Condair Mk5 User manual

INSTALLATION AND OPERATING INSTRUCTIONS
Resistive Humidifiers
2562241 EN 1108
Condair Mk5

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Contents
1 Introduction 4
1.1 To the very beginning 4
1.2 Notes on the installation and operating instructions 4
2 For your safety 5
3 Product overview 6
3.1 Unit types 6
3.2 Standard delivery 7
3.3 Humidicationsystemoverview 8
3.4 Steamhumidierconstruction 8
3.5 Functional description 9
4 Basic planning 10
4.1 Selecting the unit 10
4.2 Selecting the control system 13
4.3 Options 15
4.4 Accessories 16
4.4.1 Accessoriesoverview 16
4.4.2 Accessory details 17
4.5 Additional planning instructions 19
5 Mounting and installation works 20
5.1 Safetyinstructionsformountingandinstallationworks 20
5.2 Unittting 20
5.2.1 Humidierlocation 20
5.2.2 Mountingthehumidier 22
5.2.3 Inspecting the installed unit 22
5.3 Steam installation 23
5.3.1 Positioning and mounting of the steam distribution pipes 23
5.3.2 Positioning and mounting of the fan unit 26
5.3.3 Installing the steam hose 27
5.3.4 Installing the condensate hose 28
5.3.5 Inspecting the steam installation 29
5.4 Water installation 30
5.4.1 Performingthewaterinstallation 30
5.4.2 Inspectingthewaterinstallation 32
5.5 Electric installation 33
5.5.1 Electricinstallationoverview 33
5.5.2 Wiring diagram 34
5.5.3 Notes on component installation 36
5.5.4 Inspecting the electrical installation 39
6 Operation 40
6.1 Unitconguration 40
6.2 Putting into operation 42
6.3 Takingoutofoperation 43
6.4 Interrogation of the operating status 44
6.5 Setting the operating parameters 48
6.6 Maintenance 53
6.6.1 Notes on maintenance 53
6.6.2 Dismantlingandre-assemblywork 54
6.6.3 Notes on cleaning 57
6.6.4 To reset the maintenance indication 57
6.7 Fault elimination 58
6.7.1 Fault indication 58
6.7.2 What, if..? 59
6.7.3 Replacing unit fuses 61
6.7.4 Resetting fault indication “Error” 61
7 Technical data 62

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Limitation
The subject of these installation and operating instructions arethesteamhumidierCondair Mk5 in
the versions: “Visual” and “Process”.Thevariousaccessories(humidistats,waterlter,etc.)areonly
described insofar as this is necessary for proper operation of the equipment. Further information on
accessories can be obtained in the respective instructions.
These installation and operating instructions are restricted to:
– the planningofahumidifyingsystemthatistobeequippedwithasteamhumidierCondairMk5
– the installation, commissioning, operation and servicing ofthesteamhumidierCondairMk5
These installation and operating instructions are supplemented by various separate items of documenta-
tion(sparepartslist,installationinstructionsforelectricalinstallation,etc.).Wherenecessary,appropriate
cross-references are made to these publications in these installation and operating instructions.
Conventions
Thissymboldrawsattentiontosafety instructions and warnings of potential danger
which,ifunheeded,couldresultininjurytopersonsand/ordamagetoproperty.
Safekeeping
Please safeguard these installation and operating instructionsinasafeplace,whereitcanbeimmedi-
atelyaccessed.Iftheequipmentchangeshands,thedocumentationshouldbepassedontothenew
operator. If the documentation gets mislaid, please contact your Supplier.
Language versions
These installation and operating instructions are available in various languages. Please contact your
supplier for information.
1 Introduction
1.1 To the very beginning
Wethankyouforhavingpurchasedthesteam humidier Condair Mk5.
ThesteamhumidierCondairMk5incorporatesthelatesttechnicaladvancesandmeetsallrecognized
safetystandards.Nevertheless,improperuse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steamhumidierCondairMk5,pleaseob-
serveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallation and
operating instructions.
Ifyouhavequestions,whicharenotorinsufcientlyansweredinthisdocumentation,pleasecontact
yourSupplier.Theywillbegladtoassistyou.
1.2 Notes on the installation and operating instructions

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2 For your safety
Intended use
SteamhumidiersCondairMk5areintendedexclusivelyfordirect or indirect room hu-
midication or for humidication in laboratory and process applications withinthe
speciedoperatingconditions.Anyothertypeofapplication,withoutthewrittenconsent
ofyoursupplier,isconsideredasnotconformingwiththeintendedpurpose.Themanu-
facturer/suppliercannotbemadeliableforanydamagesresultingfromimproperuse.The
user bears full responsibility.
Operation of the equipment in the intended manner requires that all the information in
these instructions is observed (in particular the safety instructions).
General safety instructions
– ThesteamhumidierCondairMk5mustonlybeinstalled,operatedservicedandin
all cases repaired only by persons who are adequately qualiedtoundertakesuch
workandarewellacquaintedwiththeproduct.Ascertainingthequalicationsisthe
customer‘s responsibility.
– Caution, danger of electric shock! The Condair Mk5 is operated with mains voltage.
Before commencing workontheCondairMk5,theunitistoberendered inopera-
tiveinaccordancewithsection6.3andpreventedfromfurtherinadvertentoperation(
isolateunitfromtheelectricalpowersupply,isolatewatersupply).
– Observe all local safety regulations.
– relating to the operation of mains-operated electrical and electronic equipment
– and the provision of water, steam and electrical installations
– Poorlymaintainedhumidicationsystemscanendangerhealth.The servicing inter-
vals should therefore be adhered to without reservation and the servicing work
carried out correctly.
– If it is suspected that safe operation is no longer possible,thentheCondairMk5
should immediately be shut down and secured against accidental power-up. This
canbethecaseunderthefollowingcircumstances:
– iftheCondairMk5isdamaged
– iftheCondairMk5isnolongeroperatingcorrectly
– ifconnectionsand/orpipingarenotsealedorcablesareloose
– TheCondairMk5mustonly be operated under the specied operating conditions
(seesection7).
– TheCondairMk5isprotectedaccordingtoIP21.Makesuretheunitsareinstalledin
a drip-proof location
– Caution! IftheCondairMk5isinstalledinanareawithoutawaterdrain,watersensors
mustbettedinthearea,suchthatintheeventofleakageinthewatersystem,the
waterfeedissafelyshutoff.
– Caution, danger of corrosion! In order to avoid damage, no corrosion-sensitive
components should be located in the area of the aerosol streams.
– No work/repairshouldbecarriedoutontheCondairMk5otherthanthatdescribedin
these instructions.
– Useexclusivelyoriginal accessories and spare parts available from your supplier.
– No modications must be undertakenontheCondairMk5withouttheexpresswrit-
ten consent of the manufacturer.

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3 Product overview
3.1 Unit types
ThesteamhumidiersCondair Mk5 are available in 2 different type series:
– Visual
Fordirectorindirectroomairhumidicationwithstandard requirements for control precision.
– Process
Fordirectorindirectroomairhumidicationinlaboratory and process applicationswherethere
are increased requirements for control precision.
Basically,thedevicesofbothtypeseriesareofthesameconstructionexceptforthelevelcontroland
electronics.TheVisualunits>10kg/hareequippedwithacombinedcontactor/electroniccontroland
alevelunitwithasingleoat.ToachieveahigherlevelofaccuracytheProcessunitsincludeadedi-
catedelectroniccontrolwithspecialcontrolsoftwareandareequippedwithalevelunitcomprisingtwo
oats.
Theyareavailableinversionssuitableforoperationwithuntreated drinking water (with lime collec-
tor tank)orwithfully demineralized water (without lime collector tank).Allversionsareequipped,
asstandard,withanoperating and display unit,bymeansofwhichthecurrentoperatingparameters
canbereadandtheequipmentconguredforoperation,andanintegrated PI controller. The equip-
mentcanbesuppliedwithvariousotheroptions.
Type overview and type designation
Theunitsofbothtypeseriesareavailableinvariousversionswithdifferent steam capacities and
layout of the power section(heatingvoltage).Thefollowingtableprovidesanoverviewofthevarious
models and their capacity ranges.
Condair Mk5 Visual ..-../Process..-.. Heating voltage
small large double unit large
5 8 10 16 20 24 30 40 50 1) 60 1) 80 1)
max. steam capacity in kg/h
5.0 8.0 10.0 16.0 20.0 24.0 30.0 40.0 50.0 60.0 80.0 400V/3~/50...60Hz
4.6 7.3 9.0 14.6 18.0 21.9 27.0 36.2 45.0 54.0 72.4 220V/3~/50...60Hz
5.1 8.4 10.3 16.7 20.6 25.1 30.6 41.5 51.2 61.2 83.0 415V/3~/50...60Hz
5.1 8.7 10.3 ––– ––– ––– ––– ––– ––– ––– ––– 240V/1N~/50...60Hz
5.1 8.0 10.0 ––– ––– ––– ––– ––– ––– ––– ––– 230V/1N~/50...60Hz
3.9 5.8 7.1 11.6 14.3 17.4 21.5 28.8 35.6 43.0 57.6 200V/3~/50...60Hz
1) Mk5 ... 50 ... Mk5 ... 60 ... Mk5 ... 80 ...
Unit A: 20 kg/h 30 kg/h 40 kg/h
Unit B: 30 kg/h 30 kg/h 40 kg/h

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Thetypedesignationisstructuredasfollow:
Designation Code
Brand name Condair
Product line Mk5
Type series –Directorindirectroomhumidication
 –Humidicationforlaboratoryandprocessapplications
Visual
Process
Operating mode – Operation with untreated drinking water (with lime collector tank)
 –Operationwithfullydemineralizedwater(withoutlimecollectortank)
–
VE
Steam capacity in kg/h – 5, 8, 10, 16, 20, 24, 30, 40, 50, 60 or 80 ..
Heating voltage – 400V/3~/50...60Hz
– 220V/3~/50...60Hz
– 415V/3~/50...60Hz
– 240V/1N~/50...60Hz
– 230V/1N~/50...60Hz
– 200V/3~/50...60Hz
400V/3~
220V/3~
415V/3~
240V/1N~
230V/1N~
200V/3~
3.2 Standard delivery
The standard delivery includes:
– SteamhumidierCondairMk5compl.(accordingtotypedesignation)equippedwiththedesired
options(remoteoperatingandfaultindication,pressurecompensationkit,etc.)accordingtochap-
ter 4.3
– Fixingsetincludingdowelsandxingscrews(forsingleunitsupto40kg/h),mountingprolewith
dowelsandxingscrews(fordoubleunits50...80kg/h)
– Installation and operating instructions
– Sparepartslist(red)
– Orderedaccessories(steamdistributionpipe,steamhose,etc.)accordingtochapter4.4

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3.3 Humidication system overview
 1 Steamhumidier
2 Electrical connections
3 Water drainage
 4 Limecollectortank(onlyonunitsforoperation
with untreated drinking water)
5 Filter valve (accessory “Z261”)
6 Water supply (building side)
7 Fan unit (accessory “FAN..”)
8 Condensate hose (accessory “KS10”)
9 Steam hose (accessory “Z10”)
10 Steam distribution pipe (accessory “81–...”)
3.4 Steam humidier construction
1 Housing (500 or 600)
2 Power board
3 Heating contactor (Visual >10 kg/h only)
4 Mains contactor
5 Supply module
6 Control board
7 Cable openings
8 LC-Display
9 Control keys
10 Unit switch
11 Drain switch
12 Status indicator (LED)
13 Limecollectortank(onlyonunitsforoperation
with untreated drinking water)
14 Drain
15 Water connection
16 Steam cylinder
17 Drain pump
18 Resistance heating element
19 Inletvalvewithlter
20 Water supply
21 Filling pipe
22 Overowpipe
23 Steam outlet connector
24 Water cup
25 Pressure equalizing pipe
26 Level unit
5
6
4
3
7
1
2
10
8
9
23
1
26
2
3
4
5
6
7
8
9
10111213
15
14
17
16
18
19
20
21
22
24
25

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3.5 Functional description
TheCondairMk5steamhumidierisanunpressurizedsteamgenerator.Itoperatesontheresistance
heatingprincipleandisdesignedfordirect(withfanunit)andindirect(withsteamdistributionpipe)
roomairhumidicationinventilatingandair-conditioningsystems.Inconjunctionwitha“Process”steam
distributionpipetheunitmaybeusedforhumidicationinlaboratoryandprocessapplications.
Water supply
Thewateristakenviaaltervalve(accessory“Z261”)tothesteamhumidier.Itreachesthesteam
cylinderviatheinletvalve(levelcontrolled)andtheopenwatercup.
Level regulation
Thewaterlevelinthesteamcylinderiscontinuouslymonitoredwiththelevelunit.Ifthewaterlevel
reachesapresetlevel(owingtotheevaporationprocess)thelevelunitsuppliesasignaltothecon-
troller.Thisopenstheinletvalveandthesteamcylinderislledup.Whenthepresetoperatinglevelis
reached, the level unit supplies another signal to the controller to close the inlet valve.
Thepressureequalizingpipebetweenthesteamconnectionandthelevelunitensuresthatthewater
levels are the same in the steam cylinder and the level unit.
Steam generation regulation
Thesteamisproducedinthesteamcylinderbyseveralresistanceheatingelements.Anexternalor
the internal regulator for connection as required control the steam production fully variably from 0 to
100 %.
Flushing
Theevaporationprocessincreasestheconcentrationofmineralsinthewaterofthesteamcylinder.A
suitablevolumeofwatermustbeushedthroughthesteamcylinderfromtimetotimeandreplaced
byfreshwatertoensurethatthisconcentrationdoesnotexceedaspecicvalueunsuitableforopera-
tion.
TheMk5steamhumidierperformsanauto-adaptiveushing.Thisconsistsofthefollowingtwoforms
ofushing:
– Automatic ushing takesplaceassoonasthewaterinthesteamcylinderexceedstheupper
operatinglevel(e.g.byfoamingofthewater).
– Flushing dependent on time performstheushingprocessatpreselectedtimeintervals(seesec-
tion6.1“Adjustments”).
Automaticortime-dependentushingtakesplacedependingonthewaterqualityandtheoperating
data.Ifthelowestoperatinglevelisreachedduringtheushingprocess,theinletvalveremainsopen
untilthewaterlevelinthesteamcylinderhasreachedthenormalworkinglevelagain.Ifthelowest
operating level is not reached, the inlet valve is closed.
Lime collector tank
The minerals precipitated by the evaporation process accumulate at the bottom of the steam cylinder.
Unitsdesignedforoperationwithuntreateddrinkingwaterareequippedwithanadditionallimecol-
lectortanklocateddirectlyunderneaththesteamcylinder.Thiswaythemineralsdonotaccumulate
inthesteamcylinderbutmainlyinthecollectortankthusextendingtheserviceintervalsandreducing
the maintenance costs.
Unitsdesignedforoperationwithfullydemineralizedwaterdonothavealimecollectortankasfully
demineralizedwatercontainsonlysmallamountsofminerals.

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4 Basic planning
AllthedatanecessaryfortheselectionandlayoutofaCondairMk5humidiersystemareprovidedin
thefollowingchapters.
4.1 Selecting the unit
Theselectionoftheunitisreectedinthetypedescription:
1. Application
2. Supplywaterquality
3. Requiredmaximumsteamcapacity
4. Required heating voltage
1. Application
Thetypeseriescanbeselectedonthebasisofthefollowingtable:
Scopeofuse Type series
For direct or indirect room air humidication with
standard requirements for control precision.
Visual
For direct or indirect room air humidication in labora-
toryand processapplications wherethereareincreased
requirements for control precision.
Process
Achievable control precision
Note:Thecontrolprecisionmaydependonthelocationofthehumiditysensor.
– Visual: ±5 %rh(PI-controlanduseofuntreated drinking water)
±2 %rh(PI-controlanduseoffully demineralized water)
Note:Duringthedraincycle(operationwithdrinkingwater)orduringtherellcycle(operationwithfullydemineralized
water)thecontrolprecisioncandeviatefromtheabovestatedvalues.
– Process: ±2 %rh(PI-controlanduseofuntreated drinking water)
±1 %rh(PI-controlanduseoffully demineralized water)
Note:WhenoperatingtheMk5Processwithdrinkingwaterthecontrolprecisioncandeviatefromtheabovestatedvalues
duringthedraincycle.ForprocessairhumidicationwithconstantcontrolprecisiontheMk5Processmustbeoperated
withfullydemineralizedwaterandthedraincyclemustbesettoPos.0(seechapter6.1).
2. Supply water quality
Description Version
Unit withalimecollectortankforoperationwithuntreated
drinking water and partially softened water (see also
notes on water quality in chapter 5.4.1).
–
Unit withoutalimecollectortankforoperationwithfully
demineralized water with a conductivity value <15 µS.
Caution! Unit without lime collector tanks should not
be operated with untreated drinking water or partially
softened water.
VE
Mk5 Visual VE 24-400V/3~
Mk5 Visual VE 24-400V/3~
Mk5 Visual VE 24-400V/3~

11
3. Calculating the maximum required steam capacity
Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:
V • ρ
mD = • (x2- x1)
1000
V
mD = • (x2- x1)
1000 • ε
mD: maximumsteamdemandinkg/h
V: volume of supply air portion per hour in m3/h(forindirectroomhumidication)orroomvolumeto
behumidiedperhourinm3/h(fordirectroomhumidication)
ρ: specicgravityofairinkg/m3
ε: specicvolumeofairinm3/kg
x2: desired absolute room air humidity in g/kg
x1: minimum absolute supply air humidity in g/kg
The values for ρ, ε,x2and x1can be gathered from the h,x-diagram or the Carrier-Diagram for moist
air respectively.
Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalues
listedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroom
air humidity of 45 %rh.
Max.portionofsupplyairinm3/hr or
roomvolumetobehumidiedperhourinm3/hr
max. steam
capacity
in kg/h
Temperature/rel.humidityofsupplyair
-15 °C/90 %rh -5 °C/80 %rh 5 °C/60 %rh
650
1000
2000
2500
3000
3750
5000
6250
7500
10000
850
1350
2650
3300
4000
5000
6600
8250
9900
13200
1000
1600
3200
4000
4800
6000
8000
10000
12000
16000
5
8
16
20
24
30
40
50
60
80
Example:
Max.portionofsupplyair3000m3/h, temperature/rel.
humidityofsupplyair-15°C/90%rh
or
Important notes:
– Therequiredmaximum steamcapacity dependson thespecic applicationand theinstallation.
Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionof
theairtobehumidieddoesnotconsideranysteamloss(e.g.duetocondensationinthesteam
hosesandthesteamdistributors),anyheatlossoftheunitaswellasanyabsorptionorreleaseof
humidityofmaterialslocatedintheroombeinghumidied.
In addition, the calculated steam capacity does not consider any losses caused by the draining rate
dependingonthewaterquality.
Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsiderationwhen
calculating the required steam capacity. If you have any questions regarding the calculation of the
steam capacity please contact your supplier.
– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesorfor
systemswithvariableairvolumeow,etc.),pleasecontactyoursupplier.
Mk5 Visual VE 24-400V/3~

12
4. Heating voltage/control voltage
Heating voltage
The Condair Mk5 steam humidiers are available with various heating voltages. The maximum
achievable steam capacity and the power consumption are directly dependent on the selected
heatingvoltage(seetable).
400 V/3~ 220 V/3~ 415 V/3~ 240 V/1N~ 230 V/1N~ 200 V/3~
50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz
Condair Mk5
Visual.../Process...
kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A
...5-.. 5.0 3.8 5.5 4.6 3.4 9.0 5.1 4.0 6.0 5.1 4.0 17.0 5.1 4.0 16.5 3.9 3.0 8.2
...8-.. 8.0 6.0 8.7 7.3 5.5 14.4 8.4 6.5 9.0 8.7 6.5 27.2 8.0 6.0 26.0 5.8 4.5 13.1
...10-.. 10.0 7.5 11.0 9.0 6.7 17.7 10.3 8.0 11.5 10.3 8.0 33.0 10.0 7.4 32.0 7.1 5.5 16.1
...16-.. 16.0 12.0 17.4 14.6 10.9 28.7 16.7 13.0 18.1 –– –– –– –– –– –– 11.6 9.0 26.1
...20-.. 20.0 14.9 21.5 18.0 13.5 35.4 20.6 16.0 22.3 –– –– –– –– –– –– 14.3 11.1 32.2
...24-.. 24.0 18.1 26.2 21.9 16.4 43.1 25.1 19.5 27.2 –– –– –– –– –– –– 17.4 13.5 39.2
...30-.. 30.0 22.3 32.3 27.0 20.2 53.1 30.6 24.0 33.5 –– –– –– –– –– –– 21.5 16.7 48.3
...40-.. 40.0 30.0 43.3 36.2 27.2 71.4 41.5 32.3 45.0 –– –– –– –– –– –– 28.8 22.4 64.9
...50-.. A20.0
+
30.0
14.9
+
22.3
21.5
+
32.3
18.0
+
27.0
13.5
+
20.2
35.4
+
53.1
20.6
+
30.6
16.0
+
24.0
22.3
+
33.5
–– –– –– –– –– ––
14.3
+
21.5
11.1
+
16.7
32.2
+
48.3
B
...60-.. A 30.0
+
30.0
22.3
+
22.3
32.3
+
32.3
27.0
+
27.0
20.2
+
20.2
53.1
+
53.1
30.6
+
30.6
24.0
+
24.0
33.5
+
33.5
–– –– –– –– –– ––
21.5
+
21.5
16.7
+
16.7
48.3
+
48.3
B
...80-.. A 40.0
+
40.0
30.0
+
30.0
43.3
+
43.3
36.2
+
36.2
27.2
+
27.2
71.4
+
71.4
41.5
+
41.5
32.3
+
32.3
45.0
+
45.0
–– –– –– –– –– ––
28.8
+
28.8
22.4
+
22.4
64.9
+
64.9
B
Shouldyourequireaunitwithadifferentheatingvoltage,pleasecontactyoursupplier.
Control voltage
CondairMk5steamhumidiersaredesignedforastandardcontrolvoltageof220...240V/50...60Hz.
Ifusedinsystemswithoutseparatecontrolvoltagesupply,theCondairMk5maybeequippedwith
an optional transformer 400-500 V/230V(seechapter4.4).
Mk5 Visual VE 24-400V/3~

13
4.2 Selecting the control system
The various control systems
– System 1: Room humidity control
System 1 is suited for direct room humidication and air conditioning systems with mainly
recirculated air. The humidity sensor or humidistat respectively is preferably located in the room
itselforintheexhaustairduct.
A1 humidity sensor
B1 ventilation interlock
B2 airowmonitor
B3 safetyhumidistat
B4 humidistat
PII internal continuous controller (PI-controller)
PIEexternal continuous controller (e.g. PI-controller)
Y inputsignalfromA1
– System 2: Room humidity control with continuous limitation of the supply air humidity
System2issuitedforairconditioningsystemswithalarge portion of supply air, low supply air
temperature, post-humidication, or variable airow volume.Ifthesupplyairhumidityexceeds
the preset value, the continuous limitation is effected prior to the room humidity control.
Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.Thehu-
miditysensor(A2)forthelimitationofthesupplyairhumidityislocatedinthesupplyairductafter
the steam distribution pipe. This control system requires a external continuous controllerwiththe
option to connect a second humidity sensor.
Attention! The continuous limitation of the supply air humidity is no substitute for the safety hu-
midistat.
A1/2 humidity sensor
B1 ventilation interlock
B2 airowmonitor
B3 safetyhumidistat
PIEexternal continuous controller (e.g. PI-controller)
Y inputsignalfromA1
Z inputsignalfromA2
Condair
Mk5
Condair
Mk5

14
– System 3: Supply air humidity control
Supply air humidity control (humidity sensor installed in supply air duct) should be used
only where room humidity control is impracticable for technical reasons.Suchsystemsalways
requireaPI-controller.Thehumiditysensor(A1)islocatedinthesupplyairductafterthesteam
distribution pipe.
A1 humidity sensor
B1 ventilation interlock
B2 airowmonitor
B3 safetyhumidistat
PII internal continuous controller (PI-controller)
PIEexternal continuous controller (e.g. PI-controller)
Y inputsignalfromA1
Which humidity control system for which application?
Application Location of the humidity sensor
Room or exhaust air duct supply air duct
Air conditioning systems with:
supply air portion up to 33% System 1 System 1
supply air portion up to 66% System 1 or 2 System 2 or 3
supply air portion up to 100% System 2 System 3
supply air humidity control — System 3
Directroomhumidication System 1 —
Pleasecontactyoursupplier,ifyourapplicationmeetsthefollowingconditions:
– Humidicationofsmallroomsupto200m3
– Airconditioningsystemswithahighnumberofairexchanges
– Systemswithvariableairvolumeow
– Testfacilitieswithextremecontrolaccuracyrequirements
– Roomswithahighvariationinmax.steamcapacity
– Systemswithtemperatureuctuations
– Coldroomsandsystemswithdehumidication
Condair
Mk5

15
4.3 Options
Thefollowingtablepresentsanoverviewofalloptionswhichareavailableforthesteamhumidier
CondairMk5.
Condair Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Interface RS232/RS485
(Interface PCB RS232/RS485 for data
exchange with a building control system)
RS
number 111111
Remote operating and fault indication
(PCBwithrelaycontactsfortheconnection
ofremotedisplaysfor“Operation”,“Steam”,
“Fault” and “Service”)
RFS
number 111111
Pressure compensation kit
up to 10’000 Pa
(Assembly kit for the installation of the
lling bowl on the equipment cover, for
theoperation of the steam humidier in
installations with duct air pressures up to
10’000 Pa)
OVP
number 112112
Transformer 400-500V/230V
(Transformerforsystemswithoutasepa-
rate control voltage supply)
TRAF 1)
number 1111
Connection terminal 400-415 V/3~
(Separate terminals for systems where
direct connection of heating voltage to
main contactor (standard version) is not
permitted by local regulations)
KLK KLG KLK KLG
number 112112
Unit housing stainless steel S-Inox L-Inox S-Inox L-Inox
number 112112
1) Whenorderingindicatethetypeofunit

16
4.4 Accessories
4.4.1 Accessories overview
Thefollowingtablepresentsanoverviewofallaccessorieswhichareavailableforthesteamhumidi-
erCondairMk5.
Condair Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Steam distribution pipe
(see accessory details in chapter 4.4.2)
81-...
number 1 2 1 2
Steam distribution pipe Process
(see accessory details in chapter 4.4.2)
Z..
number 1 2 1 2
OptiSorp steam distribution system
(see accessory details in chapter 4.4.2)
System 1 System 2 System 1 System 2
number 1 1 1 1
Fan unit
(see accessory details in chapter 4.4.2)
FAN3 Mk
M BC
FAN3 Mk
L BC
FAN3 Mk
M BC
FAN3 Mk
L BC
number 1 1 2 1 1 2
Steam hose / meter Z10 (ø54/42)
number 1 2 1 2
Condensate hose / meter KS10
number 1 2 1 2
Filter valve Z261
number 1 (per system)
Mounting prole BS4 BS5 BS6 1) BS4 BS5 BS6 1)
number 1 1 1 1 1 1
Humidity sensor, room EGH 130
number 1 (per system)
Humidity sensor, duct EGH 110
number 1 (per system)
1) FordoubleunitsthemountingprolesBS6areincludedinthestandarddelivery

17
Steam distribution pipes 81-... for indirect room humidication
The steam distribution pipes are selected on the basis of the duct width(forhorizontalinstallation)or
the duct height(forverticalinstallation)andthecapacityofthesteamhumidier.
Important!Always select the longest possible steam distribution pipe(optimum humidication dis-
tance).
4.4.2 Accessory details
Steam distribution pipes 81-...
for Condair Mk5 (CrNi steel)
Duct width (B) Steam output
Type Length in mm (L) 3) in mm max. in kg/h
81-200 1) 200 210...400 10
81-350 2) 350 400...600 30
81-500 2) 500 600...750 30
81-650 650 750...900 50
81-800 800 900...1100 50
81-1000 1000 1100...1300 50
81-1200 1200 1300...1600 50
81-1500 1500 1600...2000 50
81-1800 1800 2000...2400 50
81-2000 2000 2200...2600 50
81-2300 2300 2500...2900 50
81-2500 2500 2700...3100 50
1) Onlyforunitswithamax.steamcapacityof10kg/h
2) Onlyforunitswithamax.steamcapacityof30kg/h
3) Special length available on request
Note:Ifthehumidicationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,the
amountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesorthe OptiSorp
steam distribution system must be used. If this is the case, contact your supplier.
Steam distribution pipe “Process” (accessory “Z...”)
The steam distribution pipe “Process” is used for direct humidication of material in manufacturing
processes (process humidication), or in ventilation ducts with a critical saturation distance (the
steamdistributionpipe“Process”reducesthesaturationdistancebyapproximately30%).Thedesired
lengthmustbespeciedwhenordering.
Pleasecontactyoursupplier,theywillassistyouincustomizingthesteamdistributionhead“Process”.
Pleasehavethefollowinginformationreadilyavailable:
– steamquantityinkg/h
– dimensionsofventilationduct(widthxheight)
Important! Thetableforthedeterminationofthehumidicationdistanceprovidedinchapter5.3.1does
not apply to the Process steam distribution pipe.

18
OptiSorp steam distribution system
TheOptiSorpsteamdistributionsystemisusedinventilationductswhereonlyashorthumidication
distanceisavailable(seechapter5.3.1forcalculationofhumidicationdistance).Ductdimensions
shouldbegivenwhenordering.Pleasenotethefollowingdataforthis:
OptiSorp Number of
steam connections
max. steam
capacity in kg/h 1)
Duct dimension
Width in mm Height in mm
System 1 1 45 (30) 450...2700 450...1650
System 2 2 90 (60) 450...2700 450...2200
1) For duct width <600 mm the values in parenthesis are valid
Note: Further information on the OptiSorp steam distribution system can be found in the separate in-
stallation and operating instructionssuppliedwiththeproduct.
Fan unit
Thefanunits–incombinationwiththesteamhumidiersCondairMk5Visual–areusedforthedirect
roomhumidication.Theycanbemountedseparately above the unittothewall.
The type of fan unit (FAN3 Mk M BC or FAN3 Mk L BC)andtheamountrequiredisdependentonthe
steamcapacityofthebasicunit(s)andcanbegatheredfromthetableinchapter4.4.1.
Note: Further information on the fan unit can be found in the separate installation and operating instruc-
tionssuppliedwiththeproduct.
Thefanunitsaredeliveredwith:
– Installation accessories including steam hose
– Installation and operating instructions Fan unit

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4.5 Additional planning instructions
Inadditiontotheselectionofthesteamhumidier,theaccessoriesandtheoptions,otherpointsshould
beconsideredduringplanning.Pleasenotetheinformationinthefollowingchapters:
– Unittting(seechapter5.2)
– Steaminstallation(seechapter5.3)
– Waterinstallation(seechapter5.4)
– Electricinstallation(seechapter5.5)
If you have other questions relating to planning that are not adequately covered by these installation and
operating instructions,pleasecontactyoursupplier.Hewillbehappytoprovidefurtherassistance.

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5 Mounting and installation works
5.1 Safety instructions for mounting and installation works
– Allmountingandinstallationworkmustbeperformedonly by adequately qualied
personnel.Ascertainingthequalicationsisthecustomer‘sresponsibility.
– Alllocalregulationsrelatingtotheexecutionoftherespectiveinstallationwork(Water,
steamandelectricalinstallation)mustbenotedandcompliedwith.
– All the information contained in these installation and operating instructions relating to
equipmentassemblyandtowater,steamandelectricalinstallationmustbeuncondi-
tionallyobservedandcompliedwith.
– Caution - Danger from electric shock! The connection of the steam humidier to
the mains electrical supply must not be made until all installation work has been
completed.
– Electronic components are very sensitive to electrostatic discharges. In order to protect
thesecomponents,duringallinstallationworkwiththeequipmentopened,precautions
mustbetakenagainstdamageduetoelectricaldischarge(ESDprotection).
5.2 Unit tting
5.2.1 Humidier location
Theinstallationsiteofthesteamhumidierdependslargelyonthelocationofthesteamdistribution
pipeorfanunit(seechapter5.3.1and5.3.2),respectively.Toensureproperfunctioningofthesteam
humidierandtoobtainanoptimalefciency,thefollowingpointsmustbeconsideredandobserved
whenchoosingthelocationforthesteamhumidier:
– Installthesteamhumidiersothatthelength of the steam hose is kept as short as possible
(max. 4 m) and that the minimum bend radius (R= 300 mm) and up-slope (20 %) or down-slope
(5 %)ofthesteamhoseisobserved(seechapter5.3.3).
– ThesteamhumidiersCondairMk5aredesignedforwall-mounting.Makesurethattheconstruc-
tion(wall,pillar,oor-mountedconsole,etc.)towhichthehumidiersaretobemounted,offersa
sufcientlyhighload-bearingcapacity(takenoticeoftheweightinformationfoundinthischapter),
and is suitable for the installation.
Warning!Donotmountthesteamhumidierdirectlytotheventilationduct(insufcientsta-
bility).
– ThebackpaneloftheCondairMk5isretainingheatduringoperation(max.surfacetemperatureof
themetalhousingapprox.60-70°C).Makesure,therefore,thattheconstruction(wall,pillar,etc.)
towhichtheunitsaretobemounted,doesnotconsistofheat-sensitivematerial.
– Foroperationinvolvingafanunit,thesteamhumidiermustalwaysbeinstalledlowerthanthefan
unit.
– Installthesteamhumidierinsuchamannerthatitisfreelyaccessiblewithsufcientspaceavail-
ableformaintenancepurposes(refertothefollowingillustrationforminimumdistances).