36.5 73.0 109.5 146.0 182.5 219.0

Gasous fuel Naturalgas(G20,G25,G25.1,G27,GZ350)orPropanegas(G31)

Electric connections

powersupply 230V/50…60Hz/1Phase

powerconsumption W 460 690 920 1150 1380 1610

powersupplyfuse 10A,slowacting

Mechanical Connections

Fillwaterinlet Inch BSP3/4"

Drain Inch 3/4"(19mm)

Auxiliarydrain Inch NPT 1/2"

Gas line Inch BSP1/2" BSP3/4" BSP1" BSP1" BSP11/4" BSP11/4"

Steam hose connection Inches 1 3/4" (45 mm) 3" (76 mm) 3" (76 mm) 4"(101mm) 4"(101mm) 4"(101mm)

Flue pipe connection Inches 3" (76 mm) 4"(101mm) 5" (127 mm) 5" (127 mm) 6" (152 mm) 6" (152 mm)

Humiditycontrol

Possible control signals 0…5VDC/1…5VDC/0…10VDC/0…20mA/4…20mA

Dimensions

Height cm 81 (158 unit on stand)

Width cm 114

Depth cm 53 69 109 109 149 149

Shipping weight kg 174 210 295 319 358 382

Operating weight

filled kg 211 273 459 471 610 623

empty kg 140 162 238 261 290 314

Operating conditions

Admissiblewaterpressure bar 3…8

Water quality untreateddrinkingwaterorfullydemineralizedwater

Admissible gas supply pressure mbar G20:17…25/G25:20...30/G25.1:20...30G27:17.5…23/GZ350:10.5...16/G31:25...57.5

Admissible ambient temperature °C 5…30

Overpressureattheflueoutletat full loadat minimum load

PaPa

805

Type of protection IP20

Admissible duct air pressure Pa –800...+1700

Furtherinformations

Conformity CE

Patents Condair®internationaltrademark/internationalpatents

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11.2 Fluegasspecifications

NaturalgasG20 Natural gas G25full load part load full load part load

Condair GS 40energy consumption kW 36.5 10.5 36.5 10.5

gas consumption kg/h 2.4 0.68 3.04 0.87m3/h 3.478 0.8695 4.0443 1.0111

exhausttemperature °C 180 120 180 120exhaustmassflow kg/s 0.015 0.0034 0.017 0.0058CO2-content % 8.9 8 8.7 8fluegaspressure Pa 80 5 80 5exhaustdiameter mm 76 76

Condair GS 80energy consumption kW 73 10.5 73 10.5

gas consumption kg/h 4.72 0.68 6.08 0.87m3/h 6.956 0.8695 8.0886 1.0111

exhausttemperature °C 180 72 180 72exhaustmassflow kg/s 0.03 0.0067 0.034 0.0113CO2-content % 8.9 4.4 8.7 4.3fluegaspressure Pa 80 5 80 5exhaustdiameter mm 101 101

Condair GS 120energy consumption kW 109.5 10.5 109.5 10.5

gas consumption kg/h 7.08 0.68 9.12 0.87m3/h 10.434 0.8695 12.133 1.0111

exhausttemperature °C 180 57 180 57exhaustmassflow kg/s 0.045 0.0099 0.051 0.0169CO2-content % 8.9 2.9 8.7 2.9fluegaspressure Pa 80 5 80 5exhaustdiameter mm 127 127

Condair GS 160energy consumption kW 146 10.5 146 10.5

gas consumption kg/h 9.44 0.68 12.16 0.87m3/h 13.9121 0.8695 16.1773 1.0111

exhausttemperature °C 180 49 180 49exhaustmassflow kg/s 0.06 0.0131 0.068 0.0224CO2-content % 8.9 2.2 8.7 2.2fluegaspressure Pa 80 5 80 5exhaustdiameter mm 127 127

Condair GS 200energy consumption kW 182.5 10.5 182.5 10.5

gas consumption kg/h 11.8 0.68 15.2 0.87m3/h 17.3902 0.8695 20.2216 1.0111

exhausttemperature °C 180 44 180 44exhaustmassflow kg/s 0.075 0.0164 0.085 0.0279CO2-content % 8.9 1.8 8.7 1.7fluegaspressure Pa 80 5 80 5exhaustdiameter mm 152 152

Condair GS 240energy consumption kW 219 10.5 219 10.5

gas consumption kg/h 14.16 0.68 18.24 0.87m3/h 20.8682 0.8695 24.2659 1.0111

exhausttemperature °C 180 41 180 41exhaustmassflow kg/s 0.09 0.0196 0.102 0.0335CO2-content % 8.9 1.5 8.7 1.5fluegaspressure Pa 80 5 80 5exhaustdiameter mm 152 152

WhenoperatingwithnaturalgasG25.1,G27,GZ350orpropanegas(G31),pleasecontactyourCondairsup-plierforthecorrespondingfluegasspecifications

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© condair ltd., Printed in switzerlandtechnical modifications reserved

© 01.2016 Condair GmbH. Technical modifications reserved.

Condair GmbH Parkring3, 85748 Garching-Hochbrück Tel. (0) 89 207 008 -0, Fax (0) 89 207 008 -140, www.condair.de