Condair HP User manual

INSTALLATION AND
OPERATION MANUAL
Adiabatic humidification system
Condair HP/HPRO
Valid from 2021
2579409-0 EN 2106
Humidication and Evaporative Cooling
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Thank you for choosing Condair
Installation date (MM/DD/YYYY):
Commissioning date (MM/DD/YYYY):
Site:
Model:
Serial number:
Manufacturer
Condair A/S
Parallelvej 2, DK-8680 Ry
phone [phone]
[e-mail], www.condair.dk
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair A/S. Neither this document, nor
the information contained herein shall be reproduced, used, or disclosed to others without the written authorization
of Condair A/S, except to the extent required for installation or maintenance of recipient's equipment.
Liability Notice
Condair A/S 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 A/S.
Copyright Notice
Copyright 2021, Condair A/S All rights reserved.
Technical modications reserved

3Contents
Contents
1 Introduction 6
1.1 To the very beginning 6
1.2 Notes on the installation and operation manual 6
1.2.1 Symbols used in this manual 7
1.2.2 Safekeeping 7
1.2.3 Language versions 7
2 Health and Safety 8
2.1 General 8
2.2 Intended use 8
2.3 Danger that may arise from the Condair HP 9
2.4 Preventing unsafe operation 9
2.5 Prohibited modications to the unit 10
2.6 Hygiene 10
2.7 Disinfection 12
3 Overview of Condair HP and HPRO 13
3.1 Model code 13
3.2 Condair HP system overview 13
3.2.1 Stand-alone system Condair HP (master conguration) 13
3.2.2 Compound system Condair HP (master-slave conguration) 14
3.2.3 Overview pump station Condair HP 15
3.2.4 Flow diagram pump station Condair HP 100 - 800 16
3.2.5 Part specication pump station Condair HP 100 - 800 16
3.2.6 Flow diagram pump station Condair HP 1300 17
3.2.7 Part specication pump station Condair HP 1300 17
3.2.8 Brief description of high-pressure pump station 18
3.3 Condair HPRO system overview 19
3.3.1 Stand-alone system Condair HPRO (master conguration) 19
3.3.2 Compound system Condair HPRO (master-slave conguration) 20
3.3.3 Overview pump station Condair HPRO 100, 200, 300 21
3.3.4 Flow diagram pump station Condair HPRO 100, 200, 300 21
3.3.5 Part specication pump station Condair HPRO 100, 200, 300 22
3.3.6 Overview pump station Condair HPRO 500 23
3.3.7 Flow diagram pump station Condair HPRO 500 24
3.3.8 Part specication pump station Condair HPRO 500 24
3.3.9 Overview pump station Condair HPRO 800 25
3.3.10 Flow diagram pump station Condair HPRO 800 26
3.3.11 Part specication pump station Condair HPRO 800 26
3.3.12 Brief description of pump station 27
3.4 Humidier unit 28
3.4.1 Nozzle unit 29
3.4.2 Droplet separator 29
3.5 Functional description 29
3.5.1 General function 29
3.5.2 Control 30
3.5.3 Humidication 30
3.5.4 Monitoring of high-pressure pump 30
3.6 Scope of delivery 30

4Contents
4 Notes on planning 31
4.1 Record of site-specic data 31
4.2 Options and Accessories 32
5 Installation works 33
5.1 Important notes on installation 33
5.2 System set-up 34
5.2.1 Stand-alone system (master conguration) 34
5.2.2 Compound system (master-slave conguration 1 or 2 slaves) 35
5.2.3 Compound system (master-slave conguration 3 slaves) 36
5.2.4 Compound system (slave conguration 4 slaves) 37
5.2.5 Compound system >800 l/h (master-slave conguration 3 slaves) 38
5.2.6 Compound system >800 l/h (slave conguration 4 slaves) 39
5.3 Mounting of the humidier unit 40
5.3.1 Notes on positioning and mounting of the humidier unit 40
5.3.2 Mounting the nozzle unit 41
5.3.3 Mounting the Condair droplet separator 49
5.3.4 Pressure loss over the droplet seperator 54
5.4 Mounting the pump station 55
5.4.1 Notes on positioning 55
5.4.2 Dimension and weights of pump station 56
5.4.3 Pump station installation 62
5.4.4 Water installation, Condair HP 63
5.4.5 Water installation, Condair HP RO 65
5.5 Electrical installation 68
5.5.1 How to connect to power supply 69
6 Initial commissioning 70
6.1 Cabinet layout 70
6.2 Insert inlet lter 71
6.3 Insert RO membrane (only for Condair HPRO models) 72
6.4 Mount sterile breathing lter (only for Condair HPRO models) 73
6.5 Set up the controller 73
6.6 Flushing procedure 74
6.6.1 Flushing the HPRO pump unit and RO membrane 75
6.6.2 Bleed air from the RO pump 76
6.6.3 Adjusting the reverse osmosis 77
6.6.3.1 Explanation of technical terminology 77
6.6.3.2 Water quality 78
6.6.3.3 Adjustment of outlet amount 79
6.6.3.4 Adjustment of permate amount 81
6.6.4 Manual operation 82
6.6.5 Flushing hoses and nozzle lines 83
6.7 Check list initial commissioning Condair HPRO 84
7 Controller set-up 86
7.1 Menu structure 87
7.2 Basic settings 88

5Contents
8 Operation 94
8.1 Daily operation 94
8.2 Weekly inspection 95
8.3 Taking the HP/HPRO out of operation 96
8.4 Dismantling and disposal 97
9 Maintenance 98
9.1 Important notes on maintenance 98
9.2 Maintenance work 99
9.3 Part list for preventive maintenance 101
9.4 Maintenance indications 102
9.5 Disassembling and assembling of the mist eliminator for cleaning 102
10 Troubleshooting 103
10.1 Important notes on troubleshooting 103
10.2 Malfunction with error indication 103
10.3 Resetting the error indication 104
10.4 Malfunction without error indication 105
11 Product data 106
11.1 Technical data 106
11.1.1 Technical data Condair HP 106
11.1.2 Technical data Condair HPRO 107
11.2 Water quality requirements HP 108
11.3 Water quality requirements HPRO 108

6Introduction
1 Introduction
1.1 To the very beginning
We thank you for having purchased the Condair HP or HPRO Adiabatic High Pressure Humidier
(“Condair HP” for short).
The Condair HP incorporates the latest technical ad van ces and meets all recognized safety stand-
ards. Nevertheless, improper use of the Condair HP may result in danger to the user or third parties
and/or impairment of material assets.
To ensure a safe, proper, and economical operation of the Condair HP, 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.
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 installation and operation manual
Limitation
The subject of this installation and operation manual is the Condair HP and HPRO Adiabatic
High Pressure Humidiers. The various options and accessories are only described insofar as this is
necessary for proper operation of the equipment. Further information on options and accessories can
be obtained in the respective instructions.
This operation manual is restricted to the commissioning, operation,maintenance and troubleshoot-
ing of the Condair HP and is meant for well trained personnel being sufciently qualied for their
respective work.
This installation and operation manual is supplemented by various separate items of documentation
(installation drawings, technical specications, etc.). Where necessary, appropriate cross-references
are made to these publications in this installation and operation manual.

7Introduction
1.2.1 Symbols used in this manual
CAUTION!
The catchword “CAUTION” used in conjunction with the caution symbol in the circle designates notes
in this installation and operation 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 installation and operation manual that, if neglected, may cause to injury to
persons.
DANGER!
The catchword “DANGER” used in conjunction with the general caution symbol designates safety and
danger notes in this installation and operation manual that, if neglected, may lead to severe injury
or even death of persons.
1.2.2 Safekeeping
Please safeguard this installation and operation manual in a safe place, where it may be immediately
accessed. If the equipment changes hands, the documentation must be passed on to the new operator.
If the documentation gets misplaced, please contact your Condair representative.
1.2.3 Language versions
This installation and operation manual is available in various languages. Please contact your Condair
representative for information.

8Health and Safety
2 Health and Safety
2.1 General
This manual has been written to ensure the safe use, performance and longevity of the equipment and
is intended for use by engineers and properly trained technical personnel. Please read this manual
thoroughly before specifying, designing or installing a Condair HP system. Retain for reference.
Condair’s policy is one of continuous research and development. Condair reserves the right to amend,
without notice, the specications provided in this document. Condair does not guarantee, or accept li-
ability for, the accuracy of information in this document.
Installation, maintenance, repair work or de-commissioning should only be carried out by appropriately
qualied and properly trained technical personnel. It is the customer’s responsibility to ensure their
suitability.
The customer is responsible for ensuring that the installation of the equipment complies with all local
regulations and is in accordance with the local health and safety authorities’ technical guidance on the
control of bacteria in water systems.
It is the responsibility of the user to ensure that the water system complies with local regulations, byelaws
and guidelines (such as the HSE ACoP L8, VDI 6022, ISO 22000, HACCP or equivalent). Any risks or
hazards relating to the system, including during installation and maintenance, should be identied by
a competent Health & Safety representative who shall be responsible for introducing effective control
measures as needed.
All ideograms, signs and markings applied to the unit must be observed and kept in a readable state.
2.2 Intended use
The Condair HP is intended exclusively for humidication in ventilation systems within the speci-
ed operating conditions. Any other type of application without the express written consent of the
manufacturer is considered as not conforming with the intended purpose and may lead to the Condair
HP becoming dangerous.
Operation of the equipment in the intended manner requires that all the information in this installation
and operation manual be observed (in particular the safety instructions).

9Health and Safety
2.3 Danger that may arise from the Condair HP
DANGER!
Risk of electric shock!
A person may come in contact with live parts when the pump station/control unit is open.
Touching live parts may cause severe injury or danger to life.
Prevention: before carrying out any work on the Condair HP, take the unit out of operation as described
in Section 8.3 (switch off the unit, disconnect it from the mains and stop the water supply) and secure
the unit against inadvertent power-up.
DANGER!
Health risk because of inadequate hygiene!
Poorly maintained humidication systems may endanger health. When insufciently maintained,
harmful germs can build up in the air duct and affect the duct air.
Prevention: read, understand and follow guidelines to ensure your system stays clean, in the Health
and Safety section of this manual..
WARNING!
During operation the water system is at high pressure. Inappropriately fastened hoses can be
torn out of the screw connections during operation due to the high pressure. There is danger
of injury, in no circumstances loosen any hoses or screw connections during operation.
Prevention: always correctly tighten the high-pressure hoses and screw connections and do not loosen
any hoses or screw connections during operation. Before carrying out any work on the Condair HP,
take the unit out of operation as described in Section 8.3 (switch off the unit, disconnect it from the
mains and stop the water supply) and secure the unit against inadvertent power-up.
WARNING!
To prevent water stagnation and microbial contamination, the Condair HP power supply should be
left switched on continuously. If the system is switched off for more than 48 hours the pipework and
system should be disinfected as per the instructions and a full risk assessment undertaken to ensure
safe operation
2.4 Preventing unsafe operation
If it is suspected that safe operation is no longer possible, the Condair HP should immediately be
shut down and secured against accidental power-up according to Section 8.3. This can be the case
under the following circumstances:
– if components of the Condair HP are damaged, worn or badly soiled.
– if the Condair HP does not work correctly.
– if connectors and lines are leaking.
– after long-time storage under unfavourable conditions.
– after transportation under unfavourable conditions.
All persons working with the Condair HP must report any alterations to the unit that may affect its safety
to the owner without delay.

10 Health and Safety
2.5 Prohibited modications to the unit
No modications may be undertaken on the Condair HP without the express written consent of the
manufacturer.
For the replacement of defective components use exclusively original accessories and spare parts
available from your Condair representative.
2.6 Hygiene
Clean water is important!
If the atomised water contains too many bacteria, these are carried along into the air. Once inhaled, they
enter the lungs, where there is less resistance than in the stomach. By way of comparison, lung tissue
provides a nice, warm environment for bacteria to live, where they have access to oxygen and nutrition
so they can multiply quickly – and this can result in lung infections such as the dangerous Legionnaires’
disease.
It is important that the feed water is of the same quality as drinking water and does not contain too many
bacteria. If it is not possible to supply water of the same quality as drinking water, it is important to lter
the water, as well as cleaning and disinfecting the system.
Your attention is drawn to the local Health & Safety Executive’s technical guidance on the control of
Legionellosis in water systems. If inadequately maintained, water systems, of which any humidier is
a part, can support the growth of micro-organisms, including the bacterium that causes Legionnaires’
disease. The Condair HP is produced according to HACCP principles, which means that we have
considered all aspects of this equipment to reduce as far as possible the risk of Legionnaires’ disease
and other similar conditions. However, keeping the system clean is the responsibility of the customer.
Guidelines to ensure your system stays clean and prevent the growth of Legionella
• Carry out a risk assessment of the water system using a competent person, and implement an ap-
propriate monitoring and control programme.
• Initiate procedures for checking the UV system (if any), cleaning tanks, changing lters, disinfection,
etc.
• The Condair HP & HPRO must be connected to a clean, potable mains water supply.
• Arrange a service contract to suit your company.
• Stop the system if polluted drinking water is found in your area.
• Avoid water temperatures which favour the growth of Legionella.
• Do not stop the system unless it is faulty or is leaking (Avoid water stagnation)
• Refrain from closing nozzles or sections, unless there is leakage or a fault (Avoid water stagnation)
• Disinfect the high-pressure system at least once a year and every time maintenance or repairs have
been carried out. Always carry out a complete disinfection of the system if It has been turned off for
more than 48 hours
• Have water samples taken and tested for harmful bacteria at least once a year.
• Have follow-up measurements done until the system is clean if bacteria have been detected in the
system.

11Health and Safety
The Condair service team can help. Condair has specially trained technicians who can provide:
• Bacteriological troubleshooting relatively rapidly*
• Cleaning and disinfecting
• Preventive maintenance
• Repair and fault nding
• Problem-solving advice
* Condair uses a fast method for measuring bacterial activity in the water, the approved, patented
BactiQuant. Once the water sample has been taken, we can read the bacteriological quality of the
water within 30 minutes, and disinfect the system if this proves to be necessary.
Condair follows the guidelines in VDI 6022 for CFU counts in humidiers. The CFU count in the hu-
midication water must hence not exceed 200 CFU/ml, corresponding to a maximum BQ value of 57.
Not all Condair service centres can offer a bacteriological troubleshooting locally, please contact
your local Condair representative for further information.

12 Health and Safety
2.7 Disinfection
We recommend Sanosil as a disinfection agent in HP Systems. Disinfection should be carried out at
least once a year, depending on the inlet water quality.
Calculation of mixing ratio between water and chemical - 5 % Sanosil S010 Ag to 0.1 %
Wanted concentration: 0.1 %
Concentration of chemical: 5 %
Mixed solution Water Chemical Chemical part
Liter Liter Liter Liter %
10.98 0.02 0.00 0.1
2 1.96 0.04 0.00 0.1
3 2.94 0.06 0.00 0.1
4 3.92 0.08 0.00 0.1
5 4.90 0.10 0.01 0.1
65.88 0.12 0.01 0.1
76.86 0.14 0.01 0.1
8 7.84 0.16 0.01 0.1
98.82 0.18 0.01 0.1
10 9.80 0.20 0.01 0.1
11 10.78 0.22 0.01 0.1
12 11.76 0.24 0.01 0.1
13 12.74 0.26 0.01 0.1
14 13.72 0.28 0.01 0.1
15 14.70 0.30 0.02 0.1
16 15.68 0.32 0.02 0.1
17 16.66 0.34 0.02 0.1
18 19.64 0.36 0.02 0.1
19 18.62 0.38 0.02 0.1
20 19.60 0.40 0.02 0.1
25 24.50 0.50 0.03 0.1
50 49.00 1.00 0.05 0.1
60 58.80 1.20 0.06 0.1
100 98.00 2.00 0.10 0.1
150 147.00 3.00 0.15 0.1
200 196.00 4.00 0.20 0.1
300 294.00 6.00 0.30 0.1
400 392.00 8.00 0.40 0.1
500 490.00 10.00 0.50 0.1
600 588.00 12.00 0.60 0.1
700 686.00 14.00 0.70 0.1
800 784.00 16.00 0.80 0.1
900 882.00 18.00 0.90 0.1
1000 980.00 20.00 1.00 0.1

13Overview of Condair HP and HPRO
3 Overview of Condair HP and HPRO
3.1 Model code
High Pressure (Type)
Integrated Reverse Osmosis system
Nominal ow of high pressure pump l/h
HPRO 100
3.2 Condair HP system overview
3.2.1 Stand-alone system Condair HP (master conguration)
Fig. 1: Stand-alone system Condair HP (master conguration)
3
2
7
4
1
8
6
5Humidier unit consisting of:
1 Step valves MV REG1, MV REG2 and MV REG3
2 Nozzle unit
3 Droplet separator (option)
4 Flushing valve MV5 high-pressure system
Pump station consisting of:
5 High-pressure pump
6 Control unit, with touch screen
7 High-pressure exible hose
8 UV-light system (option)

14 Overview of Condair HP and HPRO
3.2.2 Compound system Condair HP (master-slave conguration)
Assuming the system data is within a dened range, the pump station of a stand-alone system may
supply pressurized water to up to three further HP systems (slave systems). A so-called master-slave
conguration is shown below.
Fig. 2: Compound system Condair HP (master-slave conguration)
Slave 3
Slave 2
Slave 1
Master
Slave 0
Pump station Master-Slave system consists of either
a pump station and a Master unit which
is controlled by the pump station and
addition 3 Slaves, if needed, or it can
consist of a pump station and up to
4 Slaves.
High pressure hose
Control unit slave
Slave systems
consisting of:
– Control unit slave
– Humidier unit
Humidier unit

15Overview of Condair HP and HPRO
3.2.3 Overview pump station Condair HP
Fig. 3: Overview pump station Condair HP
K1
M1
G1
F
P1
T
MV1
UV
V1
PS
G2
G3
R
K2

16 Overview of Condair HP and HPRO
Fig. 4: Flow diagram pump stations Condair HP 100 - 800
3.2.5 Part specication pump station Condair HP 100 - 800
FInlet lter 20", 1µm
FD Frequency drive VFD
G1 Pressure gauge 0-16 bar
G2 Pressure gauge 0-16 bar
G3 Pressure gauge 0-160 bar
K1 Check valve
M1 Motor for high pressure pump
MV1 Inlet solenoid valve
P1 PAHT high-pressure pump
PS Inlet pressure switch 0.5 bar
PT Pressure transmitter for VFD
R Pressure regulator, 65 bar
T PT1000 temperature transmitter
V1 Test water tap
Options:
EC (Option) Inlet conductivity sensor
UV (Option) UV system
WM (Option) Water meter
3.2.4 Flow diagram pump station Condair HP 100 - 800

17Overview of Condair HP and HPRO
3.2.6 Flow diagram pump station Condair HP 1300
Fig. 5: Flow diagram pump station Condair HP 1300
3.2.7 Part specication pump station Condair HP 1300
FInlet lter 20", 1µm
FD Frequency drive VFD
G1 Pressure gauge 0-16 bar
G2 Pressure gauge 0-16 bar
G3 Pressure gauge 0-160 bar
K2 Check valve
K3 Check valve
M1 Motor for high pressure pump
MV1 Inlet solenoid valve
P1 PAHT high-pressure pump
PS Inlet pressure switch 0.5 bar
PT Pressure transmitter for VFD
R Pressure regulator, 65 bar
T PT1000 temperature transmitter
V1 Test water tap
Options:
EC (Option) Inlet conductivity sensor
UV (Option) UV system
WM (Option) Water meter
Fig. 4: Flow diagram pump stations Condair HP 100 - 800
3.2.5 Part specication pump station Condair HP 100 - 800
F Filter 1µm
FD (Option) Frequency converter
G1 Pressure gauge 0-10 bar
G2 Pressure gauge 0-10 bar
G3 Pressure gauge, high pressure
K1 Check valve
K2 Check valve
M1 Motor
MV1 Solenoid valve
P1 High-pressure pump
PS Pressure switch
PT (Option) Pressure transmitter
R Pressure reduction
T PT1000, temperature transmitter
UV (Option) UV system
V1 Test water tap 1/8”
WM (Option) Water meter

18 Overview of Condair HP and HPRO
3.2.8 Brief description of high-pressure pump station
The hoses are drinking waterapproved high-pressure hoses, stainless braided or high-pressure hoses
in dimension 1/4" or 3/8".The system is tted on a frame and all components are assembled, tested
and ready to use.
Pump unit: The water-lubricated high-pressure stainless steel pump is directly mounted on the electric
motor.
The pump is protected against dry running by a pressure switch that stops the system if the water
pressure drops. The high-pressure pump is protected against overheating by a temperature circuit that
measures the current temperature in the pump.
Control unit: the control unit consists of the touch display and PLC. A power board, for control of the
high-pressure pump and connection terminals for power supply (208...480V/3N~/50-60Hz).
The power board has an alarm switch (NC).
The pump station can be tted with various options and extras described in Section 4.
The pump station is electrically wired at the factory. At the installation site, main power supply, the humid-
ity signal or humidity sensor, external safety chain, step valves and chosen options must be electrically
connected to the control unit.

19Overview of Condair HP and HPRO
3.3 Condair HPRO system overview
3.3.1 Stand-alone system Condair HPRO (master conguration)
Fig. 6: Stand-alone system Condair HPRO (master conguration)
3
2
7
4
1
8a
6
5
8b
9
8c
10
Humidier unit consisting of:
1 Step valves MV REG1, MV REG2 and MV REG3
2 Nozzle unit
3 Droplet separator (option or product of other manufacturer)
4 Flushing valve MV5 high-pressure system
Pump station consisting of:
5 High-pressure pump
6 Control unit, with touch screen
7 High-pressure exible hose
8 RO water treatment system (option)
a: RO pump
b: RO Membrane
c: RO water storage tank
9 UV-light system
10 Water meter

20 Overview of Condair HP and HPRO
3.3.2 Compound system Condair HPRO (master-slave conguration)
It is possible to add up to three slave humidiers to one master conguration. A so-called master-slave
conguration as shown below.
Fig. 7: Compound system Condair HPRO (master-slave conguration)
Slave 3
Slave 2
Slave 1
Master
Slave 0
Pump station
Master-Slave system consists of either
a pump station and a Master unit which
is controlled by the pump station and
addition 3 Slaves, if needed, or it can
consist of a pump station and up to
4 Slaves.
High pressure hose
Control unit slave
Slave systems
consisting of:
– Control unit slave
– Humidier unit
Humidier unit
Important: Max. length of
the high-pressure piping
from the pump station to
the last Slave unit must
not exceed 60 m (only
valid for systems on the
same oor!)