Condair RS series User manual

Steam humidifier
Condair RS
2580645-A EN 1610
INSTALLATION MANUAL
Humidication and Evaporative Cooling

Thank you for choosing Condair
Installation date (MM/DD/YYYY):
Commissioning date (MM/DD/YYYY):
Site:
Model:
Serial number:
Manufacturer
Condair Operations GmbH
Schnackenburgallee 43-45
DE - 22525 Hamburg
Phone [phone], Fax [phone]
[e-mail], www.condair.com
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Group AG. Neither this document,
nor the information contained herein shall be reproduced, used, or disclosed to others without the written authori-
sation of Condair Group AG, except to the extent required for installation or maintenance of recipient's equipment.
Liability Notice
Condair Group AG does not accept any liability due to incorrect installation or operation of the equipment or due
to the use of parts/components/equipment that are not authorised by Condair Group AG.
Copyright Notice
© Condair Group AG, All rights reserved.
Technical modications reserved

3Contents
Contents
1 Introduction 5
1.1 To the very beginning 5
1.2 Notes on the installation manual 5
2 For your safety 7
3 Product Overview 9
3.1 Models overview 9
3.1.1 Single units Small ("S") , RS 5...10 and Medium ("M"), RS 16...40 9
3.1.2 Single units Large ("L"), RS 50...80 10
3.1.3 Double units (2 x "M"), RS 40...80 11
3.1.4 Linkup systems (3 x "M"), RS 100...120 12
3.1.5 Linkup systems (4 x "M"), RS 140...160 13
3.2 Product designation 14
3.3 Options 16
3.4 Accessories 18
3.4.1 Accessories overview 18
3.4.2 Accessory details 19
3.4.2.1 DV81-... steam distribution pipe 19
3.4.2.2 OptiSorp steam distribution system 20
3.4.2.3 Blower pack 21
4 Receiving and storage 22
4.1 Inspection 22
4.2 Storage and Transportation 23
5 Mounting and installation work 24
5.1 Safety notes on mounting and installation work 24
5.2 Installation overviews 25
5.3 Mounting the unit 27
5.3.1 Notes on locating the unit 27
5.3.2 Mounting the humidier 29
5.3.2.1 Standard mounting 29
5.3.2.2 Rail mounting (option) 32
5.3.3 Inspecting the installed unit 34
5.4 Steam installation 35
5.4.1 Overview steam installation for duct humidication 35
5.4.2 Positioning of the steam distributor 37
5.4.3 Installing the steam distributors 42
5.4.4 Positioning and mounting of the blower packs (accessory BP) 43
5.4.5 Installing the steam and condensate lines 44
5.4.6 Common steam and condensate line errors 48
5.4.7 Inspecting the steam installation 49

4Contents
5.5 Water installation 50
5.5.1 Overview water installation 50
5.5.2 Notes on water installation 52
5.5.3 Inspecting the water installation 53
5.6 Notes on humidity control systems/humidity control 54
5.6.1 System 1 – Room humidity control 54
5.6.2 System 2 – Room humidity control with continuous limitation of the supply air humidity 54
5.6.3 System 3 – Supply air humidity control with continuous output limit ation 55
5.6.4 Which humidity control system for which application 55
5.6.5 Admissible control signals 56
5.7 Electrical installation 57
5.7.1 Notes on electrical installation 57
5.7.2 Wiring diagram Condair RS 5...40 - Single units "S" and "M" 58
5.7.3 Wiring diagram Condair RS 50...80 - Single units "L" 59
5.7.4 Wiring diagram Condair RS 40...80 - Double units 2 x "M" 60
5.7.5 Wiring diagram RS 100...160 - Linkup systems 3 x "M" or 4 x "M" 61
5.7.6 Installation work external connections 63
5.7.7 Performance data / Fuses "F3" Heating voltage supply 71
5.7.8 Inspecting the electrical installation 72
6 Appendix 73
6.1 Unit dimensions 73
6.1.1 Unit dimensions unit "S" (RS 5...10) 73
6.1.2 Unit dimensions unit "M" (RS 16...160) 74
6.1.3 Unit dimensions unit "L" (RS 50...80) 75
6.2 EC Declaration of conformity 76

5Introduction
1 Introduction
1.1 To the very beginning
We thank you for having purchased the Condair RS steam humidier.
The Condair RS steam humidier incorporates the latest technical ad van ces and meets all recognized
safety standards. Nevertheless, improper use of the Condair RS steam humidier may result in danger
to the user or third parties and/or damage to property.
To ensure a safe, proper, and economical operation of the Condair RS steam humidier, 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 manual
Limitation
The subject of this installation manual is the Condair RS steam humidier in its different versions.
The various options and accessories are only described insofar as is necessary for proper operation
of the equipment. Further information on options and accessories can be obtained in their respective
instructions.
This installation manual is restricted to the installation of the Condair RS steam humidier and is meant
for well trained personnel being sufciently qualied for their respective work.
This installation manual is supplemented by various separate items of documentation (operation manual,
spare parts list, etc.), which are included in the delivery as well. Where necessary, appropriate cross-
references are made to these publications in the installation manual.

6Introduction
Symbols used in this manual
CAUTION!
The catchword "CAUTION" used in conjunction with the caution symbol in the circle designates notes
in this installation manual that, if neglected, may cause damage and/or malfunction of the unit or
damage to property.
WARNING!
The catchword "WARNING" used in conjunction with the general caution symbol designates safety
and danger notes in this installation manual that, if neglected, may cause injury to persons.
DANGER!
The catchword "DANGER" used in conjunction with the general caution symbol designates safety and
danger notes in this installation manual that, if neglected, may lead to severe injury or even death
of persons.
Safekeeping
Please safeguard this installation manual in a safe place, where it can 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.
Language versions
This installation manual is available in other languages. Please contact your Condair representative for
information.

7For your safety
2 For your safety
General
Every person, who is in charge of the installation work on the Condair RS must have read and understood
this installation manual and the Condair RS operation manual before carrying out any work.
Knowing and understanding the contents of the installation manual and the operation manual is a basic
requirement for protecting personnel against any kind of danger, to prevent faulty operation, and to
operate the unit safely and correctly.
All icons, signs and markings applied to the Condair RS must be observed and kept in readable state.
Qualication of personnel
All installation work described in this installation manual may only be carried out by specialists who
are well trained and adequately qualied and are authorised by the customer.
For safety and warranty reasons any action beyond the scope of this manual must be carried out only
by qualied personnel authorised by Condair.
It is assumed that all persons working with the Condair RS are familiar and comply with the appropriate
regulations on work safety and the prevention of accidents.
Intended use
The Condair RS steam humidier is intended exclusively for air humidication via a steam distributor
or blower pack approved by Condair within specied operating conditions (see Condair RS operation
manual). Any other type of application, without the written consent of Condair, is considered as not
conforming with the intended purpose and may lead to the Condair RS becoming dangerous and will
void any warranty.
Operation of the equipment in the intended manner requires that all the information contained in this
installation manual are observed (in particular the safety instructions).
Danger that may arise from the Condair RS
DANGER!
Danger of electric shock!
The Condair RS is mains powered. Live parts may be exposed when the unit is open. Touching
live parts may cause severe injury or danger to life.
Prevention: The Condair RS must be connected to the mains only after all mounting and installation
work has been completed, all installations have been checked for correct workmanship and the unit
is closed and properly locked.

8For your safety
Preventing unsafe operation
All persons working with the Condair RS are obliged to report any alterations to the unit that may affect
safety to the owner without delay and to secure the Condair RS against accidental power-up.
Prohibited modications to the unit
No modications must be undertaken on the Condair RS without the express written consent of Condair.
For the replacement of defective components use exclusively original accessories and spare parts
available from your Condair representative.

9Product Overview
3 Product Overview
3.1 Models overview
Condair RS steam humidiers are available as single units with different housing sizes (S, M and
L), as double units (2 x "M") and as Linkup systems (3 x "M" or 4 x "M") with different heating
voltages and steam capacities ranging from 5 kg/h up to a maximum of 160 kg/h.
3.1.1 Single units Small ("S") , RS 5...10 and Medium ("M"), RS 16...40
Housing
size
Condair 230 V/1~ 200V/3~ 230V/3~ 380V/3~ 400V/3~ 415V/3~ 440V/3~ 460V/3~ 480V/3~ 500V/3~ 600V/3~
kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h
S
RS 5 5.0 –– 5.0 4.6 5.0 5.4 –– –– –– –– ––
RS 8 8.0 –– 8.0 7.3 8.0 8.7 –– –– –– –– ––
RS 10 9.8 –– 9.8 9.0 10.0 10.7 10.8 11.8 12.8 13.9 10.3
M
RS 16 –– 14.9 16.0 14.5 16.0 17.3 15.3 16.7 18.2 19.8 14.2
RS 20 –– 18.1 19.7 17.9 20.0 21.4 17.2 18.8 20.5 22.2 21.3
RS 24 –– 22.3 24.0 21.8 24.0 26.0 –– –– –– –– ––
RS 30 –– 30.0 29.5 26.9 30.0 32.0 24.0 26.2 28.6 31.0 32.0
RS 40 –– –– –– 36.1 40.0 43.1 36.0 39.4 42.9 46.5 42.7
Fig. 1: Overview single units Small ("S") and Medium ("M")
I/O
Driver board
Module A
Control
board
RFI
Heating voltage
Module A
Control voltage
Control signal
External enable
Limiter signal
Safety chain
Remote indication
Main
Module A

10 Product Overview
3.1.2 Single units Large ("L"), RS 50...80
Housing
size
Condair 230 V/1~ 200V/3~ 230V/3~ 380V/3~ 400V/3~ 415V/3~ 440V/3~ 460V/3~ 480V/3~ 500V/3~ 600V/3~
kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h
LRS 50 –– –– –– –– 50.0 53.4 –– –– –– –– ––
LRS 60 –– –– –– –– 60.0 64.0 –– –– –– –– ––
LRS 80 –– –– –– –– 80.0 86.2 –– –– –– –– ––
Fig. 2: Overview single units Large ("L")
Module
BModule
A
I/O
B
A
Driver board
Module A
Driver board
Module B
Control
board
RFI
Main
Module A
Main
Module B
Heating voltage
Module A / B
Control voltage
Control signal
External enable
Limiter signal
Safety chain
Remote indication

11Product Overview
3.1.3 Double units (2 x "M"), RS 40...80
Housing
size
Condair 230 V/1~ 200V/3~ 230V/3~ 380V/3~ 400V/3~ 415V/3~ 440V/3~ 460V/3~ 480V/3~ 500V/3~ 600V/3~
kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h
2*M
RS 40 –– 2*18.1 2*19.7 –– –– –– –– –– –– –– ––
RS 50
A
+
B
––
18.1
+
30.0
19.7
+
29.5
17.9
+
26.9
20.0
+
30.0
21.4
+
32.0
17.2
+
24.0
18.8
+
26.2
20.5
+
28.6
22.2
+
31.0
21.3
+
32.0
2*M RS 60 –– 2*30.0 2*29.5 2*26.9 2*30.0 2*32.0 2*24.0 2*18.8 2*20.5 2*22.2 2*21.3
2*M RS 80 –– –– –– 2* 36.1 2*40.0 2*43.1 2*36.0 2*39.4 2*42.9 2*46.5 2*42.7
A= Module A, B= Module B
Fig. 3: Overview double units (2 x "M")
Main
Module B
Main
Module A
50 mm
I/O
Driver board
Module A
Driver board
Module B
Control
board
RFI
Heating voltage
Module A
Heating voltage
Module B
Control voltage
Control signal
External enable
Limiter signal
Safety chain
Remote indication
Main
Module A Main Module B
Data cable
Supply cable

12 Product Overview
3.1.4 Linkup systems (3 x "M"), RS 100...120
Housing
size
Condair 230 V/1~ 200 V/3~ 230 V/3~ 380 V/3~ 400 V/3~ 415 V/3~ 440 V/3~ 460 V/3~ 480 V/3~ 500 V/3~ 600 V/3~
kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h
3*M RS 100
M
+
E
–– –– –– ––
2*30.0
+
40.0
2*32.0
+
43.1
–– –– –– –– ––
RS 120 –– –– –– –– 3*40.0 3*43.1 –– –– –– –– ––
M= Main unit, E= Extension unit
Fig. 4: Overview Linkup systems (3 x "M")
Extension
Module A
Main
Module B
Main
Module A
50 mm 50 mm
I/OI/O
Driver board
Main A
Driver board
Main B
Control
board
RFI
Heating voltage
Main A
Heating voltage
Main B
Control voltage
Control signal
External enable
Limiter signal
Safety chain
Remote indication
Main
Module A Main Module B Extension Module A
Data cable
Supply cable
Driver board
Extension A
Control
board
Heating voltage
Extension A
Control voltage
Extension
Linkup cable

13Product Overview
3.1.5 Linkup systems (4 x "M"), RS 140...160
Housing
size
Condair 230 V/1~ 200 V/3~ 230 V/3~ 380 V/3~ 400 V/3~ 415 V/3~ 440 V/3~ 460 V/3~ 480 V/3~ 500 V/3~ 600 V/3~
kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h kg/h
4*M RS 140
M
+
E
–– –– –– ––
2*30.0
+
2*40.0
2*32.0
+
2*43.1
–– –– –– –– ––
RS 160 –– –– –– –– 4*40.0 4*43.1 –– –– –– –– ––
M= Main unit, E= Extension unit
Fig. 5: Overview Linkup systems (4 x "M")
Extension
Module A Extension
Module B
Main
Module B
Main
Module A
50 mm 50 mm 50 mm
I/OI/O
Driver board
Main A
Driver board
Main B
Control
board
RFI
Heating voltage
Main A
Heating voltage
Main B
Heating voltage
Extension B
Control voltage
Control signal
External enable
Limiter signal
Safety chain
Remote indication
Main
Module A Main Module B Extension Module A Extension Module B
Data cable Data cable
Supply cable Supply cable
Driver board
Extension A
Driver board
Extension B
Control
board
Heating voltage
Extension A
Control voltage
Extension
Linkup cable

14 Product Overview
3.2 Product designation
The identication of the unit is found on the specication label.
Fig. 6: Location of the specication label
Condair Operations GmbH, Schnackenburgallee 43-45, DE - 22525 Hamburg
Type: Condair RS 40 P-VE Serial: XXXXXXX 05.15
Voltage: 400V 3~ / 50...60Hz El. Power: 30.0 kW / 43.3 A
Steam capacity: 40.0 kg/h Steam humidier
Water press.: 100..1000 kPa (1..10 bar) Main Unit, Module A
Engineered in Switzerland, Made in Germany
Production
Month/Year
Serial number (7 digits)Type designation
Heating voltage
Maximum steam capacity
Admissible water supply pressure
Field with certication symbols
Power consumption
Device type
Module designation
(shown on specication label of double units and Linkup systems only)

15Product Overview
Key model designation
Example:
Condair RS 50 L 400V/3~ P VE
Product designation
Unit model:
Housing size:
L: large housing
Heating voltage:
230V/1~/50...60Hz: 230V/1~
200V/3~/50...60Hz: 200V/3~
230V/3~/50...60Hz: 230V/3~
380V/3~/50...60Hz: 380V/3~
400V/3~/50...60Hz: 400V/3~
415V/3~/50...60Hz: 415V/3~
440V/3~/50...60Hz: 440V/3~
460V/3~/50...60Hz: 460V/3~
480V/3~/50...60Hz: 480V/3~
500V/3~/50...60Hz: 500V/3~
600V/3~/50...60Hz: 600V/3~
Control accuracy:
P: high control accuracy
Water management:
VE: without lime collector tank for de-ionized water

16 Product Overview
3.3 Options
Voltage Condair RS
230V/1~ 5...10 ––– ––– ––– –––
200V/3~ ––– 16...30 40...60 ––– –––
230V/3~ 5...10 16...30 40...60 ––– –––
380V/3~ 5...10 16...40 50...80 ––– –––
400...415V/3~ 5...10 16...40 50...80 100...120 140...160
440...600V/3~ 10 16/20/30/40 50...80 ––– –––
Remote operating and fault indication
PCB with relay contacts for the connec-
tion of remote displays for "Operation",
"Steam", "Fault" and "Service".
1xRFI 2xRFI
Accessory board
PCB with relay contacts for the connection
of remote fan enable (cylinder A/B) as well
as remote enable of an external hygiene
ush ush valve in the water supply line
(cylinder A/B).
1xACC 2xACC
Pressure compensation kit
Assembly kit for the installation of the lling
cup on the equipment cover, for the opera-
tion of the steam humidier in installations
with duct air pressures up to 10’000 Pa.
1xOVP 2xOVP 3xOVP 4xOVP
Transformer for internal control voltage
supply (for 400...500 V mains supplies
without neutral conductor) *
Kit including terminal strip and transformer
to provide control voltage supply for sites
with 3 phase single voltage supply without
neutral conductor. Only available for supply
voltages 400...500 V/3~/50...60 Hz.
1xTR-S (RS 5 ... RS 20)
1xTR-M (RS 24 ... RS 40)
1xTR-S
(RS 50)
or
1xTR-M
(RS 60/RS80)
2xTR-M 2xTR-M
CVI for internal control voltage supply
(for 400...415 V mains supplies with
neutral conductor) *
Terminal strip kit to provide control volt-
age supply for sites with 3 phase sin-
gle voltage supply with neutral conduc-
tor. Only available for supply voltages
400...415 V/3~N/50...60 Hz.
1xCVI-S (RS 5 ... RS 20)
1xCVI-M (RS 24 ... RS 40)
1xCVI-S
(RS 50)
or
1xCVI-M
(RS 60/RS80)
2xCVI-M 2xCVI-M
Connection terminals **
Separate terminals for systems where
direct connection of heating voltage to
main contactor (standard version) is not
permitted by local regulations
1xTHV-S (RS 5 ... RS 20)
1xTHV-M (RS 24 ... RS 40)
1xTHV-S
+
1xTHV-M
(RS 50)
or
2xTHV-M
(RS 60/RS80)
3xTHV-M 4xTHV-M
Mounting rail
Mounting rail for mounting the Condair
RS to a wall or the mounting rack basic.
1xMP-S 1xMP-M 2xMP-M
or
1xMP-L
for units "L"
3xMP-M 4xMP-M
LonWorks board
Supplementary board to connect the Con-
dair RS to a building management system
via LonWorks.
1xLW

17Product Overview
Voltage Condair RS
230V/1~ 5...10 ––– ––– ––– –––
200V/3~ ––– 16...30 40...60 ––– –––
230V/3~ 5...10 16...30 40...60 ––– –––
380V/3~ 5...10 16...40 50...80 ––– –––
400...415V/3~ 5...10 16...40 50...80 100...120 140...160
440...600V/3~ 10 16/20/30/40 50...80 ––– –––
Set of cable glands
Set with cable glands for the control com-
partment of the Condair RS.
1xCG 2xCG
or
1xCG
for units "L"
3xCG 4xCG
Total drain valve
Set including solenoid drain valve and
hose for automatic draining of the lime
collector tank.
1xSV 2xSV 3xSV 4xSV
Insulation jacket for steam cylinder 1xIC-S 1xIC-M 3xIC-M 3xIC-M 4xIC-M
Drain water cooling set
Set including special inlet valve, hose and
support for drain water cooling.
1xDWC-S 1xDWC-M 2xDWC-M 3xDWC-M 4xDWC-M
* Not available for "L" units
** Connection terminals (1x) included with "L" units

18 Product Overview
3.4 Accessories
3.4.1 Accessories overview
Voltage Condair RS
230V/1~ 5...10 ––– ––– ––– –––
200V/3~ ––– 16...30 40...60 ––– –––
230V/3~ 5...10 16...30 40...60 ––– –––
380V/3~ 5...10 16...40 50...80 ––– –––
400...415V/3~ 5...10 16...40 50...80 100...120 140...160
440...600V/3~ 10 16/20/30/40 50...80 ––– –––
Steam distribution pipe
Steam distribution pipe for steam dis-
tribution inside a air duct (see details in
chapter 3.4.2.1).
1xDV81 2xDV81 3xDV81 4xDV81
Steam distribution system OptiSorp
Steam distribution system for steam
distribution inside a air duct for reduced
absorption distances (see details in
chapter 3.4.2.2).
OptiSorp
System 1
OptiSorp
System 2
OptiSorp
System 3
OptiSorp
System 4
Blower pack
Blower pack for direct room humidication.
The blower pack can be mounted either
directly onto the Condair RS or separated
from the unit to the wall (see details in
chapter 3.4.2.3).
1xBP 2xBP 3xBP 4xBP
Support steam for distribution pipe
Support for vertical mounting of the steam
distribution pipe DV81-....
1xVS-DV81 2xVS-DV81 3xVS-DV81 4xVS-DV81
Steam hose (ø57/45 mm) / meter 1xDS80 2xDS80 3xDS80 4xDS80
Condensate hose (ø12/8 mm) / meter 1xKS10 2xKS10 3xKS10 4xKS10
Filter valve
Filter valve for the installation in the water
supply line.
1xZ261 2xZ261 3xZ261 4xZ261
Mounting rack basic *
Mounting rack for Condair RS.
1xMR-B 2xMR-B 3xMR-B 4xMR-B
Height extension proles for mounting
rack basic *
Height extension proles for mounting rack.
1xMR-E 2xMR-E 3xMR-E 4xMR-E
Screw feet for mounting rack basic *
Screw feet for levelling the mounting rack.
1xMR-A 2xMR-A 3xMR-A 4xMR-A
Humidity sensor - Room CRC
Humidity sensor - Duct CDC
Humidity controller with sensor - Room RCC
Humidity controller with sensor - Duct DCC
Humidistat - Room CHR
Humidistat - Duct CHD
* Not available for "L" units

19Product Overview
3.4.2 Accessory details
3.4.2.1 DV81-... steam distribution pipe
The steam distribution pipes are selected on the basis of the duct width "B" (for horizontal installation)
or the duct height "H" (for vertical installation) and the capacity of the steam humidier.
Important! Always select the longest possible steam distribution pipe (opti mum humidication distance).
Steam distribution pipe DV81-... made of CrNi steel Duct width/duct height Max. Steam capacity
Type Length in mm (L) *** in mm in kg/h
DV81-200 * 200 210...400 10
DV81-350 ** 350 400...600 30
DV81-500 ** 500 600...750 30
DV81-650 650 750...900 50
DV81-800 800 900...1100 50
DV81-1000 1000 1100...1300 50
DV81-1200 1200 1300...1600 50
DV81-1500 1500 1600...2000 50
DV81-1800 1800 2000...2400 50
DV81-2000 2000 2200...2600 50
DV81-2300 2300 2500...2900 50
DV81-2500 2500 2700...3100 50
* for units with steam capacities up to a maximum of 10 kg/h only
** for units with steam capacities up to a maximum of 30 kg/h only
*** Special length on request
Note: for further information regarding the DV81-... steam distribution pipe please refer to the separate
installation and operating instructions of this product.
L
B
H

20 Product Overview
3.4.2.2 OptiSorp steam distribution system
The OptiSorp steam distribution system is used in ventilation ducts with a short humidication distance
(for the calculation of the humidication distance refer to chapter 5.4.2). When ordering an OptiSorp
system the duct dimension must be specied. Please consult the data in the following table:
System 1 System 2 System 3 System 4
Number of
steam connector
1234
Max. steam capacity 45 (30) kg/h 90 (60) kg/h 135 (90) kg/h 180 (120) kg/h
Duct width (B) 450...2700mm
Duct height (H) 450...1650 mm 450...2200 mm 800...3200 mm 800...3200 mm
* For duct widths <600 mm the value in brackets apply
Note: further information on the OptiSorp steam distribution system can be found in the separate manual
supplied with the OptiSorp steam distribution system.
H
B
H
B
H
B
H
B