Condair CP3 D Series Guide

TECHNICAL DOCUMENTATION
Steam generator for steam baths
2538965 EN 0806
Condair CP3 D

1 Introduction 4
1.1 To the very beginning 4
1.2 Notes on the technical documentation 4
2 For your safety 6
3 Product Overview 8
3.1 Models overview 8
3.2 Identification of the unit 9
3.3 Steam generator construction 10
3.4 Functional description 11
3.5 System overview 12
3.6 Options 13
3.6.1 Options overview 13
3.6.2 Option details 14
3.7 Accessories 15
3.8 Standard delivery 16
3.9 Storing/Transportation/Packaging 16
4 Notes for the planning engineer 17
4.1 Selecting the unit version 17
4.1.1 Determination of the required steam capacity 17
4.1.2 Selecting the unit 18
4.2 Selecting the options an accessories 18
5 Mounting and installation work 19
5.1 Important notes for mounting and installation work 19
5.2 Installation overview 20
5.3 Mounting the unit 21
5.3.1 Notes on locating the unit 21
5.3.2 Mounting the unit 23
5.3.3 Inspecting the installed unit 24
5.4 Steam installation 25
5.4.1 Overview steam installation 25
5.4.2 Positioning/mounting the steam distributor 25
5.4.3 Installing the steam hose 26
5.4.4 Inspecting the steam installation 27
5.5 Water installation 28
5.5.1 Overview water installation 28
5.5.2 Notes on water installation 29
5.5.3 Inspecting the water installation 30
5.6 Electric installation 31
5.6.1 Wiring diagram Condair CP3 D 31
5.6.2 Notes on electric installation 32
5.6.3 Inserting the CP3 Card 34
5.6.4 Inspecting the electrical installation 34
6 Operation 35
6.1 Commissioning 35
6.2 Notes on operation 36
6.2.1 Function of the display and operating elements 36
6.2.2 Remote operating and fault indication 36
6.2.3 Inspections during operation 37
6.2.4 Carrying out manual draining 37
6.3 Taking the unit out of operation 37
6.4 Overview and operating of the menu 38
6.5 Interrogation functions 39
6.5.1 Information in the operating display 39
6.5.2 Interrogation of unit information 39
6.5.3 Interrogation of the malfunction list 40
6.6 Unit settings 40
6.6.1 Setting the setpoint temperature 40
6.6.2 Setting the control mode 40
6.6.3 Setting the fragrance pump settings 41
6.6.4 Unit settings in the settings menu 42
6.6.4.1 Launching the settings menu 42
6.6.4.2 Selecting the dialogue language 42
6.6.4.3 Steam bath control settings 42
6.6.4.4 Setting the date 45
6.6.4.5 Setting the time 45
6.6.4.6 Cylinder settings 45
6.6.4.7 Setting the capacity limitation 46
6.6.4.8 Activating/Deactivating fault current relay operation 46
6.6.4.9 Water management settings 46
6.6.4.10 Performing remote relay tests 47
6.6.4.11 Performing steam bath tests 48
6.6.4.12 Setting the display contrast 48
6.7 Modbus settings 48
7 Maintenance 49
7.1 Important notes on maintenance 49
7.2 Maintenance list 50
7.3 Removing and installing parts for maintenance 51
7.3.1 Removal and installation of the steam cylinder 51
7.3.2 Disassembly and assembly of
the cleanable steam cylinder type D... 53
7.3.3 Removal and installation of the water cup
and the water hoses 54
7.3.4 Removal and installation of the drain pump 55
7.3.5 Removal and installation of the inlet valve 55
7.4 Notes on cleaning the unit components 56
7.5 Notes on cleaning agents 57
7.6 Resetting the maintenance indication 58
8 Malfunctions 59
8.1 Malfunction list 59
8.1.1 System faults 59
8.1.2 Unit faults 60
8.2 Notes on fault elimination 62
8.3 Resetting the error indication (red LED lights) 62
9 Taking out of service/Disposal 63
9.1 Taking out of service 63
9.2 Disposal/Recycling 63
10 Product specifications 64
10.1 Technical data 64
10.2 Unit dimensions 65
Contents

4
Limitation
The subject of this technical documentation is the steam generator Condair CP3 D.The various
accessories 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.
This technical documentation is restricted to the installation, commissioning, operation, servic-
ing and trouble shooting of the steam generator Condair CP3 D and is meant for well trained
personnel being sufficiently qualified for their respective work.
The technical documentation is supplemented by various separate items of documentation (spare
parts list, manuals for accessories, etc.). Where necessary, appropriate cross-references are made
to these publications in the technical documentation.
1 Introduction
We thank you for having purchased the steam generator Condair CP3 D.
The steam generator Condair CP3 D incorporates the latest technical advances and meets all rec-
ognized safety standards. Nevertheless, improper use of the Condair CP3 D 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 generator Condair CP3 D, please
observe and comply with all information and safety instructions contained in the present technical
documentation as well as the instructions given in the manuals for the components used in the
humidification system.
If you have questions, which are not or insufficiently answered in this documentation, please contact
your Condair supplier. They will be glad to assist you.
1.2 Notes on the technical documentation
1.1 To the very beginning

5
Symbols used in this manual
CAUTION!
The catchword “CAUTION” designates notes in this technical documentation that, if
neglected, may cause damage and/or malfunction of the unit or other material
assets and/or may lead to injury to persons.
WARNING!
The catchword “WARNING” used in conjunction with the general caution symbol
designates safety and danger notes in this technical documentation that, if neglected,
may lead to severe injury or even lethal violation of persons.
Safekeeping
Please safeguard this technical documentation in a safe place, where it can be immediately accessed.
If the equipment changes hands, the documentation should be passed on to the new operator.
If the documentation gets mislaid, please contact your Condair supplier.
Language versions
This technical documentation is available in various languages. Please contact your Condair supplier
for information.
Copyright protection
The present technical documentation is protected under the Copyright Act. Passing-on and reproduc-
tion of the manual (or part thereof) as well as exploitation and communication of the contents are
prohibited without written permission by the manufacturer. Violation of copyright terms is subject
to legal prosecution and arises liability for indemnification.
The manufacturer reserves the right to fully exploit commercial patent rights.

6
2 For your safety
General
Every person working with the Condair CP3 D must have read and understood the Technical Docu-
mentation before carrying out any work.
Knowing and understanding the contents of the Technical Documentation is a basic requirement for
protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the
unit safely and correctly.
All ideograms, signs and markings applied to the unit must be observed and kept in readable
state.
Qualification of personnel
All actions described in the present Technical Documentation (installation, operation, maintenance,
etc.) must be carried out only by well trained and sufficiently qualified personnel authorised by
the owner.
For safety and warranty reasons any action beyond the scope of this manuals must be carried out
only by qualified personnel authorised by the manufacturer.
It is assumed that all persons working with the Condair CP3 D are familiar and comply with the ap-
propriate regulations on work safety and the prevention of accidents.
Intended use
The steam generator Condair CP3 D is intended exclusively for generation of steam for a steam
bath within the specified operating conditions (see chapter 10 “Product specifications”). Any
other type of application without the express written consent of the manufacturer is considered as not
conforming with the intended purpose and may lead to the Condair CP3 D becoming dangerous.
Operation of the equipment in the intended manner requires that all the information in these
instructions is observed (in particular the safety instructions).

7
Danger that may arise from the unit
– The Condair CP3 D is mains powered.
WARNING!
One may get in touch with live parts when the unit is open. Touching live
parts may cause severe injury or danger to life.
Prevention: Before carrying out any work set the Condair CP3 D out of operation as de-
scribed in chapter 6.3 (switch off the unit, disconnect it from the mains and
stop the water supply) and secure the unit against inadvertent power-up.
– The Condair CP3 D produces steam.When producing steam, the steam cylinder inside the
steam generator gets very hot (up to 100 °C).
WARNING!
If the unit is opened immediately after having produced steam there is danger
of burning when touching the steam cylinder.
Prevention: Before carrying out any work set the Condair CP3 D out of operation as de-
scribed in chapter 6.3, then wait until the evaporation unit has cooled down
sufficiently thus preventing danger of burning.
Behaviour in case of danger
If it is suspected that safe operation is no longer possible, then the Condair CP3 D should imme-
diately be shut down and secured against accidental power-up according to chapter 6.3. This
can be the case under the following circumstances:
– if the Condair CP3 D or its mains cable is damaged
– if the Condair CP3 D is no longer operating correctly
– if connections and/or piping are not sealed
All persons working with the Condair CP3 D must report any alterations to the unit that may affect
safety to the owner without delay.
Prohibited modifications to the unit
No modifications must be undertaken on the Condair CP3 D 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 supplier.

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3 Product Overview
3.1 Models overview
The steam generators Condair CP3 D are available with different heating voltages and steam
capacities ranging from 5 kg/h up to a max. of 45 kg/h.
Heating voltage * Max. steam capacity
in kg/h
Graduation
in kg/h
Model
Condair CP3 D
Unit size
small large
400V3
(400V/3~/50...60Hz)
5...15 1 5...15 1
16...45 1 16...45 1
230V3
(230V/3~/50...60Hz)
5...15 1 5...15 1
16...30 1 16...30 1
230V1
(230V/1~/50...60Hz) 5...8 1 5...8 1
* Other heating voltages on request
The steam generators Condair CP3 D are equipped, as standard, with an exchangeable steam cylinder,
a control with an integrated continuous controller, as well as a complete steam bath control (connec-
tion and control of: fan, lighting, fragrance pump and remote maintenance and fault indicator).
All models are controlled steplessly via the KTY temperature sensor supplied and the built-in trans-
mitter and the continuous controller.
Note: a special version of the Condair CP3 D without steam bath control is available on demand.
Key model designation
Example:
Condair CP3 D 45 400V3
Unit version
Maximum steam capacity in kg/h:
Heating voltage:
400V/3~/50...60Hz: 400V3
230V/3~/50...60Hz: 230V3
230V/1~/50...60Hz: 230V1

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Walter Meier (Climate International) Ltd. 8808 Pfäffikon
Made in Switzerland
Condair CP3 D 45
Dampf/Steam/Vapeur = 45.0 kg/h
Wasser/Water/Eau = 1...10 bar
Wechselstrom AC
Main Unit / Modul A
400V 3~ / 50...60Hz 33.8 kW
XXXXXXX 11.06
3.2 Identification of the unit
The identification of the unit is found on the type plate (for the location of the type plate see unit
overview):
Type designation Serial number (7 digits) Month/Year
Unit voltage (heating voltage)
Maximum steam capacity per unit
Admissible water supply pressure
Operation note
Unit designation
Total steam capacity in kg/h

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3.3 Steam generator construction
1 Housing (small, large)
2 Cable openings, top side
3 Main contactor
4 Power board
5 Control board with CP3 Card
6 Display and control unit
7 Remote operating and fault indication board
8 Operation status indicators
9 Cable openings, bottom side
10 Drain key
11 Unit switch
12 Steam hose connector (option)
13 Water cup
14 Filling hose
15 Water supply hose
16 Inlet valve
17 Overflow hose
18 Drain connection (not visible)
19 Water supply pipe
20 Drain pump
21 Type plate
22 Data plate CP3 Card
23 Steam cylinder
24 Level sensor
25 Auxiliary drain hose
26 Electrode plug
The illustration above shows the large unit
1
12
13
15
14
17
16
19
18
20
23
25
26
24
2
3
7
4
5
6
8
11
10
9
21
22

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3.4 Functional description
The Condair CP3 D is a pressureless steam generator that utilizes an electrode heating. The Condair
CP3 D is designed for steam generation in a steam bath.
Steam generation
Any time steam is requested, the electrodes are supplied with voltage via main contactor. Simulta-
neously, the inlet valve opens and water enters the steam cylinder from the bottom via water cup
and supply line. As soon as the electrodes come in contact with the water, current begins to flow
between the electrodes, eventually heating and evaporating the water.The more the electrode surface
is exposed to water, the higher is the current consumption and thus the steam capacity.
Upon reaching the requested steam capacity, the inlet valve closes. If the steam generation de-
creases below a certain percentage of the required capacity, due to lowering of the water level (e.g.
because of the evaporation process or drainage), the inlet valve opens until the required capacity is
available again.
If the required steam capacity is lower than the actual output, the inlet valve is closed until the de-
sired capacity is achieved by lowering of the water level (evaporation process).
Level monitoring
A sensor provided in the steam cylinder cover detects when the water level gets too high. The mo-
ment the sensor comes in contact with water, the inlet valve closes.
Drainage
As a result of the evaporation process, the conductivity of the water increases due to an escalating
mineral concentration. Eventually, an inadmissibly high current consumption would take place if this
concentration process were permitted to continue. To prevent this concentration from reaching a
value, unsuitably high for the operation, a certain amount of water is periodically drained from the
cylinder and replaced by fresh water.
Control
The steam production is controlled steplessly (continuous control) by the KTY temperature sensor
supplied (or an 0-10V temperature sensor) and the integrated continuous controller.
Below a minimum controllable steam output a two-point control (On/Off) is used.

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3.5 System overview
1 Steam generator
2 Steam connection
3 Water drain connection
4 Water supply connection
5 Filter valve (accessory “Z261”)
6 Manometer (installation recommended)
7 Funnel with siphon (building side)
8 Water drain hose (accessory “DS80”)
9 Control voltage supply
10 Heating voltage supply
11 Cable openings
12 Steam hose (accessory “DS..”)
13 Steam distributor (accessory “W..”)
DS80
8
7
9
10
125...1250 µS/cm
1...10 bar
1...40 °C
1
2
3
4
5
6
Z261
11
DS60
DS22
DS80
W30
W22
W45
12
13

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3.6 Options
3.6.1 Options overview
Condair CP3 D
230V1 5...8
400V3 5...8 9...15 16...45
230V3 5...8 9...15 16...30
D... Cleanable steam cylinder
Cleanable steam cylinder as an alternative to the
disposable steam cylinder built in as standard (see
also chapter 3.6.2).
1x D3.. 1x D4.. 1x D6..
RFI Remote operating and fault indication
PCB with relay contacts for the connection of remote
displays for “Operation”, “Steam”, “Fault” and
“Service” as well as an analogue output for remote
temperature indication and an analogue output for
the temperature-dependent control of an optional
flap control system.
1x RFI 1x RFI 1x RFI
THV Terminals heating voltage
Separateterminalsforsystemswheredirectconnection
of heating voltage to main contactor (standard version)
is not permitted by local regulations.
1x M-THV 1x M-THV 1x L-THV
PG Cable gland 1x PG 1x PG 1x PG
SC.. Steam hose connector 1x SC22 1x SC60 1x SC80
MP Mounting profile 1x MP 1x MP 1x MP
CVI Internal control voltage 1x M-CVI 1x M-CVI 1x L-CVI
TRAFO Transformer (400V/230V) 1x M-Trafo 1x M-Trafo 1x L-Trafo

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3.6.2 Option details
Steam cylinder
The steam generator is available with two different types of steam cylinders:
– Exchangeable steam cylinder type A... (standard version)
– Cleanable steam cylinder type D... (option)
The following tables present an overview of the steam cylinders used in the different models.
Condair CP3 D...400V3 5...8 9...15 16...25 26...45
For water conductivity from 125 to 1250 µS/cm
Exchangeable steam cylinder 1xA363 1xA464 1xA674 1xA664
Cleanable steam cylinder 1xD363 1xD464 1xD674 1xD664
For low water conductivity
Exchangeable steam cylinder 1xA343 1xA444 1xA654 1xA654
Cleanable steam cylinder 1xD343 1xD444 1xD654 1xD654
Condair CP3 D...230V3 5...8 9...15 16...21 22...30
For water conductivity from 125 to 1250 µS/cm
Exchangeable steam cylinder 1xA343 1xA444 1xA654 1xA644
Cleanable steam cylinder 1xD343 1xD444 1xD654 1xD674
Condair CP3 D...230V1 5...8
For water conductivity from 125 to 1250 µS/cm
Exchangeable steam cylinder 1xA342
Cleanable steam cylinder 1xD342
If you have questions regarding the steam cylinders please contact your Condair representative.

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3.7 Accessories
Accessories for water installation
Condair CP3 D
230V1 5...8
400V3 5...8 9...15 16...45
230V3 5...8 9...15 16...30
Filter valve 1x Z261
Accessories for steam installation
Condair CP3 D
230V1 5...8
400V3 5...8 9...15 16...45
230V3 5...8 9...15 16...30
Steam distributor
(Details see chapter 5.4)
1x W22 1x W30 1x W45
Steam hose / meter 1x DS22 1x DS60 1x DS80
Condensate hose / meter 1x KS10
Fragrance pump 1x SR25 230 VAC
Accessories for operation control
Condair CP3 D
230V1 5...8
400V3 5...8 9...15 16...45
230V3 5...8 9...15 16...30
Temperature sensor 1x KTY

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3.9 Storing/Transportation/Packaging
Storing
Store the unit in a protected area meeting the following requirements:
– Room temperature: 1 ... 40 °C
– Room humidity: 10 ... 75 %rh
Transportation
For optimum protection always transport the unit in the original packaging.
The weight of the small and the large unit is more than 20 kg (weight without packaging: small unit
23 kg, large unit 28 kg). Therefore, always transport the unit with the help of another person or use
a forklift or a crane. Always place the unit on its back side.
Packaging
Keep the original packaging of the Condair CP3 D for later use.
In case you wish to dispose of the packaging, observe the local regulations on waste disposal. Never
dispose of the packaging to the environment.
The standard delivery includes:
– Steam generator Condair CP3 D cpl. equipped with the options ordered according to chapter 3.6
with KTY temperature sensor, water connection pipe G3/4" - 1/2", fixing set, Technical Documen-
tation (this document) and spare parts list, packaged in cardboard box:
– Unit small (WxHxD): 450 mm x 620 mm x 280 mm, shipping weight: 26 kg
– Unit large (WxHxD): 559 mm x 667 mm x 350 mm, shipping weight: 31 kg
– Ordered accessories with operating instructions according chapter 3.7, packed separately
– Spare parts list
3.8 Standard delivery

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4.1 Selecting the unit version
The steam capacity required for a particular steam bath can be determined with the following table:
Cabin size Required steam capacity
in m3Plastic cabin brick lined cabin
4 5 kg/h 8 kg/h
8 8 kg/h 12 kg/h
12 10 kg/h 15 kg/h
16 12 kg/h 18 kg/h
20 13 kg/h 21 kg/h
24 15 kg/h 24 kg/h
28 17 kg/h 26 kg/h
32 18 kg/h 29 kg/h
36 20 kg/h 31 kg/h
40 21 kg/h 34 kg/h
44 23 kg/h 36 kg/h
48 24 kg/h 38 kg/h
52 26 kg/h 41 kg/h
56 27 kg/h 43 kg/h
60 29 kg/h 45 kg/h
4 Notes for the planning engineer
To select the unit version the following planning steps are required:
1. Calculating the required maximum steam capacity according chapter 4.1.1
2. Selecting the unit version from the table in chapter 4.1.2
4.1.1 Determination of the required steam capacity

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4.1.2 Selecting the unit
Heating voltage * Max. steam capacity
in kg/h
Graduation
in kg/h
Model
Condair CP3 D
Unit size
small large
400V3
(400V/3~/50...60Hz)
5...15 1 5...15 1
16...45 1 16...45 1
230V3
(230V/3~/50...60Hz)
5...15 1 5...15 1
16...30 1 16...30 1
230V1
(230V/1~/50...60Hz) 5...8 1 5...8 1
* Other heating voltages on request
4.2 Selecting the options an accessories
For selecting the options and accessories see chapters 3.6 and 3.7.
Condair CP3 D 45 400V3

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5 Mounting and installation work
Qualification of personnel
All mounting and installation work must be carried out only by well qualified personnel authorised
by the owner. It is the owner’s responsibility to verify proper qualification of the personnel.
General note
Strictly observe and comply with all information given in the presentTechnical Documentation regard-
ing the location of the unit and the installation of water, steam and electricity.
Observe and comply with all local regulations dealing with water, steam and electrical installa-
tions.
Safety
Some installation work requires removal of the unit cover. Please note the following:
WARNING!
Danger of electrical shock! You may get in touch with live parts when the unit
is open. The steam generator must be connected to the mains only after all
mounting and installation work has been completed and the cover has been
relocated properly.
CAUTION!
The electronic components inside the steam generator are very sensitive to
electrostatic discharge. When the unit is open for installation work, appropriate
measures must be taken to protect these components against damage caused by
electrostatic discharge (ESD protection).
5.1 Important notes for mounting and installation work

20
125...1250 µS/cm
1...10 bar
1...40 °C
≥ 40 mm
min. 10 %
–
60...70 °C
ø40 mm
ø10/8 mm 230V/1~/50...60Hz
400V/3~/50...60Hz
230V/3~/50...60Hz
230V/1~/50...60Hz
G 1/2"
G 1/2"
1 ... 40 °C
max. 75 %rh
IP20
min. 300 mm
DS80
Z261
DS60
DS22
DS80
W30
W22
W45
Rmin. 300 mm
min. 5 %
–
min. 20 %
+
Rmin. 300 mm
max. 4 m
5.2 Installation overview
Water installation,
see chapter 5.5
Electric installation,
see chapter 5.6
Steam installation,
see chapter 5.4
Mounting the unit,
see chapter 5.3