Condair Omega Pro User manual

Steam generator
Condair Omega Pro
2588794-B EN 2002
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:
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") , Omega Pro 5...10 and Medium ("M"), Omega Pro 16...40 9
3.1.2 Single units Large ("L"), Omega Pro 50...80 10
3.1.3 Double units (2 x "M"), Omega Pro 40...80 11
3.1.4 Linkup systems (3 x "M"), Omega Pro 100...120 12
3.1.5 Linkup systems (4 x "M"), Omega Pro 140...160 13
3.2 Product designation 14
3.3 Options 16
3.4 Accessories 18
4 Receiving and storage 19
4.1 Inspection 19
4.2 Storage and Transportation 20
5 Mounting and installation work 21
5.1 Safety notes on mounting and installation work 21
5.2 Installation overviews 22
5.3 Mounting the unit 24
5.3.1 Notes on locating the unit 24
5.3.2 Mounting the steam generator 26
5.3.2.1 Standard mounting 26
5.3.2.2 Rail mounting (option) 29
5.3.3 Inspecting the installed unit 31
5.4 Steam installation 32
5.4.1 Overviews steam installation 32
5.4.2 Positioning/mounting the steam distributor 34
5.4.3 Positioning and mounting of the blower packs (accessory BP) 35
5.4.4 Installing the steam and condensate lines 36
5.4.5 Common steam and condensate line errors 41
5.4.6 Inspecting the steam installation 42
5.5 Water installation 43
5.5.1 Overview water installation 43
5.5.2 Notes on water installation 45
5.5.3 Inspecting the water installation 46
5.6 Notes on humidity control for direct room humidication 47
5.6.1 Principle diagram room humidity control 47

4Contents
5.7 Electrical installation 48
5.7.1 Notes on electrical installation 48
5.7.2 Wiring diagram Condair Omega Pro 5...40 - Single units "S" and "M" 49
5.7.3 Wiring diagram Condair Omega Pro 50...80 - Single units "L" 50
5.7.4 Wiring diagram Condair Omega Pro 40...80 - Double units 2 x "M" 51
5.7.5 Wiring diagram Condair Omega Pro 100...160 - Linkup systems 3 x "M" or 4 x "M" 52
5.7.6 Installation work external connections 54
5.7.7 Performance data / Fuses "F3" Heating voltage supply 61
5.7.8 Inspecting the electrical installation 62
6 Appendix 63
6.1 Unit dimensions 63
6.1.1 Unit dimensions unit "S" (Omega Pro 5...10) 63
6.1.2 Unit dimensions unit "M" (Omega Pro 16...160) 64
6.1.3 Unit dimensions unit "L" (Omega Pro 50...80) 65
6.2 EC Declaration of conformity 66

5Introduction
1 Introduction
1.1 To the very beginning
We thank you for having purchased the Condair Omega Pro steam generator.
The Condair Omega Pro steam generator incorporates the latest technical ad van ces and meets all
recognized safety standards. Nevertheless, improper use of the Condair Omega Pro steam generator
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 Omega Pro steam generator, 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 Omega Pro steam generator 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 Omega Pro steam generator 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 Omega Pro must have read and
understood this installation manual and the Condair Omega Pro 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 Omega Pro must be observed and kept in read-
able 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 Omega Pro are familiar and comply with the
appropriate regulations on work safety and the prevention of accidents.
Intended use
The Condair Omega Pro steam generator is intended exclusively for generation of steam for SPA
applications within the specied operating conditions (see Condair Omega Pro 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 Omega Pro 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 Omega Pro
DANGER!
Danger of electric shock!
The Condair Omega Pro 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 Omega Pro 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 Omega Pro are obliged to report any alterations to the unit that may
affect safety to the owner without delay and to secure the Condair Omega Pro against accidental
power-up.
Prohibited modications to the unit
No modications must be undertaken on the Condair Omega Pro 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 Omega Pro steam generators 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") , Omega Pro 5...10 and Medium ("M"), Omega Pro 16...40
Housing
size
Condair
Omega Pro
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
55.0 –– 5.0 4.6 5.0 5.4 –– –– –– –– ––
88.0 –– 8.0 7.3 8.0 8.7 –– –– –– –– ––
10 9.8 –– 9.8 9.0 10.0 10.7 10.8 11.8 12.8 13.9 10.3
M
16 –– 14.9 16.0 14.5 16.0 17.3 15.3 16.7 18.2 19.8 14.2
20 –– 18.1 19.7 17.9 20.0 21.4 17.2 18.8 20.5 22.2 21.3
24 –– 22.3 24.0 21.8 24.0 26.0 –– –– –– –– ––
30 –– 30.0 29.5 26.9 30.0 32.0 24.0 26.2 28.6 31.0 32.0
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"), Omega Pro 50...80
Housing
size
Condair
Omega Pro
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
L50 –– –– –– –– 50.0 53.4 –– –– –– –– ––
L60 –– –– –– –– 60.0 64.0 –– –– –– –– ––
L80 –– –– –– –– 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"), Omega Pro 40...80
Housing
size
Condair
Omega Pro
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
40 –– 2*18.1 2*19.7 –– –– –– –– –– –– –– ––
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 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 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"), Omega Pro 100...120
Housing
size
Condair
Omega Pro
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 100
M
+
E
–– –– –– ––
2*30.0
+
40.0
2*32.0
+
43.1
–– –– –– –– ––
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"), Omega Pro 140...160
Housing
size
Condair
Omega Pro
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 140
M
+
E
–– –– –– ––
2*30.0
+
2*40.0
2*32.0
+
2*43.1
–– –– –– –– ––
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 Group AG, Gwattstrasse 17, 8808 Pfäfkon SZ, Switzerland
Type: Condair Omega Pro 40 P-VE Serial-No: XXXXXXX 05.15
Voltage: 400V 3~ / 50...60Hz El. Power: 30.0 kW / 43.3 A
Steam capacity: 40.0 kg/h Contr.volt.: AC 200-240V/50-60Hz
Water press.: 100..1000 kPa (1..10 bar) Steam generator
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
Control voltage
Device type
Module designation
(shown on specication label of double units and Linkup systems only)
Main Unit
Module A

15Product Overview
Key model designation
Example:
Condair Omega Pro 50 L 400V/3~ 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 water from a reverse osmosis system or de-ionized water

16 Product Overview
3.3 Options
Condair Omega Pro
Housing size
Voltage Small
(S)
Medium
(M)
Double
(2xM)
Large
(L)
Linkup
(3xM)
Linkup
(4xM)
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 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
Pressure compensation kit
Assembly kit for the installation of the lling
cup on the equipment cover, for the opera-
tion of the steam generator 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) 1)
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
(Omega Pro 5 ... 20)
1xTR-M
(Omega Pro 24 ... 40)
1xTR-S
(Omega Pro 50)
or
1xTR-M
(Omega Pro 60/
Omega Pro 80)
1xTR-L 2xTR-M
CVI for internal control voltage supply
(for 400...415 V mains supplies with
neutral conductor) 1)
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
(Omega Pro 5 ... 20)
1xCVI-M
(Omega Pro 24 ... 40)
1xCVI-S
(Omega Pro 50)
or
1xCVI-M
(Omega Pro 60/
Omega Pro 80)
1xCVI-L 2xCVI-M
Connection terminals 1)
Separate terminals for systems where
direct connection of heating voltage to
main contactor (standard version) is not
permitted by local regulations
1xTHV-S
(Omega Pro 5 ... 20)
1xTHV-M
(Omega Pro 24 ... 40)
1xTHV-S
+
1xTHV-M
(Omega Pro 50)
or
2xTHV-M
(Omega Pro 60/
Omega Pro 80)
1xTHV-L 3xTHV-M 4xTHV-M
Mounting rail
Mounting rail for mounting the Condair
Omega Pro to a wall or the mounting
rack basic.
1xMP-S 1xMP-M 2xMP-M 1xMP-L 3xMP-M 4xMP-M
LonWorks board
Supplementary board to connect the
Cond-
air Omega Pro to a building management
system via LonWorks.
1xLW

17Product Overview
Condair Omega Pro
Housing size
Voltage Small
(S)
Medium
(M)
Double
(2xM)
Large
(L)
Linkup
(3xM)
Linkup
(4xM)
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 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 Omega Pro.
1xCG 2xCG 1xCG 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 2xIC-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
Pure water system Condair RO-A
Pure water system for operating the Cond-
air Omega Pro with UO water.
1xRO-A40 2xRO-A100
1) For "L" units only possible if they are connected with two separate heating voltage supply lines.

18 Product Overview
3.4 Accessories
Condair Omega Pro
Housing size
Voltage Small
(S)
Medium
(M)
Double
(2xM)
Large
(L)
Linkup
(3xM)
Linkup
(4xM)
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 50...80 100...120 140...160
440...600V/3~ 10 16/20/30/40 50...80 ––– ––– –––
Blower pack
Blower pack for direct room humidication.
The blower pack can be mounted either
directly onto the Condair Omega Pro or
separated from the steam generator to
the wall.
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 Omega Pro.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 controller with sensor - Room RCC
Humidistat - Room CHR

19Receiving and storage
4 Receiving and storage
4.1 Inspection
After receiving:
– Inspect shipping boxes for damage.
Any damages of the shipping boxes must be reported to the shipping company without delay.
– Check packing slip to ensure all parts has been delivered.
All material shortages are to be reported to your Condair supplier within 48 hours after receipt of the
goods. Condair Group AG assumes no responsibility for any material shortages beyond this period.
The standard delivery includes:
– Condair Omega Pro steam generator equipped with the options ordered according chapter 3.3,
packed in cardboard box with:
– Fastening set
– Installation manual (this document), operation manual and spare parts list
– Water drain hose with hose clamp
– Supply cable between Module A to Module B (for double units and Linkup systems only)
– Data cable between Module A to Module B (for double units and Linkup systems only)
– Linkup cable between "Main A" and "Externsion"A" (for Linkup systems only)
Note: the supply cable, the data cable and the Linkup cable are supplied in the box of main unit A.
– Ordered accessories with manual according chapter 3.4, packed separately.
– Unpack the parts/components and check for any damage.
If parts/components are damaged, notify the shipping company immediately.
– Check whether the components are suitable for installation on your site according to the unit data
stated on the specication label.

20 Receiving and storage
4.2 Storage and Transportation
Storing
Until installation store the Condair Omega Pro in its original packaging in a protected area meeting the
following requirements:
– Room temperature: 5 ... 40 °C
– Room humidity: 10 ... 75 %rh
Transportation
For optimum protection always transport the unit and components in their original packaging and use
appropriate lifting/transporting devices.
WARNING!
It is the customer's responsibility to ensure that operators are trained in handling heavy goods and that
the operators comply with the appropriate regulations on work safety and the prevention of accidents.
Packaging
Keep the original packaging of the components for later use.
In case you wish to dispose of the packaging, observe the local regulations on waste disposal. Please
recycle packaging where possible.