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INSTALLATION, COMMISSIONING AND

SERVICE INSTRUCTIONS

Gasﬁred steam humidiﬁer

2562346 EN 1101

Condair GS… C series

Contents

1 Introduction 4

1.1 At the very beginning 4

1.2 Notes on the installation, commissioning and service instructions 4

2 For your safety 6

3 Product Overview 8

3.1 Product versions/Model designations 8

3.2 Delivery 8

3.3 Humidicationsystemoverview 9

3.4 Constructionofthegasredsteamhumidier 10

3.5 Principle of operation 11

4 Basic planning 13

4.1 Selecting the unit 13

4.2 Selecting the control system 15

4.3 Options 17

4.4 Accessories 17

5 Mounting and installation works 19

5.1 Importantnotesonmountingandinstallationworks 19

5.2 Unittting 20

5.3 Steam installation 24

5.4 Water installation 31

5.5 Gas installation 34

5.6 Flue gas installation 37

5.7 Installation of the air inlet line for room air-independent units (RS units) 42

5.8 Installation of control and monitoring devices 44

5.9 Electrical Installation 45

6 Inspecting the installations (Check list) 47

7 Operation 49

7.1 Important notes on operation 49

7.2 Function of the display and operating elements 50

7.3 Commissioning 51

7.4 Notes on operation 53

7.5 Takingtheunitoutofoperation 54

8 Maintenance 55

8.1 Important notes on maintenance 55

8.2 Maintenance instructions 55

8.3 Dismantlingworkformaintenanceandthereplacementofcomponents 57

8.4 Notes on cleaning agents 67

8.5 Resetting the maintenance reminder 67

9 Troubleshooting 68

9.1 Important notes on troubleshooting 68

9.2 Error indication 68

9.3 Resetting the error indication 68

9.4 ReplacingthebackupbatteryonthecontrolboardoftheCondair GS 69

10 Taking out of service/Disposal 70

10.1 Takingoutofservice 70

10.2 Disposal/Recycling 70

11 Specications 71

11.1 Technical Data 71

11.2 Fluegasspecications 72

1.1 At the very beginning

ThankyoufordecidingontheCondairGSCseriesGasredSteamHumidier (abbreviated as

“Condair GS”).

The Condair GS incorporates the latest technical ad van ces and satisestherequirementsofthe

EuropeanGasEquipmentDirective(90/396/EEC)andallknownsafetystandards.Nevertheless,

improper use may result in danger to the user or third parties and/or impairment of the installation

or other material assets.

To ensure a safe, proper, and economical operation of the Condair GS, please observe and comply

withallinformationandsafetyinstructionscontainedinthepresentinstallation,commissioningand

serviceinstructionsaswellastheinstructionsgiveninthemanualsforthecomponentsusedinthe

humidicationsystem.

Ifyouhavequestions,whicharenotorinsufcientlyansweredinthisdocumentation,pleasecontact

yourCondairsupplier.Theywillbegladtoassistyou.

1.2 Notesontheinstallation,commissioningandserviceinstructions

Limitation

The subject of these installation, commissioning and service instructions is the Condair GS C series

GasredSteamHumidier in its different versions. 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, commissioning and service instructions is restricted to the planning, installation,

commissioning,operation, servicing and trouble shootingofthegasredsteamhumidierCon-

dair GS and is meant for welltrainedpersonnelbeingsufcientlyqualiedfortheirrespective

work.

These installation, commissioning and service instructions are supplemented by various separate

items of documentation (operating instructions for Condair GS/GS...OC - C series control, spare

parts list, etc.). Where necessary, appropriate cross-references are made to these publications in

the installation, commissioning and service instructions.

1 Introduction

Symbolsusedinthisdocumentation

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 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 this documentation that, if neglected, may lead to severe injury or even

death of persons.

Safekeeping

Pleasesafeguardtheseinstallation,commissioningandserviceinstructionsinasafeplace,where

they can be immediately accessed. If the equipment changes hands, the installation, commissioning

andserviceinstructionsshouldbepassedontothenewoperator.

If the installation, commissioning and service instructions get mislaid, please contact your Condair

supplier.

Language versions

These installation, commissioning and service instructions are available in various languages. Please

contact your Condair supplier for information.

The present installation, commissioning and service instructions are protected under the Copyright

Act. Passing-on and reproduction of the installation, commissioning and service instructions (or

partthereof)aswellasexploitationandcommunicationofthecontentsareprohibitedwithoutwrit-

ten permission by the manufacturer. Violation of copyright terms is subject to legal prosecution and

arisesliabilityforindemnication.

Themanufacturerreservestherighttofullyexploitcommercialpatentrights.

General

EverypersonworkingwiththeCondairGSmusthavereadandunderstoodtheinstallation,commis-

sioningandserviceinstructionsbeforecarryingoutanywork.

Knowingandunderstandingthecontentsoftheinstallation,commissioningandserviceinstructions

isabasicrequirementforprotectingthepersonnelagainstanykindofdanger,topreventfaultyop-

eration, and to operate the unit safely and correctly.

Iftheinformation intheseinstallation,commissioningandserviceinstructions isnotfol-

lowedexactly,areorexplosionmayresultcausingpropertydamage,personalinjuryor

loss of life.

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, commissioning and service instructions (commis-

sioning, operation, maintenance, 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Conairrepresentative.

ItisassumedthatallpersonsworkingwiththeCondairGSarefamiliarandcomplywiththeappropri-

ateregulationsonworksafetyandthepreventionofaccidents.

Intended use

ThegasredsteamhumidierCondairGSisintendedexclusivelyforhumidicationinventila-

tionsystemswithinthespeciedoperatingconditions.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 GS becoming dangerous.

Operation of the equipment in the intended manner requires that all the information in these

installation, commissioning and service instructions is observed (in particular the safety

instructions).

Dangerthatmayarisefromtheunit

DANGER! Danger of electric shock

TheCondairGS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GSoutofoperationasdescribedin

chapter6.3(switchofftheunit,disconnectitfromthemainsandstopthewaterandgassupply)

andsecuretheunitagainstinadvertentpower-up.

2 For your safety

DANGER! Danger of explosion

TheCondairGSisworkingwithgas.Improperinstallation,adjustment,alteration,service,

maintenance,orusecancausecarbonmonoxidepoisoning,anexplosion,re,orother

conditionswhichmaycausepersonalinjuryorpropertydamage.

Prevention:anyworkonthegassystemmustbecarriedoutonlybywelltrainedandsufciently

qualiedpersonnelauthorisedbytheowner.Beforecarryingoutanyworkonthegassystemset

theCondairGSoutofoperationasdescribedinchapter6.3.(switchofftheunit,disconnectitfrom

themainsandstopthewaterandgassupply)andsecuretheunitagainstinadvertentpower-up.

Donotstoreorusegasolineorotherammablevaporsandliquidsinthevicinityofthisorany

other appliance

Whattodoifyousmellgas: do not try to light any appliance. Do nottouchanyelectricalswitch;

do not use any telephone in your building. Immediately call your gas supplier from a neighbor’s

telephone.Followthegassupplier’sinstructions.Ifyoucannotreachyourgassupplier,callthe

redepartment.

DANGER! Danger of burning

Thewatertank,thesteamlineandtheexhaustsystemgetveryhotduringoperation.

Thereisdangerofburningwhentouchingthesecomponentsduringorshortlyafteropera-

tion.

Prevention:Donottouchthewatertank,thesteamlineandtheexhaustsystemduringoperation.

BeforecarryingoutanyworksettheCondairGSoutofoperationasdescribedinchapter6.3,then

waituntilthecomponentshascooleddownsufcientlythuspreventingdangerofburnin.

Behaviour in case of danger

If it is suspected that safe operation is no longer possible, then the Condair GS should immediately

be shut down and secured against accidental power-up according to chapter 6.3. This can be

thecaseunderthefollowingcircumstances:

– if you smell gas

– if the Condair GS or its mains cable is damaged

– if the Condair GS is no longer operating correctly

– if connections and/or piping are not sealed

– ifcomponentsoftheCondairGShumidierarewornorbadlysoiled.

– iftheCondairGSoranycomponentshasbeenexposedtoexcesshumidity.

– after longtime storage under unfavorable conditions.

– after transportation under unfavorable conditions.

AllpersonsworkingwiththeCondairGS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GS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.

3 Product Overview

TheCondairGSgasredsteamhumidierisavailablein6differentmodelswithdifferentmaxi-

mumsteamoutputperformance(40,80,120,160,200and240kg/h).

All models can be supplied in a version suitable for operation independent of the room air conditions

(Withaseparateairinlet)andcanbeoperatedwithnaturalgasorpropane(theunitissuppliedEx-

worksforaspecictypeofgasoperation).

Model designation

GS 40 C G20 RS

Product line

(gasred steam humidier with

operation and display unit)

Steam output (kg/h)

120

160

200

240

Equipment series

Fuel

Natural gas H, E, E(S): G20

Natural gas L, ELL: G25

Natural gas HS: G25.1

Natural gas Lw: G27

Natural gas Ls: GZ350

Propane gas P: G31

Room air-independent unit

(with separate air intake)

Thehumidiersareequippedwithanoperating and display unit,asstandard,bymeansofwhich

thecurrentoperatingparameterscanbeinterrogatedandtheequipmentcanbeconguredforop-

eration.Thehumidiersarecontrolledviatheinternal PID controlleroranexternalcontinuous

controller.

3.2 Delivery

The standard delivery includes:

– GasredsteamhumidierCondairGScompl.withunitstand(accordingtothemodeldesigna-

tion)

– Installation, commissioning and service instructions Condair GS C series

– Operating instructions Condair GS control

– Spare parts list

– Accessories ordered according to chapter 4.4 (steam distribution pipes, steam hoses, etc.).

3.1 Product versions/Model designations

3.3 Humidicationsystemoverview

 1 Gasredsteamhumidier

2 Electrical connections

3 Gas supply connection

4 Shut-off valve gas supply line (building side)

5 Gas supply line (building side)

6 Sediment trap (building side)

 7 Fillwaterconnection

8 Filter valve (accessory “Z261”)

9 Water supply line (building side)

10 Drainwaterconnection

11 Drainwaterline

12 Funnelwithtrap

13 Auxiliarydrainconnection

14 Shut-offvalveauxiliarydrain(buildingside)

15 Flue gas pipe

16 Fluegasadapterwithcondensatedrain

(accessory “FA...”)

17 Airintakepipe(RS-unitsonly)

18 Main steam pipe (building side)

19 Steam hose adapter (accessory “SA...”)

20 Steam hose (accessory “DS80”)

21 Steam distribution pipe (accessory “81–...”)

22 Condensate hose (accessory “KS10”)

5 6

7 98

1311

 1 Watertank

2 Steam outlet(s) (1 to 6)

 3 Heatexchanger(1to3)

 4 Burner(1to6)

5 Level unit

6 Key pad and display unit

7 Indication LED’s

green: “Steam production”

  yellow:“Maintenance”

red: “Error”

 8 Drainkey(manualdraining)

 9 Unitswitch

10 Tansformer

11 Control board

12 Driver board

13 Remote operating and fault indication board

3.4 Constructionofthegasredsteamhumidier

14 Ignition modules

15 Burnerelectronic

16 Combustionairblower(1to6)

17 Flame sensor

18 Igniter

19 Drain pump

20 Airpressureswitch

21 Gas pressure control valve (1 to 6)

22 Auxiliarydrainline

23 Drain connection

24 Doubleinletvalvellingwater

25 Connectionllingwater

26 Connection gas supply line

27 Vacuumbreak

28 Filling chamber

29 Pressure equalizer line (level unit)

3.5 Principle of operation

CombustionSystem

Thecombustionsystemisbasedonafullymodulatingforceddraftcombustionairblower,anegative

pressureregulatorgasvalveanda100%premixburner.Onacallforhumidity,thecombustionair

blowerstartsandcreatesanegativepressureacrossanoricelocatedattheairinlet.Theblower

starts for a moment to purge the system, then the hot surface ignitor is activated. During this time

theelectronicignitionmoduledoesadiagnosticcheckofsafetysystemsincludingtheairproving

switchwhichsensesthenegativepressureattheairinlet.

Afterthefunctionofthesafetysystemshasbeenveried,thegasvalvewillopenandthegas/air

mixtureisignitedbythehotsurfaceignitor.Ifameissensedbytheamesensorwithin7 seconds

thegasvalveremainsopenandcombustioncontinues.Ifameisnotsensed,theabovesequence

isrepeatedamaximumofthreetimesafterwhichtheignitionmodulewilllockoutandarespective

errormessagewillappearinthedisplay.

ThegasvalvemaintainsaconstantratioofairtoNaturalGasorPropaneindependentofblower

speedorexternalconditions.Thisairandfuelisthoroughlymixedintheblowerandthenforced

throughtheburnerportswhereignitionoccurs.

Hotproductsofcombustionareforcedthroughabafeinsidetheheatexchangerandthenvented

outside.Theheatexchangerhaslargeverticalsurfacestominimizescalebuild-upandpromotescale

sheddingtothebottomofthetank.Thisself-cleaningactionhelpstomaintaintheefciencyofthe

heatexchangerwhilethesmoothsurfacesallowforeasycleaningwhennecessary.

TheGS40hasasinglecombustionchamber/heatexchanger.Thecombustionsystemisduplicated

onlargerunitswithmultiplechambersinsideacommontank.

Regulation of the water level in the tank

Thelevelinthewatertankiscontinuouslymonitoredbythelevelunit.Oninitialstart-up,thecontrol

unitchecksthefunctionofthelevelunit.Duringthistestthetankislleduprsttolevel“A”,then

drainedtolevel“C”andlledupagaintolevel“A”.Assoonaslevel“B”isreachedandthetestofthe

levelunitwassuccessfulthehumidierisreadyforoperation,ifahumidicationdemandispresent

the combustion process starts.

Level unit

Pressure equalizer

Filling chamber

Vacuumbreak

Mainllline

Doublellvalve

Drain outlet

Drain pump

Auxiliarydrain

Mixingpipe

Whenthewaterlevelduetotheevaporationprocessreacheslevel“B”,thelevelunitsendsasignal

tothecontrolsystem,whichopensthedoubleinletvalveandthewatertankislledup.Onreach-

ing level “A”, the level unit again sends a signal to the control system and the double inlet valve is

closed.

Ifthewaterlevelgoesbelowlevel“C”,thecombustionwillbeinterrupteduntilthewaterlevelreaches

“C” again.

To ensure safe operation, the control system constantly monitors the proper function of the level unit

in regular intervals.

Steamgeneration/control

Thesteamisgeneratedinthewatertankviatheheatexchanger/s.Thesteamproductionisregulated

continuouslybytheinternalPIDcontrolleroranexternalcontinuouscontroller.

Flushing

Theconcentrationofmineralsinthewaterinthetankincreasesduetotheevaporationprocess.In

orderthatthisconcentrationdoesnotexceedaspeciedvalue,anappropriatequantityofwateris

pumpedofffromthetankataxedtimeintervalandreplacedbyfreshwater.Theseushingcycles

arebasedonsteamproductiontoincreasetheefciencyofthehumidier.

Whenaushingcycleisinitiatedthedrainpumpisactivatedandtheinletvalveopens.Inthemixing

pipebelowthellingchamberthehotdrainwaterismixedwiththecoldcoolingwaterandleaves

theunitwithatemperatureapprox.around60-70°C.

Ifthelowestoperatinglevelisreachedinthetankduringtheushingprocess,theinletvalveremains

openuntilthewaterlevelinthetankhasagainreachedthenormaloperatinglevel.

4 Basic planning

Condair GS 80 C G20 RS

1. Requiredmaximumsteamcapacity

2. Required combustion gas

3. Combustion air supply

4.1 Selecting the unit

Theselectionoftheunitisreectedinthetypedescription:

4.1.1 Calculatingthemaximumrequiredsteamcapacity

Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:

 V•ρ

=  •(x2-x1)

1000

=  •(x2-x1)

 1000•ε

: maximumsteamdemandinkg/h

V: volume of supply air portion per hour in m

/h(forindirectroomhumidication)orroomvolume

tobehumidiedperhourinm

/h(fordirectroomhumidication)

ρ: specicgravityofairinkg/m

ε: specicvolumeofairinm

/kg

: desired absolute room air humidity in g/kg

: minimum absolute supply air humidity in g/kg

Thevaluesforρ,ε,x2andx1canbegatheredfromtheh,x-diagramortheCarrier-Diagramformoist

air respectively.

Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalues

listedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroom

air humidity of 45 %rh.

Note:Toroughlyestimatethecalculatedmaximumsteamcapacityforlargersupplyairportionsor

room volumes, the values listed in the table can be projected accordingly.

Max.portionofsupplyairinm3/hrorroomvol-

umetobehumidiedperhourinm3/hr

max.steam

capacity

in kg/h

Temperature / rel. humidity of supply air

-15°C/90%rh -5°C/80%rh 5°C/60%rh

5000 6600 8000 40

10000 13200 16000 80

15000 19800 24000 120

20000 26400 32000 160

25000 33000 40000 200

30000 39600 48000 240

Example:

Max.portionofsupplyair10000m

/h,

temperature/rel. humidity of supply air

-15°C/90%rh

Condair GS 80 C G20 RS

Importantnotes:

– Therequiredmaximumsteamcapacitydependsonthespecicapplicationandtheinstallation.

Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionof

theairtobehumidied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.

Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsideration

whencalculatingtherequiredsteamcapacity.Ifyouhaveanyquestionsregardingthecalculation

of the steam capacity please contact your Condair supplier.

– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesor

forsystemswithvariableairvolumeow,etc.),pleasecontactyourCondairsupplier.

4.1.2 Combustiongas

TheCondairGScanbeoperatedwithnatural gas or propane.Theequipmentisconguredex-

worksfortherespectivecombustiongasthatistobeemployed.Ifrequired,theequipmentcanbe

convertedatalaterdatetoworkwithoneoftheothercombustiongas.

Combustion gas Designation

Natural gas H, E, E(S) G20

Natural gas L, ELL G25

Natural gas HS G25.1

NaturalgasLw G27

Natural gas Ls GZ350

Propane gas P (Liquid gas) G31

Condair GS 80 C G20 RS

4.1.3 Combustionairsupply

Toensurecorrectcombustion,caremustbetakentoprovideeitheraventilation opening in the

roomwheretheequipmentisinstalled(roomair-dependentdevice) or a separate air inlet pipe

(roomair-independentdevice) so that an adequate supply of clean, fresh air, is available.

Equipment version Designation

Roomair-dependentdevice

Forrooms witha sufcientlylarge ventilationopening

andasourceofcleanintakeair.

Caution! Local building regulations must be observed.

___

Roomair-independentdevice(RSequipment)

Air supply through a separate pipe from outside the

building.Forclosedrooms,roomswithlowairpressure

androomswithdirtyintakeair.

Condair GS 80 C G20 RS

4.2 Selectingthecontrolsystem

Thevariouscontrolsystems

– System1:Roomhumiditycontrol

System1issuitedforairconditioningsystemswithmainlyrecirculatedair.Thehumiditysensor

ispreferablylocatedintheroomitselforintheexhaustairduct.

A1/2 humidity sensor

B1 ventilationinterlock

B2 airowmonitor

B3 safetyhumidistat

 externalcontinuouscontroller(e.g.PIcontroller)

PID

internal continuous controller (PID controller)

Y input signal from A1

Z input signal from A2

A1 humidity sensor

B1 ventilationinterlock

B2 airowmonitor

B3 safetyhumidistat

 externalcontinuouscontroller(e.g.PIcontroller)

PID

internal continuous controller (PID controller)

Y input signal from A1

– System2:Roomhumiditycontrolwithcontinuouslimitationofthesupplyairhumidity

System2issuitedforairconditioningsystemswithalargeportionofsupplyair,lowsupplyair

temperature,post-humidication,orvariableairowvolume.Ifthesupplyairhumidityexceeds

the preset value, the continuous limitation is effected prior to the room hum idity control.

Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.The

humidity sensor (A2) for the limitation of the supply air humidity is located in the supply air duct

after the steam distribution pipe. This control system requires the internal PID controller or an

externalcontinuouscontrollerwiththeoptiontoconnectasecondhumiditysensor.

Attention! The continuous limitation of the supply air humidity is no substitute for the safety -

humidistat.

– System3:Supplyairhumiditycontrolwithcontinuousoutputlimitation

Supply air humidity control (humidity sensor installed in supply air duct) should be used only

whereroomhumiditycontrolisimpracticablefortechnicalreasons.Suchsystemsalwaysrequire

a PI-controller.

The humidity sensor (A1) is located in the supply air duct after the steam distribution pipe. The

humidity sensor (A2) for the continuous output limitation is located in the supply air duct before

thesteamdistributionpipe.SuchasystemrequirestheinternalPIDcontrolleroranexternalPI-

controllerwiththeoptiontoconnectasecondhumiditysensor.

A1/2 humidity sensor

B1 ventilationinterlock

B2 airowmonitor

B3 safetyhumidistat

 externalPI-controller

PID

internal continuous controller (PID controller)

Y input signal from A1

Z input signal from A2

Whichhumiditycontrolsystemforwhichapplication?

Application Locationofthehumiditysensor

Roomorexhaustairduct supply air duct

Airconditioningsystemswith:

Supply air portion up to 33% System 1 System 1

Supply air portion up to 66% System 1 or 2 System 2 or 3

Supply air portion up to 100% System 2 System 3

Supply air humidity control ––– System 3

PleasecontactyourCondairsupplier,ifyourapplicationmeetsthefollowingconditions:

– Humidicationofsmallroomsupto200m

– Airconditioningsystemswithahighnumberofairexchanges

– Systemswithvariableairvolumeow

– Testfacilitieswithextremecontrolaccuracyrequirements

– Roomswithahighvariationinmax.steamcapacity

– Systemswithtemperatureuctuations

– Coldroomsandsystemswithdehumidication

4.3 Options

At the moment no options are needed for the Condair GS.

4.4 Accessories

4.4.1 Accessories overview

Model Condair GS 40 ... 80 ... 120 ... 160 ... 200 ... 240 ...

Steamdistributionpipe

(see accessory details in chapter 4.4.2)

81-...

number 1 2 3 4 5 6

OptiSorpsteamdistributionsystem

(see accessory details in chapter 4.4.2)

System1 System2 System3 System4 System2

System3

number 1 1 1 1 1 of each 2

Steamhoseadapter ––– SA80

(3"/2x13/4")

SA120

(3"/3x13/4")

SA160

(4"/4x13/4")

SA200

(4"/6x13/4")

SA240

(4"/6x13/4")

number ––– 1 1 1 1 1

Steamhose/meter DS80

number 1 2 3 4 5 6

Condensatehose/meter KS10

number 1 2 3 4 5 6

Filter valve Z261 (1 pc. per system)

Flue gas adapter with

condensate drain

FA40 FA80 FA120/160 FA200/240

number 1 1 1 1

Control/input signals

TheCondairGSisregulatedviatheinternalPIDcontrolleroranexternalcontinuouscontroller(e.g.

PI controller).

Important!Forthecontrolsystems2and3theexternalcontrollermustbeequippedwithtwocontrol

signal inputs.

TheCondairGSprocessesthefollowingcontrolsignals:

– 0 ... 10 VDC

– 2 ... 10 VDC

– 0 ... 10 mADC

– 2 ... 10 mADC

– 0 ... 20 mADC

– 4 ... 20 mADC

– 0 ... 5 VDC

– 1 ... 5 VDC

Further information is provided in Chapter 5.9.

Output signals

TheCondairGSprovidesthefollowingoutputsignals:

– 10VDC(max.20mA)

– Remote operating and fault signals (4 potential-free contacts)

Further information is provided in Chapter 5.9.

OptiSorp Numberofsteam

connections

Max.steamcapacity

in kg/h

Ductdimensions

Widthinmm Heightinmm

System1 1 45 (30) 450...4000 450...1650

System2 2 90 (60) 450...4000 450...2200

System3 3 135 (90) 450...4000 800...3200

System4 4 180 (120) 450...4000 800...3200

Forductwidths<600mmthevaluesinbracketsapply

4.4.2 Accessory details

Steamdistributionpipes

Thesteamdistributionpipesareselectedonthebasisoftheductwidth(forhorizontalinstallation)

ortheductheight(forverticalinstallation)andthecapacityofthesteamhumidier.

Important!Alwaysselectthelongestpossiblesteamdistributionpipe(optimumhumidicationdis-

tance).

Steam distribution pipes

for

GS 40, 80, 120, 160, 200 and 240

Ductwidth(B) Steam capacity

Type Length in mm (L)

in mm max.inkg/h

81-350 350 400…600 30

81-500 500 600…750 30

81-650 650 750…900 50

81-800 800 900…1100 50

81-1000 1000 1100…1300 50

81-1200 1200 1300…1600 50

81-1500 1500 1600…2000 50

81-1800 1800 2000…2400 50

81-2000 2000 2200…2600 50

81-2300 2300 2500…2900 50

81-2500 2500 2700…3100 50

Material: CrNi steel

Special length on request

 TofullyexploittheoverallcapacityofyourGShumidier,theoutputofeach

steam outlet may be fed to more than one distribution pipe. If more than one

steam distribution pipe is fed per steam outlet the steam line must be divided

intomultiplebranches.Appropriatettingsareavailableonrequest.

Note:Ifthehumidicationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,the

steamoutputofyourunitmustbedividedbetweentwosteamdistributionpipes or the OptiSorp

steamdistributionsystem must be used. If this is the case, contact your Condair supplier.

OptiSorpsteamdistributionsystem

TheOptiSorpsteamdistributionsystemisusedinventilationductswithashorthumidicationdistance

(forthecalculationofthehumidicationdistancerefertochapter5.3.1).WhenorderinganOptiSorp

systemtheductdimensionmustbespecied.Pleaseconsultthedatainthefollowingtable.

5 Mounting and installation works

Qualicationofpersonnel

Allmountingandinstallationworkmustbeperformedonlybyadequatelyqualiedpersonnelfamiliar

withtheCondairGS.Ascertainingthequalicationsisthecustomer‘sresponsibility.

General notes

All the information contained in these installation, commissioning and service instructions relating to

equipmentassemblyandtogas,uegas,water,steamandelectricalinstallationmustbeuncondi-

tionallyobservedandcompliedwith.

Thelocaldirectivesandregulationsfortheinstallationofgasredequipment(Steamhumidiers)

mustbeunconditionallyobservedandcompliedwith.

Alllocalregulationsrelatingtotheexecutionofgas,uegas,water,steamandelectricalinstallations

mustbeobservedandcompliedwith.

Safety

The connection of the Condair GS to the mains electrical supply must not be made until all installa-

tionworkhasbeencompleted.

Incorrectlyexecutedinstallationscanresultinpersonalinjuryand/ordamagetopropertythrough

explosions,res,carbonmonoxidepoisoning,electricshock,etc.Ifyourequireassistance,please

contactaqualiedinstaller,yourlocalgassupplieroryourCondairrepresentative.Intheinstallation

itself, use only materials available from your Condair representative and accessories approved by

him.

5.1 Importantnotesonmountingandinstallationworks

5.2 Unittting

5.2.1 Humidierlocation

The positioning of the Condair GS is largely dependent on the location of installation of the steam

distributionpipe(seeChapter5.3.1)andonthedetailsoftheuegaspipe(seeChapter5.6)andthe

air supply line (RS units only, see Chapter 5.7). To ensure proper functioning of the steam humidi-

erandtoobtainoptimumefciency,thefollowingpointsmustbeconsideredandobservedwhen

choosingthelocationforthesteamhumidier:

– thelocalandnationalregulationsforinstallationofgasredequipmentmustbeobservedand

followed.Themanufactureracceptsnoliabilityfornon-compliancewiththeseregulations.

– Installthesteamhumidiersothat:

– thelengthofthesteamhoseisasshortaspossible(ideally2m,max.4m),theminimum

bendradius(R=300mm)andtheminimumupslope(20%)andtheminimumdownslope(5

%) of the steam hose can be maintained (see Chapter 5.3.2).

Note:Longsteamlinesreducethemaximumsteamoutputofthehumidier,duetotheheat

loss involved. The static pressure also increases.

– theuegaspipecanbeinstalledinaccordancewiththeapplicablelocalbuildingandinstal-

lation regulations.

– in the case of room air-independent units (RS units) the installation location can be reached

withanairsupplylineandgoodaccessibilityisassured.

– Inthecaseofroomair-dependentunitscaremustbetakentoprovideanadequateintakeofair

(inaccordancewithlocalbuildingregulations).

ForUKonly:PleaserefertoBS5440:PartIIorBS6644wheninstallingunits.Wedrawyourat-

tention especially to combustion an ventilation air supply requirements for plant rooms. Permanent

lowandhighlevelopeningscommunicatingdirectlywiththeoutsideairshallbettedwithgrilles

havingatotalminimumfreeareaasfollows.

Free area grille sizes

Lowlevel High level

GS 40 14,400 mm

14,400 mm

GS 80 55,800 mm

27,900 mm

GS 120 70,200 mm

35,100 mm

GS 160 84,600 mm

43,300 mm

GS 200 89,000 mm

50,500 mm

GS 240 113,400 mm

57,700 mm

Theroomair-independenthumidiers(RSunits)donotrequireaseparateventilationopening,

sincethecombustionairrequiredisprovidedbyanairintakepipefromoutsidethebuilding.

CAUTION!

Operationofthehumidierwithuncleanaircanleadtosafetyproblemsandreducetheoutput

oftheunit.Impuritiesintheairare,forexample:Halogens,ammonia,chloride,excessivedust,

lime and dirt. For questions about air quality, please refer to the technical service department

of your Condair distributor

– TheCondairGSgasredsteamhumidiersaredesignedforoormountingontheunitstand

(includedinthedelivery)xedtotheoor.

– ThesheetcoveringoftheCondairGSheatsupduringoperation(max.surfacetemperatureapprox.

60-70°C).Thereforemakesurethatnoheat-sensitivematerialsareplacedintheimmediate

vicinityofthehumidier.

min. 1000 mm

769 mm

min. 1000 mm

– NocombustiblematerialsmustbeplacedintheimmediatevicinityoftheCondairGShumidier

(Insulationmaterials,woodenoorcoverings,etc.).Observelocalregulations!

– Donotmountthehumidierinalocationthatisendangeredbyheatorfrost!Ifthehumidiermust

bemountedoutside,itmustbehousedinaweatherproofandthermostaticallyventilatedcabinet.

If necessary, please contact your Condair representative.

– Donotmountthehumidieronabasethatissubjecttovibration.Ifnecessary,pleasecontact

your Condair representative.

– TheCondairGSmustbeinstalledonlyinlocationsequippedwithawaterdrainorwithsensors

thatsafelyinterruptwatersupplyincaseofleakage.

– Donotcovertheairopeningsinthetopandbottomcoversofthehumidierhousingotherwise

theairowmaybeinsufcient.Furthermore,donotplacetheunitinanarrownicheoraclosed

compartment (observe minimum distances).

– Positionthehumidiersothattheunitiseasilyaccessibleandthereissufcientspaceformain-

tenancework.Theminimumdistancesshowninthefollowingillustrationmustbemaintained.

465

538

633

15 1094

974

780

353

1133

844

727

802

769

353

139

GS 160

353

139

GS 40

1 3/4"

907

353

139

GS 120

353

139

GS 80

353

139

GS 200

250 203

139

GS 240

139

Dimensions (in mm)

Connections and weights

Model Connections Net

weight

Operating

weight

Flue gas Steam

No. x ø

Filling

Water

Gas Water

Drain

Auxiliary

Water Drain

GS 40 3" (76 mm) 1 x 1 3/4" (45 mm) BSP 3/4" BSP 1/2" 3/4" (19 mm) NPT 1/2" 140 211

GS 80 4" (101 mm) 1 x 3" (76 mm) BSP 3/4" BSP 3/4" 3/4" (19 mm) NPT 1/2" 162 273

GS 120 5" (127 mm) 1 x 3" (76 mm) BSP 3/4" BSP 1" 3/4" (19 mm) NPT 1/2" 238 459

GS 160 5" (127 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1" 3/4" (19 mm) NPT 1/2" 261 471

GS 200 6" (152 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1 1/4" 3/4" (19 mm) NPT 1/2" 290 610

GS 240 6" (152 mm) 1 x 4" (101 mm) BSP 3/4" BSP 1 1/4" 3/4" (19 mm) NPT 1/2" 314 623

Steam outlet

Flue gas outlet

Air intake

(RS units only)

Control signal

Gas supply

Water supply

Water drain

Auxiliary

water drain

Power supply

A B C D E F

GS 40 528 271 377 421 236 160

GS 80 689 431 537 588 372 295

GS 120 1086 827 933 984 371 278

GS 160 1086 827 933 984 371 278

GS 200 1482 1224 1330 1381 366 187

GS 240 1482 1224 1330 1381 366 187

TheCondairGShumidiersmustbemountedontheunitstand supplied with the unit. If mounting

on the unit stand supplied is not possible in your particular case, select a method of mounting that

is of similar stability. In case of doubt, please contact your Condair supplier.

5.2.2 Mountingthehumidier

Mounting instructions

1. Assembletheunitstandasshownintheseparateinstallationinstructions.Handtightenallbolts

only.

2. Liftuphumidierwithaliftingdeviceapprox.900mmabovetheoor.

3. Positionunitstandbelowthehumidier.

4. Lowerthehumidierandalignwiththeholesoftheunitstand.

5. Fastenthehumidiertotheunitstandusingthebolts,cupwashersandnutsprovided.

6. Tighten all nut and bolt pairs to 22.6 Nm (200 lb-in) or until secure.

7. Positiontheentireassemblytothedesiredlocation.Makesurethehumidierisstable,shimming

oftheoorbelowthesupportlegsoftheunitstandmaybenecessary.

8. Fixtheunitstandtotheoor(mandatory)viathefourholesinthesupportplatesoftheunitstand.

5.3 Steaminstallation

5.3.1 Positioningandmountingofthesteamdistributionpipes

The location for the steam distribution pipes should be determined at the time of dimensioning the

airconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidicationofthe

duct air.

Calculatingthehumidicationdistance

Thewatervapor,emittingfromthesteamdistributionpipes,requiresacertaindistancetobeabsorbed

bytheambientairsothatitisnolongervisibleassteam.Thisdistanceisreferredtoashumidica-

tiondistance“B

” and serves as a basis for the determination of the minimum distances from the

upstream components in the system.

Thecalculationofthehumidicationdistance“B

” is dependent on several factors. For a rough es-

timationofthehumidicationdistance“B

”,thefollowingtableisuseful.Recommendedstandard

valueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevalues

given inboldprintonlyapplytosteamdistributionpipes81-.., the values in brackets apply to

theOptiSorpsteamdistributionsystem.

Input humidity

φ1in%rh

LengthofhumidicationdistanceB

in m

Outputhumidityφ2in%rh

40 50 60 70 80 90

5 0.9 (0.22) 1.1 (0.28) 1.4 (0.36) 1.8 (0.48) 2.3 (0.66) 3.5 (1.08)

10 0.8 (0.20) 1.0 (0.26) 1.3 (0.34) 1.7 (0.45) 2.2 (0.64) 3.4 (1.04)

20 0.7 (0.16) 0.9 (0.22) 1.2 (0.30) 1.5 (0.41) 2.1 (0.58) 3.2 (0.96)

30 0.5 (0.10) 0.8 (0.17) 1.0 (0.25) 1.4 (0.36) 1.9 (0.52) 2.9 (0.88)

40 – 0.5 (0.11) 0.8 (0.20) 1.2 (0.30) 1.7 (0.45) 2.7 (0.79)

50 – – 0.5 (0.13) 1.0 (0.24) 1.5 (0.38) 2.4 (0.69)

60 – – – 0.7 (0.16) 1.2 (0.30) 2.1 (0.58)

70 – – – – 0.8 (0.20) 1.7 (0.45)

For duct widths <600 mm the humidication distance forthe OptiSorp system increases by ap-

prox.50%

φ1in%rh: Relativesupplyairhumiditypriortohumidicationatthelowestsupplyairtemperature

φ2in%rh: Relativesupplyairhumidityafterthesteamdistributionpipeatmaximumcapacity

Example

given:φ1=30%rh,φ2=70%rh

humidicationdistanceB

: 1.4m (0.36 m for steam distribution system OptiSorp)

Note:Ifthehumidicationdistancehastobereducedfortechnicalreasons,theamountofsteamper

steamoutletmustbedividedbetweentwosteamdistributionpipesorthesteamdistributionsystem

OptiSorp must be used. If this is the case, contact your Condair supplier.

Humidication

distanceB

Expansion-andmixingzone

φ1:Incomingairhumiditybeforehumidication

φ2:Airhumidityafterhumidication

Minimumdistancestobeobserved

Topreventthewatervapor,thatisemittingfromthesteamdistributionpipe,fromcondensingon

downstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeob-

served(dependsonthehumidicationdistance“B

”).

before/after constriction after expansion before bend

 beforebranch beforediffuser beforecontrol/temperaturesensor

 before/afterlter/register before/afterfan,zoneexit

* 2,5xB

beforesubmicronparticlelter

Installationnotesanddimensions

Thesteamdistributionpipesaredesignedforeitherhorizontalinstallation(ontheductwall)or,with

accessories,forverticalinstallation(intheductoor).Theoutletoricesshouldalwayspointupwards

andatrightanglestotheairow.

Ifpossible,thesteamdistributionpipesshouldbeinstalledonthepressuresideoftheduct(max.

duct pressure 1700 Pa). If the steam distribution pipes are installed on the suction side of the duct,

themaximumvacuummustnotexceed800Pa.

Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)and

position the steam distribution pipes in the duct so that a uniform distribution of steam is achieved.

0.5 x B

5 x B

1.5 x B

5 cm

Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved:

min

g min.= 100 mm

h min.= 85 mm

H min.= 250 mm H≥400mm H min.= 200 mm

H min.= 400 mm H min.= 350 mm H min.= 300 mm

H min.= 600 mm H min.= 500 mm H min.= 400 mm

H min.= 720 mm H min.= 600 mm H min.= 500 mm

H min.= 840 mm H min.= 700 mm H min.= 600 mm

H min.= 960 mm H min.= 800 mm H min.= 700 mm

Drain pan

to drain

Shallowduct

Drain pan

Ceiling

to drain

Branchduct

Note: When locating the OptiSorp steam distribution system please note the instructions in the

separate documentation for this product.

Guidelinesfordimensioningtheventilationducts

– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufciently

sized control opening should be planned.

– Withintherangeofthehumidicationdistance,theventilationductshouldbewaterproofed.

– Lowtemperatureductsbelow15°C,shallowducts,orbranchductsmightrequiretheuseofa

eldsuppliedcondensatedrainpanbelowthesteamdistributor(seegurebelow).

– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidiedairfromcon-

densingalongtheductwall.

– Poorairowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canlead

tocondensationofthehumidiedair.

– Steam distribution pipes must not be mounted to round ducts.

– Exerciseextremecautionwheninstallinginberglassorinternallylinedducts.Ifnecessary,re-

move10-15cmoftheliningwherethesteamisbeingintroduced.

IfyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithCondair

steamhumidiers,contactyourCondairsupplier.

Installingthesteamdistributionpipes/OptiSorpsteamdistributionsystem

Detailed information on the installation of steam distribution pipes and OptiSorp steam distribution

system can be found in the separate “Mounting Instructions” for this products.

5.3.2 Installingthemainsteampipe

Thesteampipebetweenthesteamoutletoftheunitandthesteamhoseadapter(mainsteampipe)

mustbemadewithsolidpiping.

Thefollowingnotesmustbeobserved:

– The internal diameter of the steam outlet on the unit must be maintained over the entire length

of the main steam piping.

– Themaximumlengthofthemainsteampipeis6m.

Important!Allowancemustbemadeforapressurelossof10mmwatercolumn(approx.

100 Pa)permeterlengthorper90°bend.

– The minimumbendradius for solid pipes is 4-5 x internaldiameter.90°bendsshould be

avoided.Whereverpossible,pipebendswithlargeradiusshouldbeused(e.g.producedusing

apipebendingmachine,orconstructedfromapairof45°bends).Thisreducestheperformance

loss due to the formation of condensate, and in addition, the static pressure in the steam line.

– UseCupipe(foroperationwithuntreateddrinkingwateronly)orstainlesssteelpipe(min.DIN

1.4301)exclusively.

– To minimize the condensate formation (= loss), the steam pipes must be insulated over the entire

length of the piping.

– Connection of the steam pipe to the steam outlet on the unit and the connection on the steam

hoseadapteriseffectedbymeansofshortlengthsofsteamhosesecuredwithhoseclamps.

– Atspotswherecondensatecouldaccumulateinsidethepipeacondensatedrainwithsiphon

(min. hose bend Ø200 mm) must be mounted.

Main steam pipe

(max.length6m)

steam hose adapter

(accessory “SA..”)

steam hoses

(max.length4m)

min. 1 m

Important!UseoriginalCondairsteamhoseexclusively.Othertypesofsteamhosescancause

undesired operational malfunctions.

Thefollowingnotesmustbeobserved:

– Leadthesteamhosewithanupslope of at least 20%orwithaminimumdownslopeof5% to

the steam distribution pipe.

– Thesteamhoseshouldbekeptasshortaspossible(ideally2m,max.4m)whileobservingthe

minimumbendradiusof300mm. Important!Allowancemustbemadeforapressure loss

of10mmwatercolumn(approx.100Pa) per meter steam hose.

– Reductionsinthecrosssectionsuchaskinksshouldbeavoidedthroughouttheentirelengthof

thehose.Theinstallationofastopcockinthesteamhoseisnotpermissible.

– Steamhosesmustbepreventedfromsagging(condensatepockets);ifnecessary,supportwith

pipeclamps,railsorwallbrackets.Ifsaggingcannotbeprevented(e.g.whenpassingbyobsta-

cles)acondensatedrainwithsiphon(min.hosebendØ200mm)mustbemountedatthelowest

pointofthesteamhose(seefollowingillustration).

min. 5 %

min. 20 %

max. 4 m

Rmin.

300 mm

5.3.3 Installingthesteamhosesbetweensteamhoseadapter

andsteamdistributors

– Important! When deciding on the length and layout of the hose, it should be noted that the steam

hosemaybecomesomewhatshorterwithprogressiveageing.

R min. 300 mm

min. 20 %

min. 5 %

max. 4 m

min. 20 %

min. 300 mm

Ø min. 200 mm

Securing the hose

Thesteamhosemustbesecuredtothesteamdistributionpipeandhumidiersteamoutletbymeans

of hoseclamps.

Steamlinewithxedpiping

Forsteamlineswithxedpiping,thesameinstructionsapplytothelayingofthepipingasalready

described.Thefollowingadditionalnotesshouldbeobserved:

– The minimuminternaldiameterof45mmshouldbeappliedoverthewholelengthofthepiping.

– UseexclusivelyCupipe(foroperationwithuntreateddrinkingwateronly)orstainlesssteel(min.

DIN 1.4301).

– To minimize the condensate formation (=loss), the steam pipes must be insulated.

– The minimumbendradius for solid pipes is 4-5xinternaldiameter.

90°bendsshouldbeavoided.Whereverpossible,tubebendswithlargeradiishouldbeused(e.g.

producedusingatubebendingmachine,orconstructedfromapairof45°bends).Thisreduces

the performance loss due to the formation of condensate, and in addition, the static pressure in

the steam line.

– Important!Allowancemustbemadeforapressurelossof10mmwatercolumn(approx.

100 Pa)permeterlengthorper90°bend.

– Connectionofthesteampipestothesteamdistributionpipeandsteamhumidieriseffectedby

meansofshortlengthsofsteamhosesecuredwithhoseclamps.

5.3.4 Installing the condensate hoses

The individual condensate hoses of the main steam pipe (if present), the steam hose adapter (if

present)andthesteamdistributionpipesmustbeleddownwithaminimumdownslopeof20%

via a siphon (min. hose bend ø200 mm) into a discharge funnel.

Important!Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbelled

withwater.

Important!UseoriginalCondaircondensatehoseexclusively.Othertypesofhosescancauseoper-

ational malfunctions.

5.4 Water installation

5.4.1 Performingthewaterinstallation

Overview water installation

 1 FillingwaterconnectionBSP3/4"(outsidethread)

2 Filter valve (accessory “Z261”)

 3 Fillingwatersupplyline(min.innerØ:12mm)

4 Manometer (installation recommended, building side)

 5 Pressurereducingvalve(compulsoryforwaterpressures>8bar,buildingside)

6 Water drain connection 3/4" (Ø19 mm)

 7 Drainline,buildingside(min.innerØ:45mm,min.50cmdirectedverticallydownwards)

8 Funnel (building side, min. height 15 cm)

 9 Siphon(min.innerØ:>45mm,buildingside)

10 AuxiliarywaterdrainconnectionNPT 1/2" (inside thread)

11 Shut-off valve (installation recommended, building side)

4 5

min. 50 cm

min. 15 cm

Water supply

Thewatersupplypipeistobeconnectedviatheltervalve(accessory“Z261”),totheconnection

ontheunit(seeforegoingillustration).Theltervalveshouldbeinstalledasclosetothehumidier

as possible.

Note:Insteadoftheltervalve,ashut-off valve and a waterlter5µm ( (both essential) can be

used.

Thefollowingspecicationsmustbeobserved:

– Connections on unit: BSP 3/4" (outside thread)

– Min. inner diameter of supply line: 12mm

– Admissible mains pressure 3.0 to 8.0 bar (hammer-free system)

Formainspressures>8bar,connectionmustbemadeviapressurereducingvalve(adjustedto

3.0bar).Formainspressures<3.0barpleasecontactyourCondairsupplier.

– Supply rate: 10l/min

– Admissible supply temperature: 1…30 °C

– Notesonwaterquality:

– ForthewatersupplyoftheCondairGS,useexclusivelyuntreated drinking water or fully

demineralizedwater.

Note:Theuseoffullydemineralizedwaterreducesthemaintenanceandthecleaningofthe

watertanktoaminimum.

– The use of additives such as corrosion inhibitors, disinfectants, etc. is not allowed, since

these additives may endanger health and affect proper operation.

– IftheCondairGSshallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyour

Condair supplier.

– Theconnectionmaterialmustbepressure-proofandcertiedforuseindrinkingwatersupply

systems.

CAUTION!

Fullydemineralizedwaterisaggressive.Whenmakingconnectionstoafullydemineralizedwater

system,useexclusivelyplasticorstainlesssteelinstallationmaterials(min.DIN1.4301).

– Important!Beforeconnectingthewaterlinetotheunit,thelinemustbeushedthoroughly.

Water drain

The drain line should be connected to the unit drain connection using a hose coupling. The drain

lineshoulddropverticallydownforaminimumof50cmandintoanopendrainfunnel(min.height

15 cm). The drain line is then connected via a siphon to the building drain line. The minimum internal

diameterof45mmmustbemaintainedoverthefulllengthofthebuildingdrainline.Makesurethat

the drain line is correctly attached and easily accessible for the purpose of inspection and cleaning.

Thefollowingconnectiondatashouldbeobserved:

– Connection on unit (hose connection): 3/4"(Ø19mm)

CAUTION!

Use only temperature-resistantinstallation materials!

Whenusingfullydemineralizedwater,onlystainlesssteel(min.DIN1.4301)orchemically-re-

sistant plastic (e.g. Polypropylene) connection components must be used.

– Drainage capacity: approx.20l/min

– Min. inner diameter of the building drain line: 45mm

– Min.downslopeaftersiphon:10 %

Note:Itisnotpermissibletocurvethedrainpipeupwards,becausethiscanleadtothecollection

ofdepositsatthelowestpointinthepipeandtotheblockageofthepipe.

5.5 Gas installation

Installation notes

The gas supply pipe must be connected to the connection on the unit via a shut-off valve (essential

requirement),whichisinstalledintheimmediatevicinityoftheunit.Whensteelgaspipesareinuse,

itisessentialthatasedimentseparatorbettedbetweentheshut-offvalveandtheunitconnection.

Thefollowingconnectiondatamustbeadheredto:

– Permissible gas operating pressure:

Gas Operatingpressure(mbar)

Nominal Min Max

Natural gas H, E, E(S) G20 20 17 25

Natural gas L, ELL G25 25 20 30

Natural gas HS G25.1 25 20 30

NaturalgasLw G27 20 17.5 23

Natural gas Ls GZ350 13 10.5 16

Propane gas P G31 37 or 50 25 57.5

– The connection material used must be pressure tested and approved for gas installations.

– Donotuseteontapeongaslinepipethreads.AexiblesealantsuitableforusewithNatural

Gas and Propane Gas is recommended.

– Plangassupplypipingsoitwillnotinterferewithremovalofgasvalvesorblowerassembliesand

front or side service doors.

Allinstallationworkmustbecarriedoutinaccordancewiththe applicable local building and in-

stallation regulations.

5.5.1 Performingthegasinstallation

Overview Gas installation

1 Gas supply connection

Model Connection

GS 40 BSP1/2"

GS 80 BSP3/4"

GS 120 and GS 160 BSP1"

GS 200 and GS 240 BSP11/4"

2 Gas shut-off valve (building side)

3 Sediment trap (Installation - building side -

essential in the case of the use of steel

gas pipes)

5.5.2 Leak testing

Aftercompletionoftheinstallationwork,thewholegaslinemustbetestedtoamaximumpressure

of40mbar(4.0kPa)fornaturalgasor150mbar(15kPa)forpropaneandcheckedforleaksus-

ingacommerciallyavailablesoapsolution.Thebubblesindicateleaks.Allleaksmustbeeliminated

beforethehumidierisputintooperation.

DANGER!

Neveruseanopenametocheckforleaks.Thepresenceofanyleakageisasourceofdanger

topersonsandtoproperty,duetothepossibilityofreandexplosion.

Ifthegascircuitmustbetestedtoapressureofover150mbar(15kPa),thegassupplypipemust

be removed from the unit connection. After the test, the gas line must be depressurized before it is

reconnected to the unit.

CAUTION!

Non-observance of the above instruction can lead to damage to the gas pressure regulating valve.

Gas pressure valves overloaded due to high pressure are not covered by the manufacturer‘s

guarantee.

5.5.3 Conversioninstructionsforoperatingthehumidierwithanothertypeofgas

Exworkstheapplianceisequippedtooperateononetypeofgas.Toconvertanapplianceforopera-

tiononanothertypeofgas,followthedirectionsbelow(seealsoillustrationonthefollowingpage).

Important:Theconversionshallbecarriedoutbyamanufacturer’sauthorizedrepresentative

orpersontrainedandlicencedforsuchactivities,inaccordancewiththerequirementsofthe

manufacturerorlocalauthoritieshavingjurisdictionintheareaofinstallation.

1. Disconnectthehumidierfromtheelectricalpowersupplyandtakeprecautionsagainstinadvert-

entswitchingon.

2. Turn off gas supply to appliance and secure it against inadvertent open ing.

3. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

4. Disconnectthehose(s)fromtheinletelbow(notethelayout).Then,loosenthehoseclampand

removetheinletelbow.

5. Undothecouplingofthecorrespondingexiblegaspipeanddisconnectgaspipefromthegas

pressure regulating valve.

6. Disconnectelectricalcablestothegaspressureregulatingvalveandtheairpressureswitch

(note assignment before removal).

7. Undothetwoscrewsthatmounttheventurimanifoldtothecombustionairblower,thenliftup

themanifoldtogetherwiththegaspressureregulatingvalve.

8. Undo the four screws and remove the gas pipe connection of the gas pressure regulating

valve.

9. Undothethreescrewsoftheairpressureswitchsupportandremovethepressureswitchas-

sembly from the gas pressure regulating valve.

10.Checkthecorkgasket andtheO-ring in thegaspipe connectionfordamageand replaceif

necessary.

11. Attachthegaspipeconnection(withmountedO-ring)andthepressureswitchassemblytothe

gaspressureregulatingvalvesupplied(comeswithventurimanifoldattached).

Warning!Makesurethegastypeindicatedonthelabeloftheventurimanifoldcorrespondsto

the gas you are using. Donotchangethesettingofsealedadjustmentscrew“A”.

12.Fixthenewventurimanifold(don’tforgetthecorkgasket)togetherwiththegaspressureregulat-

ingvalvewiththetwoscrewstothecombustionairblower.

13.Reconnecttheexiblegaspipetothegaspressureregulatingvalveandtightenthecoupling.

14.Fixtheinletelbowwiththehoseclamptotheventurimanifold.

15.Reconnectthehosefromtheairpressureswitchandifpresentfromtheairinletmanifold(on

RSunitsonly)totheinletelbow.

16. Reconnect the electrical cables to the gas pressure regulating valve and the air pressure

switch.

17. On multiple burner units repeat steps 4 to 16 for each gas valve assembly.

18.Carryoutaleakagetest(Refertoinstructionsin5.5.2).

19.Turnpowertounitbackonandinitiateatestresequencetocheckforproperignitioncharac-

teristics.

20.Iftestsareacceptable,afxappropriateconversionlabeltodataplate.Replacedoorpaneland

xitwithscrew.Then,returnunittonormaloperation.

21.Conversionisnowcomplete.

Hose to air inlet manifold

(RS units only)

Corkgasket

Inletelbow

Hose clamp

Gas pressure

regulating valve

Flexiblegaspipe

Combustionairblower

Hose to

pressureswitch

Pressureswitch

Venturi manifold

gas pipe connection

O-ring

5.6 Flue gas installation

Important:Since the regulations fortheinstallationofueingsystemsdifferfromcountrytocountry,

therelevantlocalregulationsmustbeadheredtowithoutreservation.

In any case, please consult your Condair representative. Thisappliesinparticulartotheroom

air-independentsteamairhumidiers(RSunits).

Pleasenotethatueingmustbedesignedforoverpressureorunderpressure,dependingonlocal

regulations.

Allworkconcerningtheuepipeinstallationmustbeperformedonlybyadequatelyqualiedperson-

nel.Ascertainingthequalicationsisthecustomersresponsibility.

5.6.1 Performinguegasinstallation

Overview

1 Flue gas connection on the unit

– GS 40: ø76 mm (3")

– GS 80: ø101 mm (4")

– GS 120/GS 160: ø127 mm (5")

– GS 200/GS 240: ø152 mm (6")

2 Fluegasadapterwithcondensatedrain(accessory“FA...”)

– GS 40: FA40 (D

= 80 mm)

– GS 80: FA80 (D

= 100 mm)

– GS 120/GS 160: FA120/160 (D

= 130 mm)

– GS 200/GS 240: FA200/240 (D

= 160 mm)

3 Flue gas pipe (building side)

4 Condensate drain (building side)

5 Siphon (min. diameter 300 mm, building side)

max.40mm

ø15 mm

GS 40 ø80 mm

GS 80 ø100 mm

GS 120 / GS 160 ø130 mm

GS 200 / GS 240 ø160 mm

Applicableuesystemsforroomair-dependentunits

Type B23

Fluearrangement

TherearedifferenttypesofapplicableuesystemsfortheCondairGSdependingontheunittype

(roomair-dependentorroomairindependentunits).Thefollowinguegasdiagramsareforguidance

only,andmustbereadinaccordancewiththelocalcountrycodesforuegassystems.

min. 1.5 m

≥ 1m

min.1m

≤ 2.5m> 2.5m

Rain cap (by client)

FluelengthfortypeB23uesystems:min.2.1m,max.30m (see installation notes)

uegasterminal

(according local

regulations)

Applicableuesystemsforroomair-independentunits–RSunits

Type C33

min. 1.5 m

Rain cap (by client)

min.1m

FluelengthfortypeC33uesystems:

min.2.1m,max.21m (see installation notes)

correct

not

correct

air inlet terminal

(according local regulations)

Rain cap (by client)

uegasand

air inlet terminals

(according local

regulations)

Type C53

min. 1.5 m

min.1m

> 2.5 m ≤ 2.5 m

≥ 1m

min. 1.2 m

FluelengthfortypeC53uesystems:min.2.1m,max.21m (see installation notes)

Note:Wherelocalregulationspermit,theRSunitscanbeinstalledasC63x

appliances.AsaC63xappliance,theCondairGScanbeconnectedtoa

separatelyapprovedandmaketedsystemforthesupplyofcombustionair

anddischargeofuegases.Forsuchapplications,refertotheapplicable

local regulations and the separate Installation Instructions “Installation as

a C6 appliance” available from your Condair dealer.

Type C63x

General installation notes

Thefollowinginstructionnotesmustbeobserved:

– Fluegasspecications:--->seetableinchapter10.2

– The ue gas temperature during normal application and when the maintenance schedule is

fullledisbetween160-180°C.Iftheunitisnotmaintainedproperlytheuegastemperature

couldincrease.Inthiscasethetemperatureswitchwouldshutdowntheunitifthetemperature

exceeds200°Cforsafetyreasons.

– Useexclusivelycorrosionfreeinstallationandsealingmaterialstestedandapprovedforuegas

systems.

– AllconnectionsoftheuegaspipemustbesealedwithhightemperatureRTVsiliconeratedfor

atleast250°C.

– Selectasuitablepipingarrangementforthedischargeofuegasesfromthebuilding.

– Theminimuminternaldiametermustbeobservedovertheentirelengthoftheuegaspipe.

– GS 40: ø76 mm (3")

– GS 80: ø101 mm (4")

– GS 120/GS 160: ø127 mm (5")

– GS 200/GS 240: ø152 mm (6")

– Horizontalpipesectionsshouldhaveaminimumupwardslopeof21mm/mandshouldbesup-

ported every 1.5 m and additionally supported at every pipe bend.

– Foranyuelengthsover7mlong,useinsulatedpipes.

– WhentheuepipeisleadthroughnearbyroomsthepipemustbeequippedwithanF90-type

insulation.

– Provideare-proofscreenorbarrier(ataminimumdistanceof50mmtouegaspipe)toprevent

personalinjuryinareaswhereinadvertentpersonnelcontactwithuepipecanoccurorwhere

heat-sensitive products are stored.

– Securetheuepipe(e.g.bymeansofbeadingthepipe,seeoverview)topreventitfromslipping

intotheueconnectoroftheunit.

– AcondensatedischargepointshouldbeinstalledatanappropriatepositionintheGShumidier

uegassystem(seeoverview).Asiphonwithaminimum300mmheadofwatermustbeinstalled

inthecondensatedischargeline,sothatnouegasescanescapeviathedischargepipe.

Beforeoperatingthehumidier,makesurethatthesiphoninthecondensatedischargeislled

withwaterandthecondensateoutletisinaccordancewiththeapplicablelocalregulationsfor

sanitary installations.

Flueing with overpressure

Whenueingwithoverpressurethemaximumadmissiblelengthoftheuepipeequals30metersfor

room air-dependent units and 21 meters for room air-independent RS unit (assuming same diameter

asconnectoronCondairGS)whereeach90°elbowisequalto3mandeach45°elbowisequalto

1.5mofstraightpipe.Threeelbowsoutsidethehumidiercasingisarecommendedmaximumfor

ueingsystems.

Werecommend30mor21mrespectivelyuelengthmaximumtoensurethatoutputismaintained.

For lengths over 30 m or 21 m respectively, please consult your Condair supplier.

Flueing with underpressure

Iflocalregulationsrequireueingwithunderpressure,theunderpressuremustbewithin-0.2and

-0.62mbar.Theapplicablelocalregulationsforthelayoutofuegaspipesforunderpressuremust

beobservedandcompliedwith.

Additionalrequirementswhenueingthroughasidewall

Attention!Somecountriesprohibitleadingtheuepipethroughasidewall.Observelocalregulations

andcontactthelocalauthoritiesand/orthechimney-sweep.

Positionthehumidierasnearaspossibletothewallthroughwhichtheuepipeistobetaken.

Locatetheueterminalatleast1maboveanyforcedairinletlocatedwithin3m;oratleast1m

below,1mhorizontallyfrom,or0.5maboveanydoor,window,orgravityairinletintoanybuilding.

A minimum horizontal clearance of 1 m from electric meters, gas meters, regulator and relief equip-

ment is required.

Locatetheueterminalatleast2.5mabovegradewhenitisadjacenttopublicwalkways.

Locatethebottomoftheueterminalatleast45cmabovegradeorground,ornormallyexpected

snowaccumulationlevel.Thesnowlevelmaybehigheronwallsexposedtoprevailingwinds.

Avoidareaswherelocalexperienceindicatesthatcondensatedrippagemaycauseproblemssuch

asaboveplanters,patios,oroverpublicwalkways,oroveranareawherecondensateorvaporcould

create a nuisance or hazard, or could be detrimental to the operation of regulators, relief valves, or

other equipment.

Refertotheuemanufacturer’sinstallationinstructions.

AdditionalrequirementsforuegassystemsofRSunits

TheRSunitsarecertiedasC33andC53appliances.Wherelocalregulationspermit,theRSunits

can be installed as C6 appliances. For such applications, refer to the separate Installation Instruc-

tions “Installation as a C6 appliance” available from your Condair dealer.

PleaseobservethefollowingadditionalrequirementsfortheuegasinstallationofRSunits:

– Onlyuseinstallationmaterialinaccordancewiththelocalregulations.

– Theuegaspipeandtheairinletpipemusthavethesamelength(min.2.1m,max.21m).

– Observe the requirements regarding terminal locations in section 5.7.

5.7 Installationoftheairinletlineforroomair-independentunits(RSunits)

Important:Since the regulations fortheinstallationofairsupplysystemsforgasredappliancesdiffer

from country to country, therelevantlocalregulationsmustbeadheredtowithoutreservation.

In any case, please consult your Condair representative.

Installationoftheairsupplylinemustonlybecarriedoutbyadequatelyqualiedpersonnel.

Overview

5.7.1 Performingairsupplyinstallation

1 Air supply connection on RS units

– GS 40: ø76 mm (3")

– GS 80: ø101 mm (4")

– GS 120/GS 160: ø127 mm (5")

– GS 200/GS 240: ø152 mm (6")

2 Connection hose (building side)

3 Hose clamps (building side)

4 Air supply line, hose or rigid pipe (building side)

Airsupplyarrangement

Installation notes

– Max.admissiblesupplyairtemperatureis30°C.Makesuretheairsupplylineisnotheatedup

bytheuegasline.

– Themaximumpipelengthfortheairsupplylineisequivalentto21meters.Theminimumdiam-

eter(seeabove)mustbemaintainedovertheentirelengthoftheline.Inthisestimate,each90°

bendisequalto3mofstraightpipelengthandeach45°bendisequalto1.5mofstraightpipe

length. Not more than 3 pipe bends must be built into the air supply line.

Theairsupplylineshouldbeapproximatelyaslongastheuegaslineandmustbesupported

at least every 1.5 m of its length and additionally supported at every pipe bend.

– Theairsupplylinecanbeprovidedeitherasaxedtubeorasahose.Theminimuminternal

diameter must be observed over the entire length.

– GS 40: ø76 mm (3")

– GS 80: ø101 mm (4")

– GS 120/GS 160: ø127 mm (5")

– GS 200/GS 240: ø152 mm (6")

– Allconnectionsontheairsupplylinemustbepositivelysealedwithasiliconesealanttoensure

proper sealing of the air supply line.

– Theairsupplylinemustbeinstalledwiththesuppliedairintakewallterminal(seeillustration

above and refer to section “Terminal locations”).

– Atlowtemperatures(under18°C),waterofcondensationcanformontheoutsideoftheairsup-

plyline.Topreventthis,werecommendthatairsupplylinesthataresituatedincoldroomsare

insulated.

min. 1.2 m

5.8 Installationofcontrolandmonitoringdevices

– Install the roomhumiditysensorand the safetyhumidistatat the same height as thermostats

andinalocationwherethemeasuredhumiditycorrespondstothatoftheroom.Undernocir-

cumstancesshouldthehumiditysensorsbepositionedinthevicinityoftheairowfromventila-

torunitsorairintakegrids.Donotmounthumiditysensorsonanouterwall,wheretemperature

uctuationscanaffectthecontrolbehavior.

– Installtheducthumiditysensorinapositionwherethemeasuredhumiditycorrespondstothat

oftheroomthatisbeinghumidied(usuallyintheductreturncircuit).Donotpositionhumidity

sensors in the immediate vicinity of steam distribution pipes, nor in sections of a duct subject to

airturbulence,norwithinthepathofthehumidicationprocessitself.

– Installthesafetyhumidistatintheduct,afterthesteamdistributionpipesandfarenoughaway

from these, that all the steam has been absorbed into the air (minimum distance 3 m). The safety

humidistatmustbepositionedsuchthatitonlydetectsthatthehumidityistoohighwhentheroom

humidity is in reality too high or has reached the saturation limit.

– Installtheowmonitorsuchthatreliablydetectstheexistenceofanairowandtheabsenceof

anairow.Connectitinsuchaway,thatthecircuitisclosedwhenairowispresentandopens

whenthereisnoairow.

– Beforestartingthehumidier,checkallcontrolandmonitoringdevicesforcorrectfunction.

– Calibrationofthecontrolandmonitoringdevices(On/Offandcontinuous)followingtheinstallation

isrecommended.Theaccuracyofthehumiditysensorandthesafetyhumidistatmustalwaysbe

checkedbeforecommissioningthehumidiersystem.

Terminallocations

When locating the airintake and the ue gasterminals the following requirements must be ob-

served:

– All terminal must terminate at an outside location.

– Locationofairintakeanduegasterminalmustcomplywithalllocalandnationalregulations.

– Airintakeanduegasterminalcanbeinstalledindifferentpressurezones.

– Airintakeanduegasterminalcannotbeinstalledonoppositewallsofthebuilding.

– Aminimumdistanceof1.2mmustbemaintainedbetweentheairintakeandtheuegasterminal

topreventrecirculationofuegases(seegureabove).

– Whentheuegasorairintaketerminalislocatedlessthan2.75mfromthegroundorcanbe

accessed by personnel a guard must be installed at a minimum distance of 50 mm to the terminal

to prevent personal injury.

5.9 Electrical Installation

A1 control or sensor signal Y

(signaltypesetviacontrolsoftware)

A2 control or sensor signal Z (air supply limit signal)

(signaltypesetviacontrolsoftware)

A3 Output 24 Vdc (JP4) or 5 Vdc (JP3)

B1 Safety high limit humidistat (building side)

B2 Flowcontrol(buildingside)

B3 Ventilationinterlock(buildingside)

F1 ExternalFuse(10A,slow-acting,buildingside)

220...240VACpowersupply

F2 Fuse(6A,fast-acting)24VACpowersupply

H1 Remote operating and fault indication

J1 Cable bridge (if no monitoring devices are connect ed)

JP3 Jumper(tosetoutputA3to5Vdcmax.500mA)

JP4 Jumper(tosetoutputA3to24Vdcmax.150mA)

K1 Externalsafetyloop(24Vac)

Q Externalserviceswitchorplug-typeconnector

RJ45 Communication interface (for detailed informations

refer to the separate documentation)

S1 Fulltankblowdown(24Vac)

Wiringdiagram

1 2 3 4 5 6 7 8

B1B2B3

0…10 mADC

2…20 mADC

0…20 mADC

4…20 mADC

0…10 VDC

2…10 VDC

0…5 VDC

1…5 VDC

24VAC “Hot”

24VAC “COM”

100mA

Unit ONSteamServiceError

1 2 3 4 5 6 7 8 9 10

L1NPE

220...230V/50...60Hz

L1 N PE

JP3: 5 Vdc, max. 500 mA

JP4: 24 Vdc, max.150 mA

24 Vac

CH1

CH2

+5 Vdc

FTBD

GND

J13-Feedback

JP4

JP3

J10-Modul

J1-RJ45

J2-Driver Board 1

J3 J4-Driver Board 2

PMW1

J19

Float

PMW2

PMW3

J16

Drain

J15

Fill

Driver

Board 1

Control

Board

J18

24VAC

J17

24VAC

J5-Ign4J3-A/P J7-Ign5 J9-Ign6

J2a-RS485J1-CPU Board

J14

Blower

J13-FeedbackJ10-Modul

Driver

Board 2

J2a-RS485J1-CPU Board

RJ45

Installation notes

Allworkconcerningtheelectricinstallationmustbeperformedonlybyadequatelyqualiedperson-

nel(electricianorworkmanwithequivalenttraining).Ascertainingthequalicationsisthecustomer‘s

responsibility.

Observe all local regulations concerning the electric installation.

DANGER! Danger of electric shock!

Thesteamhumidiermaybeconnectedtoelectricmainsonlyafterallinstallationworkhasbeen

completed.

CAUTION!

Theelectronicpartsinsidethehumidierareverysensitivetoelectrostaticdischarge.Toprevent

damage,appropriatemeasuresagainstelectrostaticdischarge(ESDprotection)mustbetaken

whencarryingoutinstallationwork

Primarywiring

Humidiersrequireeldwiringtoprimaryvoltageterminalblocks.Powerrequirementis220…240V/50…60Hz,

10Aslow-actingfused(“F1”)circuit,singlephase.Wiringisfedthrougha22mmholeinthebottomofthe

controlcompartment.Installationofexternalserviceswitch“Q”(allpoledisconnectingdevicewithaminimum

contact opening of 3 mm) is mandatory.

Wheninstalled,theappliancemustbeelectricallygroundedinaccordancewithlocalcodes,ifanexternal

electrical source is utilized.

Connectgroundwiretocabinetgroundclamp.

Externalwiringsizesmustbeinaccordancewithexistinglocalelectricalcodesandby-laws.

Remoteoperationandfaultindication(H1)

TheRemoteoperationandfaultindicationboardisequippedwith4relaysforremoteoperationandfault

indication.

– “On”:thisrelayclosesafterthehumidierhasbeenpoweredup

– “Steam”: this relay closes as soon as steam is produced

– “Service”: thisrelaycloseswhenthesetmaintenanceintervalhasexpired

– “Error”: thisrelaycloseswhenanerroroccurs

External safety circuit (K1)

Toguaranteethesafetyofthehumidicationsystem,monitoringtheoperationbymeansofasafetycircuit

isanabsoluterequirement.Toaccomplishthis,thepotential-freecontacts(250V/2A)ofexternalmonitoring

devices(B1:safetyhighlimithumidistat,B2:airowmonitor,B3:ventilationinterlock,etc.)areconnectedin

series to terminals 1 and 2.

Control or sensor signal

The control signal (signal Y) is connected to terminals 3 and 4. The air supply limit signal (signal Z) is con-

nectedtoterminals3and5.BydefaulttheCondairGSisconguredfora0…10VDCcontrolsignals.The

controlsignaltypecanbemodiedviathesoftware(seemenu“usersettings”,intheoperatinginstructions

fortheCondairGScontrol).ThecongurationwhethertheCondairGSiscontrolledviatheinternalorviaan

externalcontrollerisalsodoneviathesoftware.

Output A3

This output is available for custom purposes. The lines are connected to terminals 6 and 7. The output signal

typeisconguredbysettingthejumperonJP3(5Vdcmax.500mA)oronJP4(24Vdcmax.150mA).

Full tank blow down 24 VAC (S1)

Thisinputsignalcanbeusedforremotetriggeringafulltankblowdown.Ifa24VACsignalispresentformore

than60secondsthetankblowsdown.Thesignallineisconnectedtoterminals8and7.

6 Inspecting the installations (Check list)

BeforetheCondairGSisoperatedforthersttime,theresponsiblepersonnelmustinspect all

installations for correct execution (observing of local regulations)andcheckthattheunit is

correctlycongured.Alldecienciesmustbecorrectedbyspecialistactionbeforecommissioning

takesplace.

Usethefollowingchecklisttoascertainthattheinstallationswereperformedcorrectly:

– Unit installation

Is the unit in the correct place (see chapter 5.2.1)?

Is the unit correctly aligned vertically and horizontally?

 Issteamhumidierproperlysecured(unitstandxedtotheoor)?

– Steaminstallation

– Steam distribution pipe

 Steamdistributionpipecorrectlypositionedandsecured(screwstightened)?

 Aretheoutletoricesatrightanglestotheairowdirection?

– Steampipebetweensteamoutletonunitandsteamhoseadapter(mainsteampipe)

 Maximumlengthof6m?

 Minimumbendradiusof4-5xinternaldiameterofsolidsteampipe?

Is the pipe properly insulated?

Is the correct installation material used?

Is the minimum internal diameter maintained over the entire pipe length?

– Steamhosebetweensteamhoseadapterandsteamdistributor

 Maximumlengthof4m?

 Minimumbendradiusof300mm(4-5xinternaldiameterwithxedpiping)?

 Havetheinstructionsforhosepositioningbeenfollowed?

 Steamhose:nosagging(condensatepocket)?

Rigid steam lines: properly insulated? Correct installation material used? Minimum internal

diameter maintained?

 Steamhosesecurelyattachedwithclamps?

 Heatexpansionduringoperationandshorteningofthehosewithageingtakenintocon-

sideration?

– Condensate hoses

 Downslopeofatleast20%?

 Siphonsexistingandlledwithwater?

 Condensatehosescorrectlyxed?

– Water installation

– Fillingwatersupply

 Hasltervalve(accessory“Z261”)orshut-offvalveandlter5µmrespectivelybeenin-

stalled in supply line?

 Have admissible water pressure (3.0 – 8 bar) and temperature (1–30 °C) been ob-

served?

 Doessupplycapacitymatchthehumidier(s)?

Is the piping properly secured and sealed?

– Water drain

Has minimum inside diameter of drain pipe (at least 45 mm) been maintained throughout

the entire length?

 Hasdrainpipebeeninstalledwithadownslopeofatleast10%?

 Havetemperature-resistantmaterialsbeenused(upto100°C)?

 Arethehosesandpipescorrectlyattachedandsealed(hoseclampsandscrewedcon-

nections tightened)?

Is the minimum funnel height of 150 mm observed?

– Gas installation

 Istheshut-offvalvetted?

Is a sediment separator installed, if steel pipes are used?

 Isthegascircuitcorrectlysealed(leakagecheckcarriedout)?

Is the permissible gas pressure being maintained (see the table in 5.5.1)?

Have the correct sealing materials been used?

– Flue gas system

 Doestheuegassystemcomplywiththelocalregulations?

 Doesuegaspipelengthcomplywiththemaximumrecommended(see5.6.1)?

Is the minimum pipe cross-section (corresponding to the internal diameter at the unit connec-

tion) maintained over the entire length of the pipe?

 Havecondensatedischargeoutletsbeenincorporatedwherenecessaryandprovidedwitha

siphonandisthesiphonlledwithwater?

 Istheuegaspipesealedandhasthepermittedsealingmaterialbeenused?

 Haveallheat-sensitiveandeasilyammablematerialsbeenremovedfromthevicinityofthe

uegaspipe?

 Istheuegaspipeinsulatedatallthenecessarypositions?

 Istheuegasoutletterminaloutsidethebuildingcorrectlylocated?

Have the permitted sealing materials been used?

– Air supply system for room air-independent units (RS units)

 Doestheairsupplysystemcomplywiththelocalregulations?

 Doesairsupplylinelengthcomplywiththemaximumrecommended(see5.7)?

Is the minimum pipe cross-section (corresponding to the internal diameter at the unit connec-

tion) maintained over the entire length of the air supply line?

Is the air supply line correctly sealed and has the permitted sealing material been used?

Is the inlet terminal outside the building correctly located?

– Electrical installation

 Doestheelectricalinstallationcomplywiththelocalregulations?

Do the mains voltages applied correspond to the supply voltage stated on the rating plate of

the unit?

Is the voltage supply correctly fused?

 Istheserviceswitch“Q”installedinthesupplycable?

 Areallcomponentscorrectlyconnectedinaccordancewiththewiringdiagram?

 Areallconnectioncablesxed?

 Are the connecting cables free of tension (tted through cable glands/secured with cable

clamps?)

 IstheCondairGScorrectlycongured?

7 Operation

Qualicationofpersonnel

TheCondairGSmustonlybecommissionedandoperatedbypersonswhoarefamiliarwithequip-

mentandadequatelyqualiedtoundertakethiswork.Monitoringsuchqualicationisamatterfor

the customer.

InitialcommissioningmustonlybeundertakenbytheCondairservicetechnicianorbythecustomer‘s

ownspeciallytrainedpersonnel.

Safety

Donotstoreorusegasolineorotherammablevaporsandliquidsinthevicinityofthisoranyother

appliance.

Should overheating occur, or the gas fail to shut off, shut off the manual gas valve to the appliance

before shutting off the electrical supply.

Donotoperatethisapplianceifanyparthasbeenexposedtoexcesshumidity.Immediatelycalla

qualiedservicetechniciantoinspecttheapplianceandtoreplaceanypartofthecontrolsystem

andanygascontrolwhichhasbeenunderwater.

Anopenunitmustnotbeoperated.BeforeputtingtheCondairGShumidierintooperationmake

surealldoorsareclosedandlockedwiththescrew.

ForsafeoperationoftheCondairGShumidier,makesuretheambientconditionsmeettherespec-

tivespecicationsdenedinthisdocumentation.

TopreventexcesshumidicationtheoperationoftheCondairGSmustbemonitoredbyahighlimit

on/off humidistat (see chapter 5).

7.1 Importantnotesonoperation

Display and control unit

Function: CongurationoftheCondairGS.

Indication of operating parameters.

Reset of maintenance counter.

redLED“Fault”

Function: The LED ashes in case of a temporary

malfunction of the unit (Warning status). Fur-

ther operation of the unit is still possible.The

warningmessageisshowninthedisplay.

The LED lights in case of a severe malfunction

of the unit (Fault status). Further operation is

not possible any longer. The fault message

isshowninthedisplay.

 TheLEDashesalternatelywiththegreen

LEDiftheexternalsafetychain(ventilation

interlockhastriggered)isopen.Assoonas

the safety chain is closed again, the indica-

tion disappears.

yellowLED“Maintenance”

Function: The LED lights if the maintenance is due.

greenLED“Humidication”

Function: The LED lights if the unit produces steam.

   TheLEDashesalternatelywiththered

LEDiftheexternalsafetychain(ventilation

interlockhastriggered)isopen.Assoon

as the safety chain is closed again, the

indication disappears.

Drain key

Function: Manualdrainingofthewatertank.After

havingpressedthedrainkey,thedraining

is controlled via the display and control

unit.

Unit switch

Function: Switchestheunitonandoff.Theswitchis

illuminatedwhentheunitisrunning.

7.2 Functionofthedisplayandoperatingelements

BeforetheCondairGSisoperatedforthersttime,theresponsiblepersonnelmustinspect all

installations for correct executionandcheckthattheunitiscorrectlycongured(seecheck

list in chapter 6).Alldecienciesmustbecorrectedbyspecialistactionbeforecommissioningtakes

place.

Thehumidierisoperatedasfollows:

1. Examinethehumidierandallinstallationsforpossibledamage.

CAUTION!

Damagedunitsandunitswithdamagedinstallationsmustnotbeoperated!

2. Checkthecleanlinessoftheoutercabinet:

Thepanelsmaybecleanedwithadampclothandwarmsoapywater.

CAUTION!

Makesurenowaterisdrippingintothecabinetthroughtheventilationopeningsintheunit

housing.

3. Fillthewatertank:

• Closetheshut-offvalveinthegassupplyline.

• Opentheshut-offvalveinthewatersupplypipe.

• Sethumiditycontrollertomaximumhumiditydemand.

• Switch-ontheserviceswitchintheelectricalsupplycircuit.

• Switch-onthehumidierattheunitswitch.

• Thellingvalveopensandthewatertanklls(llingtime:approx.30minutesforthelargest

model,forsmallerunitsthellingtimeisshorter).Attheendofthellingcyclethecontrolunit

checksthefunctionofthewaterlevelunit.Ifthecontrolunithasveriedtheproperfunction

ofthewaterlevelunittheignitionsequencestarts.Afterthreeattemptsatignitiontheauto

ignitionswitchesoff.TheredLEDlightsandacorrespondingerrormessageisshowninthe

display.NowswitchthehumidierOff.

4. Checkignition:

Theregulatorisstillsettomaximumhumiditydemandandtheshut-offvalveinthegaslineis

closed.

• Switch-Onthehumidierattheunitswitch.

Thecombustionairblower(s)start(s).Note:Onmulti-blowerunits,waituntilallblowershave

started.

Then, 15 seconds later (pre-purging time) the igniter is activated and the gas pressure regulat-

ing valve opens. After 7 seconds the gas pressure regulating valve closes and the igniter is

de-energized (due to missing ignition).

Note: On multi-burner units, this process is successively completed for all burners.

Afterthreeignitionattemptsperburner(completewithpre-purging),thehumidiergoesinto

safetylockout.

• Opentheshut-offvalveinthegassupplypipe.

Nogasshouldowtothemainburner.Endofthetest.

• Switch-offthehumidierattheunitswitch.Note:Toresetthesafetyswitch-off,switch-offthe

humidierforatleastvesecondsandthenswitchitonagain.

• Adjustthehumiditycontrolleragaintothesethumidityvalue.

7.3 Commissioning

5. Pre-purge of the gas pressure regulating valve(s):

• Disconnectallignitorsfromtheignitionmodules.

• Switch-Onthehumidierattheunitswitch.

Thecombustionairblower(s)start(s).Note:Onmulti-blowerunits,waituntilallblowershave

started.

Then, 15 seconds later (pre-purging time) the gas pressure regulating valve opens for 7 sec-

onds, then it closes again (due to missing ignition).

Note: On multi-burner units, this process is successively completed for all burners.

Afterthreeignitionattemptsperburner(completewithpre-purging),thehumidiergoesinto

safetylockout.

Note:Toresetthesafetyswitch-off,switch-offthehumidierforatleastvesecondsandthen

switchitonagain.

Repeatthissequenceminimum2 timesinordertomake surenoairisleftinthegassy-

stem.

• Switch-offthehumidierattheunitswitch.

• Reconnectallignitorstotheignitionmodules.

6. Startthehumidier:

• Opentheshut-offvalveinthewatersupplypipe.

• Opentheshut-offvalveinthegassupplypipe.

• Switchontheexternalserviceswitch.

• SwitchthehumidierOnattheunitswitch.

The Condair GS carries out a systemandleveltest,duringwhichallthe

LEDs light up.

If a failure occurs on the system test, a corresponding error message is

showninthedisplay.

After the system test the unit is in normaloperationmode.Thedisplayshows

the standard operating display(rstpageoftheindicationlevel).

Note: The contents of the standard operating display depends on the actual

operatingstatusandonthecongurationoftheCondairGSandcandiffer

from the opposite display.

As soon as the humidity controller demands humidity, the combustion air

blower(s)start(s).Then,15secondslater(pre-purgingtime)theignition

process for the burner(s) is started. The burner(s) ignite(s) and steam is

generatedinthetankviatheheatexchanger(s).ThegreenLEDlightsand

theadjacentdisplayisshown.

If no ame is detected by the ame sensor within 7 seconds after the

ignition of a burner, the gas pressure regulation valve closes again. The

ignitionsequenceisrepeatedamaximumofthreetimesperburner.Ifno

burnercouldbeignited,thehumidiergoesintosystemlockout.The red

LED lights and an appropriate fault message appears in the display. At

the same time, the operating and remote fault alarm potential-free contact

(“Error”) closes.

Note:Thesystemlockoutisresetbyswitchingthehumidier offbriey

(5 seconds) and then on again.

If only individual burners of a multi-burner unit could not be ignited the

humidier remains operational. In the display a corresponding warning

messageappearsinthedisplayindicatingwhichburner(s)has/havefailed

to ignite.

Condair GS 240

START UP

Condair GS 240

Standby

03.03.2009 12.00.00

Condair GS 240

Demand :50%

03.03.2009 12.05.00

Note:fordetailedinformationregardingtheoperationofthecontrolunitandthecongurationset-

tings please observe the information given in the separate operating instructions to the Condair

GS control.

7.4 Notes on operation

7.4.1 Remoteoperatingandfaultindication

Viatheoperatingandfaultindicationthefollowingoperatingstatusareshownremotely:

Activatedremote

indication relay

When? Display on unit

“Error” A malfunction (fault status) is

present, further operation is not pos-

sible.

Red LED lights

A corresponding fault message is

showninthedisplay

“Service” Maintenance is due. The unit re-

mains operational for a certain time.

YellowLEDlights

Theservicewarningmessageis

showninthedisplay

“Steamdemand” Steam demand/

Steam production

Green LED lights.

The standard operating display is

shown.

“Uniton” Unitswitchedon Unitswitchlights.

The standard operating display is

shown.

7.4.2 Inspections during operation

DuringoperationtheCondairGSandthehumidicationsystemhavetobeinspectedweekly.On

thisoccasioncheckthefollowing:

• thewater,gasandsteaminstallationforanyleakage.

• thehumidierandtheothersystemcomponentsforcorrectxingandanydamage.

• theelectricinstallationforanydamage.

Iftheinspectionrevealsanyirregularities(e.g.leakage,errorindication)oranydamagedcompo-

nentstaketheCondairGSoutofoperationasdescribedinchapter7.5.Then,contactyourCondair

representative.

7.5 Taking the unit out of operation

Ifthehumidiermustbetakenoutofoperation,e.g.formaintenancework,proceedasfollows:

1. Close the shut-off valve in the gas supply pipe.

2. Closetheshut-offvalveinthewatersupplypipe.

3. Pressthedrainswitch.Thegaspressureregulationvalve/sclose/sandthetankempties.

Important!Ifdrainpumpisdefective,draintankmanuallyviatheauxiliarydrain.

4. Waituntilthewatertankempties.Nowswitchoffthehumidierattheunitswitch.

5. Isolatethehumidierfromtheelectricalpowersupply:Switchofftheexternalserviceswitchinthe

powersupplycircuitandsecuretheswitchintheOffpositiontosafeguardagainstunintentional

switch-on.

8 Maintenance

Qualicationofpersonnel

Allmaintenanceworkmustbecarriedoutonlybywellqualiedandtrainedpersonnelauthorised

by the owner.

Maintenance and repair of the electrical installation of the Cond air GS must be carried out only by

qualiedpersonnel(e.g.electrician)beingawareofpossibledangerandimplications.

Itistheowner’sresponsibilitytoverifyproperqualicationofthepersonnel.

General notes

Theinstructionsanddetailsformaintenanceworkmustbefollowedandupheld.

Onlythemaintenanceworkdescribedinthisdocumentationmaybecarriedout.

Only use original Condair spare parts to replace faulty parts.

Safety

Beforemaintenanceisinitiated,theCondairGSmustbetakenoutofoperationinaccordance

with instructions in chapter 7.5 and protected against unintentional switching on.

8.2 Maintenance instructions

To maintain operating reliability, the Condair GS mustbeservicedatregularintervals. Here, a

distinctionismadebetweentherstserviceafter500hoursofoperation(I), theminorservice

everytimethemaintenancealarmappears(II) and the annualmaintenance(III).

Important!Dependingonthehardnessofthewaterandtheaveragesteamoutput,undercertain

circumstancesitmaybenecessarytoreducetheserviceintervalfortheminormaintenancework.

If the limeresiduesdepositedontheoorofthetankexceedaheightof5cm the interval must

bereduced.Iftheheightislessthan5cmtheintervalcanbeextended.

Important: Every service action must be documented in the “Maintenance” report sheet (a copy of

this document is provided in these installation, commissioning and service instructions). Warranty

isvoidifthespeciedmaintenanceintervalsarenotobservedandthemaintenanceworkarenot

carried out according the instructions.

Thefollowingisanoverviewoftheworktobecarriedoutateachoftheservicestages.

Components Interval Workrequired

I II III

Watertank X X X Drainthetank,thenopenitandmeasuretheheightofthe

limeresiduesonthetankoor(max.5cm).Removethe

limefromthetank.

Checkallpipeconnectionstothetank(speciallythelevel

unit passages). Clean if necessary.

Water outlet pipes, including

siphon

X X X Pressthedrainswitchandcheckforfreedrainage.

Inspect all pipes for lime deposits and for correct sealing.

Cleanorreplacepipeswithlimedeposits.Reseal/replace

leakingpipes.

8.1 Importantnotesonmaintenance

Components Interval Workrequired

I II III

Water installation X X X Checkallwaterhosesintheunitforcracksandcorrect

xing,replacedefectivehoses.

Checksupplypipesforsealing,sealifnecessary.Clean

theltervalve(orwaterlter).

Checkcorrect functionoflevelunit.Clean orreplaceif

necessary.

Unit inner chamber X X X Checktheinnerchamberfordirtanddepositsandclean

if necessary.

Steam installation X X Inspectthesteamandcondensatehosesforcracksand

correctxing,replacedefectivehoses.

Electrical installation X X Checkallcablesintheunitforsecurexingandcondition

andchecktheinsulation.

Air supply pipe (RS units) X X Checkforsealing,sealifnecessary.

Checkscreeninairintaketerminal,cleanifnecessary.

Flue gas temperature sensor X X Visualcheckthatsensorisintact,wiredandattachedto

theexhaust.

Flue gas system X X Checkuegassystemforsealingandremovealltraces

ofcondensate.Checkscreeninuegasterminal,cleanif

necessary.Ifspecied,havetheuegassysteminspected

by an appropriate specialist.

Igniterandamesensor X Everyyearorevery2000hours(whichisreachedrst).

Remove and replace igniter and ame sensor (special

sparesset“Burnerpartssubjecttowear”).

Burner/combustionairblower X Remove burner and inspect the condition of burner mat.

Blowoutburnermatwithcompressedairorreplaceburnerif

necessary.Replaceallburnersealswithnewones(special

sparesset“Burnerpartssubjecttowear”).

Cleancombustionairblowerifnecessary.Theelectricmo-

torsoftheblowersareprovidedwithpermanentlubrication

and do not require maintenance.

8.3 Dismantlingworkformaintenanceandthereplacementofcomponents

Prepare water tank for cleaning

Torque: 5.7 Nm (50 in-Lb)

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Unlockandremovetheleftfrontpanel.Then,unscrewthenutsofthesidetankcoverandremove

the cover.

3. OnGS120...240only:unlockandremovethelefttoppanel.Then,unscrewthenutsofthetop

tankcoverandremovethecover.

There-assemblyofthewatertanktakesplaceinthereversesequence.Makesurethatthesealsof

thetankcoversarenotdamaged(replaceifnecessary).

Important!Tightenthenutsof the tankcover(s)witha torquewrench(torque:5.7 Nm).Donot

overtighten the nuts.

Cleaning the water tank

WARNING!

Dangerofcombustion!

Thewaterandalllimedepositsinthetankcanbeextremelyhotandmayleadtoburningoncontact.

Therefore,allowthehumidiertocoolbeforecommencingcleaningwork.

Thecombustionchamberwallsareusuallyself-cleaning.Duetotheexpansionandcontractiondur-

ingthehumidicationprocess,limedepositspeelfromthewallsandsinktotheoorofthetank.An

accumulationoflimeontheoorofthetankuptoamaximumheightof50mmispermissibleand

doesnotaffecttheoperationofthehumidier.

• Removethelimedepositsinthetankandcombustionchamberwallswithaplasticscraper.Do

notusemetalspatulasorscrapers,becausethesearelikelytoscratchtheinternalwallsofthe

tank.

• Removelimedepositsfromtheoorofthetankwithaspatulaand/orwithanindustrialwater

suctionapparatus.Rinseoutresidualaccumulationsoflimewithfreshtapwaterviatheopen

auxiliarywaterdrainconnection(Usingabucket).Neverrinseawaylimeaccumulationsdirectly

intotheconnectedwaterdrainoutlet,becausethereisadangerofthedrainpump,thedrainpipe

andthesiphonbecomingblocked.

• Removethehoseconnectionstothetankandcleantheminternally.

Gasket

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Disconnectcablestocombustionairblower,gaspressureregulatingvalveandpressureswitch

(note assign ment of the connections).

4. On RS units only:Undothehoseclampandremovetheairsupplyhosefromtheinletelbow.

Alsodisconnectthesmallairhosefromtheinletelbow.

5. Undothecouplingofthecorrespondingexiblegaspipeanddisconnectthegaspipe.

6. Undothetwoscrewsoftheventurimanifoldandliftupthemanifoldtogetherwiththegaspres-

sure re gulat ing valve.

7. Undothetwoscrewsoftheelectronicboard(ifpresent)andremoveelectronicboard.

8. Undothenutsontheoutletsideoftheblowerandremovetheblowerunit.

Reinstallationisachievedbyfollowingthereversesequence.Replacedefectivesealswithnewones.

Makesurethatallsealsareinsertedcorrectlyandallcablesareconnectedcorrectly.

DANGER!

Danger of explosion!

Followingmaintenance workonthegassystem,aleakagetestmustalwaysbeundertakenin

accordancewithchapter5.5.2.

Removalandinstallationofthecombustionairblower

Removalandinstallationoftheburner

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Removethecombustionairblower(seethesection“Removalandinstallationofthecombustion

airblower”above).

4. Disconnectthecablestotheigniterandtotheamemonitoringunitandremovethecomponents

(seethesectionon“Removalandinstallationoftheigniterandtheamesensor”).

5. Unscrewthefournutsintheburnerangeandcarefully removetheburnerunit.Makesurethat

the burner is not damaged.

Note: Grease, dirt and dust at the ceramic matting can affect the performance of the burner.

Re-installationisachievedbyfollowingthereversesequence.Renewtheangesealandreplace

igniterandamesensorifnecessary.Tightthenutsoftheburnerangewithatorquewrench(torque:

10Nm).Makesureallcablesareconnectedcorrectly.

DANGER!

Danger of explosion!

Followingmaintenance workonthegassystem,aleakagetestmustalwaysbeundertakenin

accordancewithchapter5.5.2.

Cleaningtheburnerelements

Carefullyblowouttheburnerelementmats(ceramicbrematerial)fromoutsidewithcompressed

air. Severely soiled burner elements should be replaced.

Cleaningtheblower/burnerchamberoftheunit

Carefullycleantheblowerandtheburnerchamberbyfreeinganykindofsoilingandaccumula-

tions.

CAUTION!

Wetcleaningoftheblowerandtheburnerchamberisnotpermitted!

Ceramic matting, do not touch!

Hold burner only on metal pipe

Removalandinstallationofthegaspressureregulatingvalve

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. On RS units only:Undothehoseclampandremovetheairsupplyhosefromtheinletelbow.

Alsodisconnectthesmallairhosefromtheinletelbow.

4. Disconnectelectricalwiringtothegaspressureregulatingvalveandthepressureswitch(note

the connection layout).

5. Undothecouplingofthecorrespondingexiblegaspipeanddisconnectthegaspipe.

6. Undothetwoscrewsoftheventurimanifoldandliftupthemanifoldtogetherwiththegaspres-

sure re gulat ing valve.

7. Undo the four screws and remove the gas pipe connection of the gas pressure regulating

valve.

8. Pulloffthehoseconnectedtothepressureswitch(notetheconnectionlayout).Then,undothe

threescrewsofthepressureswitchsupportandremovepressureswitchassemblyfromthegas

regulating valve.

9. Undothethreescrewsxing the gaspressureregulatingvalve to theventurimanifoldthen,

remove the gas pressure regulating valve from the venturi manifold.

Reinstallationisachievedbyfollowingthereversesequence.Replacedefectivesealswithnewones.

Makesurethatallsealsareinsertedcorrectlyandallcablesareconnectedcorrectly.

DANGER!

Danger of explosion!

Followingmaintenance workonthegassystem,aleakagetestmustalwaysbeundertakenin

accordancewithchapter5.5.2.

Removalandinstallationoftheigniterandtheamesensor

CAUTION!

Whenreplacingtheigniterandtheamesensor,useonlythesetofspares“burnerspareparts

subject to wear” available from your Condair supplier, since otherwise the humidier could be

damaged.

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Disconnectthewiringconnectiontotheigniterandtotheamesensor.

4. Unscrewthexingnutsfortheigniterandtheamesensor.Nowcarefullyremovetheigniter

andamesensor.

CAUTION!

Thesiliconcarbideigniterisbreakable.Thereforehandleitwithgreatcaretoavoiddamage.

Reinstallationisachievedbyfollowingthereversesequence.Inspectgasketsandreplaceifdefective.

Makesurethatallgasketsareinsertedcorrectlyandallcablesareconnectedcorrectly.

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

3. Pulloffthehoseconnectedtothepressureswitch(notetheconnectionlayout).

4. Removetheconnectioncabletothepressureswitch(noteassignmentbeforeremoval).

5. Unscrewthetwoxingscrewsandremovetheairpressureswitch.

Re-installationfollowsinthereversesequence.Makesurethecablesandthehoseareconnected

correctly.

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

3. Note the cable assignment, then remove all connection cables to the ignition module.

4. Unscrewthetwoxingscrewssecuringtheignitionmoduleandthenremoveignitionmodule.

Re-installationfollowsinthereversesequence.Makesuretheconnectingcablesareconnected

correctly.

Replacementoftheairpressureswitch

Replacementoftheignitionmodule

Replacingthetransformer

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

3. Remove the connection cables to the transformer, if necessary labeling the cables before removal.

4. Unscrewthetwonutsandremovehetransformer.

Re-installationiscarriedout inthereversesequence. Make surethecablesare connected cor-

rectly.

Replacingthedrainpump

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

Important!Ifdrainpumpisdefective,draintankmanuallyviatheauxiliarydrain.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Remove the connection cables to the drain pump (note assignment before removal).

4. Remove hose clamps on the drain pump connections and pull off the hoses, then remove the

drain pump.

Re-installationiscarriedoutinthereversesequence.Makesurethehosesarecorrectlysecured

withthehoseclampsandthecablesareconnectedcorrectly.

Replacingthellvalve

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Removetheconnectioncablestothellvalve(noteassignmentbeforeremoval).

4. Removehoseclampsonthellvalveconnectionsandpulloffthehoses.

5. Undothetwoscrewsxingthellvalvetothehousing,thenremovethellvalve.

Re-installationiscarriedoutinthereversesequence.Makesurethehosesarecorrectlysecured

withthehoseclampsandthecablesareconnectedcorrectly.

Replacing the water level unit

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetheleftfrontpanel.

3. Remove the connection cable to the level unit.

4. Remove hose clamps on the level unit connections and pull off the hoses.

5 Squeezebothsidesofthemountingbrackettoreleaseitfromtheslotsinthesupportbracket

behindthewaterlevelunit,thenremovethelevelunit.

Re-installationiscarriedoutinthereversesequence.Makesurethehosearecorrectlysecuredwith

the hose clamps and the cable is connected correctly.

Replacingthellingchamber

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightsidepanel.

3. Removehoseclampsonthellingchamberconnectionsandpulloffthehoses.

4 Undothetwonutssecuringthellingchambertothefaceofthetank,thenremovethelling

chamber.

Re-installationiscarriedoutinthereversesequence.Makesurethehosearecorrectlysecured

withthehoseclamps.

Removaloftheheatexchanger(seefollowingillustration)

1. Takethehumidieroutofoperation,asdescribedinchapter7.5.

2. Disconnectthegassupplypipefromtheconnectiononthehumidierandcloseoffthepipe.

3. Undothescrew(s)(phillipsscrewdriver)andremovetherightsidepanel(s).

4. On RS units only:Removethehosesfromairintakemanifoldandairinletelbows.Then,dis-

mount air supply pipe at the air supply connection.

5. Dismountuegaspipeattheuegasoutletconnection.

6. Undothescrew(s)(phillipsscrewdriver)andremovetheleftandtherighttoppanels.

7. Freeallcableconnectionstothecomponents(combustionblower,ignitionmodule,airpressure

switch,etc.)oftherespectiveheatexchanger.

Important!Notetheconnectorassignment.

8. Undothecouplingoftherespectiveexiblegaspipeandremovetheexiblegaspipe.

9. Dismounttheburnerwiththeairblowerandthegaspressureregulatingvalveoftherespective

heatexchanger.

10.Unscrewthenutsandremovetheuegasmanifoldfromtheheatexchanger.

11.Unscrewthenutsontheheatexchangerandpullouttheheatexchangerfromthetank.

Re-installationiscarriedoutinthereversesequence.Replaceallsealswithnewones.Makesure

all cables are connected correctly.

DANGER!

Danger of explosion!

Followingmaintenance workonthegassystem,aleakagetestmustalwaysbeundertakenin

accordancewithchapter5.5.2.

Theinformationandspecicationsrelatingtothecleaningagentstobeusedmustbestrictlyobserved.

In particular: Information on personal protection, environmental protection and all restrictions in the

use of cleaning agents.

The use of disinfectants is only permitted if they deposit no poisonous residues. In all cases, the

componentsthathavebeencleanedinthiswayaretoberinsedwithwater.

CAUTION!

Donotusesolventsforcleaningpurposes,noraromatizedorhalogenizedhydrocarbons

or other aggressive substances.

Followlocalenvironmentalprotectionregulationswithoutreservation.

8.4 Notes on cleaning agents

8.5 Resettingthemaintenancereminder

Aftercompletingmaintenancework,themaintenanceremindermessagemustberesetviathere-

set function in menu mode of the control (see chapter 5.6 in the separate operating instructions for

Condair GS control).

9 Troubleshooting

9.2 Error indication

Malfunctionsduringoperationareindicatedbyacorrespondingwarningmessage(operationstillpos-

sible,redLEDashes)orafaultmessage(operationnotpossibleanylonger,redLEDlights)inthe

display of the operating and control unit. Detailed information thereto can be found in the separate

operating instructions for Condair GS control.

9.1 Importantnotesontroubleshooting

Qualicationofpersonnel

Have faults eliminated by adequatelyqualiedandtrainedpersonnel only. Malfunctions caused by

theelectricalinstallationmustberepairedbyauthorizedpersonnel(e.g.electrician)only.

Safety

When eliminating faults, the Condair GS mustbetakenoutofoperation, as described in chapter

7.5, and prevented from further inadvertent operation.

Make sure the power supply to the unit is cut off (test with voltage tester) and that the stop

valves in the water and gas supply line are closed.

General note

Most operational malfunctions are not caused by faulty equipment but rather by improper installa-

tionordisregardingofplanningguidelines.Therefore,acompletefaultdiagnosisalwaysinvolvesa

thoroughexaminationoftheentiresystem.Often,thesteamhoseconnectionhasnotbeenproperly

executed,orthefaultlieswiththehumiditycontrolsystem.

9.3 Resetting the error indication

To reset the error indication:

DisconnecttheCondairGSfromthemainsforapprox.5seconds,thenreconnectagain.

Note:Ifthefaulthasnotbeeneliminated,theerrorindicationreappearsafterashortwhile.

9.4 Replacing the backup battery on the control board of the

Condair GS

1. Set the Condair GS out of operation as described in chapter 7.5.

2. Undothescrew(phillipsscrewdriver)andremovetherightfrontpanel.

CAUTION!

The electroniccomponentsinsidethehumidierarevery sensitive to electrostatic discharge.

Beforecarryingoutthenextstep,appropriatemeasuresmustbetakentoprotecttheelectronic

componentsagainstdamagecausedbyelectrostaticdischarge(ESDprotection).

3. Undothe2screws“A”ofthedisplayandcontrolunit,thencarefullyremovethedisplayandcontrol

unit to the front.

4. Undothe7fasteningscrews“B”ofthecontrolboard,thencarefullypull-offthecontrolboardfrom

the display and control unit assembly.

5. Replacethebackupbattery(CR2032,Lithium3V).

6. Reassemble the unit in reverse order.

7. If necessary set date and time (see operating instructions of the control).

WARNING!

Environmentalhazard!

The old battery must be returned to an authorised collecting point for correct disposal/

recyclinginaccordancewithlocalregulations.Innocasetheoldbatterymustbe

disposedofinthedomesticwasteorintotheenvironment.

10 Taking out of service/Disposal

10.1 Taking out of service

IftheCondairGSmustbereplacedorifthehumidicationsystemisnotneededanymore,proceed

asfollows:

1. Taketheunitoutofoperationasdescribedinchapter7.5.

2. Havetheunit(andallothersystemcomponents,ifnecessary)unmountedbyaqualiedservice

technician.

10.2 Disposal/Recycling

Componentsnotusedanymoremustnotbedisposedofinthedomesticwaste.Please

disposeoftheunitortheindividualcomponentsinaccordancewithlocalregulations

at the authorised collecting point.

If you have any questions, please contact the responsible authority or your local

Condair representative.

Thankyouforyourcontributiontoenvironmentalprotection.

11 Specications

11.1 Technical Data

Condair GS 40 80 120 160 200 240

Steamoutput

room air-dependent kg/h 10…40 10…80 10…120 10…160 10…200 10…240

room air-independent (RS units) kg/h 10…40 10…80 10…120 10…160 10…200 10…240

Energyconsumption kw 36.5 73.0 109.5 146.0 182.5 219.0

Gasous fuel Natural gas (G20, G25, G25.1, G27, GZ350) or Propane gas (G31)

Electric connections

powersupply 230V/50…60Hz/1Phase

powerconsumption W 460 690 920 1150 1380 1610

powersupplyfuse 10A,slowacting

Mechanical Connections

Fillwaterinlet Inch BSP3/4"

Drain Inch 3/4" (19 mm)

Auxiliarydrain Inch NPT 1/2"

Gas line Inch BSP1/2" BSP3/4" BSP1" BSP1" BSP11/4" BSP11/4"

Steam hose connection Inches 1 3/4" (45 mm) 3" (76 mm) 3" (76 mm) 4" (101 mm) 4" (101 mm) 4" (101 mm)

Flue pipe connection Inches 3" (76 mm) 4" (101 mm) 5" (127 mm) 5" (127 mm) 6" (152 mm) 6" (152 mm)

Humiditycontrol

Possible control signals 0…5VDC / 1…5VDC / 0…10VDC / 0…20mA / 4…20mA

Dimensions

Height cm 81 (158 unit on stand)

Width cm 114

Depth cm 53 69 109 109 149 149

Shipping weight kg 174 210 295 319 358 382

Operating weight

lled kg 211 273 459 471 610 623

empty kg 140 162 238 261 290 314

Operating conditions

Admissiblewaterpressure bar 3…8

Water quality untreateddrinkingwaterorfullydemineralizedwater

Admissible gas supply pressure mbar G20: 17…25 / G25: 20...30 / G25.1: 20...30

G27: 17.5…23 / GZ350: 10.5...16 / G31: 25...57.5

Admissible ambient temperature 5…30

Overpressureattheueoutlet

at full load

at minimum load

Type of protection IP20

Admissible duct air pressure Pa –800 ... +1700

Furtherinformations

Conformity CE

Patents Condair®internationaltrademark/internationalpatents

11.2 Fluegasspecications

Natural gas G20 Natural gas G25

full load part load full load part load

Condair GS 40

energy consumption kW 36.5 10.5 36.5 10.5

gas consumption

kg/h 2.4 0.68 3.04 0.87

/h 3.478 0.8695 4.0443 1.0111

exhausttemperature °C 180 120 180 120

exhaustmassow kg/s 0.015 0.0034 0.017 0.0058

-content % 8.9 8 8.7 8

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 76 76

Condair GS 80

energy consumption kW 73 10.5 73 10.5

gas consumption

kg/h 4.72 0.68 6.08 0.87

/h 6.956 0.8695 8.0886 1.0111

exhausttemperature °C 180 72 180 72

exhaustmassow kg/s 0.03 0.0067 0.034 0.0113

-content % 8.9 4.4 8.7 4.3

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 101 101

Condair GS 120

energy consumption kW 109.5 10.5 109.5 10.5

gas consumption

kg/h 7.08 0.68 9.12 0.87

/h 10.434 0.8695 12.133 1.0111

exhausttemperature °C 180 57 180 57

exhaustmassow kg/s 0.045 0.0099 0.051 0.0169

-content % 8.9 2.9 8.7 2.9

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 127 127

Condair GS 160

energy consumption kW 146 10.5 146 10.5

gas consumption

kg/h 9.44 0.68 12.16 0.87

/h 13.9121 0.8695 16.1773 1.0111

exhausttemperature °C 180 49 180 49

exhaustmassow kg/s 0.06 0.0131 0.068 0.0224

-content % 8.9 2.2 8.7 2.2

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 127 127

Condair GS 200

energy consumption kW 182.5 10.5 182.5 10.5

gas consumption

kg/h 11.8 0.68 15.2 0.87

/h 17.3902 0.8695 20.2216 1.0111

exhausttemperature °C 180 44 180 44

exhaustmassow kg/s 0.075 0.0164 0.085 0.0279

-content % 8.9 1.8 8.7 1.7

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 152 152

Condair GS 240

energy consumption kW 219 10.5 219 10.5

gas consumption

kg/h 14.16 0.68 18.24 0.87

/h 20.8682 0.8695 24.2659 1.0111

exhausttemperature °C 180 41 180 41

exhaustmassow kg/s 0.09 0.0196 0.102 0.0335

-content % 8.9 1.5 8.7 1.5

uegaspressure Pa 80 5 80 5

exhaustdiameter mm 152 152

WhenoperatingwithnaturalgasG25.1,G27,GZ350orpropanegas(G31),pleasecontactyourCondairsup-

plierforthecorrespondinguegasspecications

Condair GS

Maintenance record

Unit type Serial number Commissioning Software version Location Responsible Internal no.

Date Time First

Maintenance

Small

Maintenance

Annual

Maintenance

III

Working

hours

[h]

Water hardness

in d° or ppm

or mg/l CaCO

Remarks

(e.g. height of the lime residues in the water tank, replaced

parts, measures, etc.)

Signature

Side

Notes

Technical modiﬁcations reserved

Reg.No. 40002-2

Manufacturer:

Walter Meier (Climate International) Ltd.

Talstr. 35-37, P.O. Box, CH-8808 Pfäﬃkon (Switzerland)

Phone +41 55 416 61 11, Fax +41 55 416 62 62

www.waltermeier.com, international.climate@waltermeier.com

Solutions for Indoor Climate

CONSULTING, SALES AND SERVICE:

JS Humidifiers plc

Artex Avenue, Rustington,

LITTLEHAMPTON, West Sussex

BN16 3LN (United Kingdom)

Phone +44 (0)1903 850 200, Fax +44 (0)1903 850 345

www.jshumidifiers.com, sales@jshumidifiers.com

Condair GS Handleiding

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