Condair BP User manual
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Blower Pack
Condair BP
2582479_E_EN_1803
Humidication and Evaporative Cooling
Thank you for choosing Condair
Installation date (DD/MM/YYYY):
Commissioning date (DD/MM/YYYY):
Site:
Model:
Serial number:
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Group AG. Neither this document,
nor the information contained herein shall be reproduced, used, or disclosed to others without the written authori-
zation of Condair Group AG, except to the extent required for installation or maintenance of recipient's equipment.
Liability Notice
Condair Group AG does not accept any liability due to incorrect installation or operation of the equipment or due
to the use of parts/components/equipment that are not authorised by Condair Group AG.
Copyright Notice
© Condair Group AG, All rights reserved.
Technical modications reserved.
3Contents
Contents
1 Introduction 5
1.1 Before You Start! 5
1.2 General 5
2 For Your Safety 7
3 Receiving and Storage 9
3.1 Inspection 9
3.2 Storage and Transportation 9
4 Product Overview 10
4.1 General Description 10
4.2 Identication of the Unit 11
4.3 Options and Accessories 12
4.4 Functional Description 12
5 Installation 14
5.1 General 14
5.2 Installation Overview 15
5.3 Site Requirements 18
5.3.1 Location and Clearances 19
5.4 Best Practices for Steam and Condensate Lines Installation 20
5.5 Common Steam and Condensate Line Installation Mistakes 24
5.6 Installation Kit 25
5.7 Remote-Mounted Blower Pack Installation 26
5.8 Direct-Mounted Blower Pack Installation 33
5.9 Post-Installation Checklist 40
6 Commissioning 41
6.1 General 41
6.2 First-time Commissioning 41
7 Operation 42
7.1 Controls 42
7.2 Starting and Stopping 42
8 Maintenance 43
8.1 General 43
8.2 Maintenance List 44
9 Fault Isolation 45
9.1 General Troubleshooting 45
4Contents
10 Replacement Parts 46
11 Wiring Diagram 48
12 Decommissioning 49
12.1 General 49
12.2 Removing Unit from Service for Disposal 50
12.3 Disposal/Recycling of the Unit 50
13 ProductSpecications 51
13.1 Technical Data 51
13.2 Operating Data 51
13.3 Size and Weight 51
13.4 EC Declaration of Conformity 53
5Introduction
1 Introduction
1.1 Before You Start!
Thank you for purchasing the Condair Blower Pack.
Condair humidiers and blower packs incorporate the latest technical advances and meet all recognized
safety standards. Never-the-less, improper use of the Condair equipment may result in danger to the
user or third parties, and/or damage to property.
To ensure a safe, proper and economical operation of the Condair humidier and blower pack, please
observe and comply with all information and safety instructions contained in this manual as well as all
the relevant documentation of the installed humidication system.
If you have additional questions, please contact your Condair representative. They will be glad to assist
you.
1.2 General
Limitations
The subject of this manual is the Condair Blower Pack. The various options and accessories may only
be described in-so-far as is necessary for proper installation, operation and maintenance of the equip-
ment. Additional information on available options and accessories can be obtained in the respective
instructions that are supplied with them.
This manual is restricted to the installation, operation and maintenance of the Condair Blower Pack, and
is intended for well trained personnel who are suitably qualied for their respective jobs.
Symbols used in this manual
CAUTION!
The word "CAUTION" in conjunction with the general caution symbol is used to provide safety instruc-
tions that, if neglected, may cause damage and/or malfunction of the unit or damage to property.
WARNING!
The word "WARNING" in conjunction with the general warning symbol is used to provide safety in-
structions that, if neglected, may cause injury to personnel. Other specic warning symbols may also
be used in place of the general symbol.
6Introduction
DANGER!
The catchword "DANGER" in conjunction with the general danger symbol is used to provide safety
instructions that, if neglected, may cause severe injury to personnel or even death. Other specic
danger symbols may also be used in place of the general symbol.
Storage of Manual
Keep this manual in a place where it is safe and readily accessible. If the equipment is moved to another
location, ensure that the manual is passed on to the new user/operator.
If the manual is lost or misplaced, please contact your Condair representative for a replacement copy.
Language Versions
This manual is also available in other languages. Please contact your Condair representative for more
information.
7For Your Safety
2 For Your Safety
General
Every person who is tasked with the installation, maintenance or operation of the Condair humidier
and blower pack must read and understand this manual and the Condair humidier manuals before
performing any work.
Knowing and understanding the contents of this manual is a basic requirement for protecting person-
nel against any kind of danger, preventing faulty operation, and operating the unit safely and correctly.
All labels, signs and marking applied to the Condair humidier and blower pack must be observed and
kept in a readable state.
PersonnelQualications
All procedures described in this manual must only be performed by personnel who are adequately quali-
ed, well trained and are authorized by the customer.
For safety and warranty reasons, any activity beyond the scope of this manual must only be performed
by qualied personnel authorized by the manufacturer.
All personnel working with the Condair humidier and blower pack must be familiar with and comply with
the appropriate regulations on workplace safety and prevention of accidents.
Intended Use
The Condair Blower Pack is intended exclusively for air humidication within the specied operating
conditions (refer to "Operating Data" on page 51). Any other type of application, without the express
written consent of the manufacturer, is considered to be NOT conforming to its intended purpose, and
may lead to dangerous operation of the unit.
In order to operate the equipment in the intended manner all information contained in this manual, in
particular the safety instructions, must be observed closely.
Dangers that may arise from the Condairhumidierandblowerpack:
DANGER!
Risk of electric shock!
TheCondairhumidierandblowerpackaremainspowered.Livepartsmaybeexposedwhen
the door panels/covers are removed. Touching live parts may cause severe injury or even death.
Prevention:The Condair humidier and blower pack must be connected to the mains only after all
installation work has been completed, checked for correct workmanship, and the door panels/covers
are installed and fastened properly. The units must also be disconnected from the mains whenever
work must be performed on them.
8For Your Safety
WARNING!
Risk of severe burns from contact with hot steam vapours!
The Condair humidier and blower pack use hot steam vapours for humidication. Bare skin exposed
to hot steam vapours can result in severe burns.
Prevention:Wear appropriate personal protective equipment when working near steam vapours.
WARNING!
Risk of severe burns from contact with hot surfaces!
Components of the stream system (including the steam cylinder, steam distributors, etc.) get
up to 100 °C during operation. Contact with the hot surfaces can result in severe burns.
Prevention:Shut down the humidier and allow it to cool down before performing any work on the
steam system.
Preventing Unsafe Operation
All personnel working with the Condair humidier and blower pack must immediately report to the
customer any alterations to the unit that may aect safety, and secure the Condair units against ac-
cidental power-up.
ModicationstotheUnitProhibited
ModicationsareNOTpermitted on the Condair humidier and blower pack without the express writ-
ten consent of Condair.
9Receiving and Storage
3 Receiving and Storage
3.1 Inspection
After receiving the shipment, inspect the goods as follows:
– Inspect the shipping boxes for damage.
Report any shipping box damages to the shipping company without delay.
– Check the goods against the packing slip to ensure that all items have been delivered.
Report any shortages to your Condair representative within 48 hours of receipt of the goods. Condair
does not assume responsibilities for any shortages beyond this period.
– Unpack the parts/components and check for any damage.
If parts/components are damaged, notify the shipping company immediately.
– Verify the model type on the specication label to ensure that it is suitable for your installation. Refer
to Figure 2 on page 11.
3.2 Storage and Transportation
Storage
Store the Condair Blower Pack in its original packaging inside a protected area that meets the following
requirements until it is installed, or if it needs to be stored for an extended period of time:
– Room temperature: 5 to 40°C
– Room humidity: 10 to 75% RH
Transportation
For optimum protection always transport the unit and components in their original packaging, and use
appropriate lifting/transporting devices.
Packaging
Keep the original packaging of the unit/components for later use.
If the packaging needs to be disposed o observe local regulations on waste disposal. Please recycle
packaging where possible.
10 Product Overview
4 Product Overview
4.1 General Description
The Condair Blower Pack is used along with an atmospheric steam generating humidier to distribute
steam directly into local areas or into structures that do not have a built-in air distribution system.
The blower pack can be direct-mounted on the Condair EL series or RS series humidiers, or mounted
remotely with the Condair EL series, RS series or the GS series humidiers. Multiple blower packs can
also be installed remotely with large humidiers. Refer to Figure 1.
1
2
3
Figure 1: Condair Blower Pack Mounting Congurations
1 Remote-mounted multiple blower packs (on large humidiers)
2 Direct-mounted blower pack
3 Remote-mounted blower pack
11Product Overview
4.2 IdenticationoftheUnit
The specication label on the side of the blower pack shows its model type, serial number and other
rating details. Refer to Figure 2.
Figure 2:
MODEL:
VOL TS:
POWER:
Condair BP
S/N:
1234567
200-240V
PHASE:
1
Hz : 50/60
108W
DATE:
Jan. 2015
Made in Canada
Talstrasse 35-37 8808 Pfäffikon
1
2
3
4
5
6
7
8
Condair Blower Pack Specication label
1 Current phase
2 Serial number (7-digit)
3 Frequency rating
4 Year/month of manufacture
5 Certication symbols
6 Power consumption
7 Voltage rating
8 Model type
12 Product Overview
4.3 Options and Accessories
There are no options or accessories for the Condair Blower Pack.
4.4 Functional Description
The blower pack consists of an electrically-driven fan, an air lter assembly, a distributor assembly, a
steam inlet, a thermostat assembly, a safety relay, fuse and a high/low speed switch. The fan is controlled
by the thermostat assembly and the high/low speed switch. Refer to Figure 3 on page 13.
When the blower pack is powered on, the safety relay closes and permits the humidier to generate
steam when it receives a demand signal. The generated steam enters the blower pack through the steam
adapter into the distributor assembly. A normally-open contact in the thermostat assembly closes when
the temperature reaches approximately 60°C, at which time the fan starts. Air drawn through the air
lter then mixes with the steam and is dispersed into the room/facility through the distributor assembly.
The high/low speed switch controls the speed of the fan, which is set to the specic humidication re-
quirements of the room/facility. Once set, the switch setting should not be altered.
When the steam supply stops, the fan continues to run until the contact in the thermostat assembly
opens as its temperature drops down to approximately 50°C.
A security loop cable attached to the back of the blower pack prevents the humidier from starting if the
safety interlock is disabled. A warning message "Blower pack not connected" is displayed on the humidier.
13Product Overview
Figure 3:
1
2
3
7
8
9
10
11
12
5
13
4
6
Condair Blower Pack Components
1 Air lter assembly
2 Cover assembly
3 Fan assembly
4 Safety relay
5 Housing
6 Specication label
7 Security loop cable
8 Power cable
9 Fuse
10 High/low speed switch
11 Steam adapter
12 Distributor assembly
13 Thermostat assembly
14 Installation
5 Installation
5.1 General
Strictly observe and perform all installation tasks including the mounting of the unit and connection of
the water, steam and power supplies as described in this manual.
Observe and comply with all local regulations dealing with water, steam and electrical installations.
Condair does not accept any liability for installation of humidication equipment by unqualied personnel,
or the use of equipment/parts that are not authorized by Condair.
PersonnelQualications
All installation work must be performed only by well qualied personnel authorized by the customer. It
is the customer’s responsibility to verify qualications of the personnel.
Safety
Some installation work requires removal of the door panels/covers on the blower pack and humidier.
Please note the following:
DANGER!
Risk of electric shock!
The Condairhumidierandblowerpackaremainspowered.Livepartsmaybeexposedwhen
the door panels/covers are removed. Touching live parts may cause severe injury or even death.
Prevention:The Condair humidier and blower pack must be connected to the mains only after all
installation work has been completed, checked for correct workmanship, and the door panels/covers
are installed and fastened securely.
CAUTION!
Electrostatic discharge (ESD)!
Theelectroniccomponentsinsidethehumidieraresensitivetoelectrostaticdischarge(ESD).
Prevention: Take appropriate measures to protect the electronic components inside the units against
damage caused by electrostatic discharge (ESD). Refer to IEC 61340.
15Installation
5.2 Installation Overview
The multi-platform Condair blower pack can be installed remotely with any Condair EL or RS humidier,
or mounted directly onto the Condair EL (5-45 kg/h) or the Condair RS (5-40 kg/h) humidiers. Multiple
blower packs can also be used remotely with large humidiers equipped with two steam cylinders. Figure
4 shows typical mounting congurations of the blower pack(s) and humidier.
Figure 4:
1
13
11
14
12
10
9
5
6
4
7
8
2
3
Typical Installation of Blower Pack with Condair EL/RS Humidier
1 Blower packs (multiple, remote-mounted with
large humidier)
2 Electrical disconnect switch - control voltage
supply
3 Electrical disconnect switch - heating voltage
supply
4 Drain line (see Note 1 below)
5 Air gap funnel and trap (see Note 2 below)
6 Condensate drain connection to cylinder (for
remote unit)
7 Condensate drain connection to drain (for
remote unit)
8 Condensate drain line (alternate, to oor drain)
9 Condensate drain line (see Note 3 below)
10 Blower pack (single, remote-mounted)
11 Steam line (see Note 4 below)
12 Blower pack (single, direct-mounted)
13 High limit humidistat (external security loop)
14 Humidity sensor or controller
16 Installation
Note 1: The drain line should have a minimum internal diameter of 30 mm, with a constant downslope
(minimum 15% or 8.5°) to the air gap funnel, and must not touch the sides or bottom of the funnel. Use
stainless steel or plastic pipe if using DI or RO water.
Note 2: The air gap funnel and trap should be located away from the control cabinet in the humidier to
prevent any rising steam from damaging the electrical components in the cabinet.
Note 3: Condensate drain line should have a constant downslope (minimum 15% or 8.5°), with no re-
strictions and a trap diameter of 150 mm. The trap should be located a minimum of 300 mm below the
blower pack/steam line. Also see note below.
Note 4: The steam line should be as short as possible, to a maximum of 4 m long, with constant up-
slope/downslope (minimum 15% or 8.5°), and without any restrictions in the line. Steam lines must not
merge except at the blower pack (and only through a Condair adapter). A condensate line must also be
installed just before the restriction. Condensate line must be installed at the lowest point in the steam
line, and must connect into a full-size "Tee" connector.
17Installation
In addition, multiple blower packs can also be used remotely with Condair GS 195/260 humidiers with
the aid of an adapter. Refer to Figure 5. Contact your Condair representative for additional details.
Figure 5:
1
4
3
3
2
3
Typical Installation of Multiple Blower Packs with Condair GS Humidier
1 Blower packs (multiple, remote-mounted)
2 Floor drain (see Note 1 above)
3 Condensate drain line (see Note 3 above)
4 Adapter
To mount the blower pack remotely refer to "Remote-Mounted Blower Pack Installation" on page 26.
For humidier-mounted blower pack refer to "Direct-Mounted Blower Pack Installation" on page 33.
18 Installation
5.3 Site Requirements
In preparation for installation of the Condair Blower Pack, the following site requirements must be satisi-
ed. Report any discrepancies to the site engineer.
Steam and Condensate Lines
The selected location for installation of the blower pack should allow proper routing of the steam
and condensate lines as described in "Best Practices for Steam and Condensate Lines Installation"
on page 20.
The length of the steam line is kept as short as possible (to a maximum of 4 m) to minimize heat
loss through the steam line.
Mounting
The selected location for the humidier and blower pack should meet the requirements described
in "Location and Clearances" on page 19.
The blower pack is designed for wall-mounting in protected interiors. The surface (wall, pillar, etc.) to
which the blower pack and humidier are to be mounted must oer a suciently high load-bearing
capacity, and be suitable for the installation. Refer to "Size and Weight" on page 51.
The blower pack has an ingress protection rating of IP21. As a safeguard, the unit should be installed
and operated in a drip-proof location within buildings where the permissible ambient temperature
and humidity conditions are maintained. Refer to "Operating Data" on page 51 for details.
The blower pack should not be mounted on hot or very cold surfaces, or near vibrating components,
or on the oor.
The blower pack should not be used as a ducted blower. The air volume from the blower pack is not
sucient for proper operation in a ducted system.
Power Supply
The available voltage and phase of the power supply should match the requirements for the blower
pack, as indicated on the specication label. Refer to Figure 2 on page 11.
19Installation
5.3.1 Location and Clearances
The installation of the blower pack depends largely on the location of the humidier as well as clearances
required to ensure steam does not come in contact with any surfaces before it is absorbed into the air.
Refer to Figure 6 and Table 1 for blower pack minimum clearance requirements.
The clearance dimensions shown are for reference only, and are the minimums required for the proper
functioning of the equipment. Consult local and national installation codes. Condair does not accept
responsibility for violations of installation codes.
Figure 6:
A
B
B
CC
D
D
D
E
D
A
2
1
Blower Pack Clearance Requirements
1 Direct-mounted blower pack
2 Remote-mounted blower pack
Table 1: Minimum Clearances
Fan speed: Low Fan speed: High
Humidier steam capacity kg/h 5...10 >10...20 >20...30 >30...45 5...10 >10...20 >20...30 >30...45
A (minimum) m2.5 5.5 8.0 9.5 2.0 3.0 4.5 6.5
B (minimum) m0.5 0.5 0.5 1.5 0.5 0.5 0.5 1.0
C (minimum) m2.2
D (minimum) m0.5
E (minimum) m1.0
E (maximum) m4.0 (recommended: 2.0)
Note:
The values shown are based on nominal conditions: 15 ˚C, 60% RH
Blower pack should not be installed near cold surfaces or where dew point may be reached.
Higher humidity or lower room temperature may require increased clearances.
20 Installation
5.4 Best Practices for Steam and Condensate Lines Installation
Before proceeding with installation, Condair recommends that you familiarize yourself with the best
practices for installing atmospheric steam lines and condensate lines described below. Refer to Figure
7 on page 23.
Steam Lines
– Use rigid steam pipes made of copper or stainless steel (minimum DIN 1.4301) exclusively, and use
steam hoses for short distances only. Use original steam and condensate hoses from your Condair
representative. Steam and condensate lines made of any other materials may adversely aect the
operation of the unit.
WARNING!
Excessivebackpressurecanresultinseriousinjuryordamagetoequipment!
Excessive backpressure in the steam line may aect the proper functioning of the humidier, and
may also cause unexpected release of hot steam vapours. Bare skin exposed to the hot steam
vapours can result in severe burns.
Prevention: Minimize the length of the steam line and the number of bends, as the backpressure
can rise approximately 100 Pa for every meter of steam line, and every 90° elbow.
– The length of the steam line should be kept as short as possible – maximum 4 m. Exceeding the
maximum length can aect performance of the unit.
IMPORTANT! When determining the length and routing of steam lines, allowances must be made
for thermal expansion. If a steam hose is used, allowances must be made for shrinkage in the
length of the hose due to aging.
– The inside diameter of the steam line must match the diameter of the steam adapter on the humidier.
– Use long radius elbows for steam lines – the minimum bend is 5× the internal diameter. Steam hoses
should have a minimum bend radius of radius of 300 mm.
– Do not decrease the diameter of the steam line, as it increases the backpressure in the line and
condensation of the steam. If necessary, increase the diameter of the steam line on the downslope,
and install a condensate line at the lowest point. Once expanded, a reduction in diameter is not
permitted except at the blower pack. Install a Condair steam line reducer at the connection to the
blower pack, and install a condensate line just before the restriction. Contact your Condair repre-
sentative for details of the reducer.
– If using blower packs with large humidiers (with dual steam cylinders), do not connect the output from
both steam cylinder to a single blower pack. Each blower pack has a maximum capacity of 45 kg/h.
– For Condair GS humidiers use an adapter to distribute the stream to more than one blower pack
– refer to Figure 5 on page 17. For details of steam lines for Condair GS humidiers contact your
Condair representative.
– The steam line from the humidier must lead straight upwards for a minimum of 300 mm before
continuing to the blower pack. The steam line must have a constant slope – minimum upslope/
downslope of 15% (8.5°), and have no restrictions in the line.
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