Condair ME Control Adiabatic air humidification/air cooling system Operation Manual
Below you will find brief information for Adiabatic air humidification/air cooling system ME Control. The Condair ME Control is a system for humidifying and cooling air in AHU's or air ducts. It features a touch screen control unit, evaporative cassettes, and a hydraulic module. The system can be equipped with a variety of options, including droplet separators, evaporative module blanking, and remote operation and fault indication. The Condair ME Control is designed for use in a variety of applications, including commercial buildings, industrial plants, and data centers.
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2577874 EN 1412 READ AND SAVE THESE INSTRUCTIONS OPERATION MANUAL Adiabatic air humidification/air cooling system Condair ME Control Humidification and Evaporative Cooling Thank you for choosing Condair Installation date (MM/DD/YYYY): Commissioning date (MM/DD/YYYY): Location ref.: Model: Serial number: Manufacturer Condair Plc Artex Avenue, Rustington, Littlehampton, West Sussex. BN16 3LN (UK) TEL: +44(0)1903 850 200 FAX: +44(0)1903 850 345 www.condair.co.uk Proprietary Notice This document and the information disclosed herein are proprietary data of Condair Plc. Neither this document, nor the information contained herein shall be reproduced, used, or disclosed to others without the written authorization of Condair Plc, except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Plc does not accept any liability due to incorrect installation or operation of the equipment or due to the use of parts/components/equipment that are not authorized by Condair Plc. Copyright Notice Copyright 2014, Condair Plc All rights reserved. Technical modifications reserved Contents 1 1.1 1.2 Introduction5 General 5 Notes on the operation manual 5 2 For your safety 3 3.1 3.2 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 Product Overview Model overview Product designation / Which model do you have Construction of the system components Construction of the evaporative module Construction of the hydraulic module System overviews / Functional description Typical system Condair ME Control (internally mounted) Typical system Condair ME Control (externally mounted) 7 10 10 11 12 12 13 14 14 15 4Operation 4.1 Important notes on operation 4.2 Initial commissioning 4.3 Display and operating elements 4.4 Start up for daily operation 4.5 Notes on operation 4.5.1 Important notes on operation 4.5.2 Remote operating and fault indication 4.5.3 Recommended regular checks during operation 4.5.4 Manual draining of the water tank 4.5.5 Performing a matrix wash over 4.6 Decommissioning the system 18 18 19 21 22 23 23 23 23 24 25 26 5 5.1 5.1.1 5.1.2 5.2 5.3 5.3.1 5.3.2 5.4 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 27 27 28 29 30 31 31 31 34 34 34 36 38 39 Operating the Condair ME control software Standard operating display Operating status indication Maintenance and malfunction indications Navigating/operating the Condair ME control software Information functions Accessing support information Accessing system information Configuration Accessing the “Configuration” submenu Configuring dilution and drain cycle functions – “Features” submenu Control settings – “Control Settings” submenu Basic settings – “General” submenu Communication settings – “Communication” submenu Contents 3 5.5 5.5.1 5.5.2 5.5.2.1 5.5.2.2 5.5.2.3 5.6 5.6.1 5.6.2 4 Service functions Accessing the “Service” submenu Performing maintenance functions – “Service” submenu Input diagnostic functions – “Input Diagnostics” submenu Output diagnostic functions – “Output Diagnostics” submenu Relay diagnostic functions – “Relay Diagnostics” submenu Administration settings Accessing “Administrator” submenu Administration settings – “Administrator” submenu 40 40 40 44 47 48 49 49 49 6Maintenance 6.1 Important notes on maintenance 6.2 Maintenance intervals 6.3 Maintenance guide 6.4 Dismantling and installation of components for maintenance 6.4.1 Dismantling and installation of the evaporative module 6.5 Consumables guide 6.6 Health and safety requirements 6.7 Routine water sampling and testing 6.8 Cleaning and disinfection 6.9 Cleaning and disinfection method statement 6.10 Resetting the maintenance indication on Condair ME Control 6.11 Performing software updates 51 51 52 52 54 54 55 55 56 57 58 60 61 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 Fault elimination Fault indication on Condair ME Control control unit Malfunction list Saving fault and service histories to a USB memory stick Malfunctions without indication Notes on fault elimination Replacing the fuses and backup battery in the control unit Resetting the fault status on Condair ME Control 62 62 63 68 68 69 70 71 8 8.1 8.2 Taking out of service/Disposal Taking out of service Disposal/Recycling 72 72 72 9 9.1 Product specifications Technical data 73 73 10Appendix 10.1 Wiring diagram Condair ME Control 74 74 Contents 1 Introduction 1.1 General We thank you for having purchased the Condair ME Control Evaporative Humidifier and Cooler (Condair ME Control for short). The Condair ME Control incorporates the latest technical ad­van­ces and meets all recognized safety standards. Nevertheless, improper use of the Condair ME Control may result in danger to the user or third parties and/or impairment of material assets. To ensure a safe, proper, and economical operation of the Condair ME Control, please observe and comply with all information and safety instructions contained in the present documentation as well as in the separate documentations of the components installed in the humidification system. If you have questions after reading this documentation, please contact your Condair representative. They will be glad to assist you. 1.2 Notes on the operation manual Limitation The subject of this operation manual is the Condair ME Control Evaporative Humidifier and Cooler. The various options and accessories are only described insofar as is necessary for proper operation of the equipment. Further information on options and accessories can be obtained in the respective instructions. This operation manual is restricted to the operation, the maintenance and troubleshooting of the Condair ME Control and is meant for well trained personnel being sufficiently qualified for their respective work. Please note, some illustrations in this manual may show options and accessories which may not be supplied as standard or available in your country. Please check availability and specification details with your Condair representative. The operation manual is supplemented by various separate items of documentation (such as the installation manual), which are included in the delivery as well. Where necessary, appropriate cross-references are made to these publications in the operation manual. Introduction 5 Symbols used in this manual CAUTION! The catchword “CAUTION” used in conjunction with the caution symbol in the circle designates notes in this operation manual 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 operation manual that, if neglected, may cause injury to persons. DANGER! The catchword “DANGER” used in conjunction with the general caution symbol designates safety and danger notes in this operation manual that, if neglected, may lead to severe injury or even death of persons. Safekeeping Please safeguard this operation manual in a safe place, where it can be immediately accessed. If the equipment changes hands, the operation manual must be passed on to the new operator. If the operation manual gets mislaid, please contact your Condair representative. Language versions This operation manual is available in various languages. Please contact your Condair representative for information. 6 Introduction 2 For your safety General Every person working with the Condair ME Control must have read and understood the operation manual of the Condair ME Control before carrying out any work. Knowing and understanding the contents of the operation manual is a basic requirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the unit safely and correctly. All ideograms, signs and markings applied to the components of the Condair ME Control must be observed and kept in readable state. Qualification of personnel All work described in this operation manual may only be carried out by specialists who are well trained and adequately qualified and are authorized by the customer. For safety and warranty reasons any action beyond the scope of this manual must be carried out only by qualified personnel authorised by the manufacturer. It is assumed that all persons working with the Condair ME Control are familiar and comply with the appropriate local regulations on work safety and the prevention of accidents. The Condair ME Control may not be used by persons (including children) with reduced physical, sensory or mental abilities or persons with lacking experience and/or knowledge, unless they are supervised by a person responsible for their safety or they received instructions on how to operate the system. Children must be supervised to make sure that they do not play with the Condair ME Control. Intended use The Condair ME Control is intended exclusively for air humidification and air cooling in AHU's or air ducts within the specified operating conditions. Any other type of application, without the written consent of the manufacturer, is considered as not conforming with the intended purpose and may lead to the Condair ME Control becoming dangerous. Operation of the equipment in the intended manner requires that all the information contained in this operation manual are observed (in particular the safety instructions). For your safety 7 Danger that may arise from the Condair ME Control DANGER! Risk of electric shock! The Condair ME control unit (and the optional submerged UV system) contain live mains voltage. Live parts may be exposed when the control unit (or the terminal box of the optional submerged UV system) is open. Touching live parts may cause severe injury or danger to life. Prevention: Before carrying out any work on the Condair ME Control switch off the control unit, disconnect it from the mains via the electrical isolator and secure the electrical isolator in “Off” position against inadvertent power-up. DANGER! Health risk because of inadequate hygiene! Inadequately operated and/or poorly maintained evaporative humidification/cooling systems may endanger health. When inadequately operated and/or poorly maintained micro-organisms (including the bacterium which causes Legionnaire’s disease) may grow in the evaporative module, the water tank and the water system of the Condair ME Control and may affect the air in the AHU/air duct. Prevention: the Cond­air ME Control must strictly be operated and maintained in accordance with this manual. WARNING! Some type of evaporative material is manufactured from glass fibre. Though this material is not classified as hazardous, it is recommended that Personal Protection Equipment such as gloves, protective clothing and eye protection are used during handling to protect the user from fibres or dust. If dust is generated during handling it is recommended that respiratory protection is worn. Correct lifting and handling Lifting or handling of components must only be carried out by trained and qualified personnel. Ensure that the lifting operation has been properly planned and risk assessed, and that all equipment has been checked by a skilled and competent Health & Safety representative. It is the customer's responsibility to ensure that operators are trained in handling heavy goods and to enforce the relevant lifting regulations. 8 For your safety Preventing unsafe operation If it is suspected that safe operation is no longer possible, then the Condair ME Control should immediately be shut down and secured against accidental power-up according to chapter 4.6 – Decommissioning the system. This can be the case under the following circumstances: – if the Condair ME Control is damaged – if the Condair ME Control is contaminated – if the electrical installations are damaged – if the Condair ME Control is no longer operating correctly – if connections and/or piping are leaking All persons working with the Condair ME Control must report any alterations to the system that may affect safety to the owner without delay. Prohibited modifications to the unit No modifications must be undertaken on the Condair ME Control 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 representative. For your safety 9 3 Product Overview 3.1 Model overview As standard the Condair ME Control consist of: – Evaporative module (75%, 85 % or 95 % efficiency depending on the cassette type) – Hydraulic module (mounted internal or external to the duct) – Control unit with integrated controller with touch panel According to your order the Condair ME Control can be equipped with the following options: – Droplet separator – Evaporative module blanking – Hydraulic module cover – Remote operation and fault indication – BMS connectivity – Freeze protection stat – Leak detection – Conductivity monitoring – Submerged UV or In-Line UV – PureFlo Ag+ – Dosing pump – Electrical isolator 10 Product Overview 3.2 Product designation / Which model do you have The product designation and the most important unit data (e.g. serial number, evaporative module product, etc.) are found on the rating plate fixed on the left side of the evaporative module and on the right side of the control unit. Rating Plate Fig. 1: Position of rating plate Evaporative module product key Example: ME-1-0900-1125-F95 Product idenfication ME (media evaporator) Product version (consecutive version number): Width evaporative module in mm Height evaporative module in mm Material type and efficiency evaporative cassettes: F75= Glass fibre 75 % F85= Glass fibre 85 % F95= Glass fibre 95 % P85= Polyester 85 % P95= Polyester 95 % Product Overview 11 3.3 Construction of the system components 3.3.1 Construction of the evaporative module 7 6 8 5 4 3 2 air flow direction 1 1 2 3 4 9 Upstands Tank connector ø54 mm (2.125") Rating plate Droplet separator, mandatory for face velocity >3.5 m/s (>689 fpm) Fig. 2: Construction of the evaporative module 12 Product Overview 5 6 7 8 9 Evaporative cassettes (F75, F85, F95, P85 or P95) Distribution heads Blanking plates (option) Mounting frame for evaporative cassettes Water tank 3.3.2 Construction of the hydraulic module 8 9 10 11 12 13 7 6 5 4 3 14 15 2 1 1 2 3 4 5 6 7 8 9 Drain valve (normally open) Drain pump Stage pump 5 with push-fit connector ø15 mm (0.625") Stage pump 3 with push-fit connector ø15 mm (0.625") Stage pump 1 with push-fit connector ø15 mm (0.625") Stage pump 2 with push-fit connector ø15 mm (0.625") Stage pump 4 with push-fit connector ø15 mm (0.625") Level sensor Conductivity sensor (option) 10 Fixing bracket 11 Push-fit connector ø15 mm (0.625") pressure equalisation (only used when mounted outside of AHU) 12 Water supply push-fit connector ø15 mm (0.625") 13 Inlet valve (normally closed) 14 Drain connector ø28 mm (1.125") Note: drain connector can be turned 180° to drain through the left or the right duct wall 15 Interconnecting cable hydraulic module Fig. 3: Construction of the hydraulic module (figure shows layout for 2-stage control) Product Overview 13 3.4 System overviews / Functional description 3.4.1 Typical system Condair ME Control (internally mounted) Blanking plates Electrical isolator Control unit Evaporative module Hydraulic module (with supply valve, drain valve and stage pumps) Shut-off valve Water supply line Air flow direction Vent drain pipe Inter connecting cable hydraulic module Tank drain with trap AHU drain with trap Fig. 4: Typical system Condair ME Control (internally mounted) 14 Product Overview 3.4.2 Typical system Condair ME Control (externally mounted) Blanking plates Electrical isolator Control unit Evaporative module Water supply line Shut-off valve Inter connecting cable hydraulic module Air flow direction Pressure equalisation Hydraulic module (with supply valve, drain valve and stage pumps) AHU drain with trap Vent drain pipe Tank drain with trap Fig. 5: Typical system Condair ME Control (externally mounted) Product Overview 15 Schematic flow diagram AHU Shut-off valve with strainer Hydraulic module Inlet solenoid valve (NC) Evaporative cassettes Drain vent to duct 4 2 1 3 5 Water tank Level sensor Drain pump Stage pumps 2... max. 5) Gravity solenoid drain valve (NO) Drain trap (building side) Tundish (building side) Fig. 6: Schematic flow diagram Condair ME Control (internally mounted) AHU Hydraulic module Evaporative cassettes Pressure equalisation Shut-off valve with strainer Inlet solenoid valve (NC) 4 2 1 3 5 Water tank Level sensor Drain pump Stage pumps 2... max. 5) Drain vent to duct Gravity solenoid drain valve (NO) Drain trap (building side) Tundish (building side) Fig. 7: Schematic flow diagram Condair ME Control (externally mounted) 16 Product Overview Functional description The water tank is filled up to a preset upper level via the level-controlled inlet solenoid valve (NC). When the water level in the water tank drops below a certain limit, the level-controlled inlet solenoid valve opens until the upper limit is reached again. The Condair ME Control provides On/Off or stage control by means of the Condair ME Control control unit and the stage pumps. The Condair ME Control control unit processes analog sensor/control signals and uses them to control the stage pumps. In case of a humidification/cooling request with activated On/Off control the inlet solenoid valve (NC) opens and all stage pumps start and the water flows to the distribution header above the evaporative cassettes. In case of a humidification/cooling request with activated stage control the inlet solenoid valve (NC) opens, then one, two, three, four or all five stage pumps start (depending on the demand signal and evaporative module size) and the water flows to the distribution header above the evaporative cassettes. The distribution pipes inside the distribution header evenly supply the water to the entire surface of the evaporative cassettes where it flows down and humidifies the air flowing through the evaporative cassettes. The excess water not used for humidification flows to the water tank. To prevent accumulation of mineral residues and the formation of germs in the water tank, the tank is completely drained periodically (interval or time controlled). Additionally further hygiene functions can be activated: Operation-dependent draining of the water tank (fill cycle, conductivity, temperature or time controlled). Product Overview 17 4 Operation 4.1 Important notes on operation Qualification of personnel The Condair ME Control must be commissioned and op­erated only by personnel familiar with the system and adequately qualified for the respective tasks. It is the owner’s responsibility to verify proper qualification of the operating personnel. General notes The instructions and details regarding commissioning and operation must be followed and upheld. The initial commissioning of the Condair ME Control requires appropriately trained technical personnel. It is strongly recommended that your Condair representative commissions your system. Part of this initial commissioning process is a disinfection of the water tank, and if required the evaporative cassettes. Please read this document in full before commencing any work. Please pay attention to local regulations regarding working at heights and electrical work. Safety and hygiene DANGER! The Condair ME Control must be operated in accordance with this manual. Failure to do so could result in contamination that might cause Legionnaires’ disease, which can be fatal. WARNING! The Condair ME control unit should not be electrically isolated for periods exceeding 24 hours as automatic drain and purge cycles will be disabled. 18 Operation 4.2 Initial commissioning The initial commissioning of the Condair ME Control requires appropriately trained technical personnel. We strongly recommend that your Condair representative commissions your system. Inspections Prior to initial commissioning the complete system must be inspected for correct execution of the installations. Proceed as follows: 1. Switch off AHU. 2. Evaporative module installation: Check correct selection of evaporative module on rating plate if multiple units on site. Check that the evaporative module has been installed level in all planes with secure blanking plates to prevent air bypass. Check that there is sufficient access for cassette removal during maintenance. Ensure assembly is securely fixed, and that there is no visible damage. Check that the evaporative module is installed in a waterproof section. Check evaporative module (including tank) is free of dirt/ debris and clean as necessary. 3. Control unit installation: Check that the control unit is mounted in a convenient dry location 4. Supply water Installation: Ensure the water system in the building has been subject to a Risk Assessment. The Condair ME Control must be connected to a clean, wholesome mains water supply. It is the responsibility of the user to ensure that the water system complies with local regulations and bylaws, particularly those for the control of Legionella microbes. The use of mains water fed tanks and reservoirs is only permitted as part of a managed water treatment system. Check that the evaporative module has a feed water supply in excess of 2 bar (29 psi) connected to the supplied approved filling hose. Ensure that any hygiene options have been correctly installed. Check all joints and fittings for leaks. 5. Drain installation: Check that the drain line is made according to the corresponding instructions given in the installation manual. Ensure the drain line is connected to the main building drain and that drain pipework is trapped to a suitable level for the applicable working duct pressure. Check all joints and fittings. Ensure that the drain connection includes an air gap. 6. Distribution pipework: Check all water distribution pipework between the hydraulic module and the distribution headers are securely fitted. 7. Electrical wiring: Check all electrical connections with reference to the corresponding wiring diagram in this manual. Check that a 100...240V / 10A single phase supply is connected to the control unit. Ensure that this power supply is isolated with an electrical isolator within 1 m (39") of the control unit. 8. Optional controls: Check that appropriate controls connections have been made to the control unit. Refer to the controls wiring section of the installation manual. 9. Flush water supply and test supply water quality: Disconnect water supply pipe from connector on the hydraulic module. Fix hose to free end of supply pipe and lead hose to a drain. Carefully flush supply pipe a suitable amount of time without creating splashing or aerosols. Take a water quality sample to ensure that supply water meets the requirements specified in the water quality guide. The sample should be tested using a dip slide to indicate the total number of colony forming units per ml (cfu/ml). Generally, levels of 1x103 cfu/ml may be considered acceptable for this type of humidifier provided the species of microbes and/or fungi involved are themselves not considered to be harmful. If you are unsure of the quality of your water please consult your Condair distributor for advice. Then reconnect the water supply pipe to the supply connector on the hydraulic module. Operation 19 10.Perform pressure test: Turn on water supply and check for leaks. Ensure double check valve is installed correctly. After the system has been inspected and found correct proceed with the initial commissioning: 1. Ensure AHU is switched off. 2. Switch on electrical isolator, and then the <Humdification/Cooling On/Off> and the <Control unit On/Off> switch on the control unit. 3. Enter the activation code (see chapter 5.5.2 – Performing maintenance functions – “Service” submenu). 4. Perform a matrix wash over cycle (see chapter 5.5.2 – Performing maintenance functions – “Service” submenu). 5. Check correct water level and pump activation. 6. Check water can flow to drain correctly. 7. Allow system to flush until water is clean. 8. Simulate full demand and check components are operating correctly. 9. Test correct flow of water to distribution header. 10.Test any fitted options (see relevant option addendum manual). 11. If evaporative cassettes have become dirty or damp, follow the disinfection procedure described in sections 6.3 and 6.9 of this manual. 12.Switch on fan of AHU and test operation with fans running and validate air conditions against the design data. 13.From full saturation – time drain cycle (with fan in design condition). 14.Test control devices. 15.Correctly configure Condair ME control unit (setpoints, control settings, etc.) according to the situation on site (see chapter 5.4 – Configuration). 16.Drain tank, wipe tank clean, re-fill tank and add DISIFIN XL chemical according to tank volume. 17.If commissioning has not been completed by an approved Condair representative, it is recommended that records are kept of commissioning date and software settings. 18.Demonstrate system to customer and highlight hygiene and maintenance requirements. 19.Raise any installation concerns. 20.Issue commissioning documentation. The system is now ready for normal operation. 20 Operation 4.3 Display and operating elements r ifie mid Hu 1 Electrical isolator Note: the electrical isolator (supplied by the customer) must be installed in the mains supply line! 2 Touch screen 3 Status LED – green: Condair ME Control is humidifying/cooling – green pulsing: No demand or humidification/cooling is switched off – orange: Warning present or maintenance due – red: Fault present 4 <Humdification/Cooling On/Off> switch Note: with this switch the humidification/cooling function can be activated and deactivated. The hygiene functions (regular flushing of the water system) remain still active even with deactivated humidification/cooling function. 5 <Control unit On/Off> switch (located on the bottom of the control unit) Note: with this switch you can switch on and off the control unit. If the control unit is switched off all functions (including hygiene functions) of the Condair ME Control are deactivated. Fig. 8: Display and operating elements Condair ME DANGER! Risk of electric shock! Since mains supply to the control unit is not interrupted by switching off the <Humdification/Cooling On/Off> switch and there is still mains voltage inside the control unit even when you switch off the <Control unit On/Off> switch too, the electrical isolator must be switched off before open the control unit. Operation 21 4.4 Start up for daily operation It is assumed that initial commissioning has been carried out properly by the service technician of your Condair representative. If the Condair ME Control has been out of operation for a prolonged period of time, a complete system service has to be performed prior to the start up. The following description outlines the start up procedure for daily operation. Proceed as follows to prepare the Condair ME Control for operation: 1. Switch off AHU. 2. Examine the Condair ME Control for possible damage and faulty installation. Ensure tank is empty. DANGER! Damaged systems or systems with damaged components or faulty installations may present danger to human life or cause severe damage to material assets. Damaged systems and/or systems with damaged or faulty installation must not be operated. 3. Close doors of AHU if open, then switch on AHU if switched off. 4. Open shut-off valve in the water supply line. 5. Make sure the front panel of the control unit is mounted and fixed with the retaining screw. 6. Switch on the electrical isolator in the mains supply line (mains supply to control unit). 7. Switch <Control unit On/Off> and <Humdification/Cooling On/Off> switch on the control unit to “On”, and activate control unit via the external enable switch if necessary. Check for any fault or service message. 8. If Condair ME Control has been disconnected from the mains for more than 48 hours the message “Out of Commissioning” appears. If this is the case proceed as follows: • Switch off control unit via the <Control unit On/Off> switch. • Risk assess the system and check the need for disinfection. • Close shut-off valve in the water supply line. • Disconnect water supply line from the connector on the hydraulic module. Caution should be taken to ensure no splashing is created. • Connect hose to the open end of the water supply line and lead the hose into open tundish outside the AHU. • Open shut-off valve in the water supply line and flush water supply line an appropriate length of time. Then, close shut-off valve again, remove hose and reconnect supply line to the connector on the hydraulic module. • Switch on control unit via the <Control unit On/Off> switch. Note: After switching on the control unit the “Out of Commissioning” message appears again, however the message is reset automatically after 1 minute and the Condair ME Control continues with normal operation. The Condair ME Control is now in normal operating mode and the standard operating display is shown. Note: further information on the operation of the Condair ME control software can be found in chapter 5 – Operating the Condair ME control software. 22 Operation 4.5 Notes on operation 4.5.1 Important notes on operation – For hygiene reasons the supply valve opens in standby mode every 12 hours for approximately 20 seconds in order to flush water supply line. – If no demand is present for more than 23 hours the tank will be drained. 4.5.2 Remote operating and fault indication The relays on the remote operating and fault indication board indicate the following operating system status: 4.5.3 Activated remote indication relay When? “Error” An error is present, operation is stopped or further operation is possible for a limited period of time only. “Service” One of the maintenance counter has elapsed. The corresponding maintenance must be performed. “Running” Demand present/system is humidifying/cooling “Unit on” The humidification system is switched on and under voltage Recommended regular checks during operation During operation the Condair ME Control has to be checked periodically in accordance with the table below. Operations Checks Daily Weekly Monthly Quarterly Monitor humidity/temperature control Check for any low humidity/temperature concerns Check any alarms on BMS Visible check for: – Units switched on with no fault lights – No water leakage (air on and air off side) – No water flow to drain (water may flow to drain during drain cycle and when unit losses humidity demand) – system components for correct fixing and any damage – electric installation for any damage. All UV bulbs are active (with water level), if applicable Matrix media is saturated (relative to demand signal) Condition of tanks and air on matrix is clean Inspect and determine replacement frequency of sediment filter Add DisifinXL chemical (1 sachet per 2 m (6.6 ft) width of tank) Operation 23 Operations Checks Daily Weekly Monthly Quarterly Conductivity (reading below set point) Correct software settings Condition of tanks are clean (clean as required) Water level is correct (ensure unit Is not in drain cycle) If the checks reveal any irregularities (e.g. leakage, error indication) or any damaged components take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system. Then, have the malfunction eliminated or the damaged component replaced by a well trained specialist or a service technician from your Condair representative. 4.5.4 Manual draining of the water tank If a manual draining of the water tank is required proceed as follows: 1. Close shut-off valve in the water supply line. 2. Press on the <Drain> button in the standard operating display. 3. Press on the menu item <Drain>. The drain confirmation dialogue appears. 4. Press on the <Yes> button to start draining of the water system. A possible running humidification/ cooling process is interrupted. The progress bar in the display shows the current status of the drain process. After the tank is drained the control unit returns to the “Manual” submenu. Note: in order to stop the drain process press the <Cancel> button in the progress window. The drain process is stopped and the control unit returns to the “Manual” submenu. 24 Operation 4.5.5 Performing a matrix wash over At initial commissioning when the “Matrix Wash Over” (W49) message appears or any time new evaporative cassettes have been installed, a matrix wash over cycle has to be performed. If a matrix wash over cycle is required proceed as follows: Password: 8808 Condair ME Control is in normal operation mode. 1. Select the “Service” submenu (displays 1-3) 2. Select “Matrix Wash Over” function in the “Service” submenu. The matrix wash over confirmation dialogue appears. 3. Press on the <Yes> button to start the matrix wash over. A possible running humidification/cooling process is interrupted. The progress bar in the display shows the current status of the matrix wash over process. After the matrix wash over process is finished the control unit returns to the “Service” submenu. Note: in order to stop the matrix wash over process press the <Cancel> button in the progress window. The matrix wash over process is stopped and the control unit returns to the “Service” submenu. Operation 25 4.6 Decommissioning the system In order to decommission the Condair ME Control (e.g. to perform maintenance works, to eliminate a malfunction, etc.) perform the following steps: 1. If the system has to be switched off because of a malfunction, please note the Warning and Fault code(s) of the actual error message(s) shown in the fault history. 2. Close the shut-off valve in the water supply line. 3. Empty the water tank with the manual drain function (see chapter 4.5.4 – Manual draining of the water tank). 4. Switch off <Humdification/Cooling On/Off> and <Control unit On/Off> switch on the control unit, and if necessary deactivate control unit via the external enable switch. 5. Disconnect control unit from the mains: switch off the electrical isolator in the mains supply to the control unit and secure switch in “Off” position against accidentally being switched on, or clearly mark the switch. 6. Let the fan of the ventilation system run until the evaporative module is dry. 7. If work has to be carried out on the evaporative module or the hydraulic module mounted inside the duct, switch off the AHU and secure the system against accidentally being switched on. Important Notes! – For reasons of hygiene, we recommend that the control unit should be left powered on even if the Condair ME Control is not being used for a longer period of time. Only the <Humdification/Cooling On/Off> switch should be switched off. This keeps the hygiene functions (e.g. periodical flushing of water supply pipe) active and hence the build-up of germs is opposed. – If the Condair ME system is isolated from the mains for prolonged periods, water stagnation might occur in supply pipework and microbial contamination result, therefore the system, including any storage tanks or vessels should be drained and left dry. Before putting the system back into operation, a full risk assessment should be undertaken to ensure safe operation, with particular attention paid to water supply quality. Additionally a complete system service has to be performed prior to putting the system back to operation. 26 Operation 5 Operating the Condair ME control software 5.1 Standard operating display After switching on the control unit and the automatic system test the control unit is in normal operating mode and the standard operating display is shown. Note: the appearance of the standard operating display depends on the current operating status and the configuration of the humidity/temperature regulation of the system and can deviate from the display shown below. The standard operating display is structured as follows: Current operating status (see chapter 5.1.1 – Operating status indication) Humidity/temperature regulation information Maintenance/malfunctions indication field (see chapter 5.1.2 – Maintenance and malfunction indications) Access Help screen Drain tank Access system information Access main menu Fig. 9: Standard operating display Operating the Condair ME control software 27 5.1.1 Operating status indication The following operation status indications may appear during operation: Operating status indication Description The control is initialising. No humidity demand for more than 60 minutes the humidification system is in standby mode. The water system is flushed automatically for 300 seconds before the next humidification takes place. The Condair ME is humidifying. The Condair ME is cooling. The Condair ME holds the current water level in the tank to be ready for operation. The Condair ME is draining the tank. If the water conductivity is not decreasing after a dilution, a water refresh cycle will be carried out (refill of the full tank). Note: This message appears only, if the system is equipped with the conductivity monitoring option. The Condair ME is filling the tank. The water in the tank is being diluted to minimise limescale. After the demand has dropped to zero, the system drains a small amount of water to give space to the rest water held in the matrix. During operation the stage pumps are stopped periodically to bleed any air out of the pumps by the water flowing back from the distribution pipes. The Condair ME is ramping up the water duty to the matrix. The operation is manually switched off. The Condair ME was stopped via the external enable switch. The inlet pipework is being purged. The ME is in diagnostic mode, e.g. wash over activation through BMS. The humidification system is stopped due to a malfunction which obviates further operation. Additionally “Warning” or “Fault” is displayed in the maintenance and malfunction field. 28 Operating the Condair ME control software 5.1.2 Maintenance and malfunction indications The following maintenance and malfunction indications may appear during operation: Operating status indication Description No malfunction present. By pressing on the indication field the service menu can be accessed. The system service is due. If the system service is not performed within 30 days a fault message is triggered. The system remains operable. The external liquid container of the dosing pump is empty. The lifetime of the PureFlow Ag+ cartridge has expired and must be replaced. The lifetime of the UV bulb has expired and must be replaced. As new matrix has been installed, a matrix wash over cycle needs to be carried out. This message appears after switching on, if the control unit has been isolated from the mains supply for more than 48 hours. The humidification system is blocked for 5 minutes. Before operation the RO water supply line to the central unit must be flushed. The commissioning warning is reset automatically after 5 minutes or you can reset the warning in the “Service” submenu (see chapter 5.5.2 – Performing maintenance functions – “Service” submenu). The device specific activation code needs to be entered to get the system running. A malfunction with status “Warning” is active. Additionally the yellow LED lights. Depending on the malfunction the humidification system is either be stopped or stays operable for a certain period of time. A malfunction with status “Fault” is active. Additionally the red LED lights. Depending on the malfunction the humidification system is either be stopped or stays operable for a certain period of time. Operating the Condair ME control software 29 5.2 Navigating/operating the Condair ME control software Navigation element Action Accessing main menu Accessing system information Performing manual drain Accessing Help screen If you press on a field with a blue arrow symbol a new screen with additional information or settings appears. This symbol on the left side of the operating status field and of the maintenance/malfunctions indication field indicates, that the system is working ok. This symbol on the left side of the maintenance/malfunctions indication field indicates, that a Warning is present. Press on the field to get further information. This symbol on the left side of the operating status field and of the maintenance/malfunctions indication field indicates, that a Fault is present (additionally the LED lights red). Press on the field to get further information. Jumps back to previous screen (cancel and back) Scroll up/down Increase/decrease value Delete shown value Confirm set value or selected option 30 Operating the Condair ME control software 5.3 Information functions 5.3.1 Accessing support information In the standard operating display press the <Help> button. The screen with the support information appears. 5.3.2 Accessing system information In the standard operating display press the <About> button. The system information screen appears. Use the arrow buttons to scroll up and down within the system information screen. Operating data – Actual Stage: Actual number of currently operating stages of the system. – Max Stage: Number of maximum stages set to operate. – Max. Capacity: Maximum evaporating capacity in kg/h or lb/hr. Operating the Condair ME control software 31 Maintenance – Hours of Operation: Operating hours since initial commissioning of the system. – Next ME Service: Remaining time until next maintenance of the system must be performed. – Next UV Bulb: Remaining time until the UV bulb of the optional UV device must be replaced. – Next PureFlo: Remaining time until the cartridge of the PureFlo Ag+ option must be replaced. Evaporator Conditions The content of the “Evaporator Conditions” information section depends on the set dilution mode. Dilution mode set to “Fill Cycle”: – Dillution Fill cycle: Actual set fill cycles for periodical tank draining depending on the fill cycles. – Drain Interval: Actual set tank drain interval time. Dilution mode set to “Dilution µS Limit”: – Conductivity: Actual conductivity of the water in the tank in µS (µS/cm). – Water Temperature: Actual temperature of the water in the tank in °C or °F. – Dillution µS Limit: Actual set conductivity limit value if exceeded a dilution cycle is triggered. – Drain Interval: Actual set tank drain interval time. Dilution mode set to “Dilution H2O Temp”: – Water Temperature: Actual temperature of the water in the tank in °C or °F. – Dilution H2O Temp: Actual set temperature limit value Actual temperature of the water in the tank in °C or °F if exceeded a dilution cycle is triggered. – Drain Interval: Actual set tank drain interval time. Dilution mode set to “Dilution Interval”: – Dillution Interval: Actual set dilution interval time, for periodic dilution of the water in the tank. – Drain Interval: Actual set tank drain interval time. 32 Operating the Condair ME control software General – Humidifier Model: Designation of the humidifier model. – Software Version: Actual version of the control software. – Driver A.DB.A Version: Actual software version of the driver board. – Ext. A.DB.A 1 Version: Actual software version of the conductivity monitoring board. – Serial number: Serial number of the Condair ME Control. Operating the Condair ME control software 33 5.4 Configuration 5.4.1 Accessing the “Configuration” submenu Password: 8808 5.4.2 Configuring dilution and drain cycle functions – “Features” submenu In the “Features” submenu you set the parameters for the dilution and drain cycle functions. Dilution The process of evaporative humidification/cooling leads to a build up of dissolved solids in the water tank. To control the degree of dissolved solids in the tank, the Condair ME Control will trigger a dilution cycle according to the set fill cycles, interval time, water temperature or conductivity limit. During the Dilution Cycle the Condair ME Control will open the gravity drain solenoid valve until a certain level is reached to drain dissolved solids away and replenish the tank with fresh water. The Dilution Cycle does not interrupt normal system operation. – Mode: select the desired dilution cycle control mode. Factory setting: Options: Fill Cycle Fill Cycle (fill cycle controlled dilution cycle) Condu Limit (conductivity controlled dilution cycle) H2O Temp (temperature controlled dilution cycle) Interval (time controlled dilution cycle) Depending on the selected dilution cycle control mode additionally the parameters “Fill Cycle”, ”Condu Limit”, “H2O Temp” or “Interval” must be set. – Dilution Fill Cycle: set the desired fill cycles after which a dilution cycle is triggered. The number of fill cycles to be set depends on the water quality. Factory setting: Setting range: 34 Operating the Condair ME control software 10 1...200 (fill cycles) – Dilution Condu Limit: set the desired conductivity limit in µS/cm. A dilution cycle is triggered as soon as the conductivity of the water in the tank exceeds the set conductivity limit. Factory setting: Setting range: 600 µS 10...5000 µS – Dilution H2O Temp: set the desired water temperature in °C or °F. A dilution cycle is triggered as soon as the water temperature in the tank exceeds the set temperature. Factory setting: Setting range: 30 °C (86 °F) 0...50 °C (32... 122 °F) – Dilution Interval: set the desired interval time in minutes. A dilution cycle is triggered as soon as the interval time has elapsed. Factory setting: Setting range: 60 minutes 1...2160 minutes Drain The drain cycle function is designed to drain the water tank periodically to prevent conditions which favour the growth of bacterias in the tank (e.g. legionella). The drain cycle can be initiated at a fixed time of day or after a interval time has elapsed. If a drain cycle is triggered the stage pumps will be stopped and the tank is completely drained via the drain pump (the drain pump is stopped when a preset level is reached) and the gravity drain solenoid valve. If a demand is present the gravity drain solenoid valve is closed and the tank is refilled otherwise the tank remains empty until the next demand. – Mode: select the desired drain cycle control mode. Factory setting: Options: Interval Interval (interval time controlled drain cycle) Time (time of day controlled drain cycle) Depending on the selected drain cycle control mode additionally the parameters “Interval” or ”Time” must be set. – Drain Interval: set the desired interval time in hours. A drain cycle is triggered as soon as the set interval time has elapsed. Factory setting: Setting range: 12 hours 1...24 hours – Drain Time: set the desired time of day time (according to set time format) at which a drain cycle is triggered. Factory setting: Setting range: 12:00 am according to set time format Operating the Condair ME control software 35 5.4.3 Control settings – “Control Settings” submenu In the “Control Settings” submenu you determine the control settings for the Condair ME Control. The control settings available depend on the selected signal source and the control mode. Basic – Source: with this setting you determine whether the control signal comes from an analogue source (signal of a humidity sensor or demand signal from an external humidity controller) or via Modbus. Factory setting: Analog Options: Analog or Modbus – System Mode: with this setting you determine whether the Condair ME Control is configured as an air humidifier (“Humidifying”) or as an air cooler (“Cooling”). Factory setting: Options: Humidifying Humidifying (configured as air humidifier) Cooling (configured as air cooler) – Control Mode: with this setting you determine the type of controller used with the Condair ME Control. Factory setting: Options: Demand On/Off (external On/Off humidistat) Demand (external continuous controller) RH P (internal P controller) RH PI (internal PI controller) – Signal type Channel 1 / Signal type Channel 2: with this setting you determine the control signal type for Channel 1 (if System Mode is set to humidifying) or Channel 2 (if System Mode is set to cooling). Note: this setting appears only if signal source is set to “Analog” and Control Mode is set to “Demand”, “RH P” or “RH PI”. Factory setting: Options: 0-10 V 0-5V, 1-5V, 0-10V, 2-10V, 0-20V, 0-16V, 3.2-16V, 0-20mA, 4-20mA – Temperature Min: with this setting you determine the minimum temperature of the measuring range of the temperature sensor used. Note: this setting appears only if System Mode is set to “Cooling” and Control Mode is set to “RH P” or “RH PI”. Factory setting: Setting range: 0.0 °C (32 °F) –50.0 ... +100 °C (–58 ... 212 °F) – Temperature Max: with this setting you determine the maximum temperature of the measuring range of the temperature sensor used. Note: This setting appears only if signal source is set to “Analog” and control mode is set to “Demand”, “RH P” or “RH PI”. Factory setting: Setting range: 36 Operating the Condair ME control software 50.0 °C (122 °F) –50.0 ... +100 °C (–58 ... 212 °F) PI Control Parameters – Setpoint: with this setting you set the humidity setpoint in %rh (if System Mode is set to “Humidifying”) or the temperature setpoint in °C or °F (if System Mode is set to “Cooling”). Note: this setting appears only if the Control Mode is set to “RH P” or “RH PI”. Factory setting: Options: 40 % or 20 °C (68 °F) 0 ... 95 % or 5 ... 40 °C (41... 104 °F) – P-Band Channel 1 / P-Band Channel 2: with this setting you set the proportional range of channel 1 in %rh (if System Mode is set to humidifying) or of channel 2 in °C or °F (if System Mode is set to cooling). Note: this setting appears only if the Control Mode is set to “RH P” or “RH PI”. Factory setting: Options: 15 %rh or 10 °C (50 °F) 6 ... 65 %rh or 1.0 ... 50.0 °C (34 ... 122 °F) – Integral time Channel 1 / Integral time Channel 2: with this setting you set the integral time of channel 1 (if System Mode is set to humidifying) or channel 2 (if System Mode is set to cooling) in minutes. Note: this setting appears only if the Control Mode is set to “RH PI”. Factory setting: Options: 5 minutes 1 ... 60 minutes Stage switching – Threshold 1: With this setting you determine the set point at which the pump of stage 1 will switch on or off in % of the demand signal. Factory setting: Options: 5% 1 ... 99 % – Threshold 2: With this setting you determine the set point at which the pump of stage 2 will switch on or off in % of the demand signal. Factory setting: Options: 20 % 1 ... 99 % – Threshold 3: With this setting you determine the set point at which the pump of stage 3 will switch on or off in % of the demand signal. Factory setting: Options: 40 % 1 ... 99 % – Threshold 4: With this setting you determine the set point at which the pump of stage 4 will switch on or off in % of the demand signal. Factory setting: Options: 60 % 1 ... 99 % – Threshold 5: With this setting you determine the set point at which the pump of stage 5 will switch on or off in % of the demand signal. Factory setting: Options: 80 % 1 ... 99 % Operating the Condair ME control software 37 5.4.4 Basic settings – “General” submenu In the “General” submenu you determine the basic settings for operating the Condair ME Control control unit. Basic – Date: With this setting you determine the current date in the set format (”MM/DD/YYYY” or “DD/MM/YYYY”). Factory setting: 00/00/0000 – Time: With this setting you set the current hour of the day in the set time format (”12H” or “24H”). Factory setting: 12:00 – Language: With this setting you determine the dialogue language. Factory setting: Options: depending on the country different dialogue languages – Units: With this setting you determine the desired unit system. Factory setting: Options: depending on the country Metric or Imperial – Contrast: With this setting you determine the desired value for the display contrast. Factory setting: Options: 8 1 (weak contrast) ... 31 (strong contrast) – Brightness: With this setting you determine the desired value for the display brightness. Factory setting: Options: 52 1 (dark) ... 100 (white) Time/Date – Date Format: With this setting you determine the desired date format. Factory setting: Options: depending on the country DD/MM/YYYY or MM/DD/YYYY – Clock Format: With this setting you determine the desired time format. Factory setting: Options: 38 Operating the Condair ME control software depending on the country 24H (24 hours, display 13:35) or 12H (12 hours, display: 01:35 PM) 5.4.5 Communication settings – “Communication” submenu In the “Communication” submenu you determine the parameters for the communication. Modbus Parameters – Modbus: With this setting you can activate (“On”) or deactivate (“Off”) communication via a Modbus network. Factory setting: Off Options: Off or On The following parameters appear only if the Modbus function is activated. – Modbus Address: With this setting you determine the Modbus address for the adiabatic air humidification system Condair ME for the communication via a Modbus network. Factory setting: Setting range: 10 1 ... 247 – Parity: With this setting you set the parity bit for the data transfer. Factory setting: Options: Even None, Even or Odd – Baudrate: With this setting you set the Baudrate for the data transfer. Factory setting: Options: 9600 9600, 19200, 39400, 115200 – BMS Timeout: With this setting you set the timeout time for the data transfer. Factory setting: Setting range: 300 Seconds 0 ... 300 Seconds Remote Fault Board – Indication: With this setting you determine whether only maintenance messages (“Service”) or all Warning messages (“Warning”) are outputted via the service relay of the remote operating and fault indication board. Factory setting: Service Options: Service or Warning – Safety Chain Indication: With this setting you determine whether an Fault (“On”) or a Warning (“Off”) is triggered when the external safety chain is open. Factory setting: Off Options: Off or On Operating the Condair ME control software 39 5.5 Service functions 5.5.1 Accessing the “Service” submenu Password: 8808 5.5.2 Performing maintenance functions – “Service” submenu In the “Service” submenu you can enter the activation code, accessing and resetting the fault and maintenance history and performing different input and output diagnostic functions. General Service – Activation Code: Note: this menu item appears only if the activation code message is shown at system startup. Via the “Activation Code” function you can unlock the Cond­air ME if it is locked ex factory with an activation code. Once the activation code has been entered and confirmed the menu item is not shown anymore. After pressing on the “Activation Code” button a confirmation window appears where you have to confirm the activation. Afterwards you can enter the four-digit activation code and confirm it. Note: contact your Condair representative to get the activation code. 40 Operating the Condair ME control software – Commissioning Reset: with this function you can reset the “Out of Commissioning” message, which appears if the control unit has been disconnected from the mains for more than 48 hours. After pressing on the “Commissioning Reset” button a confirmation window appears where the resetting must be confirmed. Note: after resetting the control unit must be connected to the mains for at least 15 minutes, otherwise the “Out of Commissioning” message appears on the next startup again. – Matrix Wash Over: with this function you can wash over the evaporative cassette matrix. After pressing on the “Matrix Wash Over” button the wash over cycle is automatically started. Note: Use this function to wash over newly installed evaporative cassettes to remove any dust and glue left after the manufacture of evaporative cassette material. The wash over is mandatory for newly installed systems with glass fibre type evaporative cassettes. – UV Bulb Reset: with this function you can reset the UV Bulb replacement message after having replaced the UV bulb. This menu item appears only, if this option is installed and activated.. Note: Resetting the UV Bulb replacement message without having replaced the UV Bulb may lead to contamination of the system. – PureFlo Ag+ Reset: with this function you can reset the PureFlo Ag+ replacement message after having replaced the PureFlo Ag+ cartridge. This menu item appears only, if this option is installed and activated. Note: Resetting the PureFlo Ag+ replacement message without having replaced the PureFlo Ag+ cartridge may lead to contamination of the system. – ME Service Reset: with this function you can reset the System Service message after having performed a system service. Note: Resetting the System Service replacement message without having performed a system service may lead to contamination of the system. Disifin – Disifin: when DISIFIN XL sachet(s) are added to the tank for disinfection, the conductivity in the tank will increase. This would cause a fault on systems equipped with the optional conductivity monitoring. With the function “Disifin” you can override the conductivity monitoring for 1 hour once you have added DISIFIN XL sachet(s). Operating the Condair ME control software 41 Fault/Service History Note: the fault and maintenance events stored can be correctly analysed only if the data and the time of day are correctly set. – Fault History: with this function you can access the fault history list where the last 40 fault events are stored. After pressing on the “Fault History” button the fault history list appears. – Service History: with this function you can access the service history list where the last 40 service events are stored. After pressing on the “Service History” button the service history list appears. – Reset Fault History: with this function you can reset the fault history list. After pressing on the “Reset Fault History” button a confirmation window appears where the resetting of the fault history list must be confirmed. – Reset Service History: with this function you can reset the service history list. After pressing on the “Reset Service History” button a confirmation window appears where the resetting of the service history list must be confirmed. – Export History: with the function “Export History” you can export the fault and service history list to a USB memory stick via the USB port on the control board (see chapter 7.3 – Saving fault and service histories to a USB memory stick) 42 Operating the Condair ME control software Diagnostics – Input Diagnostics: with this function you can access the “Input Diagnostics” submenu where you can view different current input values the control system is receiving. Detailed information can be found in chapter 5.5.2.1 – Input diagnostic functions – “Input Diagnostics” submenu. – Output Diagnostics: with this function you can access the “Output Diagnostics” submenu where you can activate or deactivate different system functions for diagnostic reason. Detailed information can be found in chapter 5.5.2.2 – Output diagnostic functions – “Output Diagnostics” submenu. Note: By accessing the “Output Diagnostics” submenu the humidification system is automatically switched to standby operation. CAUTION! The operation of the “Output Diagnostics” submenu requires wide knowledge of the control software and must be operated only by authorised and trained personnel, since false operation may lead to damage of system components. – Relay Diagnostics: with the “Relay Diagnostics” function you can access the “Relay Diagnostics” submenu where you can activate or deactivate the relays of the optional remote operating and fault indication board. Detailed information on the individual relay diagnostic functions can be found in chapter 5.5.2.3 – Relay diagnostic functions – “Relay Diagnostics” submenu. Note: By accessing the “Relay Diagnostics” submenu the humidification system is automatically switched to standby operation. Operating the Condair ME control software 43 5.5.2.1 Input diagnostic functions – “Input Diagnostics” submenu The following input values can be viewed after accessing the “Input Diagnostics” submenu. Note: the input values can be accessed and viewed too, via the “Service Info” selection field in the standard operating display. Control – Humidity control: Actual demand signal in % – Temperature control: Temperature of area being controlled. – Safety Chain: Actual status of the safety chain (“Open”= Safety chain open, “Closed”= Safety chain closed) – Enable: Actual status of the external enable switch, if present (“Off”= switch open, “On”= switch closed). ME Conditions The ME Conditions section shows operating parameters of options, if installed: – Incoming Air Temperature: Actual air temperature of the incoming air in °C or °F if optional duct temperature sensor is installed. – Water Temperature: Actual temperature of the water in the tank in °C or °F if optional temperature sensor is installed. – Conductivity: Actual conductivity of the water in the tank in µS/cm if optional conductivity sensor is installed. Level Floats – Level: Actual level (1 to 6) in the tank of the evaporative module captured by the level sensor. – Dosing Pump Level Float: Actual level (“Empty”= Tank is empty or “OK”=Level in the tank is OK) in the liquid tank of the optional system for enhancing polyester media water absorbtion. 44 Operating the Condair ME control software Hygiene & Safety – 24V External Supply: Actual voltage of the external 24 V supply for devices outside the control unit, such as humidistat, safety chain, etc. – 10V External Supply: Actual voltage of the external 10 V supply for devices outside the control unit, such as humidity sensors, humidistat, etc. – 5V Peripheral Supply: Actual voltage of the peripheral 5 V supply for options fitted inside the control unit. Valve Feedback – Inlet Valve: Actual status of inlet solenoid valve (“Open” or “Closed”). – Drain Valve: Actual status of gravity drain solenoid valve (“Open” or “Closed”). – Drain Pump: Actual status of drain pump (“On” or “Off”). Pump Speed – Speed Pump 1: Actual speed of stage pump 1 in % of the maximum speed. – Speed Pump 2: Actual speed of stage pump 2 in % of the maximum speed. – Speed Pump 3: Actual speed of stage pump 3 in % of the maximum speed. – Speed Pump 4: Actual speed of stage pump 4 in % of the maximum speed. – Speed Pump 5: Actual speed of stage pump 5 in % of the maximum speed. – Speed Pump 6: Actual speed of stage pump 6 in % of the maximum speed. Note: only Condair ME XL systems have pump 6. – Speed Pump 7: Actual speed of stage pump 7 in % of the maximum speed. Note: only Condair ME XL systems may have pump 7. Operating the Condair ME control software 45 Pump Feedback – Stage Pump 1: Actual flow rate of stage pump 1 in kg/h or lb/hr. – Stage Pump 2: Actual flow rate of stage pump 2 in kg/h or lb/hr. – Stage Pump 3: Actual flow rate of stage pump 3 in kg/h or lb/hr. – Stage Pump 4: Actual flow rate of stage pump 4 in kg/h or lb/hr. – Stage Pump 5: Actual flow rate of stage pump 5 in kg/h or lb/hr. – Stage Pump 6: Actual flow rate of stage pump 6 in kg/h or lb/hr. Note: only Condair ME XL systems have pump 6. – Stage Pump 7: Actual flow rate of stage pump 7 in kg/h or lb/hr. Note: only Condair ME XL systems may have pump 7. 46 Operating the Condair ME control software 5.5.2.2 Output diagnostic functions – “Output Diagnostics” submenu CAUTION! The operation of the “Output Diagnostics” submenu requires wide knowledge of the control software and must be operated only by authorised and trained personnel, since false operation may lead to damage of system components. The following diagnostic functions are available after accessing the “Output Diagnostics” submenu. Hydraulic – Inlet Valve: with this function you can open and close the inlet solenoid valve. – Drain Valve: with this function you can open and close the gravity drain solenoid valve. – Drain Pump: with this function you can start and stop the drain pump. – Stage Pump 1: with this function you can set the speed of stage pump 1 in % of the maximum revolution speed. – Stage Pump 2: with this function you can set the speed of stage pump 2 in % of the maximum revolution speed. – Stage Pump 3: with this function you can set the speed of stage pump 3 in % of the maximum revolution speed. – Stage Pump 4: with this function you can set the speed of stage pump 4 in % of the maximum revolution speed. – Stage Pump 5: with this function you can set the speed of stage pump 5 in % of the maximum revolution speed. – Stage Pump 6: with this function you can set the speed of stage pump 6 in % of the maximum revolution speed. Note: only Condair ME XL systems have pump 6. – Stage Pump 7: with this function you can set the speed of stage pump 7 in % of the maximum revolution speed. Note: only Condair ME XL systems may have pump 7. Operating the Condair ME control software 47 Hygiene & Safety – UV Lamp: With this function you can switch on and off the optional UV Lamp. – Dosing Pump: With this function you can switch on and off the dosing pump of the optional system for enhancing polyester media water absorbtion. Control – Control Select: With this function you switch the humidity or demand control signal between voltage and current signal. – Temp. Select: With this function you switch the temperature control signal between voltage and current signal. 5.5.2.3 Relay diagnostic functions – “Relay Diagnostics” submenu The following diagnostic functions are available after accessing the “Relay Diagnostics” submenu. General – Running: with this function you can activate (“On”) and deactivate (“Off”) the relay “Running” on the remote operating and fault indication board, which indicates that the unit is humidifying/cooling. – Service: with this function you can activate (“On”) and deactivate (“Off”) the relay “Service” on the remote operating and fault indication board, which indicates that a service is due. – Fault: with this function you can activate (“On”) and deactivate (“Off”) the relay “Fault” on the remote operating and fault indication board, which indicates that a fault is present. 48 Operating the Condair ME control software 5.6 Administration settings 5.6.1 Accessing “Administrator” submenu Password: 8808 5.6.2 Administration settings – “Administrator” submenu In the “Administrator” submenu you can: – activate or deactivate password protection for main menu and setpoint adjustment access. – perform software updates via a USB memory medium connected to the USB port – reset user settings to factory defaults. Password Settings – Setpoint Password: with the function “Setpoint Password” you can protect the setpoint input screen with the user password “8808” against unauthorised access (“Yes”) or not (“No”). – Main Menu Password: with the function “Main Menu Password” you can protect the access to the main menu with the user password “8808” against unauthorised access (“Yes”) or not (“No”). Operating the Condair ME control software 49 Software Settings – Software-Update: with the function “Software Update” you can update the control software of the integrated controller (see chapter 6.11 – Performing software updates). – Ext.A.DB.A Update: with the function “Ext.A.DB.A Update” you can update the driver board software (see chapter 6.11 – Performing software updates). – Ext.A.DB.A.1 Update: with the function “Ext.A.DB.A.1 Update” you can update the control board software (see chapter 6.11 – Performing software updates). – Restore Factory Defaults: with the function “Restore Factory Defaults” you can reset all user settings to factory defaults. 50 Operating the Condair ME control software 6 Maintenance 6.1 Important notes on maintenance Qualification of personnel All maintenance work must be carried out only by well qualified and trained personnel authorised by the owner. It is the owner’s responsibility to verify proper qualification of the personnel. General notes The instructions and details for maintenance work must be followed and upheld. Only carry out the maintenance work described in this documentation. The Condair ME Control must be maintained in the prescribed intervals, the cleaning work must be carried out correctly. Only use original spare parts from your Condair representative to replace defective parts or parts which have elapsed their lifetime. Safety and hygiene Some maintenance work requires removal of the unit cover. Please note the following: DANGER! Danger of electric hazard! Before carrying out any maintenance work take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system and secure the system against inadvertent power-up. In addition take AHU out of operation as described in the operations instructions of the AHU and secure the AHU against inadvertent power-up. CAUTION! The electronic components inside the control unit are very sensitive to electrostatic discharge. Prevention: Before carrying out any maintenance work to the electrical or electronic equipment of the control unit, appropriate measures must be taken to protect the respective components against damage caused by electrostatic discharge (ESD protection). DANGER! Health risk by inadequate maintenance! Inadequately operated and/or poorly maintained adiabatic humidification/cooling systems may endanger health. When inadequately operated and/or poorly maintained, micro-organisms (including the bacterium which causes Legionnaire’s disease) may grow in the water system and in the area of the humidification unit and may affect the air in the AHU/air duct. Prevention: the adiabatic air humidification /air cooling system Cond­air ME must be correctly operated as described in chapter 4 – Operation, and must be correctly maintained and cleaned in the prescribed intervals as described in chapter 6 – Maintenance. Maintenance 51 6.2 Maintenance intervals In order to maintain operational safety and hygienic demands the Condair ME Control must be serviced at regular intervals. The time interval for the complete system service is to be adapted to the operating conditions. The hygiene status depends mainly on the quality of the humidifier water but also on the adherence to the exchange intervals of the upstream air filter, the air velocity and the micro-biological and chemical composition of the supply air. Therefore the service intervals must be determined for each system separately. The interval time for a complete system service is to be determined at commissioning. The default is 2000 hours of operation. Depending on the encountered hygiene status when performing a complete system service the interval time must be decreased or increased. In any case the Condair ME Control system should receive a complete service at least once annually. Note: We recommend to perform a minor service between two complete system service. The interval time for complete system service can be programmed on the control unit. To determine the interval time for a complete system service the above described procedure can be used. As soon as the maintenance time has elapsed, a maintenance message is displayed to draw your attention to the pending service. 6.3 Maintenance guide The Condair ME unit will form part or your hot and cold water system and as such require you to undertake certain duties with regards to local regulations and bylaws concerning the control of Legionella microbes in water systems. Your water sampling / testing and disinfection regime must be based on results of a site specific risk assessment. If any further assistance is required or you are interested in a planned maintenance quote, please contact your Condair distributor. Note: routine water sampling and testing is not included as part of a Condair service contract. Please note that the information given in the table below is only to act as a guide which shows the work to be carried out on “Minor Service” and “Complete System Service”. Correct maintenance is vital to ensure optimum output, reliability and safety. Operations Minor Service Complete System Service Yes Yes Check Ag element of PureFlo Ag+ (if applicable) Yes Yes Replace Ag element of PureFlo Ag+ (if applicable) ––– Yes Check water inlet solenoid valve Yes Yes Clean water inlet solenoid valve ––– Yes Replace inlet flow restrictor ––– Yes Check all hoses and connectors Yes Yes Clean inlet valve strainer ––– Yes Replace inlet water filter if applicable 52 Maintenance Operations Minor Service Complete System Service ––– Yes Check distribution headers Yes Yes Clean distribution headers ––– Yes Clean pumps ––– Yes Clean front section of tank Yes Yes Clean internal of hydraulic module (use soft cloth only) Yes Yes Check operation of level float and conductivity sensor (if applic­able) Yes Yes Clean level float and conductivity sensor ––– Yes Check droplet separator (if applicable) and evaporator cassettes in suitable condition Yes Yes Lightly brush evaporator cassettes if necessary, replace if heavily soiled ––– Yes Remove evaporator cassettes and clean all sections of tank and frame structure ––– Yes Check and secure frame structure and seal ––– Yes Run unit and check for correct water level Yes Yes Check all media for full saturation Yes Yes Check drain pump operation and correct flow Yes Yes Check operation of all distribution pumps Yes Yes Measure flow rates to distribution headers ––– Yes Check water temperature and conductivity is within calibration Yes Yes Check and secure all electrical connections Yes Yes Check overall installation for leaks and damage Yes Yes Check software settings Yes Yes Check operation of submerged UV lamps Yes Yes Replace UV kits ––– Yes Check any options as per relevant documentation Yes Yes Complete disinfection as described in this manual Yes Yes Check safety interlock and humidity/temperature control devices ––– Yes Check air velocity at face of evaporative cassettes matrix ––– Yes Reset all appropriate maintenance counters Yes Yes Update service log book Yes Yes Add DISIFIN XL disinfection sachet(s) to tank Yes Yes Replace all feed hose Maintenance 53 6.4 Dismantling and installation of components for maintenance 6.4.1 Dismantling and installation of the evaporative module 1. Take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system and allow to drain and dry. 2. Switch the AHU off, and isolate the power and water supply to the AHU. 3. Disconnect distribution hoses from the connectors on the distribution heads, the wall feed-throughs (if applicable) and the hydraulic module. 4. Remove droplet separator boxes (column by column): • Remove upper separator brackets. • Remove bank of separator boxes. • Remove lower separator brackets. 5. Remove evaporative cassettes (column by column): • Push box upwards and remove. 6. Remove distribution headers assemblies from topmost evaporative cassettes: • Remove plastic rivets fixing the distribution header assembly to the evaporative cassette. • Carefully lift off the distribution header assembly. 7. Remove optional UV lamp (if applicable). 8. Remove the cross bar (remember position). Clean dismantled components, water tank, frame structure, blanking plates and air duct as described in chapter 6.3 – Maintenance guide. If all components have been cleaned and dried, assemble the evaporative module in the reverse dismantling order. Replace any defective components with new ones. 54 Maintenance 6.5 Consumables guide Common consumables Description Standard Frequency (month) DISIFIN XL 1 Disinfection chemical (sourced locally) 6 Descaling chemical (sourced locally) as required Inlet flow restrictor 24 Distribution header feed hose 24 Evaporative matrix cassette – Wholesome mains water – RO water 36 - 60 60 - 84 + Option consumables Description Standard Frequency (month) PureFlo Ag+ sediment filter 6 PureFlo Ag+ antimicrobial filter 12 UV bulb kit 12 Contact your Condair distributor for consumables list/order codes. To help us ensure that the correct spares parts are sent, please confirm your unit serial and model number with your order. 6.6 Health and safety requirements In accordance with local regulations, users must take water samples for Legionella analysis. Samples should be taken from the same places as described in chapter 6.7 – Routine water sampling and testing, and the analysis carried out by an accredited laboratory which is part of an appropriately certified Legionella testing scheme. In the event that the Legionella content exceeds 102 cfu/l, the humidifier should be switched off and specialist advice sought regarding its disinfection. 1. If biofilm (a slimy or gel-like deposit when wet, which might be dry and crisp in a dry system) is found during any inspection of the humidifier or water system, the humidifier MUST be switched off and not put back into operation until the system has been taken apart, scrubbed and thoroughly cleaned with a suitable biocide with biofilm penetrating qualities such as 50 ppm chlorine dioxide solution. This work should only be carried out by fully trained specialist organisations or individuals. 2. The control unit of the Condair ME Control must be left powered on to allow automatic flushing and cleaning cycles to occur. If the control unit Condair ME Control is powered off for prolonged periods, water stagnation might occur and contamination result, so the system, including any storage tanks or vessels should be drained and left dry. Before putting the system back into service, the water pipework supplying the Condair ME Control should be purged carefully, avoiding the creation of aerosols by splashing, and a water sample should be taken to ensure cleanliness. In the event that the humidifier pipework contains any residual water or has remained damp, and the temperature exceeded 20 °C (68°F), the Condair ME Control should be disinfected using an appropriate solution. Contact your Condair representative for advice on water sampling and analysis, disinfection of systems, service and maintenance. Maintenance 55 6.7 Routine water sampling and testing Hygiene Your attention is drawn to local regulations and bylaws regarding the control of Legionellosis in water systems. If inadequately maintained, water systems, of which any humidifier is a part, can support the growth of micro-organisms, including the bacterium that causes Legionnaires’ disease. Condair Plc has considered all aspects of this equipment to reduce as far as possible the risk of Legionnaires’ disease and other similar conditions, but it is important that users are aware of their responsibilities under local regulations in reducing the risk of Legionellosis. To prevent the growth of Legionella, users are required to: 1. Carry out a risk assessment of the water system using a competent person, and implement an appropriate monitoring and control regime. 2. Avoid water temperatures which favour the growth of Legionella. 3. Avoid water stagnation. 4. Clean and disinfect the system in accordance with local regulations and bylaws, and the instructions in this manual. 5. The Condair ME Control system must be connected to a clean, wholesome mains water supply and it is recommended that the supply water is chlorinated. It is the responsibility of the user to ensure that the water system complies with local regulations and bylaws, particularly those for the control of Legionella microbes. The use of mains water fed tanks and reservoirs is only permitted as part of a managed water treatment system. On commissioning and at regular intervals thereafter, test for possible water contamination using dipslides. Take samples from the water supply, the evaporative cassettes and from the tank. Check for biofilm. The dipslides should be incubated for 2 days at 30°C (86°F). 1. If the microbial count from the tank exceeds 103 cfu/ml, the system should be turned off, any biofilm scrubbed clean and then disinfected using a 50 ppm chlorine solution for one hour before being put back into use. 2. If the microbial count in the water supply to the evaporative module exceeds 103 cfu/ml, this suggests contamination of the water system within the building. The system should be turned off and you should seek specialist advice on cleaning your water supply. 3. If the water temperature anywhere in the system regularly exceeds 20°C, (68°F) increase the frequency of water sampling. The frequency may be reduced if successive tests show a consistent level below 103 cfu/ml. 56 Maintenance 6.8 Cleaning and disinfection Before commencing cleaning and disinfection: At initial commissioning we recommend the use of DISIFIN XL disinfection chemical. 1 sachet per 2 m (6.6 ft) width of tank should be placed in the tank, allowed to dissolve and circulated around the system. DISIFIN XL is 100% biodegradable, non-toxic and environmentally friendly and may be left to dissolve and naturally flush away from the Condair ME Control after commissioning. Note: If your system is equipped with the optional conductivity monitoring the conductivity measuring must be deactivated via “Disifin” function in the service menu (see chapter 5.5.2 – Performing maintenance functions – “Service” submenu). Otherwise you may get a conductivity fault message, since DISIFIN XL disinfection chemical increase the conductivity in the tank. For systems in operation or where the water quality or air quality is poor, it is recommended to dismantle and scrub the system clean, to carry out a disinfection with a minimum of 50ppm chlorine or an appropriate disinfection solution circulated for 1 hour minimum or appropriate time. Please refer to the cleaning and disinfection and method statement section to ensure that the relevant chemicals, equipment and Personal Protective Equipment are available to carry out disinfection. 1. Risk assess the situation. This should include but is not limited to observance of local regulations and the use of PPE, working from heights and ensuring a full understanding of the Condair ME Control. 2. Coordinate with relevant responsible persons. 3. Check records (i.e sample results of microbiological control) for system history. 4. If possible, disinfection should be carried out when the building is unoccupied, with air flow off. Evaporative humidifiers must be regularly cleaned and maintained, to prevent contamination especially in industrial environments. All surfaces requiring disinfection or cleaning must be in contact with the appropriate concentration of disinfection solution for the correct contact period. The method statement for disinfection may need to be adapted depending on the layout of the humidifier pipework. Additional procedures will be required for supply water system pipework or water treatment systems prior to the humidifier. Condair Plc recommends that routine disinfection should take place in the following situations: • At initial commissioning (for brand new systems use DISIFIN XL disinfection chemical). • At six monthly intervals as part of the maintenance regime. • If the system or part of it has been shutdown and/or substantially altered creating a risk of contamination. • During or following any increase of bacterial activity (as per recommendations in chapter 6.7 – Routine water sampling and testing) or outbreak or suspected outbreak of Legionellosis. Maintenance 57 Recommended disinfection equipment – Disinfection solution in accordance with manufacturers guidelines. – Disinfection neutraliser (only if necessary). – Disinfection solution test kit (to measure strength). – Bucket of fresh water. – Cleaning equipment. – Mixing vessel / Measuring container. – Risk assessment / test record sheets. Appropriate report/record – Standard tools – Appropriate PPE – COSHH risk assessment / MSDS 6.9 Cleaning and disinfection method statement Step 1 - Refer to the risk assessment • Refer to the Manufacturers instructions and safety advice. • Ensure the area is well ventilated. • Ensure the Condair ME system is OFF and isolated from external controls. • If the unit is already in operation there is low risks, check for correct operation before cleaning and dismantling. Note: if there are concerns over condition of unit, drain unit, flush water supply, and disinfect tank before starting cleaning work. • Drain system, dismantle unit and scrub tank fully. For complete disinfection remove droplet separator banks (if applicable) and the evaporative cassettes to allow a full clean (refer to maintenance section). • Consider appropriate maintenance requirements at this time including parts replacement i.e. replacing distribution hoses to ensure that these are also disinfected. • Re-assemble the Condair ME system (refer to installation manual). Step 2 - Mix disinfection solution • Mix disinfection solution following the manufacturers instructions. Recommended 50ppm Chlorine solution circulated for 1 hour minimum or appropriate time. NB: For larger or particularly unclean systems this process may need to be repeated. • Calculate the total water volume of the system using wet and dry weight values (see rating plate). • Note: Solution loses strength over time and the solution may need to be increased through the process or the disinfection process may need to be repeated. Step 3 - Run the unit • *Note the various control settings in case it is necessary to override them. • Disable drain cycles or activate conductivity drain cycles to ensure solution will not be drained unnecessary. • Switch the control unit to the on and allow the tank to refill. • Place the unit into a RUN condition (*control settings may need to be overridden, refer to the configuration section of this manual). • Check for correct operation and evaporative cassettes are full saturated. 58 Maintenance Step 4 - Add disinfection solution • Add the solution to the water sump tray and allow to flow through the evaporative cassettes. • Measure the strength of the disinfection solution and check it is the correct strength in accordance with manufacturers guidelines. • Note the strengths of the disinfection solution at 15 minute intervals and record on a record appropriately. • Adjust solution strength as required. Step 5 - Circulate disinfection solution • Check all surfaces are wetted for desired time and correct solution. Step 6 - Neutralise the disinfection solution – if required based on chemical used WARNING! If a neutralising solution is required, always ensure that the neutralising solution is used in accordance with the manufacturer’s guidance. Failure to follow the manufacturer’s guidance with regard to neutralising the disinfection chemical may present a risk to health. • • • Mix neutralising agent as manufacturers instructions. Allow the neutralising agent to disperse over the matrix and circulate in the sump tray. Drain and measure the strength as per MSDS until the disinfection solution is down to desired strength. Step 7 - Drain the unit into foul drain • Turn Off any fill cycle. • Drain unit until empty into appropriate drain (depending on Risk Assessment) and rinse the tank if necessary. • Fill and drain unit including flushing over the evaporative cassettes and test to ensure that the chemical is removed to the appropriate level. • Wipe tank clean. • *Where required, reset to original setting and put unit back into operation. Test for correct operation as per commissioning section of the manufacturers manual. • Check for and complete maintenance requirements as per manufacturers instructions. • Add DISIFIN XL chemical to the tank. • Always leave work area clean, dry and tidy. Step 8 - Re-start the Condair ME system • Refer to the commissioning section of this manual. If in doubt always contact your Condair distributor. Maintenance 59 6.10 Resetting the maintenance indication on Condair ME Control After completing maintenance work, the maintenance indication or the maintenance counter, respectively must be reset. Proceed as follows to reset the maintenance counter: 1. Select in the “Service” submenu the function “System Service Reset” Password: 8808 2. The reset dialogue appears in the display: 60 • If the maintenance work has been completed, press the <Yes> button to reset the maintenance counter or the maintenance indication, respectively. The maintenance counter and the maintenance indication are reset and the control unit is restarted. • if the maintenance work has not been completed, press the <No> button and you want abort the reset procedure. The control unit returns to the “Service” submenu. Maintenance 6.11 Performing software updates To perform a software update of the control software of the Condair ME Control or one of its electronic boards, proceed as follows: 1. Switch off the voltage supply to the control unit via the electrical isolator and secure switch in the off position to prevent it from inadvertent power up. 2. Unlock the front door of the control unit and remove it. 3. Open control unit inner door. 4. Connect USB memory stick (max. length 75 mm/3") holding the update software to the USB port of the control board. 5. Close control unit inner door. 6. Relocate the front door of the control unit and lock it with the screw. 7. Switch on power supply to the control unit via the electrical isolator. 8. Select in the “Administrator” submenu the desired software update function (e.g. “Control Software Update”). Then, follow the instructions in the display of the control unit. 9. The update dialogue appears in the display: • Press the <Yes> button to start the update. • Press the <No> button to abort the update procedure. 10.During update a progress bar is shown in the display. If the update has completed the control unit returns to the standard operating display. 11. Repeat steps 1 to 6 to remove USB memory stick. Maintenance 61 7 Fault elimination 7.1 Fault indication on Condair ME Control control unit Malfunctions during operation detected by the control software are indicated by a corresponding Warning message (operation still possible) or Fault message (operation not longer possible) in the operating status field in the standard display of the control unit: Warning Temporary problems (e.g. water supply interrupted for a short time) or malfunctions which cannot cause damage to the system are indicated with a warning message. If the cause of the malfunction disappears of its own accord within a certain period of time, the alarm message will automatically switch off otherwise an fault message is triggered. Note: If warning indication has been switched off in the configuration menu, malfunctions with warning character will not be indicated by the optional remote operating and fault indication. Fault Malfunctions where further operation is not possible any longer or malfunctions which can damage the system are indicated with a fault message, additionally the red LED below the touch panel light up. If such a malfunction occurs the operation of the system is limited only or the system will be switched off automatically. By pressing on the maintenance and malfunction indication field in the standard operating display the error list shown with all active warning and fault messages. By pressing on the corresponding Warning or Fault entry additional information regarding the malfunction are displayed (see display on the far-right). 62 Fault elimination 7.2 Malfunction list Important! Most operational malfunctions are not caused by faulty equipment but rather by improper installation or disregarding of planning guidelines. Therefore, a complete fault diagnosis always involves a thorough examination of the entire system. Often, the installation of the evaporative module has not been properly executed, or the fault lies with the humidity/temperature control system. Code Message Warning Fault ––– E18 ––– W20 E19 E20 Possible causes Air Temp Snsr Freeze Prot Safety Chain Note: depending on the configuration either Warning or Fault is indicated W21 ––– Information High Water Remedy Condair ME Control stopped operation as the incoming temperature signal of the optional anti freeze protection has failed. Note: If – at any time – the temperature signal reading is correct again, the system will continue with normal operation. Sensor wiring broken or sensor defective Check wiring, replace sensor if necessary Sensor not connected Correctly connect sensor to driver board The ME stopped operating as the temperature of the incoming air fell below the preset limit of the optional anti freeze protection. Note: If – at any time – the air temperature of the incoming air rises above the limit value again, the system will continue with normal operation. Temperature too low for safe operation of the Condair ME Control No remedy Temperature limit set wrong Contact your Condair representative. The Condair ME Control stopped operating as an external device opened the safety chain. E.g. ventilation Interlock, safety humidistat, etc.. Note: If – at any time – the safety chain is closed again, the system will continue with normal operation. Ventilation interlock open. If applicable, check/turn on ventilation system. Air flow monitor triggered. Check ventilator/filter of the ventilation system. Safety humidistat triggered. Wait. If applicable, check safety humidistat Water overflow detected. Current operation status not affected. Note: If – at any time – the normal operating water level is reached, the system will continue with normal operation. Inlet solenoid valve blocked in open position or defective. Check/replace inlet solenoid valve. Gravity drain solenoid valve blocked in closed position. Check/replace gravity drain solenoid valve. Drain piping/drain trap clogged. Check/Clean drain piping and drain trap. Backpressure in drain trap. Check drain trap venting to duct. Assisted drain function not activated. Contact your Condair representative. Fault elimination 63 Code Message Warning Fault W22 E22 ___ W28 E23 E28 Information Possible causes Water Inlet Pump Error ME Service Water supply blocked: shut-off valve closed/clogged, water pressure too low. Check water supply (filter, pipes, etc.), Check/open shut-off valve, Check water pressure. Water pressure too low. Check water supply system. Water treatment unit (fully demineralised water) is regenerating. Wait. Inlet solenoid valve blocked or defective. Check/replace Inlet solenoid valve. Gravity drain solenoid valve open, blocked in open position or not electrically connected (currentless open). Check, electrically connect or replace gravity drain solenoid valve. Leakage in the water drain system. Check/seal water drain system. Control was not able to activate one or more stage pumps. Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Stage fault detection option not correctly installed. Contact your Condair representative. Electrical pump connection broken. Electrically connect or replace respective pump. Pump defective. Replace defective pump. A warning is triggered if system service interval has exceeded. If the system service is not performed and the system service counter is not reset within 30 days a fault message is triggered. Note: Condair ME Control continuous with normal operation. System service is due. W29 E29 UV Service ––– 64 Fault elimination E31 No UV lamp UV lamp OC Perform system service and reset system service maintenance counter. A warning is triggered if UV service interval (replacement of UV bulb) has exceeded. If the UV bulb is not replaced and the UV service counter is not reset within 30 days a fault message is triggered. Note: Condair ME Control continuous with normal operation. Lifetime of UV bulb(s) (option) expired. E30 Remedy Tank (re)fill timeout. The Condair ME Control stopped operation as the tank could not be (re)filled within a preset time. The Condair ME Control periodically tries to fill the tank. Note: If – at any time – the required water level is reached, the system will continue with normal operation. Replace UV bulb(s) and reset UV service counter. The Condair ME Control indicates fault as no UV lamp has been detected. Depending on the configuration of the “Shut Down” function (factory level) the Condair ME Control stops or continuous operation. The fault message must be reset after elimination of malfunction. UV bulb defective Replace UV bulb. Reset UV service counter, if all bulbs are replaced. UV bulb not wired or wiring broken. Check wiring/Reconnect UV bulb. Current consumption of UV lamp too high. Depending on the configuration of the “Shut Down” function (factory level) the Condair ME Control stops or continuous operation. The fault message must be reset after elimination of malfunction. UV bulb broken. Replace UV bulb. Reset UV service counter, if all bulbs are replaced. Short circuit on UV option. Check wiring. Code Message Warning Fault ––– E32 ––– ––– ––– ––– ––– W49 E44 E45 E46 E47 E48 ––– Information Possible causes Demand Snsr Water Temp Water Condu Water Outlet Level Sensor Water Temp Snsr Matrix Wash Over Remedy Demand signal failed, Condair ME Control automatically stopped operation. Note: If – at any time – the reading of the demand signal is correct again, the system will continue with normal operation. Sensor not connected. Correctly connect sensor. Incorrect sensor configuration. Correctly configure sensor. Sensor defective. Replace Sensor. Water supply temperature is too high, Condair ME Control changed to “Fill Cycle” mode dilution. The fault message must be reset after elimination of malfunction. Standing Water in inlet system. Check water supply system. Insufficient thermal insulation of inlet pipework. Insulate supply water pipe. Water temperature limit set too low. Check/adjust water temperature limit. Temperature sensor of conductivity sensor configured incorrectly. Contact your Condair representative. Water supply conductivity is too high, Condair ME Control changed to “Fill Cycle” mode dilution. The fault message must be reset after elimination of malfunction. Water treatment defective/needs service. Check/service water treatment system. Conductivity limit set too low. Check/adjust Conductivity limit. Conductivity sensor configured incorrectly. Contact your Condair representative. Conductivity sensor defective. Replace conductivity sensor. Tank drain timeout. The Condair ME Control stopped operation as the tank could not be drained within a preset time. Note: If – at any time – the drain level is reached again, the system will continue with normal operation. Drain pump blocked/defective. Check/replace drain pump. Drain piping or drain trap clogged. Check/clean drain piping and drain trap. Level sensor stucked or short circuited. Check/replace level sensor. Backpressure in drain pipe. Check drain pipe venting. Water level sensor signal failed. The Condair ME Control stopped operation. Note: If – at any time – the reading of the level sensor is correct again, the system will continue with normal operation. Level sensor not connected. Correctly connect level sensor. Level sensor defective. Replace level sensor. Water temperature sensor signal failed, Condair ME Control changed to “Fill Cycle” mode dilution. The fault message must be reset after elimination of malfunction. Water temperature sensor not connected. Correctly connect water temperature sensor. Incorrect water temperature sensor configuration. Correctly configure water temperature sensor. Water temperature sensor defective. Replace water temperature sensor. After installation of new evaporative cassettes a wash over procedure needs to be carried out. The wash over is mandatory for evaporative cassettes with glass fibre as evaporator media. Condair ME Control is commissioned first time. Evaporative cassettes matrix must be washed over with the Matrix wash over function in service submenu. Fault elimination 65 Code Message Warning Fault ––– E50 Information Possible causes Out of Commissioning Condair ME Control not energised for more than 48 hours. ––– ––– E51 E54 Dosing Level Standing WTR E55 Ag+ Service Liquid used up during normal operation. Refill liquid. Incorrect floater connection. Check/correctly connect floater. Floater defective. Replace floater sensor. Standing water outside the tank detected. The Condair ME Control stopped operating as a leak of the tank or pipework has been detected. Check system and seal any leaky components. PureFlo Ag+ silver ion cartridge replacement interval exceeded, current operation status not affected. Lifespan of PureFlo Ag+ silver ion cartridge exceeded. Replace PureFlo Ag+ silver ion cartridge. PureFlo Ag+ silver ion cartridge replacement interval counter not reset after replacement of cartridge. Reset PureFlo Ag+ silver ion cartridge replacement interval counter. ––– E57 Activation Activation code not yet entered. Normal operation not possible. ––– E70 Water Condu Snsr Water conductivity sensor signal failed, Condair ME Control changed to “Fill Cycle” mode dilution. The fault message must be reset after elimination of malfunction. Activation code not yet entered. ––– ––– E74 E82 Keep Alive Driver Missing ––– E83 Slave Address Enter activation code. Water conductivity sensor not connected. Correctly connect water conductivity sensor. Incorrect water conductivity sensor configuration. Contact your Condair representative. Water conductivity sensor defective. Replace water conductivity sensor. Faulty communication, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Driver board not connected. Correctly connect driver board. Wrong driver board connected. Connect correct driver board. Driver board defective. Replace driver board. Communication with driver board failed, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. RS485 Bus to driver board interrupted. Contact your Condair representative. Slave address changed during operation, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Wrong driver address. Check that each driver board connected to one controller has a different address. ––– E84 Driver faulty Unspecific driver board fault, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. ––– E85 Driver ID Wrong Driver board ID wrong, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Driver board defective. Wrong driver board connected or SAB address wrong. 66 Disconnect water supply pipe and flush supply pipe. Reconnect water supply pipe and manually flush the entire water system. Level in the liquid tank of the optional system for enhancing polyester media water absorbtion too low. Current operation status not affected. Water leakage on evaporative module or water piping inside the duct. ––– Remedy The water held in the supply pipework needs to be fully drained. Any contact with the Condair ME Control has to be avoided. Fault elimination Replace driver board. Contact your Condair representative. Code Message Warning Fault ––– E86 ––– ––– E87 E88 Information Possible causes Driver Incompatible Local 24V Supply Local 5V Supply Remedy Version of driver board doesn't match, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Fuses on driver board defective. Check fuses on driver board and replace. Short circuit in control panel. Check control panel. Switched power supply unit defective. Check/replace switched power supply unit. Local 24V supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Fuses on driver board defective. Check fuses on driver board and replace. Short circuit in control panel. Check control panel. Switched power supply unit defective. Check/replace switched power supply unit. Local 5V supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Fuses on driver board defective. Check fuses on driver board and replace. Short circuit in control panel. Check control panel. Switched power supply unit defective. Check/replace switched power supply unit. ––– E89 Local Ref Supply Local reference supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. ––– E96 Peri. 5V Supply Peripheral 5V supply out of valid range, Condair ME Control automatically stopped operation. The fault message must be reset after elimination of malfunction. Driver Board defective. ––– E100 E103 to E109 E110 E111 IO Inlet IO Stage x (e.g. IO Stage 1) IO Drain IO Drain Pump Replace driver board. Fuses on driver board defective. Check fuses on driver board and replace. Short circuit in control panel. Check control panel. Switched power supply unit defective. Check/replace switched power supply unit. The smart output driver detected short circuit or open load on the output of the inlet valve. Inlet valve defective. Replace inlet valve. Distribution board defective. Replace distribution board. Inlet valve not connected. Correctly connect inlet valve The smart output driver detected short circuit or open load on the output of the corresponding stage pump. Corresponding stage pump defective. Replace corresponding stage pump. Distribution board defective. Replace distribution board. Corresponding stage pump not connect­ ed. Correctly connect corresponding stage pump. The smart output driver detected short circuit or open load on the output of the drain valve. Drain valve defective. Replace corresponding drain valve. Distribution board defective. Replace distribution board. Drain valve not connected. Correctly connect drain valve. The smart output driver detected short circuit or open load on the output of the drain pump. Drain pump defective. Replace drain pump. Distribution board defective. Replace distribution board. Drain pump not connected. Correctly connect drain pump. Fault elimination 67 7.3 Saving fault and service histories to a USB memory stick The fault and service histories of the Condair ME Control can be saved to a USB memory stick for journaling and further analysis. To save the fault and service histories to a USB memory stick, proceed as follows: 1. Disconnect power supply to control unit by switching off electrical isolator in the mains supply line. Secure electrical isolator against inadvertent power-up. 2. Unlock retaining screw of front cover of control unit, then remove front cover. 3. Open control unit inner door. 4. Connect USB memory stick (max. length 75 mm/3") to the USB port of the control board. 5. Close control unit inner door. 6. Relocate front cover on control unit and lock it with the retaining screw. 7. Switch on power supply to control unit. 8. Select “Export History” function in the “Service” submenu. The data are saved as excel spreadsheet on the USB memory stick. 9. When the data have been saved repeat steps 1 to 5 to remove USB memory stick. 7.4 Malfunctions without indication Malfunction Cause Remedy Residual water in the section of the duct downstream of the evaporative module. Face velocity is too high. Systems without droplet separator max 3.5 m/s (689 fpm), systems with a droplet separator max. 4.5 m/s (886 fpm). Install droplet separator or reduce air velocity in the duct. Water tank, water piping or hydraulic Check/seal water tank, water piping module is leaking. and hydraulic module. Water flow to media too high. Check duty and software is correct. Evaporative cassettes have become Check set up, replace evaporative blocked with minerals. cassettes, perform system service. Humidity/cooling demand present however the Condair ME Control does not humidify. 68 Fault elimination Uneven or non laminar air flow. Check design conditions of AHU. Install perforated plate on the air supply side. Air on temperature is too low. Check design conditions of AHU. and increase temperature. Shut-off valve in the water supply Open shut-off valve. line closed. Site control are not correct. Prove controls and control module. Malfunction Cause Maximum humidification/cooling Insufficient water supply capacity. capacity is not reached. Remedy Check water supply, increase water pressure. Evaporative cassettes have become Check set up, replace evaporative blocked with minerals. cassettes, perform system service. 7.5 Notes on fault elimination – For the elimination of faults set the Cond­air ME out of operation as described in chapter 4.6 – Decommissioning the system, disconnect control unit from the mains and close shut-off valve in the water supply line. DANGER! Make sure the control unit is separated from the mains (check with voltage detector) and the shutoff valve in the water supply line is closed. – The elimination of faults must be carried out by qualified and well trained professionals only. Malfunctions relating to the electrical installation (e.g. replacement of the backup battery, replacement of fuses) must be repaired by authorized personnel (e.g. licensed electrician). or by your Condair representative’s service technician only. CAUTION! Electronic components are very sensitive to electrostatic discharge. When carrying out repairs to the control unit, appropriate measures (ESD-protection) must be taken to prevent damage to electronic components. – Repair work and the replacement of faulty components must be carried out by your Condair representative’s service technician only! Fault elimination 69 7.6 Replacing the fuses and backup battery in the control unit The fuses of the control unit must be replaced by authorized personnel only (e.g. electrician). Replace fuses of the control unit only with fuses matching the specifications below with the appropriate nominal current capacity . Never use refurbished fuses. Do not bridge the fuse holder. To replace the fuses or the backup battery proceed as follows: 1. Disconnect control unit from the mains by switching off the electrical isolator and secure electrical isolator in “Off” position against inadvertent switching on. 2. Undo the screw of the front cover of the control unit, then remove the front cover. 3. Open control unit inner door. 4. Replace desired fuse or the backup battery. DANGER! Fuse contact protection must be relocated after the fuse has been replaced. 5. Close control unit inner door. 6. Relocate front cover on control unit and lock it with the retaining screw. 7. Reconnect control to the mains by switching on the electrical isolator. Contact protection F2= 630 mA, slow acting Backup battery 3V (CR 2032) F1= 6,3 A, slow acting Contact protection 70 Fault elimination 7.7 Resetting the fault status on Condair ME Control To reset the error indication: 1. Disconnect the control unit of the Cond­air ME Control from the mains. 2. Wait approx. 5 seconds, then reconnect the control unit to the mains. Note: If the fault has not been eliminated, the fault indication reappears after a short while. Fault elimination 71 8 Taking out of service/Disposal 8.1 Taking out of service If the Condair ME Control must be replaced or if the humidification system is not needed any more, proceed as follows: 1. Take the Condair ME Control out of operation as described in chapter 4.6 – Decommissioning the system. 2. Have the system components unmounted by a qualified service technician. 8.2 Disposal/Recycling Components not used any more must not be disposed of in the domestic waste. Please dispose of 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. 72 Taking out of service/Disposal 9 Product specifications 9.1 Technical data Condair ME Control Supply voltage control unit Supply voltage circulation pumps Power consumption 1) Control signals Control accuracy Max. admissible matric face velocity Water supply Water drain (outside diameter) Admissible water supply pressure Admissible water temperature Water quality 100...240 VAC/50...60 Hz 24 Vdc/50...60 Hz < 278 W (5 stages, no options fitted) 0...5 VDC 1...5 VDC 0..10 VDC 2...10 VDC 0...16 VDC 3.2...16 VDC 0..20 mA 4..20 mA On/Off (via volt-free contact) Control accuracy depends on air conditions, control distance, water quality and on the number of On/Off cycles 3.5 m/s (689 fpm) 4.5 m/s (886 fpm) with droplet separator ø15mm (0.625") compression fitting ø 54 mm (2.125") - Tank / ø 28 mm (1.125") - Hydraulic module 2...5 bar (29...72.5 psi) 5...20 °C (41...68 °F) Tap water, softened or fully demineralised water with a max. of 100 cfu/ml Admissible operating air temperature 10...60 °C (50...140 °F) Admissible ambient temperature (Control unit) 1...40 °C (33.8...104 °F) Admissible ambient humidity (Control unit) Degree of protection of Control unit Degree of protection of Hydraulic module Conformity Fire classification of evaporative media 1) max. 75 %rh IP21 IP42 CE marking glass fibre media: A2-S2,-D0 (UL Class 1) polyester media: DIN EN 53438 Class F1 Power consumption depending on the number of vertical evaporative cassettes banks and the options fitted Product specifications 73 A1 A2 B1 B2 B3 B4 B5 B6 B7 B8 B9 BAT UV L N F4 SUPPLY PE L N 100...240 V/1~/50..60 Hz U.V. Q X5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J1 CS D.LVL D.PUMP F1 F2 F3 F4 H1 K2 PMC-24V100W1AA X4 T2 PMC-24V100W1AA T3 J3 JP4 JP5 JP/TR K1 K2 LS1 LS2 M1 NF J2 PMC-24V100W1AA J2 J3 min. °C B9 B5 24/10 V TMP HUM GND 24V E Enable J1 GND 24V IC D– D+ GND D– D+ GND 24V E 24V E GND GND B8 B7 Y Cable bridge demand signal (for commisioning only) Cable bridge if no safety chain is connected Jumper fitted= 24 V on X16 (JP5 removed) Jumper fitted= = 10 V on X16 (JP4 removed) Jumper fitted on the last driver board External safety chain Cable harness from hydraulic module Leakage monitoring board (option) Sensor leakage monitoring (option) Dosing pump (option) Mains filter B1 B2 B3 K1 X1 SF X2 Current sensor (UV lamp) Terminal level switch dosing liquid tank Terminal dosing pump Fuse mains supply (1 A slow acting) Fuse 10/24 VDC supply(630 mA slow acting) Internal fuse mains supply (6.3 A fast acting) External fuse mains supply (10 A slow acting) Remote operating and fault indication board (option) Cable bridge if no external On/Off switch is connected T1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Driver board Control board Ventilation interlock Max. humidity monitor Air flow monitor Temperature and conductivity measuring Sensor temperature and conductivity measuring Level sensor dosing pump (option) Demand or humidity/temperature signal External On/Off switch (external enable) Air temperature monitoring duct (option) Backup battery (CR2032, 3V) B6 M1 M D.PUMP D.LVL F3 A A B B X3 X4 X19 S1 B4 F2 (630 mAT) X12 X11 UV U.V. X4 T1..T3 Q S1 S3 SD SUPPLY SF 3V Ethernet RJ45 24V+ GND – + GND – + GND – + GND J14 J12 J10 J6 RS485 Electrical isolator Humidification On/Off switch On/Off switch control unit Memory card Terminal mains supply voltage Snap feritte (wrap cable 3 times through ferrite) 24V power supply (T3 for systems with 4 or 5 stages only ) UV lamp (option) Terminal UV lamp Terminal cable harness hydraulic module LS2 CR2032 LS1 USB BAT SD J2 Wiring diagram Condair ME Control L N N L1 S3 X20 X10 A2 10.1 L N N L1 H1 X9 PE N/GND L/24V P F1 (1 AT) GND 24V P X8 A1 Appendix 1 2 N L GND LEVEL/T PS3 PS2 PS1 24V P L PE N Y3 Y4 Y11 24V P NF CS GND GND GND 24V 1 24V 2 24V 3 X7 Service Running Unit On Control unit Cnd bn Cnd wh Tmp bk Tmp bu Shield SC1 SC2 GND PS4 PS5 24V P 5V P Y2 Y1 Y10 Y9 Y8 Y7 Y6 Y5 JP5: 10V JP4: 24V SHIELD AIRT– AIRT+ 24V P ERR FQ N FQ1 N FQ2 GND FQ+ GND 24V P 24V P 24V SCA 24V SCB 24V E LVL DP 24V E CS1 24V E LEAK 24V E GND X13 X14 JP/TR X15.1 X15.2 X16 PE PE PMP N PMP L PE UV– UV+ PE DOSP– DOSP+ Error Appendix 1 2 3 4 5 6 7 8 9 10 74 10 CONSULTING, SALES AND SERVICE: Condair Plc Artex Avenue, Rustington, Littlehampton, West Sussex. BN16 3LN (UK) TEL: +44(0)1903 850 200 FAX: +44(0)1903 850 345 www.condair.co.uk
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Key Features
- Touch screen control unit
- Evaporative cassettes
- Hydraulic module
- Droplet separators
- Remote operation and fault indication
- Stage control
- Hygiene functions
- Conductivity monitoring
- UV disinfection system
- Dosing pump