Condair RO Series User manual

Humidication and Evaporative Cooling
2594443-D EN UK 1811
INSTALLATION AND
OPERATION MANUAL
Pure Water System
Condair RO-A

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 docu-
ment, nor the information contained herein shall be reproduced, used, or disclosed to others without the written
authorization 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 authorized by Condair Group AG.
Copyright Notice
© Condair Group AG, All rights reserved.
Technical modications reserved

3Contents
Contents
1 Introduction 5
1.1 Read me rst! 5
1.2 About this installation and operation manual 5
2 For your safety 7
2.1 Intended use 7
2.2 General safety guidelines 7
3 Product Overview 10
3.1 Model overview 10
3.2 Condair RO-A construction 12
3.3 Hydraulic diagram Condair RO-A 13
3.4 Functional description Condair RO-A 14
3.5 Available options 15
3.6 System overview 17
4 Mounting and installation work 19
4.1 Safety notes on mounting and installation work 19
4.2 Inspection of the delivery 20
4.3 Storage and Transportation 20
4.4 Requirements on siting and installation 21
4.5 Positioning/mounting the Condair RO-A system components 23
4.6 Water installation 26
4.6.1 Principal system layout water installation 26
4.6.2 Supply water specication 27
4.6.3 Material specications water installation 27
4.6.4 Installation notes on tap water supply 28
4.6.5 Installation notes on drain lines 28
4.7 Electrical installation 29
4.7.1 Notes on electrical installation 29
4.7.2 Electrical connections of the water softener 30
4.7.3 Electrical connections of the Condair RO-A pure water unit 30
5 Operation 32
5.1 Prior to initial commissioning 32
5.2 Initial commissioning 32
5.3 Start-up sequence for daily operation 33
5.4 Notes on operation 34
5.4.1 Inspections during operation 34
5.4.2 Flushing the water supply system 35
5.4.3 Performing a complete ushing of the Condair RO-A system 35
5.5 Shut-down sequence for daily operation 36
6 Operating the control software 37
6.1 Standard operating display 37
6.1.1 Operating status indication 38
6.1.2 Maintenance and malfunction indications 38
6.2 Navigating/Operating the control software 39
6.3 Information functions 40
6.3.1 Accessing support informations 40
6.3.2 Accessing system informations 40

4Contents
6.4 Conguration 42
6.4.1 Accessing the "Conguration" submenu 42
6.4.2 Basic settings – "General" submenu 42
6.4.3 Communication settings – "Communication" submenu 43
6.5 Maintenance functions 44
6.5.1 Accessing the "Service" submenu 44
6.5.2 Performing maintenance functions – "Service" submenu 44
6.5.2.1 Input diagnostic functions – "Input Diagnostics" submenu 45
6.5.2.2 Relay diagnostic functions – "Relay Diagnostics" submenu 46
6.6 Administration settings 47
6.6.1 Accessing "Administrator" submenu 47
6.6.2 Switching on/off password protection and software updates function -
submenu "Administrator" 47
7 Maintenance 49
7.1 Important notes on maintenance 49
7.2 Maintenance work to be carried out on the Condair RO-A 50
7.2.1 Replacing the lter cartridge inside the internal lter 51
7.2.2 Determination of the desalination rate / Replacing the membrane(s) 53
7.2.3 Resetting the RO maintenance counter 57
7.3 Maintenance work to be carried out on the optional carbon lter assembly 58
7.4 Maintenance work to be carried out on the optional water softener unit
SoftCab 25 DR 59
7.5 Cleaning and disinfection 59
7.6 Performing software updates 59
8 Fault elimination 60
8.1 Fault indication 60
8.2 Malfunction list 61
8.3 Malfunctions without indication 63
8.4 Saving fault and service histories to a USB memory stick 64
8.5 Notes on fault elimination 64
8.6 Resetting the fault indication 64
9 Taking out of service/Disposal 65
9.1 Taking out of service 65
9.2 Disposal/Recycling 65
10 Productspecication 66
10.1 Technical data 66
10.1.1 Technical data RO-A pure water system 66
10.1.2 Technical data optional water softener unit SoftCab 25 DR 67
10.1.3 Free-standing pure water tank 100V for Condair RO-A200 and RO-A300 67
10.2 EC Declaration of conformity 68
11 Appendix 69
11.1 Wiring diagrams 69
11.1.1 Wiring diagram Condair RO-A Stand-alone 69
11.1.2 Wiring diagram Condair RO-A for Condair RS 70
11.1.3 Wiring plan Condair RO-A 71
11.2 Dimensional drawings Condair RO-A40 ... RO-A300 72

5Introduction
1 Introduction
1.1 Readmerst!
Thank you for choosing the Condair RO-A pure water system.
The Condair RO-A pure water system incorporates the latest technical ad van ces and meets all recog-
nized safety standards. Nevertheless, improper use of the Condair RO-A pure water system 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 RO-A pure water system, 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 used together with the Condair RO-A
pure water system
If you have questions after reading this documentation, please contact your Condair representative.
They will be glad to assist you.
1.2 About this installation and operation manual
Scope
The subject of this operation manual is the Condair RO-A pure water system. Addtional facility
components are described only as is necessary for proper installation and operation of the system.
Since the system offers a wealth of expansion options, this documentation focuses on the standard
system only. Addtional facility components can be supplied for a variety of applications and performance
requirements. Increased humidication output will affect a range of facility components. While some ac-
cessories are not essential, others form part of the standard system conguration. For further informa-
tion on accessory parts or individual custom solutions, please consult your customer-specic schematic
diagram or get in touch with your Condair representative.
Details provided in this installation and operation manual are limited to the installation, commission-
ing, operation and maintenance of the Condair RO-A pure water system.
This manual is supplemented by various other documents (brochures, purchase order forms, schematic
diagrams, etc.). Where required, you will nd the relevant cross-references to these publications in this
documentation.

6Introduction
Conventions
NOTE
This symbol highlights important information. This is also clearly indicated with the word "NOTE".
CAUTION!
The catchword "CAUTION" used in conjunction with the caution symbol in the circle designates notes
in this 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 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 manual that, if neglected, may lead to severe injury or even death of persons.
Denitions
– Raw water:
The term raw water refers to (untreated) drinking or mains water without any additivs like chlorine,
H2O2, ozone, etc.
– Soft water:
Soft water is the term applied to water produced by the water softener unit. The water softening
process replaces hard ions from calcium and magnesium with sodium.
– Pure water (RO water):
The term pure water or reverse osmosis water (RO water) refers to water partially demineralised by
the pure water unit (Condair RO-A).
Safekeeping
Please safeguard this 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 manual is available in other languages. Please contact your Condair representative for information.

7For your safety
2 For your safety
2.1 Intended use
The Condair RO-A pure water system is intended to be used exclusively for industrial pure water
production within the operating conditions as specied and must not be installed/used in explosion
hazard areas. Any other use without the written consent of Condair, is considered as not conforming
with the intended purpose and may lead to the Condair RO-A pure water system becoming dangerous
and will void any warranty.
Operation of the equipment in the intended manner requires that all the information contained in this
manual are observed (in particular the safety instructions).
WARNING!
Water from the Condair RO-A pure water system must not be used as drinking water. Do not
drink the water from the Condair RO-A pure water system.
2.2 General safety guidelines
General
Every person working with the Condair RO-A pure water system must have read and understood the
Condair RO-A pure water system installation and operation manual before carrying out any work.
Knowing and understanding the contents of this manual is a basic requirement for protecting personnel
against any kind of danger, to prevent faulty operation, and to operate the Condair RO-A pure water
system safely and correctly.
All icons, signs and markings applied to the components of the Condair RO-A pure water system must
be observed and kept in readable state.
Qualicationofpersonnel
The Condair RO-A pure water system must be installed and operated only by persons who are well
trained,andadequatelyqualiedfortherespectivetaskandareauthorizedbythecustomer.
For safety and warranty reasons any action beyond the scope of this manual must be carried out only
by service personnel authorised by Condair.
It is assumed that all persons working with the Condair RO-A are familiar and comply with the appropri-
ate regulations on work safety and the prevention of accidents.
The Condair RO-A pure water system 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 system.
Children must be supervised to make sure that they do not play with the Condair RO-A pure water system.

8For your safety
Danger that may arise from the Condair RO-A pure water system
DANGER!
Dangerofelectrichazard!
The Condair RO-A is mains powered. Live parts may be exposed when the unit is open. Touch-
ing live parts may cause severe injury or danger to life.
Prevention: Before carrying out any work set the Condair RO-A out of operation as described in
(switch off the unit, unplug mains cable, shut off the water supply and depressurise the system) and
secure the unit against inadvertent power-up.
DANGER!
Healthriskbecauseofinadequatehygiene!
Inadequately operated and/or poorly maintained pure water systems may endanger health.
Prevention: the Condair RO-A pure water system must strictly be operated and maintained in ac-
cordance with this manual.
CAUTION!
Do not use oil, grease, glue, Teon, silicone, O-ring lubrication, etc. when assembling pipes or hose
connections. All of these products can act as food for bacteria and thus pose health risks.
Only approved lubricant is: Dishwashing liquid.
Always wash your hands and wear clean disposable gloves while assembling parts in direct contact
with water.
Do not remove dust protection caps on pipe and hose ends until just before assembly.
When tting water lters, RO membranes, hoses and other components in direct contact with water,
wash your hands and wear sterile disposable gloves or touch only the packing foil to keep the lter
and RO membranes bacteria-free.
Observe all local safety standards
Observe all local safety standards regarding the handling of mains-powered electrical and electronic
devices, and the design and handling of low-pressure water systems.
Preventing unsafe operation
If it is suspected that safe operation is no longer possible, the Condair RO-A pure water system
should immediately be shut down and secured against accidental power-up according to chapter
5.5. This can be the case under the following circumstances:
– if the Condair RO-A pure water system or other system components are damaged
– if the electrical installations are damaged
– if the Condair RO-A pure water system is no longer operating correctly
– if connections and/or piping are not sealed
All persons working with the Condair RO-A pure water system must report any alterations to the system
that may affect safety to the owner without delay.

9For your safety
Prohibitedmodicationstotheunit
Nomodicationsmustbeundertaken on the Condair RO-A 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.
Recommendedreextinguishersystem:
Fire extinguishers must be suitable for tackling res in electrical installations to 1000 V. Extinguishing
agents can be foam, water, powder or CO2.

10 Product Overview
3 Product Overview
3.1 Model overview
The Condair RO-A pure water system is available in 4 models with different maximum pure water output.
All four RO-A models have the same housing and the same electrical parts.
All systems can be operated as stand-alone systems controlled via the optional Condair RO-A pure water
system control unit or as Condair RS integrated systems controlled via the Condair RS control unit.
Model
RO-A40 RO-A100 RO-A200 RO-A300
Pure water output at 5°C 40 l/h 100 l/h 200 l/h 300 l/h
Pure water output at 15°C 70 l/h 140 l/h 300 l/h 400 l/h
RO membrane type 1x 14" NSR 99.4%
Spare part: 50001
1x 21" NSR 99.4%
Spare part: 50039
2x 21" NSR 99.4%
Spare part: 50040
3x 21" NSR 99.4%
Spare part: 50041
Pure water tank internal
18 l
internal
18 l
external
100 l
external
100 l
RO-A40 RO-A100
RO-A200 RO-A300

11Product Overview
RO-A200
(Option without pure water tank)
RO-A300
(Option without pure water tank)

12 Product Overview
3.2 Condair RO-A construction
1 Outlet connector concentrate
2Outlet connector RO water
3Water inlet connector
4Inlet solenoid valve Y1 (NC)
5Probe and pure water test valve
6Pressure switch input membrane PS3 (NC)
7 Supply line
8 Pure water tank
Note: RO-A200 and RO-A300 have a external pure water
tank
9Filter 10", 5 µm
10 Drain solenoid valve Y2
11 Pressure transmitter PS2 (pure water tank pressure)
12 Throttle circulation line
13 Circulation line
14 Throttle concentrate line
15 Membrane housing
16 Valve air pressure pure water tank
17 Unit switch
18 Mains supply socket
19 Pump motor
20 Pump
21 Pressure hose to membrane
22 Pressure transmitter pump inlet PS1
23 Cable glands
8
9
10
11
12
3
4
5
6
7
2
123
15
14
13
16
17
18
19
21
22
20
Fig. 1: Construction Condair RO-A (gure shows Condair RO-A100)

13Product Overview
3.3 Hydraulic diagram Condair RO-A
1 Shut-off valve
2Pipe disconnector (where mandatory by local regulations)
3Pressure reducer (for supply pressures >6 bar)
4Carbon lter assembly (option, mandatory for occasionally
chlorinated supply water)
5Condair RO-A
6Inlet solenoid valve Y1 (NC)
7 Internal lter 10", 5 µm
8 Pressure transmitter pump inlet PS1
9Motor over temperature switch TS1
10 Motor and pump
11 Pressure switch input membrane PS3 (NC)
12 Pure water tank
13 Pressure transmitter PS2 (pure water tank pressure)
14 Probe and relieve valve
15 Drain solenoid valve Y2
16 Check valve to protect membrane
17 Throttles
18 Check valve to protect throttle
19 Consumer, e.g. steam humidier "Condair RS"
Fig. 2: Hydraulic diagram Condair RO-A (without optional water softener and prelter)
* by others
6
15
8
1-3bar
10
12
13
Y1
Y2
PS1
11
PS3
M
~16 bar
PS2
16
18
19
7
1
5
2 3 4
Condair
RS
Condair RO-A
TS1
17 17
14
9
* * * *

14 Product Overview
3.4 Functional description Condair RO-A
A reverse osmosis system demineralises the supplied water by ltration at a low energy consumption.
The product of the system is "salt-free" water (also known as RO water, pure water or permeate) and is
up to 99% free of dissolved substances in the water and microorganisms, such as minerals and germs.
Reverse osmosis systems are used in pharmaceutical and food industry, heating and power plant engi-
neering, as well as in air humidication. They are based on the economically favourable and continuous
process of water ltration by reverse osmosis. The reverse osmosis (by osmosis - diffusion through a
semi-permeable membrane) is a ltration at nanoscale level. It takes place at a differential pressure in
the reverse osmosis membrane.
The membrane is a wrapped lter, which is owed alongside by supply water. Filtered water ows un-
der pressure through various membrane layers and is separated from the additives. The product (pure
water) is collected in the center of the membrane (diaphragm). Dissolved or entrained substances of the
inlet water are carried further along the lter. The product is ltered, depending on input water quality,
up to 99%. In the concentrate minerals and other substances ow lenghtwise through the membrane.
The concentrate is passed partly into the drain and partly mixed with the supply water to reduce water
consumption.
The pure water quality is usually controlled by a conductivity measurement of the product water. The lower
the conductivity, the higher the electrical resistance and the purer the product water. Filtration quality
depends on the particle size: gases due to their small molecular size pass through the membrane layers
and increase the conductivity of the product. For sensitive applications the quality of the feedwater and
the product water must be checked and optionally be periodically monitored.
Supply water
Concentrate
Product (pure water)
Fig. 3: Functional diagram of the reverse osmosis membrane
The Condair RO-A pure water system is designed for demineralised water production. The system uses
special "low-energy" reverse osmosis membranes that are especially efcient: the membranes permit
under the listed supply water demands a particularly energy-saving water ltration at a desalination up
to 99%.
The Condair RO-A pure water system has a compact design and is characterized by an integrated
pre-lter, an internal 18 l pure water tank (RO-A40 and RO-A100) or an external 120 l pure water tank
(RO-A200 and RO-A300) and a control sampling point for the product. It is intended for rapid „movable“
installations and is bound only by hoses. The digital controller interface enables an accurate and simple
control as well as various setting and monitoring functions.

15Product Overview
3.5 Available options
Condair RO-A control unit The RO-A Control unit is used for Condair RO-A stand-alone
systems only.
The Condair RO-A control unit is equipped with a touch panel
to operate the control software, a operation status LED which
indicates normal operation (LED lights green), warning (LED
lights yellow) and error status (LED lights red).
Additionally the control unit features a USB interface for data
logging, exporting service and error histories and updating the
control and the driver board software.
Water softener "SoftCab 25 DR" The water softener constitutes the rst stage in water treatment
and should be installed, if the values of the incoming water exceed
the limits specied in chapter 4.6.2 – Supply water specication.
The water softener reduces the water hardness to 0 - 1 °dh (0
- 1.8 °fh, 0 - 18 ppm).
The water softener works on the ion exchange principle. The resin
balls inside the water softener bind the magnesium and calcium
ions of the supply water and emit salt ions into the water. After
processing a specic amount of supply water the resin balls are
exhausted and must be regenerated. During this regeneration
process the bound ions are ushed out and replaced by fresh
salt ions. This process is fully automatic and takes approximately
2 hours. The regeneration process can be triggered time of day
or quantity controlled.
The water softener is supplied with a separate operation manual.
Note: the water softener SoftCab 25 DR provides a signal to
stop the operation of the Condair RO-A during the regeneration
process of the water softener.
If you use another type of water softener, the operation of the
Condair RO-A is not stopped during the regeneration process
of the water softener.

16 Product Overview
Carbonlterassembly
Flow direction
2
1
The carbon lter assembly serves as pre-lter and must manda-
tory be installed if the supply water is chlorinated. The carbon
lter assembly consist of a 5 µm lter (1) and a chloramine
carbon lter (2).
The carbon lter assembly has to be installed after the water
softener (if installed).
Leakage monitoring The leakage monitoring option consist of the leakage monitoring
control board and 1 to 3 oor sensors. The leakage monitoring
control board is connected to driver board inside the Condair
RO-A pure water unit and the sensor(s) are connected to the
leakage monitoring control board.
Important: the leakage monitoring does not override the direction
that the Condair RO-A system must be installed in a room with
a oor drain or in a tub equipped with a drain connected to the
building drain system.

17Product Overview
3.6 System overview
Principal system layout Condair RO-A stand-alone systems
1 Shut-off valve (mandatory)
2Pipe disconnector (where mandatory by local regulations)
3Pressure reducer (mandatory for water supply pressure
>6 bar)
4Water softener "SoftCab 25 DR" (option, recommended if
the supply water hardness exceeds the limits specied in
chapter 4.6.2 – Supply water specication.)
5Carbon lter assembly (option, mandatory for occasionally
chlorinated supply water)
6Condair RO-A
7 Condair RO-A control unit
8 Leakage sensor (option leakage monitoring)
9External pure water tank (Condair RO-A200 and RO-A300
only)
10 Tank drain valve (recommended, by client)
Fig. 4: Principal system layout Condair RO-A stand-alone systems
1 2 3 4 67
810
5 9

18 Product Overview
Principal system layout Condair RO-A Condair RS integrated systems
1 Shut-off valve (mandatory)
2Pipe disconnector (where mandatory by local regulations)
3Pressure reducer (mandatory for water supply pressure
>6 bar)
4Water softener "SoftCab 25 DR" (option, recommended if
the supply water hardness exceeds the limits specied in
chapter 4.6.2 – Supply water specication.)
5Carbon lter assembly (option, mandatory for occasionally
chlorinated supply water)
6Condair RO-A
7 Leakage sensor (option leakage monitoring)
8 Steam humidier Condair RS
9External pure water tank (Condair RO-A200 and RO-A300
only)
10 Tank drain valve (recommended, by client))
Fig. 5: Principal system layout Condair RO-A Condair RS integrated systems
1 2 3 4
8
7 10
9
6
5

19Mounting and installation work
4 Mounting and installation work
4.1 Safety notes on mounting and installation work
Qualicationofpersonnel
All mounting and installation work must be carried out only by properlyinstructedandwellqualied
personnel(e.g.certiedplumbersandcertiedelectricians)authorisedbytheowner. It is the
owner’s responsibility to verify proper qualication of the personnel.
General notes
Strictly observe and comply with all information given in the present installation and operation manual
regarding the positioning and mounting of the Condair RO-A system components and the water and
electrical installations.
Observe and comply with all local regulations dealing with water and electrical installations.
Safety
Some installation work requires removal of the unit covers. Please note the following:
DANGER!
Danger of electric shock
The Condair RO-A pure water unit as well as the Condair RS are mains powered. Live parts may
be exposed when the units are open. Touching live parts may cause severe injury or danger
to life.
Prevention: The Condair RO-A pure water unit and the Condair RS unit 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 units are closed and properly locked.
CAUTION!
The electronic components inside the Condair RO-A pure water unit, the RO-A control unit and the
Condair RS are very sensitive to electrostatic discharge. Before carrying out installations work inside
these units, appropriate measures must be taken to protect the electronic components against dam-
age caused by electrostatic discharge (ESD protection).

20 Mounting and installation work
4.2 Inspection of the delivery
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 Ltd. assumes no responsibility for any material shortages beyond this period.
– 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 facility
documentation.
4.3 Storage and Transportation
Storing
Until installation store the Condair RO-A system components 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 Condair RO-A system components in their original packag-
ing 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.