Condair GS series User manual

OPERATION AND
MAINTENANCE MANUAL
Gas-fired Steam Humidifier
Condair GS-Series
xxxxxxx_A_EN_1905_Condair-GS_OM
Humidication and Evaporative Cooling

Thank you for choosing Condair
Installation date (DD/MM/YYYY):
Commissioning date (DD/MM/YYYY):
Site:
Model:
Serial number:
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Group AG. Neither this docu-
ment, nor the information contained herein shall be reproduced, used, or disclosed to others without the written
authorization of Condair Group AG, except to the extent required for installation, operation or maintenance of the
customer's equipment.
Liability Notice
Condair Group AG does not accept any liability due to incorrect installation, maintenance or operation of the equip-
ment, or due to the use of parts/components/equipment that are not authorized by Condair Group AG.
Copyright Notice
© Condair Group AG, All rights reserved.
Technical modications reserved.

3
Contents
Condair GS xxxxxxx_A_EN_1905_Condair-GS_OM
Contents
1 Introduction 5
1.1 Before You Start! 5
1.2 General 5
2 For Your Safety 7
3 Product Overview 11
3.1 General Description 11
3.2 Functional Description 12
4 Operator Interface 15
4.1 Controls 15
4.2 Control Software 15
4.2.1 Home Screen 15
4.2.2 Operating Status 16
4.2.3 Maintenance and Fault Status 17
4.2.4 Help 17
4.2.5 System Information 17
4.2.6 Main Menu 21
4.2.6.1 Conguration Menu 21
4.2.6.2 Service Menu 35
4.2.6.3 Setpoint 37
4.2.6.4 Administrator Menu 38
4.3 Software Conguration 39
4.3.1 Conguring the Control Software 39
4.3.2 Conguring for Multi-Unit Operation 40
5 Operation 41
5.1 General 41
5.2 Operating Procedures 41
5.2.1 Filling the System 41
5.2.2 Ignition Safety Shuto󰀨 Test 41
5.2.3 Starting the Humidier 42
5.2.4 Remote Monitoring 43
5.2.5 Inspections During Operation 43
5.2.6 Manually Initiate Tank Draining 44
5.2.7 Full Tank Blowdown 44
5.2.8 Shutting Down 45
5.2.9 Restarting After Shutdown 45
6 Maintenance 46
6.1 General 46
6.2 Mandatory Maintenance Schedule 47
6.3 List of Consumables 48

4Contents Condair GS
xxxxxxx_A_EN_1905_Condair-GS_OM
6.4 Management of Scale and Chloride Levels 48
6.4.1 Adjusting Blowdown Settings 49
6.5 Maintenance Procedures 50
6.5.1 Removal and Installation of Access Panels 50
6.5.2 Cleaning the Tank 51
6.5.3 Cleaning the Secondary Heat-exchanger 52
6.5.4 Cleaning the Float Chamber 53
6.5.5 Cleaning Hoses, Dual Fill Valves and Drain Pump 54
6.5.6 Cleaning the Burner Assembly 55
6.5.7 Replacing Backup Battery 57
6.5.8 Replacing Internal Fuse 57
6.5.9 Resetting Service Reminder 58
6.5.10 Installing Software Updates 58
7 Fault Isolation 59
7.1 General 59
7.2 Fault Indication 59
7.3 General Troubleshooting 59
7.4 Warning and Fault List 60
7.5 Resetting Fault Status 66
8 Decommissioning 67
8.1 General 67
8.2 Removal from Service for Disposal or Long-term Storage 67
8.3 Disposal/Recycling 67
9 Performance and Operating Data 68
9.1 Performance Data 68
9.2 Operating Data 68

5
IntroductionCondair GS xxxxxxx_A_EN_1905_Condair-GS_OM
1 Introduction
1.1 Before You Start!
Thank you for purchasing the Condair GS humidier.
The Condair GS humidier incorporates the latest technical advances and meets all recognized safety
standards. Never-the-less, improper use of the Condair GS humidier may result in danger to the user
or third parties, and/or damage to property.
To ensure safe, proper and economical operation of the Condair GS humidier, observe and comply with
all information and safety instructions contained in this manual, as well as all relevant documentation of
components of the installed humidication system. Comply with all local and regional regulations deal-
ing with gas, combustion air, ue gases, water, steam and electrical systems. Adhere to the standards
outlined in AS/NZS 5601 (if applicable).
If you have additional questions, contact your Condair representative. They will be glad to assist you.
1.2 General
Limitations
The subject of this manual is the Condair GS humidier. The various options and accessories may only
be described in-so-far as is necessary for proper installation and operation of the equipment. Additional
information on available options and accessories can be obtained in the instructions that are supplied
with them.
This manual is restricted to the operation and maintenance of the Condair GS humidier, and is intended
for well trained personnel who are suitably qualied for their respective tasks.
Symbols Used in This Manual
CAUTION!
The catchword "CAUTION" in conjunction with the general caution symbol is used to provide safety
instructions that, if neglected, may cause damage and/or malfunction of the unit or damage to
property.
WARNING!
The catchword "WARNING" in conjunction with the general warning symbol is used to provide
safety instructions that, if neglected, may cause injury to personnel. Other specic warning symbols
may also be used in place of the general symbol.
DANGER!
The catchword "DANGER" in conjunction with the general danger symbol is used to provide safety
instructions that, if neglected, may cause severe injury to personnel or even death. Other specic
danger symbols may also be used in place of the general symbol.
Other Related Publications
This manual is supplemented by other publications such as the Installation Manual , Spare Parts List,
etc., which are included in the delivery of the equipment. Where necessary, appropriate cross-references
to these publications have been added in this manual.

6Introduction Condair GSxxxxxxx_A_EN_1905_Condair-GS_OM
Storage of Manual
Keep this manual in a place where it is safe and readily accessible. 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 manual is also available in other languages – contact your Condair representative.

7
For Your SafetyCondair GS xxxxxxx_A_EN_1905_Condair-GS_OM
2 For Your Safety
General
Every person who is tasked with the operation and maintenance of the Condair GS humidier must read
and understand this manual before performing any work on the unit. Knowing and understanding the
contents of the Installation Manual, and the Operation and Maintenance Manual is a basic requirement
for protecting personnel against any kind of danger, preventing faulty operation, and operating the unit
safely and correctly.
All labels, signs and markings applied to the Condair GS humidier must be observed and kept in a
readable state.
Personnel Qualications
All procedures described in this manual must only be performed by personnel who are adequately quali-
ed, well trained and are authorized by the customer.
For safety and warranty reasons, any activity beyond the scope of this manual must only be performed
by 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 workplace safety and prevention of accidents.
Intended Use
The humidier is intended exclusively for air humidication using a Condair-approved steam distributor
within specied operating conditions (refer to "Operating Data" on page 68 for details). Any other type of
application, without the express written consent of Condair, is considered to be NOT conforming to its
intended purpose, and may lead to dangerous operation and will void the warranty.
In order to operate the equipment in the intended manner all information contained in this manual, in
particular the safety instructions, must be observed closely.
Safety Precautions that Must be Observed
DANGER!
Risk of electric shock!
The Condair GS humidier is mains powered. Live parts may be exposed when the access
panels are removed. Touching live parts may cause severe injury or even death.
Prevention:Before performing any work inside the Condair GS humidier shut down the humidier
properly and secure it against accidental power-up as described in "Shutting Down" on page 45.
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). Refer to IEC 61340.

8For Your Safety Condair GSxxxxxxx_A_EN_1905_Condair-GS_OM
DANGER!
Risk of re or explosion!
The Condair GS is a gas-red humidier. Improper installation, adjustment, alteration, ser-
vice, maintenance or use 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 o󰀨: Shut o󰀨 the gas supply at the manual gas
shuto󰀨 valve before shutting o󰀨 the electrical power supply.
DO NOT spray aerosols in the vicinity of this appliance while it is in operation.
DO NOT place articles on or against this appliance.
DO NOT use or store ammable materials in or near this appliance.
DO NOT use this appliance if any part has been under water. Call a qualied service techni-
cian immediately 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
modifying this appliance.
DO NOT store or use gasoline or other ammable vapours and liquids in the vicinity of the humidi-
er or any other appliance.
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 tank may contain steam or hot water at up to 100 °C . Contact with the hot surfaces,
steam vapours 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 vapours!
The Condair GS humidier produces hot steam vapours for humidication. Bare skin in contact with
hot steam vapours can result in severe burns.
Prevention: Never perform any work on the steam system (including the steam lines, steam dis-
tributors, etc.) while the humidier is operating. Shut down the Condair GS steam humidier, as
described in "Shutting Down" on page 45 before xing any leaks in the steam system.

9
For Your SafetyCondair GS xxxxxxx_A_EN_1905_Condair-GS_OM
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
operation. Bare skin in contact with hot surfaces can result in severe burns.
Prevention: Shut down the Condair GS steam humidier as described in "Shutting Down" on page 45
and wait for the components 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 "Manually Initiate Tank Draining"
on page 44.
WARNING!
Risk of personal injury!
Prevention: 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 clean-
ing. Disinfectants may only be used if they do not leave behind toxic residue. Rinse all parts thor-
oughly 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.
CAUTION!
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 humidifer 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 person-
nel or damage to property.
Prevention:Do not restart a damaged or improperly secured humidier.
Preventing Unsafe Operation
and if it is suspected that the Condair GS steam humidier cannot be operated safely for any of the
reasons listed below, shut it down immediately as described in "Shutting Down" on page 45 and secure it
against accidental power-up.
• Humidier is damaged
• Electrical connections are loose or damaged
• Humidier is not operating properly
• Leaks in the steam system or gas supply
• DO NOT modify this appliance.
Modications are NOT permitted on the Condair GS humidier without the express written consent
of Condair.

10 For Your Safety Condair GSxxxxxxx_A_EN_1905_Condair-GS_OM
Always use original Condair replacement parts and accessories available through your Condair
representative.
The location of the various safety labels on the Condair GS humidier is shown below.
1
2
3
4
Figure 1: Safety Labels
1 Label, gas safety warning
2 Label, keep cabinet closed warning
3 Label, general safety warning
4 Label, specication