Condair GS series User manual

INSTALLATION AND
OPERATION MANUAL
DVGW-certified exhaust gas management system for
Condair GS
Series II
2596151-C_EN_2010_Condair GS EGMS_IOM
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

32596151-C_EN_2010_Condair GS EGMS_IOM Contents
Contents
1 Notes to these instruction 4
2 For Your Safety 5
3 System overview 8
3.1 Schematic diagram 8
3.2 Description of the system 9
3.3 System requirements 9
4 Installation 11
4.1 Delivery schedule 11
4.2 Installation overview 14
4.2.1 Installation example 1 14
4.2.2 Installation example 2 15
4.3 Installation instructions 16
4.3.1 Positioning and tting the exhaust gas distribution pipe 16
4.3.2 Assembling the exhaust gas pipes 17
4.3.3 Positioning and tting the differential pressure switch 18
4.3.4 Positioning and tting the draught limiter 20
4.3.5 Positioning and installing the throttle valve 23
4.3.6 Positioning and tting the ow monitor 24
5 Monitoring devices' electrical connection 25
5.1 Electrical diagram 25
5.2 Notes on electrical installation 26
5.3 Connecting the differential pressure switch and the ow monitor 26
5.4 General wiring diagrams 27
6 Initial commissioning and operation 30
6.1 Initial commissioning 30
6.2 Operation 31
7 Trouble shooting 32

4Notes to these instruction 2596151-C_EN_2010_Condair GS EGMS_IOM
1 Notes to these instruction
Differentiation
These installation and operating instructions for the DVGW-certied exhaust gas management system
(patent pending) available as an optional extra to the Condair GS gas-red steam air humidier is a
supplement to the Condair GS installation and operating instructions.
They only describe the installation and commissioning of the DVGW-certied exhaust gas management
system for discharging exhaust gases from the Condair GS steam air humidier into the exhaust air
of an air conditioning system (for short: AC system). You can nd further information on installing and
operating the Condair GS gas-red steam air humidier in the installation and operating instructions for
this machine.
Target group
These installation and operating instructions are intended for well-trained specialists who are familiar
with the risks of operating a gas-red machine and are also familiar with the standards and regulations
applying to discharging exhaust gas into the exhaust air of an AC system.
Symbol explanation
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
These installation and operating instructions must be kept in a safe place where they will be available at
any time. Should the product be transferred to another owner the installation and operating instructions
must be passed on to the new operator.
Should you lose the documentation please contact your Condair supplier.
Language version
These installation and operating instructions are available in different languages. Please contact your
Condair supplier for this.

52596151-C_EN_2010_Condair GS EGMS_IOM For Your Safety
2 For Your Safety
General information
Any person commissioned to install and commission the DVGW-certied exhaust gas management
system must have read and understood these installation and operating instructions before starting
work.
Knowledge of the content of these installation and operating instructions is a basic pre-requisite to
protect staff from danger, to avoid incorrect installations and thus to install and operate the system
safely and properly.
Qualication of staff
All the actions described in these installation and operating instructionsmust only be performed by
trained and sufciently qualied specialists authorised by the operating company.
For safety and guarantee reasons, actions not included in these instructions must only be performed
by specialist staff authorised by the manufacturer.
It is assumed that all people entrusted with working on the DVGW-certied exhaust gas management
system are familiar with and comply with health and safety at work and accident prevention regulations
and the standards and regulations to be applied.
The DVGW-certied exhaust gas management system is not intended to be used by people (including
children) with restricted physical, sensory and mental faculties or who have a lack of experience and/
or knowledge unless they are supervised by a person responsible for their safety or have received
instructions from this person on how the system is to be used.
Children should be supervised to ensure that they do not play with the system.
Safety
Should the DVGW-certied exhaust gas management system not be installed or commissioned
properly equipment may be damaged or people injured. Therefore be sure to observe and obey
all the information and safety instructions in this manual and the installation and operating
instructions for the gas-red Condair GS steam air humidier.

6For Your Safety 2596151-C_EN_2010_Condair GS EGMS_IOM
Dangers that may arise from the Condair GS gas-red steam air humidier
DANGER!
Risk of re or explosion!
The Condair GS works with gas. Incorrectly performed installations, improper operation and
maintenance, incorrect settings and unauthorised modications to the equipment may lead
to personal injury or damage to property due to explosions, res, carbon dioxide poisoning,
electric shocks etc.
Therefore: Only trained, qualied specialists authorised by the operating company may work on the
gas system. Before starting work on the gas system, shut the Condair GS down in accordance with
the instructions in the installation and operating instructions for the Condair GS (turn the machine off,
unplug it and turn off the water and gas supply) and ensure that it cannot be turned on again accidentally.
Do not store or use any inammable substances in the vicinity of the Condair GS.
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.
DANGER!
Risk of electric shock!
The Condair GS is mains powered. Live parts can be touched if the machine is open. Touching
live parts may lead to serious injuries or death.
Therefore: Before starting work on the Condair GS, shut it down in accordance with the instructions
in the operation manual for the Condair GS (turn the unit off, disconnect it from the mains supply and
turn off the water and gas supply) and ensure that it cannot be turned on again accidentally.
WARNING!
Risk of severe burns from contact with hot surfaces!
The water tank, the steam pipes and the exhaust gas system get very hot when they are operat-
ing. There is the risk of burns if you touch these components while the machine is operating
or shortly afterwards.
Therefore: Do not touch the water tank, the steam pipes and the exhaust gas system while they are
operational. Before starting work on the Condair GS, shut it down in accordance with the instructions
in the operation manual for the Condair GS (turn the machine off, disconnect it from the mains supply
and turn off the water and gas supply) and ensure that it cannot be turned on again accidentally. Then
wait until the components have cooled sufciently so that there is no longer a risk of burns.

72596151-C_EN_2010_Condair GS EGMS_IOM For Your Safety
Danger that could arise from the DVGW-certied exhaust gas management system
WARNING!
Risk of severe burns!
During operation hot exhaust gases and condensate steam escape from the exhaust gas distribution
pipe. These may lead to burns.
Therefore: Before undertaking installation or maintenance work on the DVGW-certied exhaust gas
management system shut the Condair GS gas-red steam air humidier down in accordance with
the instructions in the operation manual of the Condair GS (turn the machine off, disconnect it from
the mains supply and turn off the water and gas supply) and ensure that it cannot be turned on again
accidentally.
Intended use
The DVGW-certied exhaust gas management system is intended exclusively for discharging
the exhaust gases from the gas-red Condair GS steam air humidier into the exhaust air of an
AC system within the specied operating conditions (see chapter 3.3 on page 9). Any other use
without the manufacturer's written consent will be considered improper use and may lead to the Condair
GS steam air humidier becoming dangerous.
Proper use also includes complying with all the information in these installation and operating
instructions (particularly all safety and danger instructions) and all standards and regulations
that must be complied with.
Unauthorised modications
No modications or extensions may be made to the DVGW-certied exhaust gas management
system without the manufacturer's written consent.
To replace defective system components only use original accessories and spare parts from your
Condair supplier.

8System overview 2596151-C_EN_2010_Condair GS EGMS_IOM
11 Exhaust air
12 Exhaust gas distribution pipe
13 Exhaust air fan
14 Steam distributor
15 Incoming air
16 Steam pipe
3 System overview
3.1 Schematic diagram
2
1
3
3
4
5
67
89
10
11
12
13
15
14
16
Air conditioning incoming air
Air conditioning
exhaust air
Fig. 1: Schematic diagram
1 DVGW-certied exhaust gas
management system
2 Gas-red steam air humidier
3 Exhaust gas discharge
connection
4 Condensate trap
5 Exhaust gas pipe
6 Differential pressure switch
7 Draught limiter
8 Condensate trap
9 Throttle valve (xed position)
10 Flow monitor

92596151-C_EN_2010_Condair GS EGMS_IOM System overview
3.2 Description of the system
With the DVGW-certied exhaust gas management system (1) the exhaust gases from the Condair GS
gas-red steam air humidier can be discharged via the exhaust air discharge unit of an air conditioning
system into the open air. To do this the Condair GS exhaust gases are fed through the exhaust gas
pipe at negative pressure to the exhaust gas distribution pipe (12) into the exhaust air unit of the air
conditioning system and there diluted by the exhaust air owing past and discharged.
The system is monitored by the differential pressure switch (6) and the ow monitor (10) that are con-
nected in series to the safety chain connections on the Condair GS connection terminal.
The differential pressure switch (6) monitors the minimum negative pressure and the ow monitor the
minimum air speed. If one or both values fall below this minimum value the safety chain is disconnected
and the Condair GS switched off.
The maximum permissible negative pressure is monitored by the Condair GS's ame monitor and
exhaust gas temperature gauge.
3.3 System requirements
In order to ensure that the DVGW-certied exhaust gas management system works properly obey the
following instructions:
– The Condair GS steam air humidier must be in the same room as the air conditioning system
exhaust air installation.
– In order to guarantee a sufcient air after ow there must be an opening in the room to the outside
air with a minimum free cross section area in accordance with the table below.
Condair
GS 23
Condair
GS 45
Condair
GS 65
Condair
GS 90
Condair
GS 130
Condair
GS 195
Condair
GS 260
Min. free cross section area cm250 88 120 150 225 350 460
– The exhaust gas distribution pipe must be installed upstream of the exhaust air fan. With this
there must be a minimum distance of 1 m from the exhaust air fan.
– The outlets of the exhaust gas distribution pipe must point in the direction of ow.
– A throttle valve and a draught limiter must be installed.
– A differential pressure switch and a ow monitor to monitor the operation must be installed.
– The permissible exhaust gas pipe lengths must be at least 4 m and no more than 10 m.
– The control unit must be switched in such a way that the Condair GS connection is shut down rst
before the air conditioning system is switched off. Otherwise the steam air humidier will be shut off
as a safety measure (error message).
– At air temperatures of <20 °C in the exhaust air system a drain outlet with inclines on all sides must
be provided in the AC system in the section downstream of the exhaust gas distribution pipe that
must be connected via a trap and an open discharge hopper to the waste water pipe in the building
(to discharge any condensate).

10 System overview 2596151-C_EN_2010_Condair GS EGMS_IOM
– Minimum air volume ow of the air conditioning unit:
Condair
GS 23
Condair
GS 45
Condair
GS 65
Condair
GS 90
Condair
GS 130
Condair
GS 195
Condair
GS 260
Steam output kg/h 23 45 65 90 130 195 260
Nominal output kW 20.5 41.0 65.1 82.0 123.0 184.5 246.0
Min. air quantity m3/h 1025 2050 3075 4100 6150 9225 12300
– Permissible negative pressure range (system limits)
Position of the throttle valve Maximum negative pressure
Exhaust air
Minimum negative pressure
Exhaust air
9 (fully open) -1200 Pa -300 Pa
8-1200 Pa -300 Pa
7-1200 Pa -300 Pa
6 -1200 Pa -300 Pa
5 -1500 Pa -400 Pa
4 -1500 Pa -400 Pa
3 - 1 For maximum negative pressure values greater than -1500 Pa 1)
1) For maximum negative pressure values greater than -1500 Pa or minimum negative pressure values lower than -300 Pa
in the air conditioning system, please contact your regional centre.

112596151-C_EN_2010_Condair GS EGMS_IOM Installation
4 Installation
WARNING
For all installation work on the gas-red Condair GS steam air humidier shut the machine down
in accordance with the instructions in the operation manual of the Condair GS (turn the machine off,
disconnect it from the mains supply and turn off the water and gas supply) and ensure that it cannot
be turned on again accidentally.
4.1 Delivery schedule
The pipework for the exhaust gas management system is supplied complete in a set for a pipe length
of 8 m. All pipe parts are made of DIN 14404 stainless steel.
Pipe diameter Part No. Standard set (8 m) 2)
Condair GS 23 / Condair GS 45 / Condair GS 65 100 mm 1) 2598918
Condair GS 90 / Condair GS 130 100 mm 2598920
Condair GS 195 / Condair GS 260 150 mm 2598921
1) 80 mm to 100 mm adaptor included in standard 8 m set
2) Standard set does NOT include differential pressure switch, ow monitoring device, or exhaust distribution pipe.
Component and Part No. Quantity in 8 m set
GS 23-65 GS 90-130 GS 195-260
1000 mm pipe
5
GS 23-130 2597025
GS 195-260 2597188
500 mm pipe
2
GS 23-130 2597033
GS 195-260 2597187
300... 500 mm adjusting component
1
GS 23-130 2597028
GS 195-260 2597186
90° rigid elbow with inspection lid
2
GS 23-130 2597046
GS 195-260 2597184
87° rigid elbow with inspection lid
2
GS 23-130 2597047
GS 195-260 2597185

12 Installation 2596151-C_EN_2010_Condair GS EGMS_IOM
Component and Part No. Quantity in 8 m set
GS 23-65 GS 90-130 GS 195-260
Moulded part for draught limiter
1
GS 23-130 2597049
GS 195-260 2597179
Draught limiter ø180 mm
1
GS 23-130 2597050
GS 195-260 2597721
Pipe with measurement connections
1
GS 23-130 2597051
GS 195-260 2597718
Throttle valve ø100 mm with condensate port
1
GS 23-130 2597052
GS 195-260 2597723
Pipe clip + lip seal (pre-installed on pipe parts)
14
GS 23-130
2597054
+
2597055
GS 195-260
2597719
+
2597720
Pipe bracket
Length 1 m
GS 23-260 2597064 5
GS 23-130 2597067
5
GS 195-260 2597068
Adapter (ø80 mm to ø100 mm)
GS 23-65 2597066 1 ––– –––
Exhaust pipe adapter with condensate
drain and brass nipple
ø100 mm GS 23-130 2599071 1 1 –––
ø150 mm GS 195-260 2599072 ––– ––– 1
Lubricant for seal GS 23-260 2597065 1

132596151-C_EN_2010_Condair GS EGMS_IOM Installation
The following items are not included in the standard set and must be ordered separately:
Component and Part No. Quantity
GS 23-65 GS 90-130 GS 195-260
Exhaust gas distribution pipe
(Fit to size of duct)
100-5 GS23-130 2569548 1 1 –––
150-5 GS195-260 2599066 ––– ––– 1
100-10 (1070 mm) GS23-130 2569549 1 1 –––
150-10 (1070 mm) GS195-260 2599067 ––– ––– 1
100-15 (1385 mm) GS23-130 2569550 1 1 –––
150-15 (1385 mm) GS195-260 2599068 ––– ––– 1
100-20 (2050 mm) GS23-130 2569551 1 1 –––
150-20 (2050 mm) GS195-260 2599069 ––– ––– 1
Differential pressure switch
1
GS23-260 1101679
CDA duct ow monitoring device
1
GS23-260 2599895
Condensate hose
(for exhaust pipe adapter and throttle valve) GS 23-260 1109730 1

14 Installation 2596151-C_EN_2010_Condair GS EGMS_IOM
min. 1 m
1
2
34
11
7
8
6
9
10
11
5
4.2 Installation overview
4.2.1 Installation example 1
Incline to the exhaust gas outlet on
the steam air humidier min. 3 °
1 Condensate trap
2 Differential pressure switch (KS..C2)
3 Measurement connection for pressure gauge
4 Draught limiter (Z180)
5 Throttle valve (DK)
6 Exhaust gas distribution pipe (AVR)
7 Flow monitor (IN511)
8 Ceiling or wall support
9 Exhaust air fan
10 Outlet with trap (compulsory for exhaust air
temperatures of <20 °C)
11 Condensate drain with trap
87° pipe elbow
Fig. 2: Installation example 1

152596151-C_EN_2010_Condair GS EGMS_IOM Installation
4.2.2 Installation example 2
min. 1 m
7
9
10
11
1
2
4
8
11
3
5
6
1 Condensate trap
2 Differential pressure switch (KS..C2)
3 Measurement connection for pressure gauge
4 Draught limiter (Z180)
5 Throttle valve (DK)
6 Exhaust gas distribution pipe (AVR)
7 Flow monitor (IN511)
8 Ceiling or wall support
9 Exhaust air fan
10 Outlet with trap (compulsory for exhaust air
temperatures of <20 °C)
11 Condensate drain with trap
Min. 3° incline to exhaust gas
outlet on the steam air humidier
87° pipe elbow
Min. 3° incline to
the exhaust gas
distribution pipe
Fig. 3: Installation example 2

16 Installation 2596151-C_EN_2010_Condair GS EGMS_IOM
4.3 Installation instructions
4.3.1 Positioning and tting the exhaust gas distribution pipe
Positioning the exhaust gas distribution pipe
The exhaust gas distribution pipe must be installed at least 1 m upstream of the exhaust air fan in the
middle of the duct wall.
Fitting the exhaust gas distribution pipe
1. Mark the hole for the pipe at the location provided on the duct wall and drill the hole.
Diameter
of hole
Condair GS 23/45 110 mm 1)
Condair GS 65 110 mm 1)
Condair GS 90/130 110 mm 1)
Condair GS 195/260 160 mm 1)
1) absolutely necessary
Fig. 4: Drilling the feedthrough hole
2. Insert the exhaust gas distribution pipe (outlet holes must point towards the exhaust air fan), align the
xing ange horizontally with a spirit level. Then x the ange to the duct wall with the 4 self-tapping
screws.
Note: The end of exhaust gas distribution pipes >800 mm long must be xed to the duct wall or the
duct ceiling (see detail in Fig. 5).
=
=
min. 1 m
min. 1 m
Fig. 5: Fixing the exhaust gas distribution pipe

172596151-C_EN_2010_Condair GS EGMS_IOM Installation
4.3.2 Assembling the exhaust gas pipes
Pipe connections
Proceed as follows to connect the exhaust gas pipes:
1. 2. 3. 4.
Large diameter
Small diameter
Pipe clamp
Rubber seal Intake side with
seal (inside)
Insertion side with ange
Intake side with
seal (inside)
Insertion side with ange
Direction of exhaust gas ow
Fig. 6: Connecting the pipes
1. Push the pipe clamp (with the large internal diameter pointing in the direction of the exhaust gas)
and the rubber seal on the insertion side onto the pipe or the pipe elbow as shown.
2. Push the pipe into the intake side of the other piece of pipe until it can go no further.
3. Push the rubber seal over the point where the two pipes meet.
4. Push the pipe clamp over the rubber seal and tighten.
Important information about the design of the exhaust gas pipe
– Only use the installation material contained in the delivery schedule.
– A condensate trap must be tted on the Condair GS downstream of the exhaust gas connection
(compulsory). The condensate pipe must be fed at a constant incline via a trap (hose bend with a
minimum diameter of 200 mm) into an open discharge hopper on the building's waste water pipe.
– All horizontal pipe sections must be designed with a constant incline (ca. 3°) to the Condair GS
condensate trap or to the condensate connection on the exhaust gas distribution pipe.
– The exhaust gas pipe must be self-supporting. Therefore the exhaust gas pipe must be xed to the
wall or ceiling using the supplied pipe clamps accordingly.
– If individual pipes must be shortened they must be shortened on the insertion side and a new crimp
made with a crimping machine.

18 Installation 2596151-C_EN_2010_Condair GS EGMS_IOM
4.3.3 Positioning and tting the differential pressure switch
Positioning the differential pressure switch
The pipe with the measurement connections (P-RM) must be inserted into the exhaust gas pipe in such
a way that the connection piece for the differential pressure switch is positioned if possible in the middle
of the Condair GS exhaust gas connection and the draught limiter. There must be a minimum distance
of 1m between the Condair GS exhaust gas connection and the draught limiter.
Fig. 7: Positioning the differential pressure switch
min. 1 m
min. 1 m
min. 1 m
min. 1 m
Draught limiter
Differential pressure switch
Draught limiter
Differential pressure switch

192596151-C_EN_2010_Condair GS EGMS_IOM Installation
1.
2.
3.
P2 (–)
P1 (+)
Fitting the differential pressure switch
Separate tting instructions are enclosed for the differential pressure switch. Please note and follow the
instructions in this manual.
Fig. 8: Fitting the differential pressure switch
1. Fix the differential pressure switch bracket onto the measurement pipe support with two screws.
2. Snap the differential pressure switch into the bracket as shown.
3. Attach the measuring hose to the connection P2(–) on the differential pressure switch and to the
connection piece of the measuring pipe.

20 Installation 2596151-C_EN_2010_Condair GS EGMS_IOM
4.3.4 Positioning and tting the draught limiter
Positioning the draught limiter
The draught limiter (Z180) must be tted as close as possible to the Condair GS exhaust gas connection.
There must be minimum distances of 2 m from the Condair GS exhaust gas connection and 1 m from
the differential pressure switch.
Fig. 9: Positioning the draught limiter
min. 1 m
min. 1 m
min. 1 m
min. 1 m
Draught limiter
Differential pressure switch
Draught limiter
Differential pressure switch