Condair GS II Series User manual

OPERATION MANUAL
Gas-fired steam humidifier
Condair GS
Series II
2596643-B_EN_2010_Condair GS_OM
Humidication and Evaporative Cooling

Thank you for choosing Condair
Installation date (MM/DD/YYYY):
Commissioning date (MM/DD/YYYY):
Site:
Model:
Serial number:
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Group AG. Neither this docu-
ment, nor the information contained herein shall be reproduced, used, or disclosed to others without the written
authorisation 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 modications reserved

32596643-B_EN_2010_Condair GS_OM Contents
Contents
1 Introduction 5
1.1 To the very Beginning 5
1.2 Notes on the Operation Manual 5
2 For your safety 7
3 Product Overview 11
3.1 Model overview 11
3.2 Functional Description 13
3.3 System overviews 15
3.3.1 System overview compact units GS 23/45 15
3.3.2 System overview full-size units 16
4 Operator Interface 17
4.1 Display and operating elements 17
4.2 Control Software 18
4.2.1 Home Screen 18
4.2.2 Operating Status 19
4.2.3 Maintenance and Fault Status 19
4.2.4 Accessing support informations 20
4.2.5 Accessing system informations 20
4.2.6 Main Menu 23
4.2.7 Conguration Menu 24
4.2.7.1 Features Menu 25
4.2.7.2 Control Settings Menu 28
4.2.7.3 General Menu 32
4.2.7.4 Communications Menu 33
4.2.7.5 Service Menu 36
4.2.7.6 Setpoint 38
4.2.7.7 Administrator Menu 38
4.3 Software Conguration 40
4.3.1 Conguring the Control Software 40
4.3.2 Conguring for Multi-Unit Operation 41
5 Operation 42
5.1 General 42
5.2 Initial Commissioning 42
5.3 Operating Procedures 43
5.3.1 Filling the water tank of the humidier 43
5.3.2 Ignition Safety Shutoff Test 44
5.3.3 Starting the Humidier 45
5.3.4 Remote Monitoring 46
5.3.5 Inspections During Operation 46
5.3.6 Manually Initiate Tank Draining 47
5.3.7 Full Tank Blowdown 48
5.3.8 Shutting Down 48

4Contents 2596643-B_EN_2010_Condair GS_OM
6 Maintenance 49
6.1 General 49
6.2 Mandatory Maintenance Schedule 50
6.3 List of Consumables 51
6.4 Management of Scale and Chloride Levels 52
6.4.1 Adjusting Blowdown Settings 53
6.5 Maintenance Procedures 54
6.5.1 Removal and Installation of Access Panels 54
6.5.2 Cleaning the Tank 55
6.5.3 Cleaning the Secondary Heat-exchanger 56
6.5.4 Cleaning the Level Control Unit 58
6.5.5 Cleaning Hoses, Dual Fill Valves and Drain Pump 59
6.5.6 Cleaning the Burner Assembly 61
6.5.7 Replacing Backup Battery and the internal fuse 63
6.5.8 Resetting Service Reminder 64
6.5.9 Installing Software Updates 64
7 Fault Isolation 65
7.1 General 65
7.2 Fault Indication 65
7.3 General Troubleshooting 66
7.4 Warning and Fault List 67
7.5 Resetting Fault Status 73
8 Decommissioning of the Condair GS 74
8.1 General 74
8.2 Removal from Service for Disposal or Long-term Storage 74
8.3 Disposal/Recycling 74
9 Productspecications 75
9.1 Performance Data 75
9.2 Gas consumption at maximum power 75
9.3 Operating Data 76

52596643-B_EN_2010_Condair GS_OM Introduction
1 Introduction
1.1 To the very Beginning
We thank you for having purchased the CondairGSsteamhumidier.
The Condair GS steam humidier incorporates the latest technical ad van ces and meets all recognized
safety standards. Nevertheless, improper use of the Condair GS steam humidier 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 GS steam humidier, please observe
and comply with all information and safety instructions contained in the present documentation as well as
in the separate documentations of the components installed in the humidication system. Comply with
all national and local regulations dealing with gas, combustion air, ue gas, water, steam and electrical
installations.
If you have questions after reading this documentation, please contact your Condair representative.
They will be glad to assist you.
1.2 Notes on the Operation Manual
Limitation
ThesubjectofthisinstallationmanualistheCondairGSsteamhumidierinitsdifferentversions.
The various options and accessories are only described insofar as is necessary for proper operation of the
equipment. Further information on options and accessories can be obtained that are supplied with them.
This installation manual is restricted to the installation of the Condair GS steam humidier and is meant
for welltrainedpersonnelbeingsufcientlyqualiedfortheirrespectivework.
Other Related Publications
This installation manual is supplemented by various separate items of documentation (installation
manual, spare parts list, etc.), which are included in the delivery as well. Where necessary, appropriate
cross-references are made to these publications in the installation manual.

6Introduction 2596643-B_EN_2010_Condair GS_OM
Symbols used in this manual
CAUTION!
The catchword "CAUTION" used in conjunction with the caution symbol in the circle designates notes
in this installation manual that, if neglected, may cause damage and/or malfunction of the unit or
damage to property.
WARNING!
The catchword "WARNING" used in conjunction with the general caution symbol designates safety
and danger notes in this installation manual that, if neglected, may cause injury to persons. Other
specic warning symbols may also be used in place of the general symbol.
DANGER!
The catchword "DANGER" used in conjunction with the general caution symbol designates safety and
danger notes in this installation manual that, if neglected, may lead to severe injury or even death of
persons. Other specic warning symbols may also be used in place of the general symbol.
Storage of the manual
Please safeguard this operation manual in a safe place, where it can be immediately accessed. If the
equipment is moved to another location, make sure that the manual is passed on to the new user.
If the manual is lost or misplaced, contact your Condair representative for a replacement copy.
Language versions
This operation manual is available in other languages. Please contact your Condair representative for
information.

72596643-B_EN_2010_Condair GS_OM For your safety
2 For your safety
General
Every person, who is in charge of any work on the Condair GS must have read and understood the instal-
lation manual and the operation manual (this document) of the Condair GS before carrying out any work.
Knowing and understanding the contents of the installation manual and the operation manual is a basic
requirement for protecting personnel against any kind of danger, to prevent faulty operation, and to
operate the unit safely and correctly.
All labels, signs and markings applied to the Condair GS must be observed and kept in readable state.
Qualicationofpersonnel
All procedures described in this operation manual may only be carried out by specialists who are
welltrainedandadequatelyqualiedandareauthorisedbythecustomer.
For safety and warranty reasons any action beyond the scope of this manual must be carried out only
by qualied personnel authorized by Condair.
All personnel working with the Condair GS humidier must be familiar with, and comply with the appro-
priate regulations on work safety and the prevention of accidents.
Intended use
The Condair GS steam humidier is intended
exclusivelyforairhumidicationviaasteamdistributor
approvedbyCondairwithinspeciedoperatingconditions (see Condair GS operation manual). Any
other type of application, without the written consent of Condair, is considered as not conforming with
the intended purpose and may lead to the Condair GS becoming dangerous and will void any warranty.
In order to operate the equipment in the intended manner all the information contained in this manual,
in particular the safety instructions, must be observed closely.
Safety Precautions that must be observed
DANGER!
Risk of electric shock!
The Condair GS is mains powered. Live parts may be exposed when the unit is open. Touching
live parts may cause severe injury or even death.
Prevention: Before carrying out any work set the Condair GS out of operation as described in Section
5.3.8 (switch off the unit, disconnect it from the mains and stop the water supply) and secure the unit
against inadvertent power-up.
WARNING!
Wiringerrorscancauseimproperanddangerousoperationofthehumidier!
Prevention: Tag all wires before disconnecting them. Reconnect all wires correctly after servicing,
and check the unit functions properly.
CAUTION!
Electrostatic discharge (ESD)!
Theelectroniccomponentsinsidethecontrolcabinetinthehumidieraresensitivetoelec-
trostatic discharge (ESD).
Prevention: Take appropriate measures to protect the electronic components inside the unit against
damage caused by electrostatic discharge (ESD).

8For your safety 2596643-B_EN_2010_Condair GS_OM
DANGER!
Riskofreorexplosion!
TheCondairGSisagas-redhumidier.Improperoperationandmaintenanceas well as incor-
rect settings and unauthorized alteration can cause carbon monoxide poisoning, explosion,
reorotherhazardsthatcancauseseriousinjury,deathorpropertydamage.
If over-heating occurs or if the gas fails to shut off: Shut off the gas supply at the manual gas
shutoff valve before shutting off the electrical power supply
DO NOT use this appliance if any part has been under water. Call a qualied service technician imme-
diately to inspect and replace any part of the control system or gas control that has been under water.
Any work on the gas system must only be performed by a qualied installer, service agency or your
local gas supplier. Use only factory-authorized and listed kits or accessories when installing or modify-
ing this appliance.
Use only factory-authorized and listed kits or accessories when replacing part or modifying this appliance.
DO NOT store or use gasoline or other ammable vapours and liquids in the vicinity of the humidier.
What to do if you smell gas:
•DO NOT try to light any appliance.
• DO NOT touch any electrical switch.
• DO NOT use any phone in the building.
•Leave the building immediately.
• Call your gas supplier immediately from a location far away from the building with the gas
leak. Follow the gas supplier's instructions. If you cannot reach your gas supplier, call the
redepartment.
WARNING!
Risk of severe burns from contact with hot surfaces, steam or hot water!
The steam tank may contain steam or hot water at up to 100 °C. Contact with the hot surfaces,
steam vapors or hot water can result in severe burns.
Prevention: Always drain the tank, and allow the unit to cool down to a safe temperature before
cleaning the tank. Never open the tank until it has been fully drained. Never use the manual drain
valve until the unit has cooled down. Use the manual drain valve to verify that the tank is empty before
removing the tank cover.
WARNING!
Risk of severe burns from contact with hot steam vapors!
TheCondairGShumidierproduceshotsteamvaporsforhumidication.Bareskinincontact
with hot steam vapors can result in severe burns.
Prevention: Never perform any work on the steam system (including the steam lines, steam distribu-
tors, etc.) while the humidier is operating. Shut down the Condair GS humidier, as described in
Section 5.3.8 before carrying out any work on the steam system.

92596643-B_EN_2010_Condair GS_OM For your safety
WARNING!
Risk of severe burns from contact with hot surfaces!
The water tank, steam line and exhaust system in the Condair GS humidier get very hot during op-
eration. Bare skin in contact with hot surfaces can result in severe burns.
Prevention: Shut down the Condair GS humidier as described in Section 5.3.8 and wait for the com-
ponents to cool down before performing any work on the unit. Never use the manual drain valve until
the unit has cooled down. Use the manual drain valve to verify that the tank is empty before removing
the tank cover. Drain the tank as described in Section 5.3.8.
WARNING!
Risk of personal injury!
Wear a safety mask and clean the burner assembly in a well ventilated area.
CAUTION!
Riskofdamagetothehumidiercomponents!
Do not use solvents, aromatized or halogenized hydrocarbons, or other harsh chemicals for cleaning.
Disinfectants may only be used if they do not leave behind toxic residue. Rinse all parts thoroughly
with clean tap water after cleaning.
WARNING!
Riskofre!
DO NOT clean the sacricial anode with any chemicals. The anode can react with acids to create
ammable hydrogen gas.
WARNING!
Riskofdamagetothehumidiercomponentsorinjury!
DO NOT over-torque the bolts. Ensure the proper order of torquing is followed. Failure to do so may
cause damage to the humidier components or injury.
DANGER!
Risk of harm to personnel or damage to property.
Operatingadamagedorimproperlysecuredhumidierpresentsariskofdangertopersonnel
or damage to property.
Prevention: Do not start a damaged or improperly secured humidier.

10 For your safety 2596643-B_EN_2010_Condair GS_OM
Preventing Unsafe Operation
All persons working with the Condair GS must report any alterations to the unit that may affect safety to
the owner without delay. If it is suspected that safe operation is no longer possible, the Condair GS
should immediately be shut down and secured against accidental power-up according to Section
5.3.8. This can be the case under the following circumstances:
– if the Condair GS is damaged
– if the electrical installations are damaged
– if the Condair GS is no longer operating correctly
– if connections and/or piping (gas, water, exhaust gas) are not sealed
Prohibitedmodicationstotheunit
Nomodicationsmustbeundertaken on the Condair GS without the express written consent of Condair.
For the replacement of defective components use exclusively original accessories and spare parts
available from your Condair representative.
Safety labels on the unit
Various safety and identication labels are attached to the Condair GS. Please note and comply with
the relevant information on these labels.
1
23
4
1 Gas safety warning label
2 Keep cabinet closed warning label
3 General safety label
4 Specication label
Fig. 1: Position of the safety and identication labels