Condair DL Series User manual

2603657-A EN 2207
Air Humidication and Evaporative Cooling
SERVICE MANUAL
Adiabatic humidification system
Condair DL II
For internal use only!
READ AND SAVE THESE INSTRUCTIONS

Contact
Condair Ltd.
2740 Fenton Road, Ottawa, Ontario K1T3T7
TEL: [phone], FAX: [phone]
EMAIL: [e-mail], WEBSITE: www.condair.com
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Ltd. Neither this document, nor
the information contained herein shall be reproduced, used, or disclosed to others without the written authorization
of Condair Ltd., except to the extent required for installation or maintenance of recipient's equipment.
Liability Notice
Condair Ltd. 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 authorized by Condair Ltd.
Copyright Notice
© Condair Ltd. All rights reserved.
Technical modications reserved

3Contents
Contents
1 Introduction 5
2 For your safety 6
3 Initial commissioning of the Condair DL 8
3.1 Requirements 8
3.2 First steps after installing the water supply and drain 8
3.3 Quick check electrical installation 13
3.4 Setup table for silver ionization capacity counter 14
3.5 Final check of control unit (with "0948") 15
3.6 Testing the options 15
4 Calculation of the nozzle output 16
4.1 Nozzle specications 16
4.2 Calculations 16
4.2.1 Calculations for systems with pump 16
4.2.2 Calculations for systems without pump 17
4.3 Spray circuit assignment and spray circuit capacities 18
5 Frequency converter (FC) 19
5.1 Diagram of frequency converter (see also wiring plan DL) 19
5.2 Programming the frequency converter 20
5.3 Buttons on the frequency converter and its operation: 21
5.3.1 Programming or data check 21
5.3.2 Procedure for activating the speed display instead of current or frequency 22
5.4 Programming instructions for adapters with SD card (1) 22
5.4.1 Programming steps 23
6 Motors 24
7 Pump 25
7.1 Pump marking 25
7.2 Starting point of pumps 25
8 Overview central units 27
9 Valve block 35
9.1 Valve block – 7 Steps 35
9.2 Valve block – 15 Steps 36
9.3 Valve block – 31 Steps 37
9.4 Valve block – 3 Steps 38
10 Integrated Controller IC 2.0 39
10.1 Software update 39

4Contents
11 Engineering settings 41
11.1 Settings in the "Engineering" submenu 41
11.1.1 Settings in the "Operating Mode" submenu 41
11.1.2 Settings in the "Flushing" submenu 42
11.1.3 Settings in the "Conductivity Flush" submenu 43
11.1.4 Settings in the "Conductivity" submenu 44
11.1.5 Settings in the "Temperature" submenu 46
11.1.6 Settings in the "Step Control" submenu 47
11.1.7 Settings in the "Frequency Converter" submenu 50
11.1.8 Settings in the "Water Inlet" submenu 52
11.1.9 Settings in the "Ag-Ion" submenu 53
11.1.10 Settings in the "Countdown" submenu 54
11.1.11 Settings in the "Reset Conguration" submenu 54
11.2 Settings in the "Hardware Options" submenu 55
11.2.1 Settings in the "Leak Monitoring" submenu 55
11.2.2 Settings in the "Disinfection Pump" submenu 56
11.2.3 Settings in the "Ext. Pipe Flush" submenu 57
11.2.4 Settings in the "Air Cleaning" submenu 57
11.2.5 Settings in the "Auxiliary Outlet" submenu 58
11.3 Settings in the "Features" submenu 59
11.3.1 Settings in the "Softstart" submenu 59
11.3.2 Settings in the "Converter" submenu 61
11.3.3 Settings in the "Pre-Wet" submenu 62
11.4 Functions and settings in the "Maintenance" submenu 63
11.4.1 Functions in the "Reset" submenu 63
11.4.2 Settings in the "Settings" submenu 64
11.4.3 Settings in the "Disinfection Timer" submenu 64
11.4.4 Functions in the "Histories" submenu 65
11.4.5 Functions in the "Diagnostics" submenu 65
11.4.5.1 Settings in the "Manual Demand" submenu 66
11.4.5.2 Display functions in the "Input Diagnostics" submenu 67
11.4.5.3 Functions in the "Output Diagnostics" submenu 68
11.4.5.4 Functions in the "RFI Diagnostics" submenu 69
12 Start sequence diagram 70
13 Hydraulic and electrical diagram 71
13.1 Hydraulic diagram 71
13.2 Wiring plan Condair DL 72
13.3 Wiring diagram Condair DL 73
14 Overview of variants 74
15 Checklist for commissioning 75

5Introduction
1 Introduction
This service manual is aimed at trained Condair service technicians and requires good knowledge of
the Condair DL. In addition, it is prerequisite that the service technician is aware of the installation and
operating instructions of the Condair DL and is familiar with the hazards involved in handling the device.
This service manual contains the following information:
– Description of initial commissioning
– Description of engineering level settings of the Condair DL control unit
– Description and fault diagnosis of the frequency converter
Symbols used in this manual
CAUTION!
The catchword "CAUTION" used in conjunction with the general caution symbol designates notes in
this service manual that, if neglected, may cause damage and/or malfunction of the unit or other
material assets.
WARNING!
The catchword "WARNING" used in conjunction with the general caution symbol designates safety
and danger notes in this service manual that, if neglected, may cause injury to persons.
DANGER!
The catchword "DANGER" used in conjunction with the general caution symbol designates safety
and danger notes in this documentation that, if neglected, may lead to severe injury or even death
of persons.

6For your safety
2 For your safety
General
The service technicians working with the Condair DL must have read and understood this service manual
as well as the installation and operating instructions of the Condair DL before carrying out any work.
Knowing and understanding the contents of the Condair DL service manual and the installation and
operating instructions is a basic requirement for protecting personnel against any kind of danger, to
prevent faulty operation, and to operate the unit safely and correctly.
Qualication of personnel
All work described in this service manual may only be carried out by specically trained Condair
service technicians.
It is assumed that all service technicians working with the Condair DL are familiar and comply with the
appropriate regulations on work safety and the prevention of accidents.
Danger that may arise from the adiabatic humidication system Condair DL
DANGER!
Risk of electric shock
The control unit of the adiabatic humidication system Condair DL is operated with mains volt-
age. Live parts may be exposed when the control unit is open. Touching live parts may cause
severe injury or danger to life.
Prevention: Before carrying out any work on the Condair DL humidication system, disconnect the con-
trol unit from the mains using the electrical isolator and secure the electrical isolator against inadvertent
power-up (Wait at least another 10 minutes before starting work on the frequency converter or motor)
WARNING!
Health risk because of inadequate hygiene
Improperly operated or poorly maintained adiabatic humidication systems may endanger
health. Improper operation or poor maintenance can lead to the proliferation of pathogenic
germs (such as Legionella, which cause Legionnaires' disease) in the water system and in
the area of the humidication unit of the humidication system Condair DL, which may also
escape into the surrounding air.
Note:
Improper changes to the engineering level parameters can lead to system malfunction.
Depending on the circumstances, fully hygienic operation cannot be ensured, such as when:
– Conductivity limits are increased
– Flushing intervals are increased
– Maintenance intervals are increased
– Flushing times are reduced
– The silver ionization current is reduced
– Spray circuit capacities are entered incorrectly
If there is any doubt, do not change any of the parameters.

7For your safety
DANGER!
Risk of electric shock
The frequency converter in the control unit of systems with booster pump contains capacitors.
These can remain charged with a potentially deadly voltage for a certain period of time after
the control unit has been disconnected from the power supply!
Prevention: Wait at least 10 minutes after disconnecting the power supply. Then make sure the ap-
propriate contacts on the frequency converter and the terminals on the pump motor are free of voltage
before starting any work on these components!

8Initial commissioning of the Condair DL
3 Initial commissioning of the Condair DL
3.1 Requirements
For the rst commissioning it is assumed that the components of the adiabatic humidication system
Condair DL (control unit, central unit and humidication unit) are correctly installed and connected and
that the installations have been checked for correct workmanship.
Before you continue with the steps in Section 3.2.
1. Remove the lter cartridge(s) from the lter housing(s) in the water supply line.
2. Disconnect the water supply line on the central unit, run it into a drain and rinse the line for at least
10 minutes to prevent the system from becoming contaminated by standing water or contamination
by chips and rust particles.
3. Then reinstall the lter cartridge(s) and connect the water supply line to the central unit.
3.2 First steps after installing the water supply and drain
1. Make sure that the control unit of the Condair DL is disconnected from the power supply via the
electrical isolator and that it is secured against being switched on unintentionally.
2. Remove the front covers of the control and central unit.
3. Open the motor terminal box in the central unit and check the position of the cable shielding braid
in the stainless-steel cable gland.
The EMC cable glands on the motor terminal box and on the housing of the control unit (below the
frequency converter, see Fig. 1 and Fig. 2) are used for contacting the shielding braid. The stripped
parts of the motor cable must be positioned in such a way that the shield can be contacted easily
through the steel spring inside the cable gland. The shielding braid must not touch a conductor under
any circumstances! Make sure that the stripping is only in the EMC cable gland area; it must not
protrude too far into the terminal box.
Fig. 1: Motor terminal box with stainless
steel EMC cable glands
Fig. 2: Motor cable with an exposed shield-
ing braid
4. If not already connected, connect the motor cable to the motor.
Note: The motor runs with 3x230V and must be congured for a delta circuit:
– Strand 1 = L1 = U
– Strand 2 = L2 = V
– Strand 3 = L3 = W

9Initial commissioning of the Condair DL
5. If the motor cable needs to be connected to the frequency converter, it is connected as follows:
Strand numbers:
1 = U
2 = V
3 = W
Warning: If a different order is chosen, the pump will run in the wrong direction!
6. Two separate protective earth conductors must be guided to the terminals into the inner part of
the control unit. There is a danger of electric shock on the motor or sheet metal part due to the dis-
charge current of the lter at the frequency converter if the protective earth conductor is missing!
Please observe the safety instructions in the operating instructions.
Earth conductors (PE)
Fig. 3: Two separate protective earth conductors
7. Connect the mains supply cable, if not already connected:
• Route the mains supply cable via an electrical isolator or provide a socket so that the device can
be isolated from the mains in all poles.
– Socket for DL type A and B: 200-240 VAC / 15 A slow acting fuse
– Socket for DL type B only: 100-115 VAC / 15 A slow acting fuse
Fig. 4: Electrical isolator (provided by customer)
• Route the mains supply cable through the cable gland and inside the control unit, wind 1x around
the snap ferrite (one loop).
Note: If it is not possible to wind a loop with the stiff wires at hand, two snap ferrite cores can
be xed one after the other to the mains supply (without a loop, route cable through directly)
Then connect to terminals as follows:
– Terminals: L1, L2 and PE for DL type A and B with 200-240 VAC
– Terminals: L1, N and PE for DL type B with 100-115 VAC
Fig. 5: Snap ferrite core for better EMC
8. If not already connected: Connect the control signal, safety loop, and enable, see wiring diagram
afxed to the inside of the cover or in the Condair installation manual!
9. Reattach and lock the front covers of the control and central unit.

10 Initial commissioning of the Condair DL
10. Switch on the electrical isolator (see Fig. 4) and the on/off switch on the right side of the control unit
housing. Then, open the shut-off valve in the water supply line.
Wait until the controller starts up.
11. If the warning message W50 "Out of Commissioning" is displayed after switching on the control
unit, access the menu with the engineering password "0948". Then, select "Menu > Password:
0948 > Maintenance > Reset > Commissioning Reset" submenu and conrm the message after
having ushed the external water supply line. The warning message W50 "Out of Commissioning"
also appears if the control unit has been disconnected from the mains for more than 48 hours (see
also Section 11.4.1).
12. Under "Menu > Password: 0948 > Maintenance > Settings" set the "Humidication" function to "Off"
so that there is no unexpected humidication.
13. Press the "Manual Functions" button in the home screen and then trigger the ushing function (see
Fig. 6) in order that the inlet valve opens, and the system is vented.
Flush the central unit with the ushing function 2 times for at least 5 min.
09/01/2021DL
07:00 pm
Manual Functions
Flushing
Ceramic Wash Over
09/01/2021DL
07:00 pm
Home
Next Maintenance
1685 hr
Demand
Standby
0%
09/01/2021DL
07:00 pm
Flushing
Manual Functions
Back Continue
09/01/2021DL
07:00 pm
Flushing
60 %
In Progress
Cancel
12 3 4
Fig. 6: Triggering a system ushing
14. Access the menu with the engineering password "0948".
15. Access "Output Diagnostics" under "Menu > Maintenance > Diagnostics".
16. Select <Y1 Inlet Valve> parameter and open the inlet valve Y1. The system will be ushed via the
drain valve Y10 (open without current)! Water must be visible or audible at the drain downstream of
the water jet pump.
17. If still open, close the safety loop to trigger the spray valves.
18. After the ushing select <Y10 Drain Valve> parameter and close the drain valve Y10.

11Initial commissioning of the Condair DL
19. Via the <Y5 Spray Valve>, <Y6 Spray Valve>, <Y7 Spray Valve>, <Y8 Spray Valve> and <Y9 Spray
Valve> parameters open one spray valve after the other and check that the piping to the nozzle
grids is correct. Close spray valve after test again. This ensures that an incorrectly connected spray
circuit will be recognized.
– Y5 red (smallest spray circuit)
– Y6 blue
– Y7 yellow (only with 7, 15 or 31 steps)
– Y8 green (only with 15 or 31 steps)
– Y9 grey (only with 31 steps)
20. This step must be carried out only on systems with pump:
• Remove the safety plug from the bottom hole in the pump adapter (see white arrow in Fig. 7).
• Set parameters <FC Status> and <FC Enable> to "On" (Path: Menu > Password: 0948 > Main-
tenance > Diagnostic > Output Diagnostics).
Caution! The water supply to the system must be open, otherwise there is danger of dam-
age the pump by dry running condition.
• Set <FC Setpoint> parameter to 0.3 V (Path: Menu > Password: 0948 > Maintenance > Diag-
nostic > Output Diagnostics).
• Visually check the direction of rotation through the bottom hole.
WARNING!
Risk of injury
There are rotating parts inside the pump adapter. Do not put your ngers or objects into
the opening of the pump adapter!
The arrow on the pump adapter points in the right direction (see white circle in Fig. 7).
Note: If the rotation direction is incorrect, 2 strands on the motor need to be exchanged.
DANGER!
Risk of electric shock
Before replacing the strands, switch off the control unit and wait at least 10 minutes.
Then check whether the corresponding connections on the frequency converter and on
the pump motor are voltage-free before you start working on the cabling!
• If the strands had to be replaced, switch on the control unit again. Check the direction of rotation
again according to the steps under point 20.
• Set <FC Setpoint> parameter to 0.0 V as well as <FC Status> and <FC Enable> parameters to
"Off" and remount the safety plug (see white arrow in Fig. 7).
Fig. 7: Rotation direction of pump
21. Check the spraying capacities of the individual spray circuits under "Menu > Password: 0948 > En-
gineering > Step Control > Spray Circuit 1...n" submenu. Spray circuits assignment and spray circuit
capacities see Section 4.3.

12 Initial commissioning of the Condair DL
22. Under "Menu > Password: 0948 > Maintenance > Settings" set the "Humidication" function to "On".
Then set the parameter "Demand" under "Menu > Password: 0948 > Maintenance > Diagnostics >
Manual Demand" to 100%. The humidier starts humidifying after a delay.
Steps 23 to 27 must be carried out only on systems with pump. Otherwise proceed with step 28.
23. Wait until the pump is running at full speed.
Target speed: 1200 – 1800 rpm (average 1500 rpm)
Fig. 8: Pump speed display of FC at 1590 rpm
For a pulsating pump, see settings in Section 11.1.7.
24. Under "Menu > Password: 0948 > Maintenance > Manual Demand", observe the parameter "PS5
Nozzle Pressure".
At a pump speed between 1200 and 1800 rpm, a pressure of 108.8 psi ±2.9 psi (7.5 bar ± 0.2 bar)
must be achieved at "PS5".
25. If the speed is not in the desired range, it can be adjusted by turning the pump adjustment screw.
Turn very slowly and wait for at least 30 seconds after every turn.
• Unscrew the adjustment screw on the pump = increase speed
• Screw in the adjustment screw on the pump = decrease speed
Fig. 9: Pump adjustment screw
26. Switch the humidication on/off by briey disconnecting the safety loop.
Similar pressure and speed values should be reached again.
27. Do not change the screw of the pressure relief valve again; secure with a dab of red paint if neces-
sary.
28. Check the tightness of the spray circuits piping.
29. Return to the home screen.

13Initial commissioning of the Condair DL
Basic setting of pump speed on systems with pump (usually does not need be done on site,
except after the replacement of the pump)
1. Unscrew the adjustment screw on the pump as far as possible so that the resulting pump pressure
is as small as possible.
Warning: If it is screwed out too far, the adjustment screw will begin to drip, or the valve may fall
out of the thread.
2. Set the parameter "Demand" under "Menu > Password: 0948 > Maintenance > Diagnostics > Manual
Demand" to 100%.
3. Under "Menu > Password: 0948 > Maintenance > Manual Demand", observe the parameter "PS5
Nozzle Pressure".
Screw in the screw of the pressure relief valve quickly until "PS5" shows a pressure of 116 psi ±2.9 psi
(8 bar ±0.2 bar). Do not adjust the pressure anymore! After 1-2 minutes a pressure of 108.8 psi
±2.9 psi (7.5 bar ± 0.2 bar) must be reached.
4. On the display of the frequency converter, a speed of between 1200 and 1800 rpm must be reached
when "PS5" shows a pressure is 108.8 psi (7.5 bar).
5. Slightly adjust the speed of the pump if necessary.
• Unscrew the adjustment screw on the pump = increase in speed
• Screw in the adjustment screw on the pump = decrease in speed
6. Briey switch off humidication and then switch on again. The approximate pressure and speed
values should be reached again.
7. Mark the adjustment screw on the pump with a dab of paint.
3.3 Quick check electrical installation
1. Is the electrical isolator (provided by the customer) installed in the mains supply by an electrician or,
alternatively, is a socket installed that allows the device to be isolated in all poles?
2. Has the mains supply been wound with one loop through the ferrite core provided?
3. Are two protective earth conductors connected?
4. Is a residual current circuit breaker with max. 30 mA fault current installed?
Note: The residual current circuit breaker must be suitable for devices with frequency converter,
e.g., Type B or F!
5. Has the bridging of the safety loop been removed?
6. Has the bridging of the enable contact been removed (if enable contact is used)?
7. Is the control signal setting correct?
8. Check the voltage and function of the remote operating and fault indication.
Warning! Pay attention to line laying at 230 V AC! Separate clearly from the 24 V.
9. If possible, check the control signal and, if present, the enable signal.

14 Initial commissioning of the Condair DL
3.4 Setup table for silver ionization capacity counter
Thecurrent data is only for informational purposes and does not need to be entered!
Total nozzle output [lb/hr]
[kg/hr]
44 66 88 132 176 220 265 276 309 353
20 30 40 60 80 100 120 125 140 160
Type of silver cartridge
"Hygiene Plus"
20 30 60 60 125 125 125 125 250 250
Ionization current [mA] 0.6 0.9 1.2 1.8 2.3 2.9 3.5 3.7 4.1 4.7
Capacity counter [Ah] 3.6 3.6 7.3 7.3 14.6 14.6 14.6 14.6 29.2 29.2
Total nozzle output [lb/hr]
[kg/hr]
180 200 220 240 250 260 280 300 320 340
397 441 485 529 551 573 617 661 705 750
Type of silver cartridge
"Hygiene Plus"
250 250 250 250 250 500 500 500 500 500
Ionization current [mA] 5.3 5.8 6.4 7.0 7.3 7.6 8.2 8.8 9.3 9.9
Capacity counter [Ah] 29.2 29.2 29.2 29.2 29.2 58.4 58.4 58.4 58.4 58.4
Total nozzle output [lb/hr]
[kg/hr]
360 380 400 420 440 460 480 500 550 600
794 838 888 926 970 1014 1058 1102 1213 1323
Type of silver cartridge
"Hygiene Plus"
500 500 500 500 500 500 500 500 500 500
Ionization current [mA] 10.5 11.1 11.7 12.3 12.8 13.4 14.0 14.6 16.1 17.5
Capacity counter [Ah] 58.4 58.4 58.4 58.4 58.4 58.4 58.4 58.4 58.4 58.4
Total nozzle output [lb/hr]
[kg/hr]
650 700 750 800 850 900 950 1000
1433 1543 1653 1764 1874 1984 2094 2205
Type of silver cartridge
"Hygiene Plus"
500 500 500 500 500 500 500 500
Ionization current [mA] 19.0 20.4 21.9 23.3 24.8 26.3 27.7 29.2
Capacity counter [Ah] 58.4 58.4 58.4 58.4 58.4 58.4 58.4 58.4

15Initial commissioning of the Condair DL
3.5 Final check of control unit (with "0948")
1. Language and units (Metric / Imperial)
(Path: "Menu > Password: 0948 > General > Region")
2. Current date, current time, date format (English / German) and clock format (12h / 24h) and day-
lightsaving (summer/winter time)
(Path: "Menu > Password: 0948 > General > Date & Time")
3. Ah meter of silver ionization
(Path: "Menu > Password: 0948 > Engineering > Ag-Ion > Capacity")
4. Spray circuit capacity in lb/hr per spray circuit (max. 5 spray circuits)
(Path: "Menu > Password: 0948 > Engineering > Step Control > Spray Circuit n")
Note: Spray circuit assignment and spray circuit capacities see Section 4.3.
5. Device type (Humidier / Humidier + FC / Humidier + FC - Off)
(Path: "Menu > Password: 0948 > Engineering > Operating Mode > DL Type")
6. Flushing time depending on system size
Note: A long supply line must possibly be rinsed longer.
(Path: "Menu > Password: 0948 > Engineering > Flushing > Time before Humidic...")
7. Control by analog control signal or via Modbus/BACnet:
(Path: "Menu > Password: 0948 > Controls > Signal Settings > Source")
8. Are installed option activated?
(Path: "Menu > Password: 0948 > Hardware Options > ...")
9. Flushing timer activated/deactivated
10. Deletion of the Error/Warning History
(Path: "Menu > Password: 0948 > Maintenance > Histories > Clear Error/Warning History")
11. Deletion of the Service History
(Path: "Menu > Password: 0948 > Maintenance > Histories > Clear Service History")
12. Exit the menu to return to home screen.
3.6 Testing the options
1. Moisten leak sensor with demineralized water; alarm must be triggered and inlet valve Y1 must close.
Bridges on sensors:
• End sensor = 1 bridge cut
• Other sensors = both bridges cut
2. Trigger ushing function.
Note: If the optional "external pipe ushing" or "air cleaning" is activated, these must also start.
3. When using an external dosing pump with hydrogen peroxide:
Check the function of the relay for controlling the external dosing pump and the level sensor of the
disinfectant tank.

16 Calculation of the nozzle output
4 Calculation of the nozzle output
4.1 Nozzle specications
Lettering SAP no. Flow rate at
58.0 psi
(4 bar)
Flow rate at
101.5 psi
(7 bar)
Flow rate at
145 psi
(10 bar)
1.5 2580035 3.3 lb/hr
(1.5 l/hr)
4.4 lb/hr
(2.0 l/hr)
5.3 lb/hr
(2.4l/hr)
2.0 2593942 4.4 lb/hr
(2.0 l/hr)
5.7 lb/hr
(2.6 l/hr)
7.1 lb/hr
(3.2 l/hr)
2.5 2580036 5.5 lb/hr
(2.5 l/hr)
7.3 lb/hr
(3.3 l/hr)
8.8 lb/hr
(4.0 l/hr)
3.0 2580037 6.6 lb/hr
(3.0 l/hr)
8.8 lb/hr
(4.0 l/hr)
10.4 lb/hr
(4.7 l/hr)
3.5 2593943 7.7 lb/hr
(3.5 l/hr)
10.1 lb/hr
(4.6 l/hr)
12.1 lb/hr
(5.5 l/hr)
4.0 2580038 8.8 lb/hr
(4.0 l/hr)
11.7 lb/hr
(5.3 l/hr)
13.9 lb/hr
(6.3 l/hr)
4.5 2593944 9.9 lb/hr
(4.5 l/hr)
13 lb/hr
(5.9 l/hr)
15.7 lb/hr
(7.1 l/hr)
5.0 2580039 11.0 lb/hr
(5.0 l/hr)
14.5 lb/hr
(6.6 l/hr)
17.4 lb/hr
(7.9 l/hr)
The ow rate in l/hr shown on the nozzles (lettering) corresponds to the 58 psi (4 bar) nozzle nominal
pressure!
4.2 Calculations
The formulas in Section 4.2.1 and Section 4.2.2 do not apply to the Number of steps "7 Steps Dual2".
Thereto please observe the instructions in the manual for the Condair Dual2.
4.2.1 Calculations for systems with pump
Nozzle output spray circuit 1 (spray valve Y5)
The nozzle output for the smallest spray circuit 1 is calculated for systems with pump as follows:
Nozzle output spray circuit 1 =
Quantity of red marked nozzles (spray circuit 1) x Lettering x Pressure factor
Example: 3 red marked nozzles (spray circuit 1), lettering = 1.5 (3.3 lb/hr), system with pump (nominal
pressure = 101.5 psi (7 bar)) :
3 pcs x 3.3 lb/hr x 1.323 = 13.1 lb/hr
Note: The nozzle output of spray circuit 1 is required to determine the nozzle output of the other spray
circuits. The calculated value may be rounded up to the next tenth (see Section 4.3).
Condair Logo
Lettering

17Calculation of the nozzle output
Total nozzle output of the system
The maximum humidication capacity (= total nozzle output) is calculated for systems with pumps as
follows:
Total nozzle output =
Quantity of red marked nozzles (spray circuit 1) x Number of steps x Lettering x Pressure factor
Example: 3 red marked nozzles (spray circuit 1), 15 steps, lettering = 1.5 (3.3 lb/hr), system with pump
(nominal pressure = 101.5 psi (7 bar)) :
3 pcs x 15 steps x 3.3 lb/hr * 1.323 = 196.5 lb/hr
Calculating the pressure factor for systems with pump:
Nominale pressure DL
= = 1.323
101.5 psi
Nominale pressure nozzle 58.0 psi
4.2.2 Calculations for systems without pump
Nozzle output spray circuit 1 (spray valve Y5)
The nozzle output for the smallest spray circuit 1 is calculated for systems without pump as follows:
Nozzle output spray circuit 1 =
Quantity of red marked nozzles (spray circuit 1) x Lettering x Working pressure
Nominal pressure nozzle
Example: 3 red marked nozzles (spray circuit 1), lettering = 1.5 (3.3 lb/hr), system without pump with
a working pressure of 72.5 psi (5 bar):
Note: If the working pressure through the reverse osmosis system is variable, then the working pressure
at 100% demand must be used in the formula.
72.5 psi = 11.1 lb/hr
58.0 psi
3 pcs x 3.3 lb/hr x
Note: The nozzle output of spray circuit 1 is required to determine the nozzle output of the other spray
circuits. The calculated value may be rounded up to the next tenth (see Section 4.3).

18 Calculation of the nozzle output
Total nozzle output of the system
The maximum humidication capacity (= total nozzle output) is calculated for systems without pumps
as follows:
Total nozzle output =
Quantity of red marked nozzles (spray circuit 1) x Number of steps x Lettering x
Working pressure
Nominal pressure nozzle
Example: 3 red marked nozzles (spray circuit 1), 15 steps, lettering = 1.5 (3.3 lb/hr), system without
pump with a working pressure of 72.5 psi (5 bar):
Note: If the working pressure through the reverse osmosis system is variable, then the working pressure
at 100% demand must be used in the formula.
72.5 psi = 166.1 lb/hr
58.0 psi
3 pcs x 15 steps x 3.3 lb/hr x
Note: The working pressure used in the calculation must correspond to the setting under "Menu > Pass-
word: 0948 > Engineering > Step Control > Nom. Pressure" menu.
4.3 Spray circuit assignment and spray circuit capacities
Spray circuit assignment and spray circuit capacities for Number of steps: 3, 7, 15 and 31 steps
Spray circuit Capacity partitioning per spray circuit
1 (spray valve Y5) Nozzle output spray circuit 1 in lb/hr
2 (spray valve Y6) 2 x Nozzle output spray circuit 1 in lb/hr
3 (spray valve Y7) 1) 4 x Nozzle output spray circuit 1 in lb/hr
4 (spray valve Y8) 2) 8 x Nozzle output spray circuit 1 in lb/hr
5 (spray valve Y9) 3) 16 x Nozzle output spray circuit 1 in lb/hr
Spray circuit assignment and spray circuit capacities for Number of steps: 7 steps Dual2
Spray circuit Capacity partitioning per spray circuit
1 (spray valve Y5) 2/9 of the total nozzle output in lb/hr
2 (spray valve Y6) 3/9 of the total nozzle output in lb/hr
3 (spray valve Y7) 1) 4/9 of the total nozzle output in lb/hr
1) for 7 steps or more
2) for 15 steps or more
3) for 31 steps
Note: The sum of all spray circuits together must match the calculated total nozzle output. See formulas
for total nozzle output calculation in Section 4.2.

19Frequency converter (FC)
5 Frequency converter (FC)
5.1 Diagram of frequency converter (see also wiring plan DL)
DANGER!
The frequency converter in the control unit of systems with booster pump contains capacitors.
These can remain charged with a potentially deadly voltage for a certain period of time after
the control unit has been disconnected from the power supply. Therefore, wait at least 10 mi-
nutes after disconnecting the power supply. Then make sure the appropriate contacts on the
frequency converter and the terminals on the pump motor are free of voltage before starting
any work on these components!
9
10
11
12
13
L1
L2
L3
1
2
4
U
BR
+
–
V
W
41
42
Digital I/O
Zero frequency
Drive enable
Run forward
Run reverse
Drive ok
1 ph/3ph
AC power supply
AC supply
Relay
Digital I/O 1
Digital input 2
Digital input 3
Digital input 4
24 V user
Analog I/O
Analog input 1
DC bus/Brake
Motor
10 V user
0 V
Frequency
reference
Thermal relay
Bracking resistor
(optional)
Fig. 10: Wiring diagram frequency converter

20 Frequency converter (FC)
5.2 Programming the frequency converter
Is the frequency converter programmed correctly? See also explanation of parameters on the cover:
Parameter Name of parameter Value for
0.37 kW
Value for
0.55 kW
Value for
0.75 kW
00.001 Minimum speed 0 Hz 0 Hz 0 Hz
00.002 Maximum speed = 2300 rpm 76.0 Hz 76.0 Hz 76.0 Hz
00.003 Acceleration time 12 s 12 s 12 s
00.004 Delay time 5 s 5 s 5 s
00.005 Signal input 0-10 V AU AU AU
00.006 Motor current
(Motor type plate)
1.8 A 2.2 A 2.9 A
00.007 Motor speed
(Motor type plate)
1370 rpm 1420 rpm 1420 rpm
00.008 Motor voltage
(Motor type plate)
230 V 230 V 230 V
00.009 Capacity factor cos phi
(Motor type plate)
0.73 0.8 0.81
00.010 Access ALL = all parameters
adjustable
11.018 Speed display
(see below!)