Condair Sigma User manual

Humidication and Evaporative Cooling
2598732-0 EN 2002
INSTALLATION- AND
OPERATING INSTRUCTIONS
Steam generator
Condair Sigma

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 and operating instructions 5
2 For your safety 7
3 Product Overview 9
3.1 Models overview 9
3.2 Identication of the unit 10
3.3 Construction of the Condair Sigma 11
3.4 Functional description 12
3.5 System overview 14
3.6 Options 15
3.7 Accessories 16
3.7.1 Accessories overview 16
3.7.2 Accessory details 17
3.7.2.1 Steam distributor DDS22 17
3.7.2.2 Steam distributor DDL35 17
3.7.2.3 Steam distributor W22/W35 18
3.8 Standard delivery 19
3.9 Storing/Transportation/Packaging 19
4 Notes for the planning engineer 20
4.1 Selecting the unit version 20
4.1.1 Determinating the maximum required steam capacity 20
4.1.2 Selecting the unit 21
4.2 Selecting the options an accessories 21
5 Mounting and installation work 22
5.1 Important notes for mounting and installation work 22
5.2 Installation overviews 23
5.3 Mounting the unit 24
5.3.1 Notes on locating the unit 24
5.3.2 Mounting the humidier 26
5.3.3 Inspecting the installed unit 27
5.4 Steam installation 28
5.4.1 Overview steam installation 28
5.4.2 Positioning/mounting the steam distributor 29
5.4.3 Installing the steam and condensate lines 30
5.4.3.1 Notes on installation 30
5.4.3.2 Installation examples 31
5.4.4 Common steam and condensate line errors 35
5.4.5 Inspecting the steam installation 36
5.5 Water installation 37
5.5.1 Overview water installation 37
5.5.2 Notes on water installation 38
5.5.3 Inspecting the water installation 39
5.6 Electric installation 40
5.6.1 Hinweise zur Elektroinstallation 40
5.6.2 Wiring diagram Condair Sigma 4 kg/h 41

4Contents
5.6.3 Wiring diagram Condair Sigma 5-65 kg/h 42
5.6.4 Installation work external connections 43
5.6.4.1 Connecting the external safety chain 43
5.6.4.2 Humidity control wiring 44
5.6.4.3 Connecting the optional remote operating and fault indication to the
Condair Sigma 5-65 kg/h (Option) 46
5.6.4.4 Connecting the control voltage to the Condair Sigma 5-65 kg/h 47
5.6.4.5 Connecting the heating voltage to the Condair Sigma 5-65 kg/h 48
5.6.4.6 Connecting the voltage supply to the Condair Sigma 5-65 kg/h via Option TR 49
5.6.4.7 Connecting the voltage supply to the Condair Sigma 5-65 kg/h via Option CVI 50
5.6.4.8 Connecting the voltage supply to the Condair Sigma 4 kg/h 51
5.6.5 Unit conguration 52
5.6.6 Inspecting the electrical installation 53
6 Operation 54
6.1 Function of the display and operating elements 54
6.2 Commissioning 55
6.3 Notes on operation 56
6.3.1 Function of the LED's in info mode 56
6.3.2 Remote operating and fault indication 56
6.3.3 Inspections during operation 57
6.4 Carrying out manual draining 57
6.5 Taking the unit out of operation 57
7 Maintenance 58
7.1 Important notes on maintenance 58
7.2 Maintenance list 59
7.3 Removing and installing parts for maintenance 60
7.3.1 Removal and installation of the steam cylinder 60
7.3.2 Removal and installation of the drain cup 63
7.3.3 Removal and installation of the water cup and the water hoses 64
7.3.4 Removal and installation of the drain valve 65
7.3.5 Removal and installation of the inlet valve 66
7.4 Notes on cleaning the unit components 67
7.5 Notes on cleaning agents 68
7.6 Resetting the maintenance indication 69
8 Fault elimination 70
8.1 Fault indication 70
8.2 Malfunction lists 71
8.2.1 System faults 71
8.2.2 Unit faults 71
8.3 Notes on fault elimination 73
8.4 Resetting the error indication (red LED lights) 73
9 Taking out of service/Disposal 74
9.1 Taking out of service 74
9.2 Disposal/Recycling 74
10 Productspecications 75
10.1 Technical data 75
10.2 Unit dimensions 76

5Introduction
1 Introduction
1.1 To the very beginning
We thank you for having purchased the steam generator Condair Sigma.
The steam generator Condair Sigma incorporates the latest technical ad van ces and meets all recognized
safety standards. Nevertheless, improper use of the Condair Sigma 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 Sigma, please
observe and comply with all information and safety instructions contained in the present installation and
operating instructions.
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 operating instructions
Limitation
The subject of these installation and operating instructions is the steam generator Condair
Sigma. 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.
These installation and operating instructions are restricted to the installation, commissioning, opera-
tion, servicing and trouble shooting of the steam generator Condair Sigma and is meant for well
trainedpersonnelbeingsufcientlyqualiedfortheirrespectivework.
These installation and operating instructions are supplemented by various separate items of documen-
tation (spare parts list, manuals for accessories, etc.). Where necessary, appropriate cross-references
are made to these publications in the present documentation.

6Introduction
Explanation of the symbols used in this manual
CAUTION!
The catchword "CAUTION" designates notes in this documentation 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 documentation 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 documentation that, if neglected, may lead to severe injury or even death
of persons.
Safekeeping
Please safeguard these installation and operating instructions 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
The present installation and operation manual is available in various languages. Please contact your
Condair supplier for information.

7For your safety
2 For your safety
General
Every person working with the Condair Sigma must have read and understood the present installation
and operating instructions before carrying out any work.
Knowing and understanding the contents of the installation and operating instructions is a basic require-
ment 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.
Qualicationofpersonnel
All actions described in the present Installation and operating instructions (installation, operation, mainte-
nance, etc.) must be carried out only by welltrainedandsufcientlyqualiedpersonnelauthorised
by the owner.
For safety and warranty reasons any action beyond the scope of this manuals must be carried out only
by qualied personnel authorised by the manufacturer.
It is assumed that all persons working with the Condair Sigma are familiar and comply with the appropri-
ate regulations on work safety and the prevention of accidents.
This unit may not be used by persons (including children) with reduced physical, sensory or mental
abilities or persons with lacking experience and/or knowledge, unless they are supervised by a person
responsible for their safety or they received instructions on how to operate the unit.
Children must be supervised to make sure that they do not play with unit.
Intended use
The steam generator Condair Sigma is exclusively intended for the production of steam for SPA
applicationswithinthespeciedoperatingconditions (see chapter 10). Any other type of applica-
tion without the express written consent of the manufacturer is considered as not conforming with the
intended purpose and may lead to the Condair Sigma becoming dangerous.
Operation of the equipment in the intended manner requires that all the information in this installation
and operation manual is observed (in particular the safety instructions).

8For your safety
Danger that may arise from the unit
DANGER!
Danger of electric hazard!
The Condair Sigma is mains powered. 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 Sigma out of operation as described in
chapter 6.5 (switch off the unit, disconnect it from the mains and stop the water supply) and secure
the unit against inadvertent power-up.
WARNING!
Hot water vapour - Danger of scalding!
The Condair Sigma produces hot water vapour. There is danger of scalding when getting in
touch with hot water vapour.
Prevention: Do not carry out any work on the steam system during operation (steam lines, steam
distributor, etc.). If the steam system is leaky set the Condair Sigma immediately out of operation as
described in chapter 6.5. Correctly seal the steam system before putting the unit into operation again.
WARNING!
Danger of burning!
During operation the components of the steam system (steam cylinder, steam distributor, etc.)
get very hot (up to 100 °C). There is danger of burning when touching the hot components.
Prevention: Before carrying out any work on the steam system set the Condair Sigma out of opera-
tion as described in chapter 6.5, then wait until the components have cooled down sufciently thus
preventing danger of burning.
Behaviour in case of danger
If it is suspected that safe operation is no longer possible, then the Condair Sigma should immediately
be shut down and secured against accidental power-up according to chapter 6.5. This can be the
case under the following circumstances:
– if the Condair Sigma is damaged
– if the electrical installations are damaged
– if the Condair Sigma is no longer operating correctly
– if connections and/or piping are not sealed
All persons working with the Condair Sigma must report any alterations to the unit that may affect safety
to the owner without delay.
Prohibitedmodicationstotheunit
Nomodicationsmustbeundertaken on the Condair Sigma 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.

9Product Overview
3 Product Overview
3.1 Models overview
Steam generators Condair Sigma are available with different heating voltages and steam capacities
ranging from 4 kg/h up to a max. of 65 kg/h.
Heating voltage ** Max. steam capacity
in kg/h
Model
Condair Sigma
Unit size
small medium large
400V3
(400 V/3~/50...60 Hz)
5534 1
8834 1
15 1534 1
23 2364 1
32 3264 1
45 4564 1
65 6564 1
400V2
(400 V/2~/50...60 Hz)
5524 1
8824 1
230V3
(230 V/3~/50...60 Hz)
5 532 1
8 832 1
15 1532 1
23 2362 1
32 3262 1
230V1
(230 V/1~/50...60 Hz)
4 422 1
5 522 1
8 822 1
** Other heating voltages on request
Key model designation
Example:
Condair Sigma 4564 400V3
Product designation:
Unit model:
Heating voltage:
400V/3~/50...60Hz: 400V3
400V/2~/50...60Hz: 400V2
230V/3~/50...60Hz: 230V3
230V/1~/50...60Hz: 230V1

10 Product Overview
3.2 Identicationoftheunit
The identication of the unit is found on the type plate:
Condair Group AG, Gwattstrasse 17, 8808 Pfäfkon SZ, Switzerland
Type: Condair Sigma 4564 Ser.Nr.: XXXXXXX 02.10
Heating voltage: 400V / 3~ / 50...60Hz Power: 33.8 kW
Steam capacity: 45.0 kg/h Ctrl. Voltage: 230V / 1~ / 50...60Hz
Water pressure: 1...10 bar
Engineered in Switzerland, Made in Germany
Type designation Serial number (7 digits) Month/Year
Heating voltage
Maximum steam capacity per unit
Admissible water supply pressure
Power consumption
Control voltage
Field with certication symbols
Abb. 1: Position of the type plate

11Product Overview
3.3 Construction of the Condair Sigma
1 Housing (small, large)
2 Cable openings, top side
3 SC pump (option)
4 Main contactor
5 Power board
6 Terminals heating voltage (option)
7 Remote operating and fault
indication board (option)
8 Control board with Smart Card
9 Power supply unit 24 V (option)
10 Drain/info key
11 Operation status indicators
12 Unit switch
13 Water cup
14 Filling hose
15 Water supply hose
16 Overow hose
17 Drain valve
18 Inlet valve
19 Water supply connector
20 Drain connector
21 Cable openings, bottom side
22 Type plate
23 Steam cylinder
24 Level sensor
25 Electrode plug
26 Steam outlet
Abb. 2: Construction of the Condair Sigma (gure shows medium unit)
3
2
1
4
5
6
7
9
12
11
10
8
19
20
21
23
24
25
26
22
13
15
18
17
14
16

12 Product Overview
3.4 Functional description
The steam generator Condair Sigma is a pressureless steam generator that utilizes an electrode heat-
ing. The steam generator Condair Sigma is designed for SPA applications.
Steam distributor
Condensate hose with siphon
(if steam distributor is installed
above the device)
Steam hose
Water cup
Overow hose
Filling hose
Water supply hose
Inlet valve
Base tub
Drain valve
Steam cylinder
Electrodes
Level sensor
Control board Power board
Unit switch
Main
contactor
Current sensor
Abb. 3: Functional diagram

13Product Overview
Steam generation
Any time steam is requested, the electrodes are supplied with voltage via main contactor. Simultaneously,
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 ow 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 decreases
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 desired
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 moment
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 perio dically drained from the cylinder and
replaced by fresh water.
Control
The steam production can be controlled with an external 0-10V continuous controller or an external
humidistat (24 VDC On/Off control).

14 Product Overview
3.5 System overview
1 Steam generator
2 Steam connector
3 Water drain connector
4 Water supply connector
5 Water connection hose G 3/4"- G 3/8"
(included in the delivery)
6 Manometer (installation recommended)
7 Filter valve (accessory "Z261")
8 Funnel with siphon (building side)
9 Water drain hose (included in the delivery)
10 Electrical isolator control voltage supply (building side)
11 Electrical isolator heating voltage supply (building side)
12 Steam hose (accessory "DS..")
13 SPA Display
14 Condair Delta SPA Control Box
15 Electrical isolator Condair Delta SPA Control Box
125...1250 µS/cm
1...10 bar
1...40 °C
DS35
DS22
Z261
1
2
3
4
5
6
78
9
11
10
13
14
15
12
Abb. 4: System overview

15Product Overview
3.6 Options
Condair Sigma...
422 522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Remote operating and fault indication
PCB with relay contacts for the connection
of remote displays for "Operation", "Steam",
"Fault" and "Service".
--- 1xRFI
Overpressure set
Kit for mounting the water cup to the unit cover
when operating the steam generator in systems
with a duct air pressure of up to 10 kPa.
--- 1xOPS
Terminals heating voltage
Separate terminals for systems where direct
connection of heating voltage to main contac-
tor (standard version) is not permitted by local
regulations.
--- 1x
S-THV
1x
M-THV
1x
L-THV
Steam hose connector with condensate trap --- 1xCT22 1xCT35 2xCT35
Cable glands (with metric thread) --- CG
Terminal strip kit for internal control vol-
tage supply
Terminal strip kit to provide control voltage sup-
ply for sites with 3 phase single voltage supply
with neutral conductor (400V/3~N/ 50..60 Hz).
--- 1x
S-CVI
1x
M-CVI
1x
L-CVI
Transformer for internal control voltage
supply
Kit including terminal strip and transformer to
provide control voltage supply for sites with 3
phase single voltage supply without neutral
conductor (400V/3~/ 50..60 Hz).
--- 1xM-Trafo 1xL-Trafo
24 VDC power supply
24 VDC power supply for the external humid-
ity sensor
--- 1x24VDC
SC pump (lime management system)
The SC pump keeps the solved minerals in
the water of the steam cylinder in motion, in
order to discharge them with the automatic
drain cycles.
--- 1xSC
Condair Sigma... (400 V/3~/50...60 Hz)
534 834 1534 2364 3264 4564 6564
Steam cylinder for low water conductivity
from 80 to 125 µS/cm
1x
534A-L
1x
834A-L
1x
1534A-L
1x
2364A-L
1x
3264A-L
1x
4564A-L
___

16 Product Overview
3.7 Accessories
3.7.1 Accessories overview
Accessories for water installation
Condair Sigma ...
422 522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Filter valve Z261 (1 pcs. per system)
Accessories for steam installation
Condair Sigma ...
422 522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
Steam distributor (up to max.5 kg/h)
(details see chapter 3.7.2.1)
1xDDS22 ___ ___ ___ ___ ___ ___
Steam distributor (15...32 kg/h)
(details see chapter 3.7.2.2)
___ 1xDDL35 ___ ___
Steam distributor (4...65 kg/h)
(details see chapter 3.7.2.3)
1xW22 1xW35 2xW35
Steam hose / meter 1xDS22 1xDS35 2xDS35
EcoTherm insulation hose / meter 1xECT22 1xECT60 2xECT60
Kondensatschlauch / Meter 1x KS10
Condensate drain 1xCD22 1xCD35 2xCD35
T-piece for fragrance injection 1xTSD22 1xTSD35 2xTSD35
Fragrance pump 1xFP 240V
Accessories for control
Condair Sigma ...
422 522
524
532
534
822
824
832
834
1532
1534
2362
2364
3262
3264
4564 6564
SPA control Condair Delta SPA Control Box

17Product Overview
3.7.2 Accessory details
3.7.2.1 Steam distributor DDS22
Abb. 5: Steam distributor DDS22 (up to max. 5 kg/h)
3.7.2.2 Steam distributor DDL35
ø22.5 mm
ø48.5 mm
max. 19 mm
ø43 mm
DDL35: ø35 mm
max. 18 mm
Abb. 6: Steam distributor DDL35 (15-32 kg/h)

18 Product Overview
3.7.2.3 Steam distributor W22/W35
W22: ø43 mm
W35: ø61 mm
W22: ø22.5 mm
W35: ø35 mm
Abb. 7: Steam distributor W22 (4-8 kg/h) / W35 (15-65 kg/h)

19Product Overview
3.8 Standard delivery
The standard delivery includes:
– Steam generator Condair Sigma with water drain hose and water connection hose G 3/4" - G 3/8"
equipped with the options ordered according to chapter 3.6, xing set and installation and operating
instructions (this document), packaged in cardboard box
– Unit small (WxHxD): 360 mm x 550 mm x 360 mm, shipping weight: 8,7 kg
– Unit medium (WxHxD): 445 mm x 755 mm x 360 mm, shipping weight: 26 kg
– Unit large (WxHxD): 560 mm x 820 mm x 435 mm, shipping weight: 31 kg
– Ordered accessories with operating instructions according chapter 3.7, packed separately
– Spare parts list
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 medium and the large unit is more than 20 kg (weight without packaging: medium 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 Sigma 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.

20 Notes for the planning engineer
4 Notes for the planning engineer
4.1 Selecting the unit version
To select the unit version the following planning steps are required:
1. Determinating 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 Determinatingthemaximumrequiredsteamcapacity
The maximum required steam capacity for a steam bath is determined according to the table below:
Cabin size Requiredsteamcapacity
Plastic cabin brick lined cabin
4 m34 kg/h 8 kg/h
8 m38 kg/h 12 kg/h
12 m310 kg/h 15 kg/h
16 m312 kg/h 18 kg/h
20 m313 kg/h 21 kg/h
24 m315 kg/h 24 kg/h
28 m317 kg/h 26 kg/h
32 m318 kg/h 29 kg/h
36 m320 kg/h 31 kg/h
40 m321 kg/h 34 kg/h
44 m323 kg/h 36 kg/h
48 m324 kg/h 38 kg/h
52 m326 kg/h 41 kg/h
56 m327 kg/h 43 kg/h
60 m329 kg/h 45 kg/h
Important notes:
– The steam capacity determined based on the table above does not consider any steam loss (e.g.
due to condensation in the steam hoses and the steam distributors), any heat loss of the unit as well
as any absorption or release of humidity of materials located in the room being humidi ed.
In addition, the calculated steam capacity does not consider any losses caused by the draining rate
depending on the water quality as well as any losses occur if the steam generator is operated on a
mains circuit with a ground fault circuit interrupter.
The total amount of losses depends on the entire system and must be taken into consideration when
determining the required steam capacity. If you have any questions regarding the calculation of the
steam capacity please contact your Condair supplier.