Condair ML Series User manual

2596061 EN 1905
Humidication and Evaporative Cooling
Adiabatic Humidification System
Condair MLP
US version
INSTALLATION AND
OPERATION MANUAL
IMPORTANT! Read and save these instructions. This manual to be left with the equipment.

Thank you for choosing Condair
Installation date (DD/MM/YYYY):
Commissioning date (DD/MM/YYYY):
Site:
Model:
Serial number:
Contact
Condair Ltd.
2740 Fenton Road, Ottawa, Ontario K1T3T7
TEL: [phone], FAX: [phone]
EMAIL: [e-mail], WEBSITE: www.condair.com
Condair Inc.
2700 90th Street
Sturtevant, WI., USA 53177
TEL: [phone], FAX: [phone]
EMAIL: [e-mail], WEBSITE: www.condair.com
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Ltd. Neither this document, nor
the information contained herein shall be reproduced, used, or disclosed to others without the written authorization
of Condair Ltd., except to the extent required for installation, operation or maintenance of the customer's equipment.
Liability Notice
Condair Ltd. does not accept any liability due to incorrect installation, maintenance or operation of the equipment,
or due to the use of parts/components/equipment that are not authorized by Condair Ltd.
Copyright Notice
© Condair Ltd., All rights reserved.
Technical modication rights reserved.

3Contents
Contents
1 Introduction 5
1.1 Before You Start! 5
1.2 General 5
2 For Your Safety 7
2.1 Safety 7
2.2 Health & Hygiene 8
3 Receiving and Storage 10
3.1 Inspection 10
3.2 Storage and Transportation 10
4 Site Planning 11
4.1 Prior to Starting 11
4.2 General Notes on Positioning 11
4.3 Experts on Site 12
5 Product overview 13
5.1 General description 13
5.2 Model Designation 14
5.3 MLP 100/300 Overview 16
5.4 MLP 500 Overview 17
5.5 MLP 2x800 overview 18
5.6 Principal installation diagram 19
5.7 Inlet water quality requirements 20
5.8 Optional equipment for MLP 20
5.9 MLP options list 21
5.10 MLP accessories list 22
6 Installation 23
6.1 General 23
6.2 Site Requirements and Sizing 24
6.3 Positioning the pump station 25
6.4 Water connection 26
6.5 Electrical installation 27
6.5.1 Power Supply Connection 28
7 Commissioning 29
7.1 Tools and materials for commissioning work 29
7.2 Inlet lter 30
7.3 Prepare for pump ush 31
7.4 Basic set-up of the controller 32
7.5 Pump ush procedure 37

4Contents
8 Operation 38
8.1 Overview control unit 38
8.2 Equipment protection 39
8.3 Alarm messages 40
8.4 Controller menu 42
8.4.1 Alarms and user messages 43
8.4.2 Parameter change menu 44
8.4.3 Settings for section parameters 44
8.4.4 Pump 45
8.4.5 Conductivity monitoring, humidity logging and CIP (options) 46
8.5 Weekly inspection 47
9 Maintenance 48
9.1 Important notes on maintenance 48
9.2 Maintenance work 49
9.3 Preventive spare parts chart 50
9.4 Weekly check list 51
9.5 Troubleshooting 52
9.5.1 Malfunction with error indication 52
9.5.2 Resetting the error indication 53
9.5.3 Malfunction without error indication 54
10 Product data 55
11 Declaration of conformity 56
A Appendix 57
A.1 Siemens Scalence Router (option) 57
A.2 Optional Modbus TCP/IP 64
A.3 Setpoint 67
A.4 Temperature Sensor 69
A.5 Electrical Settings in the Humidity Regulator 70
A.6 Overview of calibration for conductivity sensors and converters (ampliers) 71
A.7 ML-system - Condair Ltd. 73
B Appendix 77
B.1 Installation Checklist 77
B.2 Commissioning Checklist 77
B.2.1 Pre-Start-Up Checklist 78
B.2.2 Performance Checklist 80

5Introduction
Condair MLP XXXXXXX_EN_1905
1 Introduction
1.1 Before You Start!
Thank you for purchasing the Condair ML direct room high pressure adiabatic humidication system.
The Condair ML adiabatic humidier incorporates the latest technical advances and meets all recog-
nized safety standards. Never-the-less, improper use of the Condair ML adiabatic 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 ML adiabatic humidier, observe and
comply with all information and safety instructions contained in this manual, as well as all relevant docu-
mentation of components of the installed humidication system.
If you have additional questions, contact your local Condair representative. They will be glad to assist you.
1.2 General
Limitations
The subject of this manual is the Condair ML direct room humidication pump stations and associated
equipment whether ancillary or supplementary. 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 installation, operation, technical data and parts of the Condair ML direct
room humidication pump stations, and is intended for well trained personnel who are suitably qualied
for their respective tasks.
Symbols Used in This Manual
CAUTION!
The word "CAUTION" in conjunction with the general caution symbol is used to provide safety instruc-
tions that, if neglected, may cause damage and/or malfunction of the unit or damage to property.
WARNING!
The word "WARNING" in conjunction with the general warning symbol is used to provide safety in-
structions 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 word "DANGER" in conjunction with the general danger symbol is used to provide safety instruc-
tions 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.

6Introduction XXXXXXX_EN_1905 Condair MLP
Other Related Publications
This manual is supplemented by other publications such as the ML Heads Installation Guide, which
are included in the delivery of the equipment. Where necessary, appropriate cross-references to these
publications have been added in this manual.
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.

7For Your Safety
Condair MLP XXXXXXX_EN_1905
2 For Your Safety
2.1 Safety
DANGER!
Always isolate all supplies to the system before commencing any maintenance or repair.
General
Every person who is tasked with the installation, operation or maintenance of the Condair ML adiabatic
humidier must read and understand this manual before performing any work. Knowing and understanding
the contents of the installation manual and the operation and maintenance manual is a basic require-
ment for protecting personnel against any kind of danger, preventing faulty operation, and operating the
unit safely and correctly.
All labels, signs and marking applied to the Condair ML adiabatic 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 ML adiabatic humidier must be familiar with, and comply with
the appropriate regulations on workplace safety and prevention of accidents.
Intended Use
The Condair ML humidication heads are intended exclusively for adiabatic humidication and/or evapo-
rative cooling using a RO water supplied (by others) Condair MLP high pressure pump station within
specied operating conditions (refer to the Condair MLP IOM for details). Any other type of application,
without the express written consent of Condair, is considered to be not conforming to its intended pur-
pose, 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.
Safe Operation
If it is suspected that safe operation has been compromised, the ML-System should immediately be shut
down and secured against accidental power-up.
Shut down the Condair ML Humidication System if:
– Components are damaged, worn or very soiled
– Fans have stopped or are noisy
– Joints, pipes or hoses are leaking
– Unusual or very loud noise
No modications must be made on the ML-System without the manufacturer’s consent. All persons
working with the system must report to the owner if any alterations are detected.
Use only original accessories and spare parts available from your Condair representative.

8For Your Safety XXXXXXX_EN_1905 Condair MLP
2.2 Health & Hygiene
DANGER!
Risk of infection or serious illness
The Condair ML System must be installed, operated and maintained in accordance with this manual.
Failure to do so could result in contamination that might cause Legionnaires’ disease, which can be fatal.
DANGER!
Risk of water contamination
To prevent water stagnation and microbial contamination, the systems power supply should be left
switched on. If the system is switched off for more than 48 hours, the pipework and system must be
disinfected as per the instructions, and a full risk assessment must be undertaken to ensure safe
operation.
Health Risks
Please observe the local health and safety codes, standards and technical guidance on the control of
Legionella in water systems.
The user is responsible for ensuring that the water system complies with local regulations, bye-laws and
guidelines (such as the HSE ACoP L8, VDI 6022, ISO 22000, HACCP or equivalent). If inadequately
maintained, water systems, of which any humidier is a part, can support the growth of microorganisms,
including the bacterium that causes Legionnaires’ disease.
Condair ML systems, products and components are produced according to the ISO 22000 standards,
which means that we have considered all aspects of this equipment to reduce the risk of Legionnaires’
disease and other similar conditions. However, the user is responsible for ensuring that the installation,
operation and maintenance work on the equipment is performed in a manner ensuring that the system
stays clean.
Any risks or hazards relating to the system, including during installation and maintenance, should be
identied by a competent health and safety representative who is responsible for introducing effective
control measures.
Water monitoring
The quality of water being used in the Condair ML Humidication System should be checked prior to
system commissioning and comply with the guidelines in the high pressure pump manual.
The Condair ML Humidication System must be monitored for hygiene as part of the maintenance pro-
gram. Please refer to the maintenance section for further guidance.

9For Your Safety
Condair MLP XXXXXXX_EN_1905
Guidelines for a Hygienic System
• Carry out a risk assessment of the water system using a competent person, and implement an ap-
propriate monitoring and control program.
• Initiate procedures for changing lters, disinfection etc.
• Enter into a service contract that suits your company.
• Stop the system if polluted drinking water is found in your area.
• Avoid water temperatures between 77 °F (25°C) and 113 °F (45°C), which favour the growth of
Legionella.
• Do not stop the system unless it is faulty or 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 after every maintenance or repair. Always
carry out a complete system disinfection 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.
• Conduct follow-up measurements until the system is clean if bacteria have been detected in the system.
Disinfection
Depending on the system hygiene, it is advised that preventative disinfection uid be added to the ex-
ternal RO water tank at an appropriate frequency, but at least once a year.
Condair Ltd. recommends using the disinfection uid HaloSpray or Sanosil S010 AG 5% (part number:
155404000) to the System via the high pressure pump, desired concentration 0.1%. HaloSpray or Sanosil
is safe, non-toxic and eco-friendly which provides a prophylactic, disinfection dose and is effective against
all types of microorganisms, including Legionella and E.coli.
Please read the pump manual for more information on disinfection.
If you are in any doubt about the suitability of water quality, please contact your Condair distributor who
will be happy to support you.

10 Receiving and Storage XXXXXXX_EN_1905 Condair MLP
3 Receiving and Storage
3.1 Inspection
All Condair products are shipped F.O.B at the factory. All damage, breakage or loss claims are the respon-
sibility of the shipping company. Upon receipt, remove the transit packaging and inspect the components
to ensure that no damage has occurred during transit. Inspect the goods as follows:
– Inspect the shipping boxes for damage. Report any shipping box damages to the shipping company
without delay.
– Check the goods against the packing slip to ensure that all items have been delivered. Report any
shortages to your Condair representative within 48 hours of receipt of the goods. Condair does not
assume responsibilities for any shortages beyond this period.
– Unpack the parts/components and check for any damage. If parts/components are damaged, notify
the shipping company immediately.
– Verify the model type on the specication label to ensure that it is suitable for your installation.
3.2 Storage and Transportation
Storage
Store the Condair ML adiabatic humidier in its original packaging inside a protected area that meets the
following requirements until it is installed. These requirements also apply if the unit needs to be stored
for an extended period of time. If put into storage prior to use, the components must be covered and
protected from physical damage, dust, frost and rain. Avoid below freezing temperatures as this can
degrade certain wet parts and components.
For storage Condair recommends:
– Room temperature: 41 to 104°F (5 to 40°C)
– Room humidity: 10 to 75% RH
Transportation
For optimum protection always transport the unit and components in their original packaging, and use
appropriate lifting/transporting devices.
Lifting or handling must only be carried out by trained and qualied personnel. Ensure that the lifting
operation has been properly planned and risk-assessed, and that all equipment has been checked by
a skilled and competent health and safety representative.
The customer is responsible for ensuring that operators are trained in handling heavy goods, and to
enforce the relevant lifting regulations. Refer to the weights and measures section for system weight.
Packaging
It is recommended that the components be kept in its transit packaging for as long as possible prior to
installation.
Keep the original packaging of the unit/components for later use. If the packaging needs to be disposed
of, observe local regulations on waste disposal. Recycle packaging where possible.
Disposal
You must observe local laws and regulations when disposing of your Condair ML system at the end of
its working life.

11Site Planning
Condair MLP XXXXXXX_EN_1905
4 Site Planning
4.1 Prior to Starting
The basic principles for planning described below are theoretical ones. In practice, the necessary hu-
midication capacity is inuenced by parameters that cannot be covered by this documentation. For
this reason, the values that were determined in theory have to be complemented by practical values or
corrected in many cases. Condair’s technical service team will be pleased to assist you.
Notes on the planning of direct room air humidication systems in one or more zones.
Proceed as follows when selecting and/or dimensioning the air humidication system:
• Determine the volume of the room and the air changes
• Determine the set points (temperature and humidity/relative humidity)
• Determine the humidication areas
• Calculate the maximum humidication capacity
• Dene the device requirements
• Determine the placement of zone valves and hygrostats
4.2 General Notes on Positioning
The positioning of a system is always determined during planning and noted in the system documents.
Prior to mounting the ML Direct Room Humidication heads, ensure that all hose layouts, distances
between heads and atomization clearances have been considered and adhered to, as per the ML Heads
Installation Guide.
The recommended hose layouts, distances between humidication heads and atomization clearances,
are shown in the ML Heads Installation Guide. Consult local and national installation regulations. Condair
does not accept responsibility for violations of the installation codes.
The following general positioning notes, however, have to be read and complied with in any case:
• Make sure that the construction (rafter, beam, wall, pillar, ceiling construction, etc.) on which the
devices and/or system components will be mounted disposes of a sufcient load-carrying capacity
and is suitable for xing
• Position the Condair ML Direct Room Heads in such a way to enable the atomized mist to spread
freely. When the mist is prevented from spreading by obstacles (e.g. ceilings, beams, ventilation
ducts, airow, machinery, etc.), turbulences can build up and condensation may occur as a result.
• ML Heads Installation Guide shows the recommended clearances, of the expansion of the atomi-
zation stream, and the clearances that have to be maintained. These are ideal and recommended
maximum capacities using ML nozzles. Different weather, climate and indoor conditions can alter
the spread and distance of the mist.
• As shown in ML Heads Installation Guide, when the nozzles and humidication heads are placed
one opposite the other, make sure that a minimum distances are adhered to. This will avoid the
streams to condensate each other.
• Pay close attention to the airow of the room. Do not install humidication heads or nozzles in the
immediate vicinity of a supply, return or exhaust system or of a cold-air inlet.

12 Site Planning XXXXXXX_EN_1905 Condair MLP
• Do not point humidication heads or their nozzles at cold parts of a building, e.g. outside walls,
windows, etc. (risk of condensation).
• Insulate cold-water pipes in the area of the atomizing stream (risk of condensation).
• The evaporation process absorbs heat from the ambient air. For this reason, make sure that the
atomized stream is not directed on persons or on places directly above workplaces.
• In order to guarantee optimum humidication, ensure that the atomizers are sensibly distributed in
the room.
• The system components have to be mounted in such a way to provide enough space for operation
and maintenance.
Please contact Condair’s Technical Service Team in case you have questions on positioning and clearances.
4.3 Experts on Site
Condair has expert technicians employed by Condair who can provide:
• Pre-site analysis
• Positioning and site assistance or recommendations
• Installation support
• Start-up and commissioning
• Bacteriological troubleshooting on site *
• Cleaning and disinfecting
• Preventive maintenance
• Repair and fault nding
• Training and guidance
*Condair uses an industry leading method for measuring bacterial activity in the water; the approved
and patented BactiQuant test. This, unique to Condair, eld test takes water samples from critical project
locations. Thereafter, the bacteriological quality of the water can be read within 30 minutes, and the
system can be disinfected if necessary.
Condair follows the guidelines in VDI 6022 for colony forming units (CFU) counts in humidiers. The
CFU count in the humidication water must not exceed 150 CFU/ml, corresponding to a maximum BQ
value of 52. Please contact your local Condair representative for further information about our services.

13Product overview
Condair MLP XXXXXXX_EN_1905
5 Product overview
5.1 General description
The MLP series is a high-pressure pump station for direct room humidication it’s developed by Condair
Group AG with focus on reliable and hygienic humidication solutions.
The MLP comes in ve basic models, MLP 100, 300, 500, 800 and 1000. The number indicates
the maximum continuous water outlet (high-pressure) at 943 psi (65 bar). If a larger capacity than
264 gal/hr (1000 l/h) is needed the MLP’s is made in versions with double or triple high pressure pumps
called e.g. MLP 2x800 or MLP 3x1000.
Important:
All components exposed to water are made of corrosion-resistant material. All hoses are steel-reinforced
and drinking water-approved.
The high-pressure pump is directly mounted on the electric motor. Power is supplied to the 3-phase
asynchronous motor via a magnet-operated protective motor switch. The high-pressure pump is pro-
tected against dry running by a pressure switch in the inlet manifold. A temperature sensor monitors the
temperature inside the pump and protects it from overheating.
The control unit consists of a touch display and a PLC mounted in the IP 65-rated electrical cabinet as
well as a power board for control of the high-pressure pump and connection terminals for power supply
(208...480 V/3N~/50-60 Hz).
From the touch screen, the operator can easily change humidity set point in each section, adjust alarm
limits and view hour counters, logged alarms, trend curves, etc.
The pump station is electrically wired at the factory. At the installation site, main power supply, humidity
signal, external safety chain, step valves and additional options must be electrically connected to the
control unit.

14 Product overview XXXXXXX_EN_1905 Condair MLP
5.2 Model Designation
The specication label on the side of the Condair ML adiabatic humidier shows its model number, year
made, serial number, power supply and ratings. The breakdown of the model number is shown in Figure 1.
Condair MLP 300 480V/3~
Product series:
Humidication Load (liters/hour):
100
300
500
800
Voltage and phase:
208V/3~
400V/3~
480V/3~
Figure 1: Model designation
Electrical Schematics and Wiring Diagrams
A copy of the electrical schematics and wiring diagrams can be found on the inside panel of the control
panel.
The rating plate is placed in the upper left corner on the side of the control unit (when facing the front).
Figure 2: Rating plate

15Product overview
Condair MLP XXXXXXX_EN_1905
A label with the internal order number and electrical schematic diagram number is placed on the inside
of the left-hand cabinet hatch (when facing the front) on the control unit.
Figure 3: Label with the internal order number and electrical schematic diagram number

16 Product overview XXXXXXX_EN_1905 Condair MLP
5.3 MLP 100/300 Overview
Figure 4: MLP 100/300 Overview
Figure 5: Hydraulic diagram MLP 100/300
FFilter 10", 1 µm
FR Water meter
G1 Pressure gauge, 0-145 psi (0-10 bar)
G2 Pressure gauge, 0-145 psi (0-10 bar)
G3 Pressure gauge,
high-pressure 0-2321 psi (0-160 bar)
K1 Check valve
K2 Check valve
M1 Motor, high pressure pump
MV1 ON/OFF valve 1/2" 0-145 psi (0-10 bar)
P1 PAH high-pressure pump 1015 psi (70 bar)
PS Pressure switch
PT Pressure transmitter (Option)
R Pressure reduction
T Thermostat
UV UV system
V1 Test water tap
Table 1: Legend MLP 100/300 Overview

17Product overview
Condair MLP XXXXXXX_EN_1905
5.4 MLP 500 Overview
Figure 6: MLP 500 Overview
Figure 7: Hydraulic diagram MLP 500
FFilter 10", 1 µm
FR Water meter
G1 Pressure gauge, 0-145 psi (0-10 bar)
G2 Pressure gauge, 0-145 psi (0-10 bar)
G3 Pressure gauge,
high-pressure 0-2321 psi (0-160 bar)
K1 Check valve
K2 Check valve
M1 Motor, high pressure pump
MV1 ON/OFF valve 1/2" 0-145 psi (0-10 bar)
P1 PAH high-pressure pump 1015 psi (70 bar)
PS Pressure switch
PT Pressure transmitter (Option)
RPressure reduction
TThermostat
UV UV system
V1 Test water tap
Table 2: Legend MLP 500 Overview

18 Product overview XXXXXXX_EN_1905 Condair MLP
5.5 MLP 2x800 overview
Figure 8: MLP 2x800 Overview
Figure 9: Hydraulic diagram MLP 2x800
F1 Filter 10", 1 µm
FR1 Water meter
G1 Pressure gauge, 0-145 psi (0-10 bar)
G2 Pressure gauge, 0-145 psi (0-10 bar)
G3 Pressure gauge,
high-pressure 0-2321 psi (0-160 bar)
K1+K2 Check valve
K3+K4 Check valve
P1+P2 PAH high-pressure pump 1015 psi (70 bar)
PS Pressure switch
R1+R2 Pressure reduction
T1+T2 Thermostat
UV1 UV system
V1 Test water tap
Table 3: Legend MLP 2x800 Overview

19Product overview
Condair MLP XXXXXXX_EN_1905
5.6 Principal installation diagram
Figure 10: Principal installation diagram
sensor
valve
sensor
valve
sensor
valve
modules
Reverse
Osmosis
Ion exchange
Optionalwater
treatment:
Carbonfilter
Safety pre-
filtration
Softening
Solenoid Solenoid
Drain Drain Drain
Drain
Optional water
treatment:
Reverse osmosis
Carbon lter
Safety preltration
Softening
Solenoid Humididity
Power
Supply
Water
Supply
Power
Supply
Power
Supply
Humididity Humididity
Humidication zone Humidication zone Humidication zone
ML Pump station and water treatment
ML Princess
ML Solo modules
ML Flex Line system

20 Product overview XXXXXXX_EN_1905 Condair MLP
5.7 Inlet water quality requirements
The quality of water being used in the MLP system should be checked prior to system commissioning.
Condair A/S recommends that the MLP system be connected to a RO or DI mains water supply.
Table 4: Inlet water quality requirements
Water supply Reverse osmosis or demineralized water
Conductivity 5-50 µS/cm
TDS max 35 ppm
KMnO4 max 10 ppm
NTU max 1.0
Temperature max 59°F (15°C)
Fe max 0.2 ppm
Mn max 0.05 ppm
Max hardness max 1º dH
free chlorine max 0.1 ppm
5.8 Optional equipment for MLP
Choosing the right water treatment is essential for successful humidication. In the ML-System programme,
there is a large variety of water treatment and optional equipment to choose from. The ML-System is
designed to be customised to meet the specications, be it essential water treatment or features. It is
possible to combine ML Systems, water treatment and optional equipment in numerous combinations
and it is thus impossible to describe all of them here. In the following, the most commonly used ancillary
and optional equipment for the MLP system is listed.
Optional and ancillary equipment can be divided into the three following main groups:
MLP options: Added features which are intergraded into the controller of the MLP or placed on its frame,
e.g. conductivity and hardness alarm, BAS integration, ultra-pure water (mixed bed), CIP system, CO2
adding, damping water outlet, holding tanks (RTN). Options cannot be retrotted and must therefore be
listed when ordering
Water treatment: Stand-alone systems for improving the water quality in order to meet the inlet water
quality requirements for the MLP, e.g. booster pump, non-return valve, silt/pre-lter, carbon lter and
softener. See separate Water treatment / RO manual for further information.
High-pressure building installation: Added features and optional equipment – e.g. fan speed controller,
ow monitor, temperature read-out. Options for the high-pressure building installation will be described
in the I/O manual for the high-pressure building installation. See separate High-pressure equipment
manual for further information.