Condair HP Series User manual

INSTALLATION AND
OPERATION MANUAL
Adiabatic humidification system
Condair HP/HPRO
XXXXXXX EN 1412
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 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 2014, Condair A/S 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 and operation manual 5
2 Health and Safety 7
3 Overview of Condair HP and HPRO 11
3.1 Condair HP system overview 11
3.1.1 Stand-alone system Condair HP (master conguration) 11
3.1.2 Compound system Condair HP (master-slave conguration) 12
3.1.3 Pump station Condair HP 13
3.2 Condair HPRO system overview 16
3.2.1 Stand-alone system Condair HPRO (master conguration) 16
3.2.2 Compound system Condair HPRO (master-slave conguration) 17
3.2.3 Pump station Condair HPRO 100, 200, 300 18
3.3 Humidier unit 21
3.4 Functional description 22
3.5 Scope of delivery 23
4 Notes on planning 24
4.1 Record of site-specic data 24
4.2 Options 25
5 Installation works 26
5.1 Important notes on installation 26
5.2 System set-up 27
5.2.1 Stand-alone system (master conguration) 27
5.3 Compound system (master-slave conguration 1 or 2 slaves) 28
5.4 Compound system (master-slave conguration 3 slaves) 29
5.5 Compound system > 800 l/h (master-slave conguration 1-3 slaves) 30
5.6 Mounting of the humidier unit 31
5.6.1 Notes on positioning and mounting of the humidier unit 31
5.6.2 Mounting the nozzle unit 32
5.6.3 Mounting the Condair droplet separator 40
5.7 Mounting the pump station 46
5.7.1 Notes on positioning 46
5.7.2 Dimension and weights of pump station 47
5.7.3 Pump station installation 51
5.7.4 Water installation, Condair HP 52
5.7.5 Water installation, Condair HP RO 54
5.8 Electrical installation 57
5.8.1 Connections and components inside the Electrical cabinet and PLC – box 58
5.8.2 Electrical connection diagram, HP and HP VFD 59
5.8.3 Electrical connection diagram, HPRO and HPRO VFD 61
5.8.4 Electrical connection diagram, Slave 64
5.8.5 mA Control signal connection 65

4Contents
6 Initial commissioning 66
6.1 Cabinet layout 66
6.2 Insert inlet lter 67
6.3 Insert RO membrane (only for Condair HPRO models) 68
6.4 Mount sterile breathing lter (only for Condair HPRO models) 69
6.5 Set up the controller 69
6.6 Flushing procedure 70
6.6.1 Flushing the HPRO pump unit and RO membrane 71
6.6.2 Bleed air from the RO pump 72
6.6.3 Flushing the HP pump unit 73
6.6.4 Flushing hoses and nozzle lines 74
6.7 Check list initial commissioning Condair HPRO 75
7 Controller set-up 77
7.1 Menu structure 78
7.2 Basic settings 79
8 Operation 84
8.1 Daily operation 84
8.2 Weekly inspection 85
8.3 Taking the HP/HPRO out of operation 86
8.4 Dismantling and disposal 87
9 Maintenance 88
9.1 Important notes on maintenance 88
9.2 Maintenance work 89
9.3 Part list for preventive maintenance 91
9.4 Maintenance indications 92
9.5 Disassembling and assembling of the mist eliminator for cleaning 92
10 Troubleshooting 93
10.1 Important notes on troubleshooting 93
10.2 Malfunction with error indication 93
10.3 Resetting the error indication 95
10.4 Malfunction without error indication 95
11 Product data 96
11.1 Technical data 96
11.1.1 Technical data Condair HP 96
11.1.2 Technical data Condair HPRO 97
11.2 Water quality requirements HP 98
11.3 Water quality requirements HPRO 98
11.4 EC declaration of conformity 99
12 Appendix 100
12.1 Modbus TCP/IP - communication 100

5Introduction
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.

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 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.
Safekeeping
Please safeguard this installation and operation manual in a safe place, where they can be immediately
accessed. If the equipment changes hands, the documentation must be passed on to the new operator.
If the documentation gets mislaid, please contact your Condair representative.
Language versions
This installation and operation manual are available in various languages. Please contact your Condair
representative for information.

7Health and Safety
2 Health and Safety
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, bye-
laws 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.
Intended use
The Condair HP is intended exclusively for humidication in ventilation systems within the specied
operating operating conditions. Any other type 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).
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 chapter 7.4 (switch off the unit, disconnect it from the mains and stop the water supply) and secure
the unit against inadvertent power-up.

8Health and Safety
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 chapter 7.4 (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
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 chapter 8. 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.
Prohibited modications to the unit
No modications must 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.

9Health and Safety
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 ISO 22000 standards, 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, 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.

10 Health 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 Systems use 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 150 CFU/ml, corresponding to a maximum BQ value of 40.
Not all Condair service centres can offer a bacteriological troubleshooting locally, please contact your
local Condair representative for further information.
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 an 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
21.96 0.04 0.00 0.1
32.94 0.06 0.00 0.1
43.92 0.08 0.00 0.1
5 4.90 0.10 0.01 0.1
6 5.88 0.12 0.01 0.1
7 6.86 0.14 0.01 0.1
8 7.84 0.16 0.01 0.1
9 8.82 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

11Overview of Condair HP and HPRO
3 Overview of Condair HP and HPRO
3.1 Condair HP system overview
3.1.1 Stand-alone system Condair HP (master conguration)
Humidi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)
10 Water meter (option)
Fig. 1: Stand-alone system Condair HP (master conguration)

12 Overview of Condair HP and HPRO
3.1.2 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.
Slave systems consisting of:
– Control unit slave
– Humidier unit
Humidier unit
Control unit slave
High pressure hose Master System consisting of:
– Pump station
– Humidier unit
Pump station
Fig. 2: Compound system Condair HP (master-slave conguration)

13Overview of Condair HP and HPRO
3.1.3 Pump station Condair HP
Fig. 3: Pump station Condair HP
Fig. 4: Flow diagram Condair HP

14 Overview of Condair HP and HPRO
PART SPECIFICATION
D Drain
FFilter 1µ
FR Water meter (option)
G1 Pressure gauge 0-10 bar
G2 Pressure gauge 0-10 bar
G3 Pressure gauge 0-135or 0-160 bar
K1 Check valve
K2 Check valve
M1 Motor
MV1 Solenoid valve
MV5 Valve for ushing
MV REG 1 Valve for nozzle strings
MV REG 2 Valve for nozzle strings
MV REG 3 Valve for nozzle strings
P1 High-pressure pump
FD Frequency converter (Option)
PT Pressure transmitter for frequency converter
PS Pressure switch
R Pressure reduction
T Thermostat
UV-R UV light reactor tube (option)
UV-T UV transformer ( HP 100, 200, 300 placed directly on UV-R)
V1 Test water tap 1/8”

15Overview of Condair HP and HPRO
Brief description of high-pressure pump station
All components exposed to water are made of corrosion-resistant material. The hoses are drinking water
approved high-pressure hoses, stainless steel 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 (108...600V/3N~/50-60Hz).
The power board has an alarm switch (NC).
The pump stations can be tted with various options and extras described in the Notes on planning chapter.
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.

16 Overview of Condair HP and HPRO
3.2 Condair HPRO system overview
3.2.1 Stand-alone system Condair HPRO (master conguration)
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
Fig. 5: Stand-alone system Condair HPRO 100, 200, 300 (master conguration)

17Overview of Condair HP and HPRO
3.2.2 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.
Important: Max. length of the high-pres-
sure piping from the pump station to the
last Slave unit must not exceed 60 m
(only valid for systems on the same
oor!)
Slave systems consisting of:
– Control unit slave
– Humidier unit
Humidier unit
Control unit slave
High pressure hose
Master System consisting of:
– Pump station
– Humidier unit
Pump station
Fig. 6: Compound system Condair HPRO 100, 200, 300 (master-slave conguration)

18 Overview of Condair HP and HPRO
3.2.3 Pump station Condair HPRO 100, 200, 300
Fig. 7: Pump station Condair HPRO 100, 200, 300
Fig. 8: Flow diagram Condair HPRO 100, 200, 300

19Overview of Condair HP and HPRO
PART SPECIFICATION
C Permeate container, 55 L, black plastic
D Discharge system
EC Conductivity sensor (Option)
F1 Filter 20", 5 µm
F2 Sterile breathing lter 0,2 µm
FFrequency converter (Option)
FR1 Permeate - ow meter, GF (Option)
FR2 Water meter, measure of produced permeate, plastic M25
G1 Pressure gauge, input pressure 0-10 bar
G2 Pressure gauge, input pressure RO pump 0-10 bar
G3 Pressure gauge, RO pump pressure 0-10 bar
G4 Pressure gauge, high-pressure
K1 Check valve 16 bar, reverse pressure max. 0.1 bar
K2 Check valve min. 16 bar, reverse pressure max. 0.5 bar
K4 Check valve
LML Level sensor: a) Empty
b) Start level
c) Full
d) Overow
M1 Motor, RO pump
HPPRO 100: 3x400 VAC, 50Hz, 0.37kW, 1.1A
HPPRO 300/HPPRO 200 VFD: 3x400 VAC, 50Hz, 0.75kW, 1.9A
M2 Motor, high-pressure pump
HPPRO 100/HPPRO 200 VFD: 3x400 VAC, 50Hz, 0.5kW, 1.5A
HPPRO 300: 3x400 VAC, 50Hz, 0.75kW, 1.9A
MV1 ON/OFF valve 1/2" 0-10 bar
MV2 Valve for ushing at start-up, 0-10 bar, 1/2"
MV3 Valve for membrane ushing, 0-10 bar, 1/2"
MV4 Drain valve 0-10 bar 1/2"
MV5 Valve for ushing
MV6 Valve for conductivity regulating (Option)
MV REG 1 Valve for nozzle strings
MV REG 2 Valve for nozzle strings
MV REG 3 Valve for nozzle strings
PS Pressure switch 0-10 bar, pre-adjusted to 0.5 bar
P1 RO pump
P2 PAH high-pressure pump 70 bar
PT Pressure transmitter 0-100 bar. (Option (Always with VFD))
RO RO membrane in stainless steel housing
R2 Pressure regulator, 30-105 bar standard
T Thermostat
UV UV system S1Q-PA/2 (MLPRO 100/MLPRO 200 VFD) / S2Q-PA/2 (MLP RO 300)
V1 Test water tap 1/8"
V3 Nozzle for concentrate ow
V4 Test water tap 1/8"
V5 Needle valve or nozzle for conductivity regulating (Option)

20 Overview of Condair HP and HPRO
Brief description of pump station
Combined high-pressure pump station and reverse osmosis system.
All components exposed to water are made of corrosion resistant material. The hoses are drinking water
approved hoses, stainless steel 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 to the electric
motor.
In the water inlet a pressure switch protects the RO pump from dry running.
The high-pressure pump is protected against dry running by the level switch in the RO tank that stops the
system if water level drops. The high-pressure pump is protected against overheating by a temperature
sensor that measures temperature inside 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...600V/3N~/50-60Hz).
The power board has an alarm switch (NC).
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.