Condair Dual 2 User manual

INSTALLATION AND OPERATING INSTRUCTIONS
Hybrid Humidifier
1120506 EN 1308
Condair Dual 2

3
Contents
1 Introduction 4
1.1 To the very beginning 4
1.2 Notes on the installation and operating instructions 4
1.3 Special tools 5
2 Important notes 6
2.1 Correct use for intended purpose 6
2.2 Safety instructions 6
3 OverviewoftheCondairDualHybridHumidier 8
3.1 Basic design of the Condair Dual Hybrid Humidier 8
3.2 Function 9
3.3 Scope of versions 11
3.4 Options 13
4 Installationandrst-timecommissioning 15
4.1 Safety notes for installation and commissioning 15
4.2 Installation of the humidication unit 15
4.2.1 Installation of the nozzle system 17
4.2.2 Installation of the post-evaporation unit 20
4.3 Installation of the central unit 35
4.4 Installation of the components of the decentralized system 36
4.5 Water installation 38
4.6 Electrical installation 42
4.7 First-time commissioning 44
5 Operation 45
5.1 Introduction 45
5.2 Commissioning for daily operation 45
5.3 Taking the humidier out of operation 47
5.4 Inquiring operating parameters 48
5.5 Setting up operating parameters 52
6 Maintenance and replacement of parts 57
6.1 Maintenance safety instructions 57
6.2 Important notes on maintenance 57
6.3 Removal and installation of components 60
6.3.1 Removal and installation of ceramic plates 60
6.3.2 Removal and installation of the spray nozzles 62
6.4 Replacement of silver ionization “Hygieneplus” 63
6.5 Replacement of the control unit fuses 64
7 What if ...? 65
7.1 Error messages 65
7.2 Failures 68
7.3 Instructions for fault elimination 69
8 Specications/ambientconditions 70
9 Appendix 71
9.1 Notes on humidity control 71
9.1.1 Notes on humidity control with the internal PI controller 71
9.1.2 Enthalpy control for Condair Dual 72
9.2 Commissioning protocol/Maintenance record 74
9.3 Setup table silver ionization “Hygieneplus” 77

4
1 Introduction
1.1 Totheverybeginning
We thank you for having purchased the Condair Dual 2 HybridHumidier
(abbreviated as “Condair Dual”).
The Condair Dual Hybrid Humidier is designed for use in ventilation devices
and ducts. It combines the humidication technologies “atomization” and
“evaporation”. Due to its modular design, the Condair Dual covers a wide
range of power requirements.
The Condair Dual Hybrid Humidier incorporates the latest technical ad
vances and meets all recognized safety standards. Nevertheless, improper
use may result in danger to the user or third parties and/or impairment of
the installation or other material assets.
All persons working with the Condair Dual Hybrid Humidier must observe
and comply with all information and safety instructions contained in the
present installation and operating instructions.
Please contact your Condair supplier in case of trouble or if you have any
questions concerning humi dication technology in general.
1.2 Notesontheinstallationandoperatinginstructions
Limitation
The present installation and operating instructions contain all information
required for correct installation, operation and maintenance of the Condair
Dual Hybrid Humidier. The information is to be observed by the personnel
in charge of the respective work.
The installation and operating instructions are supplemented by documents
specic to the particular installation (installation drawings, technical
specications and so on). Wherever necessary, these publications are
appropriately cross-referenced in the present installation and operating in-
structions.
As a complement to the present installation and operating instructions
please observe:
– all local safety regulations regarding the handling of mains-powered
electrical devices.
– all instructions and warnings contained in the publications for the prod-
ucts used in conjunction with the Condair Dual Hybrid Humidier.
– all safety instructions regarding the installation (ventilation facility) into
which the Condair Dual Hybrid Humidier is to be incorporated.
– all instructions and warnings provided on the Condair Dual Hybrid Hu-
midier.
– all local sanitary regulations.

5
Conventions
The following conventions apply to the present installation and operating
instructions:
– Steps to be carried out (operational sequence) are preceded by a “•”
bullet.
– This symbol identies safetyanddangerinstructions which, if dis-
regarded, could result in personal injury and/or damage to material
assets.
– This symbol identies additional information and instructions designed
to assist you in handling your hybrid humidier and ensure a proper and
economical operation.
Safekeeping
Please keep these installation and operating instructions in a safe place
where they are always available. If ownership changes, they must be passed
on to the new operator.
If this documentation gets misplaced, please contact your Condair supplier
to obtain immediate replacement.
Languageversions
The installation and operating instructions for the Condair Dual Hybrid Humidi-
er are avail able in several languages. Please contact your Condair supplier
if you require another language version of the present documentation.
1.3 Special tools
Important! Fastening the outer left and right vertical sections to the cross
arms of the post-evaporation unit requires a 5 mm hexagon socket extension
with a length of at least 230 mm (not included in the delivery).
min. 230 mm
ø14 mm
5 mm

6
2 Important notes
Please read this chapter carefully. It contains important information, which
must be observed for safe, correct and economic application of the Condair
Dual Hybrid Humidier.
2.1 Correct use for intended purpose
The Condair Dual Hybrid Humidier is intended exclusively for humidi-
cation in ventilation systems. Any other type of application, without
the written consent of the manufacturer, is considered as not conforming
with the intended purpose. Themanufacturer/suppliercannotbemade
liableforanydamagesresultingfromimproperuse.Theuserbears
full responsibility.
Correct use for intended purpose further includes:
– observation of all instructions, regulations, and notes contained in the
present installation and operating instructions for the Condair Dual Hybrid
Humidier.
– strict adherence to the specied inspection and maintenance inter-
vals.
– correct maintenance of the hybrid humidier.
– compliance with specied ambient and operating conditions.
2.2 Safety instructions
– The Condair Dual Hybrid Humidier must only be installed, operated, and
serviced by persons familiar with the product and sufciently qualied
for the respective task. It is the customer’s responsibility to ensure that
the installation and operating instructions are supplemented by internal
instructions with respect to supervisory and notication liability, working
methods, personnel qualications, etc.
– Do not carry out any operations for which you are not sufciently quali
ed or unfamiliar with the consequences. In case of doubt, contact your
supervisor or Condair supplier beforehand.
– Beforecarryingoutworkingstepson particular components of the
Condair Dual Hybrid Humidier set the ventilation system and the humidi-
er out of service, disconnect them from the power supply by setting
the service switch to “Off” and securetheunitsagainstunintentional
operation.
– Installation, maintenance, and repair of the electrical installation of the
Cond air Dual must be carried out only by qualied personnel being
aware of possible danger and implications.
– Poorly maintained humidication systems may endanger health. There-
fore it is mandatory to observethespeciedmaintenanceintervals
and to carry out maintenance work in strict accordance with the
instructions.

7
– Observe all local safety regulations regarding the handling of mains-
powered electric and electronic equipment.
– Caution! For safety reasons the Condair Dual must be installed
onlyinroomsprovidedwithaoordrain.Ifforsomereasonthe
CondairDualmustbeinstalledinalocationwithoutoordrain,it
is mandatory to provide a water tub with drain or water sensors to
safelyinterruptwatersupplyincaseofleakage(e.g.option“Z402”,
seechapter3.4“Options”).
– For safe operation of the hybrid humidier, make sure the ambient con
ditions meet the respective specications (see chapter 7 “Technical
data/ambient conditions”).
– Caution! Fully demineralized water is aggressive. For this reason, perme-
ate lines and components located close to the humidication unit must
be made of corrosion-proof steel (minimum requirements according to
DIN 1.4301) or plastic.
– If it can be assumed that safe operation is no longer possible, the Condair
Dual must be taken out of service and secured against unintentional
operation. Safe operation may be affected in the following events:
– components of the Condair Dual are damaged.
– the Condair Dual does not work correctly.
– connectors and lines are leaking.
– components of the Condair Dual are worn or badly soiled.
– the post-evaporation elements are not correctly positioned, locked
or sealed.
– after longtime storage under unfavorable conditions.
– after transportation under unfavorable conditions.
– Useonlygenuineaccessoriesandspareparts available from your
Condair supplier.
– The Condair Dual Hybrid Humidier and the optional accessories must
notbemodiedinanyway without the written consent of the manu-
facturer.

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3 OverviewoftheCondairDualHybridHumidier
3.1 BasicdesignoftheCondairDualHybridHumidier
1 Control unit
2 Power supply
3 Control or sensor signal input
4 Connector for external safety circuit
5 Options (to be installed inside the control unit):
Remote operating and fault indication (Z401/Z401S)
RS232 serial interface (option Z404)
RS485 serial interface (option Z405)
6 Shut-off valve (by customers)
7 Filter (by customers, max. mesh width 0.005 mm)
8 Connector (G 1/2") for fully demineralized water
9 Booster pump
10 Minimum pressure switch
11 Excess temperature switch of pump
12 Silver ionization unit
13 Drain with siphon trap (by customers)
14 Drain valve
15 Conductance sensor
16 Connector box with 2 spray valves (3-step)
Connector box with 3 spray valves (7-step,
option Z407)
17 Maximum pressure switch
18 Spray valves
19 Duct drains with siphon trap (by customers)
20 Post-evaporation elements (porous ceramics)
21 Spray nozzles
22 Airltermin.F7/EU7 (by customers)
23a Drain valves (only with option Z409)
23b Water jet pump (only with option Z409)
24 Watertuboroordrain(bycustomers)
ME20
21
16
12
9
10 7 6
8
11
1
2
3
4
5
15
17
14
13
19
22
19
23b
24
23a
18

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3.2 Function
From the reversing osmosis system (RO system) the fully demineralized
water (also called permeate) is fed to the booster pump (9) via a shut-off
valve (7) and a lter (8). Depending on the current output re quirements
the booster pump increases the water pressure to the required operating
pressure of approximately 7 bars (yield load).
From the booster pump the fully demineralized water is fed to the connec-
tor box (16), either directly (on systems for exhaust air cooling) or via the
silver ionization unit (12) which degerminates the water.
If humidication is required, one or both spray valves (18) of the connector
box are opened, depending on the current humidication requirements (if
the optional third spray valve is available, the system opens one, two or all
three valves at a time).
The fully demineralized water is now fed to the respective spray nozzles
(21) producing ne aerosol fog. The air passing by the nozzles absorbs
the aerosol fog thus getting humidied. Aerosol fog not absorbed by the
air is retained in the post-evaporation elements (20) thus humidifying the
air passing through the postevaporation elements. Excess water is ow-
ing down to the bottom of the post-evaporation elements and is led to the
siphon trap (19), via the drain in the water tub.
Control
The system is controlled by an external controller or by the PI controller
built into the control unit.
The standard system with a 2-valve connector box provides a 3-step con-
trol corresponding to 1/3, 2/3 and 3/3 of maximum output. The rst valve
opens at approximately 20 % and the second one at approximately 50%.
If the humidication requirements reach approximately 80% both valves
are open.
Note: systems equipped with the optional third valve provide 7-step control
with respective humidication power.
Monitoring
The system continuously monitors the minimum and maximum pressure,
the conductance of the fully demineralized water, and the temperature of the
booster pump. If the conductance of the fully demineralized water exceeds
the admissible range (max. 15 µS/cm), the drain valve (14) of the connector
box opens and the water system is ushed until the conductance meets the
preset value. A fault message is displayed if the conductance value does
not reach the admissible range within a certain period.
0
0
1
0
0
1
1
1
0123
100
0
0205080 100
0
0
0
1
0
0
01
100
0
01527 100
39 51 63 75 87
0
1
0
2
0
0
1
3
1
1
0
4
1
0
1
5
0
1
1
6
1
1
1
7
Steps 1 to 3
Spray valve Y6
Spray valve Y7
Capacity [%]
Control signal [%]
Steps 1 to 7
Spray valve Y6
Spray valve Y7
Spray valve Y8
Capacity [%]
Control signal [%]

10
Y5
Y6
Y7
Y8
Y9
Y10
Y11
(18)
(17)
(16)
(19)
Spraycircledischarge(onlywithoptionZ409)
Water jet pump
On systems having a central unit with spray circle discharge (option Z409)
the spray circle drain valve Y5 opens after no humidication demand has
occurred for 12 hours. Then, the valves Y9, Y10 and Y11 open one after
the other for approximately 60 seconds to discharge each spray circle via
the water jet pump.

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3.3 Scope of versions
The Condair Dual Hybrid Humidier is available in two versions: either
as “centralized system” (type: CDZE...) or as “decentralized system”
(type: CDDZ...).
In the centralized system the control unit, the booster pump, the silver ion-
ization unit and the connector box are assembled and wired in the form of
a so-called “central unit” on a mountingbase or in a “Z409protective
cabinet”. In the decentralized system the above components can be tted
individually (decentralized).
Centralizedsystem(CDZE...)
1 Humidication unit
2 Central unit including:
2a Control unit
2b Permeate minimum pressure switch
2c Excess temperature switch of pump
2d Booster pump
2e Silver ionization unit
2f Permeate conductance sensor
2g Connector box
2h Permeate maximum pressure switch
3 Electrical connectors (power supply, control or
sensor signal input, connector for external safety
circuit)
4 Shut-off valve (by customers)
5 Filter (by customers, max. mesh width 0.005 mm)
6 Connector (G 1/2") for fully demineralized water
1
2
2h
2g
2f
2e
2d
2c
3
2b
5
4
6
2a
Z409

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Decentralizedsystem(CDDZ...)
1 Humidication unit
2a Control unit
2b Permeate minimum pressure switch
2c Excess temperature switch of pump
2d Booster pump
2e Silver ionization unit
2f Permeate conductance sensor
2g Connector box
2h Permeate maximum pressure switch
3 Electrical connectors (power supply, control or sensor signal
input, connector for external safety circuit)
4 Shut-off valve (by customers)
5 Filter (by customers, max. mesh width 0.005 mm)
6 Connector (G 1/2") for fully demineralized water
1
3
2h
2g
2f
2e
6 2c
2b
2d
5
4
2a

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3.4 Options
Remoteoperatingandfaultindication“Z401”and“Z401S”
By means of 4 potential-free relay contacts, the remote operating and fault
indication PCB (Z401: standard version, Z401S: wire breakage safe version)
allows the connection of remote indicators displaying the following stages
of operation: “standby”, “humidication in progress”, “maintenance due”
and “error”.
Note: The remote operating and fault indication PCB is supplied with sepa-
rate instructions.
SerialinterfacesRS232“Z404”orRS485“Z405”
The serial interface (RS232 or RS485) is used to transmit operational
data from the Condair Dual Hybrid Humidier to a PC or a building control
system.
Note: It is up to the customer to develop installationspecic software. In for
mation on the communication parameters and the data format supported
by the interface is available from your Condair supplier.
Connectorboxwith3sprayvalves“Z407”
The connector box with 3 spray valves allows 7-step control of the Condair
Dual Hybrid Humidier.
Casingforcentralunit“Z408”
The casing protects the central unit and its components from soiling and
damage. The casing may be installed at any time following the installation
of the humidier.
Note: The casing is supplied with separate mounting instructions.
Central unit withspraycircledischarge“Z409”
All components of the central unit with spray circle discharge are integrated
into two rugged protective cabinets. The large cabinet contains the control
unit and the silver ionization. The booster pump is located below the cabi-
net and covered in front and on both sides by a metal apron. The small
cabinet contains the connector box, the spray valves, the drain valve, the
spray circle drain valves and the water jet pump. Both protective cabinets
are constructed in accordance with industry standards and comply with
protection class IP54.
External dimensions of largecabinet (w x h x d) in cm: 60 x 60 x 21
External dimensions of small cabinet (w x h x d) in cm: 50 x 30 x 21

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Leakagemonitoringsystem“Z402”
The “Z402” leakage monitoring system interrupts the water supply in case
of leakage of the Condair Dual water system.
Contents: – 3 leakage detectors including fastening material and
electric cables
– 1 leakage signal transmitter
– 1 safety valve 24 VDC
– 1 transformer 230 VAC / 24 VDC
– Installation instructions
Function: The 3 leakage detectors “A” (in the cabinet holding the control
unit and the silver ionization) , “B” (in the cabinet holding the connector
box) and “C” (fastened to the oor) monitor the water system and report
possible leaks to the leakage signal transmitter “D” which issues an alarm
and interrupts the water supply to the Condair Dual via the safety valve “E”.
The transformer “F” built into the control unit of the Condair Dual supplies
the voltage to the leakage monitoring system.
A
B
C
D
F
E

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4 Installationandrst-timecommissioning
4.1 Safetynotesforinstallationandcommissioning
– Allinstallationandcommissioningworkmustbeperformedonlyby
adequatelyqualiedpersonnelbeingfamiliarwiththeCondairDual
HybridHumidier. It is the customer’s responsibility to ensure suitable
qualication.
– Prior to installation work, the ventilation system (into which the Condair
Dual is to be incorporated) must be taken out of operation and secured
against unintentional start-up.
– It is mandatory to observe and comply with the instructionsregarding
thelocationandinstallationofparticularcomponents of the Condair
DualHybridHumidier(seechapters4.2through4.5).
– Use only the mounting accessories included in the delivery for
installing the various system components. If for some special reasons
an installation with the supplied installation accessories is not feasible,
choose a type of installation that is equally stable. In cases of doubt,
contact your Condair supplier.
4.2 Installationofthehumidicationunit
Importantnotes
Usually, the design and dimensioning of the ventilation duct/monobloc as
wellasthelocationoftheCondairDualHybridHumidierinsidetheduct
are determined, recorded and set compulsory when planning the entire
system. Prior to installation, however, make sure the following criteria have
been taken into consideration:
– Caution,fullydemineralizedwaterisaggressive! For this reason,
allcomponentslocatedclosetothehumidicationunit(duct/monobloc,
fastening material, drain pipe, etc.) must be made of corrosion-proof
steel(minimumrequirementsaccordingtoDIN1.4301)orplastic.
– Forinstallationandmaintenanceofthehumidicationunitaviewing
windowandasufcientlylargemaintenancedoor must be available
in the duct/monobloc.
– Intheareaofthehumidicationunittheventilationduct/monoblocmust
be waterproof.
– Important!Anairltermustbeinstalledattheairinletofthehu-
midication unit. The lter must meet the quality standards F7
(EU7)orbetter.
– In case of low ambient temperature the duct must be insulated to prevent
the moist air from condensing inside the duct.
– Ifthesystemisequippedwithaheater,makesureitisatleast0.5m
awayfromthehumidicationunit.
– In order to avoid drops seeping over the ceramic elements, an evenair
owoverthefullcrosssection of the post-evaporation unit must be
guaranteed.Ifnecessary,rectiersorperforatedplatesmustbeinstalled
onthebuildingsidebeforethehumidier.
If the air velocity in the duct before the post-evaporation unit (in relation
tothehumidicationefciency)exceeds2.5m/s,boosterelementsmust
beinstalled(seechapter4.2.2).

16
– For control and maintenance purposes we recommend to provide the
duct/monobloc with an additional inspection door after the post-evapo-
ration unit.
– Thesectionof theductholdingthe humidicationunitmustbe
equipped with a sloping tub having drains before and after the
post-evaporationunit(pass-throughtub), orwithadrainbeforethe
separationaswellasdrainsbeforeandafterthepost-evaporation
unit(separatedtubs). Eachdrainmustbeconnectedseparatelyto
thewastewatersystemviaasiphon.Forhygienicreasonsconnect
thedrainpipeswithanopenoutlettothewastewatersystemof
thebuilding.
Note: The effective height of the siphon drain depends on the
duct pressure. Correct dimensioning of the siphon drain is the
customer’sresponsibility.
Dimensions
(dimensions in mm, minimum dimensions must be respected)
min. 400 555
min. 130 min. 410
1200
370
+
1200
100
70
+
Side view
slope min. 2°
to center drain
Top view
door
heater
door

17
C
G
H
D
A
B
E
F
4.2.1 Installation of the nozzle system
The components of the nozzle system are supplied separately and must
be assembled at the installation site.
The following sections explain the general installation of the nozzle system.
Detailed information (dimensions, fastening points, etc.) can be found in
the “installationdrawing” supplied with your particular system.
Important! The dimensions listed in the installation drawing are manda-
tory.
The nozzle system comprises the following main components:
A Two xing straps forxingtheverticalmountingrailstotheduct
wall
B Two or more horizontal mounting rails
C Two vertical mounting rails,whicharexedtotheductwallwith
thexingstraps
D A number of connection platesforxingthehorizontalmounting
rails to the vertical mounting rails
E One or more nozzle grids with inserted nozzles
F Four or six grid bearings per nozzle grid
G Two or three housing lead-throughs
H Connecting hoses building side (hoses must be installed with
constant downslope towards the housing lead-throughs)
Flow direction

18
First x the two vertical mounting rails on both sides in the duct (see instal-
lation drawing for positioning and xing).
Important! Use exclusively the xing materials provided. If this is not pos-
sible in your case, make absolutely sure that the xing holes are correctly
sealed from the inside of the duct with suitable components.
3. Fix the horizontal mounting rails to the connector plates using the screws
and sliding nuts provided.
4. Inductsbeingwiderthan2m:
– connect all the adjacently positioned horizontal mounting rails (at
the centre, if possible) using the proled screwed connector/s pro-
vided.
– mount the vertical strut/s between the horizontal mounting rails at
the specied position.
– mount the supplied ceiling attachment and bottom support to the duct
ceiling and the duct bottom using the self-tapping screws provided
(rst drill the ø3.3 mm holes).
1. Mark the positions of the holes for the xing straps on the duct wall and
drill the ø3.3 mm holes.
Important! Make sure that the xingholesin the left and right duct
wall are exactlyalignedoppositeeachother and that the axes of
the upperandlowerxingholesareatrightanglestotheceiling
of the duct.
Then, x the vertical mounting rails to the wall of the duct with the xing
straps and screws provided.
2. Fix the connector plates to the vertical mounting rails using the screws
and sliding nuts provided.
12 3
ø3.3 mm
4
ø3.3 mm
ø3.3 mm

19
5. Fix the grid bearings to the prescribed positions on the horizontal mount-
ing rails, using the screws and sliding nuts provided.
6. Mount bearing sleeve “A” and the three or ve bearing bushes “B” on
the nozzle grid.
7. Insert the nozzle grid/s in the frames at the appropriate position/s (note
numbering on the installation drawing).
Note: The nozzles are provided with a protective cap Ex-works, so that
no dirt can ingress. Remove these caps immediately before commis-
sioning the system.
8. Erect the housing lead-throughs (2 or 3, depending on the system) for
the spray circuits: Bore the ø19 mm holes and install the housing pas-
sages in accordance with the adjacent illustration.
Important! The housing lead-throughs must be positioned in a way
that the hoses (building side) between the connections on the nozzle
grid and the housing lead-throughs, and between the housing lead-
throughs and the the small cabinet (option Z409) can be installed with
a constant downslope.
Now connect the spray circuits with the housing lead-throughs in ac-
cordance with the installation drawing provided. In so doing, note the
following points:
– The nozzles for the individual spray circuits are identied with colored
bushings (red, blue and yellow).
– Useonlythe suppliedhoses ø10/8mm (outside the duct) and
ø8/6mm (inside the duct). Other hoses may lead to troublesome
operation.
– When cutting hoses always add at least 5 mm to the specied length.
This way the hoses can be fastened correctly (down to the stop) to
the quick-action couplings of the nipples.
Important! When cutting hoses use an appropriate tool providing
straight,kink-free cuts.
– Hoses must be free of kinks and other damage (longitudinal scratches,
in particular).
– Verify correct fastening of the hoses. Correctly mounted hoses can
not be removed without pressing the locking ring.
5
A
B
B
B
67
8
Y6
(red)
Y7
(blue)
Y8
(yellow)

20
C
A
BD
E
I
MN
L
K
F
H
G
J
4.2.2 Installationofthepost-evaporationunit
The components of the post-evaporation unit are supplied separately and
must be assembled at the installation site.
The following sections explain the general installation of the post-evaporation
unit. Detailed information (dimensions, fastening points, etc.) can be found
in the “installationdrawing” supplied with your particular system.
Important! The dimensions listed in the installation drawing are manda-
tory.
The post-evaporationunit comprises the following main components:
Flow direction
A One,twoor threecrossarms(dependingon thesize
of the system) each consisting of: 2 wall supports
and a U-section, screwed together.
B One vertical section on each side of the duct (the
openings of the sections facing the duct wall).
Note: The left vertical section is marked with an
engraved “L” while the right vertical section carries
an engraved “R”.
C Two or more vertical sections “large”
Note: These vertical sections are marked with an
engraved “M”.
D Upper ow sheets
E Upper angle bracket
F Upper plate sealings
G Lateral ow sheets left
H Lateral plate sealings
I Ceramic plates (post-evaporation elements)
J Lower plate sealings
K Lower ow sheets
L Drain-off sheets
M Lateral ow sheets right
N Tub sealing
– Anti-drip sheets (not visible)
– Lower angle bracket (not visible)