Condair GS condensing gas-fired humidifier operating manual

Condair GS condensing gas-fired humidifier operating manual
2583700_A_EN_1606
OPERATION AND
MAINTENANCE MANUAL
Gas-fired Steam Humidifier
Condair GS
Humidification and Evaporative Cooling
Thank you for choosing Condair
Installation date (DD/MM/YYYY):
Commissioning date (DD/MM/YYYY):
Site:
Model:
Serial number:
Manufacturer
Condair Ltd.
Talstrasse 35-37, CH-8808 Pfäffikon
Tel. +41 55 416 61 11, Fax +41 55 416 62 62
info@condair.com, www.condair.com
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Ltd. Neither this document, nor
the information contained herein shall be reproduced, used, or disclosed to others without the written authorization
of Condair Ltd., except to the extent required for installation, operation or maintenance of the customer's equipment.
Liability Notice
Condair Ltd. does not accept any liability due to incorrect installation, maintenance or operation of the equipment,
or due to the use of parts/components/equipment that are not authorized by Condair Ltd.
Copyright Notice
Copyright 2016, Condair Ltd, All rights reserved.
Loctite® is a registered mark of the Henkel Corporation.
Technical modification rights reserved.
Contents
1Introduction
1.1
Before You Start!
1.2
General
1
1
1
2
For Your Safety
3
3
3.1
3.2
Product Overview
General Description
Functional Description
6
6
8
4Commissioning
4.1
General
4.2
Commissioning
10
10
10
5
5.1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.7.1
5.2.7.2
5.2.7.3
5.3
5.3.1
5.3.2
11
11
12
12
13
14
15
15
16
20
21
35
40
41
41
42
Operator Interface
Controls
Control Software
Home Screen
General Navigational Elements
Operating Status
Maintenance and Fault Status
Help
System Information
Main Menu
Configuration Menu
Service Menu
Administrator Menu
Software Configuration
Configuring the Control Software
Configuring for Multi-Unit Operation
6Operation
6.1
General
6.2
Operating Procedures
6.2.1
Filling the System
6.2.2
Ignition Safety Shutoff Test
6.2.3
Starting the Humidifier
6.2.4
Remote Monitoring
6.2.5
Inspections During Operation
6.2.6
Manually Initiate Tank Draining
6.2.7
Full Tank Blowdown
6.2.8
Shutting Down
6.2.9
Restarting After Shutdown
Condair GS
43
43
43
43
43
44
45
45
46
46
47
47
2583700_A_EN_1606
Contents
iii
7Maintenance
7.1
General
7.2
Mandatory Maintenance Schedule
7.3
Management of Scale and Chloride Levels
7.3.1
Adjusting Blowdown Settings
7.4
Maintenance Procedures
7.4.1
Removal and Installation of Access Panels
7.4.2
Cleaning the Tank
7.4.3
Cleaning the Secondary Heat-exchanger
7.4.4
Cleaning the Float Chamber
7.4.5
Cleaning Hoses, Dual Fill Valves and Drain Pump
7.4.6
Cleaning the Burner Assembly
7.4.7
Replacing Backup Battery
7.4.8
Resetting Service Reminder
7.5
Installing Software Updates
49
49
50
51
52
53
53
55
57
58
59
61
62
63
64
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
Fault Isolation
General
Fault Indication
General Troubleshooting
Condair GS Warning and Fault List
Resetting Fault Status
Driver Board Layout
Integrated Control Board Layout
65
65
65
66
68
77
78
78
9
Wiring Diagrams
79
10Decommissioning
10.1
General
10.2
Removal from Service for Disposal or Long-term Storage
10.3
Disposal/Recycling
82
82
83
83
11
11.1
11.2
11.3
84
84
84
85
Product Specifications
Performance Data
Operating Data
Size and Weight
AAppendix
A.1
Torque Values
iv
Contents
i
i
2583700_A_EN_1606
Condair GS
1
Introduction
1.1
Before You Start!
Thank you for purchasing the Condair GS humidifier.
The Condair GS humidifier incorporates the latest technical advances and meets all recognized safety
standards. Never-the-less, improper use of the Condair GS humidifier may result in danger to the user
or third parties, and/or damage to property.
To ensure safe, proper and economical operation of the Condair GS humidifier, observe and comply with
all information and safety instructions contained in this manual, as well as all relevant documentation of
components of the installed humidification system. Comply with all local and regional regulations dealing
with gas, combustion air, flue gases, water, steam and electrical systems.
If you have additional questions, contact your Condair representative. They will be glad to assist you.
1.2
General
Limitations
The subject of this manual is the Condair GS humidifier. The various options and accessories may only
be described in-so-far as is necessary for proper installation and operation of the equipment. Additional
information on available options and accessories can be obtained in the instructions that are supplied
with them.
This manual is restricted to the operation and maintenance of the Condair GS humidifier, and is intended
for well trained personnel who are suitably qualified for their respective tasks.
Symbols Used in This Manual
CAUTION!
The catchword "CAUTION" in conjunction with the general caution symbol is used to provide safety
instructions that, if neglected, may cause damage and/or malfunction of the unit or damage to
property.
WARNING!
The catchword "WARNING" in conjunction with the general warning symbol is used to provide
safety instructions that, if neglected, may cause injury to personnel. Other specific warning symbols
may also be used in place of the general symbol.
DANGER!
The catchword "DANGER" in conjunction with the general danger symbol is used to provide safety
instructions that, if neglected, may cause severe injury to personnel or even death. Other specific
danger symbols may also be used in place of the general symbol.
Condair GS
2583700_A_EN_1606
Introduction
1
Other Related Publications
This Operation and Maintenance Manual is supplemented by other publications such as the Installation
Manual, Spare Parts List, etc., which are included in the delivery of the equipment. Where necessary,
appropriate cross-references to these publications have been added in this manual.
Storage of Manual
Keep this manual in a place where it is safe and readily accessible. If the equipment is moved to another
location, make sure that the manual is passed on to the new user.
If the manual is lost or misplaced, contact your Condair representative for a replacement copy.
Language Versions
This manual is also available in other languages. Contact your Condair representative.
2
Introduction
2583700_A_EN_1606
Condair GS
2
For Your Safety
General
Every person who is tasked with the operation and maintenance of the Condair GS humidifier must read
and understand this manual before performing any work. Knowing and understanding the contents of
the Installation Manual, and the Operation and Maintenance Manual is a basic requirement for protecting personnel against any kind of danger, preventing faulty operation, and operating the unit safely and
correctly.
All labels, signs and markings applied to the Condair GS humidifier must be observed and kept in a
readable state.
Personnel Qualifications
All procedures described in this manual must only be performed by personnel who are adequately qualified, well trained and are authorized by the customer.
For safety and warranty reasons, any activity beyond the scope of this manual must only be performed
by qualified personnel authorized by Condair.
All personnel working with the Condair GS humidifier must be familiar with, and comply with the appropriate regulations on workplace safety and prevention of accidents.
Intended Use
The Condair GS humidifier is intended exclusively for air humidification using a Condair-approved steam
distributor within specified operating conditions (refer to "Operating Data" on page 84 for details). Any other
type of application, without the express written consent of Condair, is considered to be NOT conforming
to its intended purpose, and may lead to dangerous operation and will void the warranty.
In order to operate the equipment in the intended manner all information contained in this manual, in
particular the safety instructions, must be observed closely.
Safety Precautions that Must be Observed
DANGER!
Risk of electric shock!
The Condair GS humidifier is mains powered. Live parts may be exposed when the access
panels are removed. Touching live parts may cause severe injury or even death.
Prevention: Before performing any work inside the Condair GS humidifier shut down the humidifier
properly and secure it against accidental power-up as described in "Shutting Down" on page 47.
Condair GS
2583700_A_EN_1606
For Your Safety
3
DANGER!
Risk of fire or explosion!
The Condair GS is a gas-fired humidifier. Improper installation, adjustment, alteration, service, maintenance or use can cause carbon monoxide poisoning, explosion, fire or other
hazards that can cause serious injury, death or property damage.
If over-heating occurs or if the gas fails to shut off: Shut off the gas supply at the manual gas
shutoff valve before shutting off the electrical power supply.
DO NOT use this appliance if any part has been under water. Call a qualified service technician immediately to inspect and replace any part of the control system or gas control that has been
under water.
Any work on the gas system must only be performed by a qualified installer, service agency or
your local gas supplier. Use only factory-authorized and listed kits or accessories when installing or
modifying this appliance.
DO NOT store or use gasoline or other flammable vapours and liquids in the vicinity of the humidifier or any other appliance.
What to do if You Smell Gas:
DO NOT try to light any appliance.
DO NOT touch any electrical switch.
DO NOT use any phone in the building.
Leave the building immediately.
Call your gas supplier immediately from a location far away from the building with the gas leak.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
WARNING!
Risk of severe burns from contact with hot steam vapours!
The Condair GS humidifier produces hot steam vapours for humidification. Bare skin in contact with
hot steam vapours can result in severe burns.
Prevention: Never perform any work on the steam system (including the steam lines, steam distributors, etc.) while the humidifier is operating. Shut down the Condair GS steam humidifier, as
described in "Shutting Down" on page 47 before fixing any leaks in the steam system.
WARNING!
Risk of severe burns from contact with hot surfaces!
The water tank, steam line and exhaust system in the Condair GS humidifier get very hot during
operation. Bare skin in contact with hot surfaces can result in severe burns.
Prevention: Shut down the Condair GS steam humidifier as described in "Shutting Down" on page 47
and wait for the components to cool down before performing any work on the unit.
CAUTION!
Electrostatic discharge (ESD)!
The electronic components inside the control cabinet in the humidifier are sensitive to electrostatic discharge (ESD).
Prevention: Take appropriate measures to protect the electronic components inside the unit against
damage caused by electrostatic discharge (ESD). Refer to IEC 61340.
4
For Your Safety
2583700_A_EN_1606
Condair GS
Preventing Unsafe Operation
If it is suspected that the Condair GS steam humidifier cannot be operated safely for any of the reasons
listed below, shut it down immediately as described in "Shutting Down" on page 47 and secure it against
accidental power-up.
•
Humidifier is damaged
•
Electrical connections are loose or damaged
•
Humidifier is not operating properly
•
Leaks in the steam system or gas supply
All personnel working with the Condair GS humidifier must immediately report to the customer any
alternations to the humidifier that may affect safety.
Modifications to the Unit Prohibited
Modifications are NOT permitted on the Condair GS humidifier without the express written consent
of Condair.
Always use original Condair replacement parts and accessories available through your Condair
representative.
The location of the various safety labels on the Condair GS humidifier is shown in Figure 1.
5
1
2
3
4
Figure 1: Safety Labels
1
2
3
Condair GS
Label, gas safety warning
Label, keep cabinet closed warning
Label, installation guidelines
4
5
2583700_A_EN_1606
Label, general safety warning
Label, specification
For Your Safety
5
3
Product Overview
3.1
General Description
The Condair GS humidifier provides clean steam humidification at an economical operating cost. It is
available in condensing high-efficiency (CS) and standard-efficiency models, in capacities ranging from
23 kg/h to 260 kg/h. It is designed for humidification through the ducts in an air handling unit using a
steam distributor.
The Condair GS humidifier has an integrated control board which not only controls the humidifier, but also
allows the humidifier to be connected to a building automation system (BACnet, Lonworks, Modbus) or the
internet so it can be controlled and monitored remotely. In addition, up to four humidifiers can be set up
in a "Main-Extension" configuration using Condair's Linkup system to satisfy large humidification needs.
The Condair GS humidifier comes in two different housing styles – compact and full-size. The compact
units are available in capacities of 23 kg/h and 45 kg/h. The full-size units range in capacities from
65 kg/h to 260 kg/h.
Figure 2 shows the various Condair GS series humidifier models.
1
3
2
5
4
Figure 2: Condair GS Series Humidifier Models
1
2
3
4
5
GS 23/45 (compact housing)
GS 65 (full-size housing)
GS 90/130 (full-size housing)
GS 195 (full-size housing)
GS 260 (full-size housing)
Table 1 lists the summary of major components in each Condair GS model. Refer to Figure 3 on page 7.
Table 1: Condair GS Components by Model
Component
GS 23/45
GS 65
GS 90/130
GS 195
GS 260
Primary heat-exchanger
1
1
2
3
4
Secondary heat-exchanger
1*
1*
2*
3*
4*
Water tank
1
1
1
1
1
Burner
1
2
2
3
4
Blower
1
2
2
3
4
Gas valve
1
2
2
3
4
Ignition control module
1
2
2
3
4
Spark-igniter and flame sensor
1
1
2
3
4
Fill box
1
1
1
2
2
Dual fill valve
1
1
1
2
2
*
6
Quantity
Secondary heat-exchanger on CS model only.
Product Overview
2583700_A_EN_1606
Condair GS
28
29 30
1
2
31
3
32
4
5
6
33
20
27
7
19
8
18
26
25
17
24
16
23
15
9
10
14
22
13
21
A
12
11
-AFigure 3: Condair GS Humidifier Components (GS 65 shown)
Note: Door, side and top panels removed for clarity.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Condair GS
Vent, exhaust
Hose, dual fill valve to fill box
Inlet, gas
Label, specification
Micro-pump (CS model only)
Inlet, dual fill valve
Switch, over-temperature
Heat-exchanger, secondary (CS model only)
Port, drain
Port, condensate (CS model only)
Trap, condensate trap (CS model only)
Valve, manual drain
Panel, front
Hose, fill box to drain pump
Hose, fill box to water tank
Hose, float chamber to water tank
Fill box and float chamber
2583700_A_EN_1606
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Switch, On/Off
Display, touchscreen
Hose, fill box overflow
Pump, drain
Cover, water tank
Tank, water
Spark-igniter and flame sensor
Combustion chamber and primary heat-exchanger
Module, ignition control
Assembly, blower
Inlet, air intake
Outlet, steam
Valve, gas
Terminal strip, low voltage
Board, integrated control
Board, driver
Product Overview
7
3.2
Functional Description
Refer to Figure 3 on page 7. Figure 4 on page 9 shows the general system overview.
Combustion
The combustion system consists of a fully modulating forced-draft combustion air blower(s), a negative
pressure regulated gas valve(s), and a premix burner(s). On a call for humidity, the blower is energized
to purge the system. During this time the control software performs diagnostic checks of the safety
systems – the air proving switch (not shown), the over-temperature switch and the external vent, as
well as the blowers. If the air proving switch is open, the warning message "AP Open Warn" appears, and
escalates to the fault message "AP Open Fault" if three consecutive warnings occur. At the same time, if
the over-temperature switch is open, the fault message "Over-Temperature Fault" appears. In addition, if any
of the blowers fail to operate during this time, the fault message "Blower Not Operational" appears. When
the functions of the safety systems have been verified successfully, the gas valve(s) opens and the gasair mixture is pushed through the burner ports into the combustion chamber(s). The spark-igniter(s) is
simultaneously activated to ignite the gas-air mixture.
If a flame is not sensed by the flame sensor(s), the above sequence is repeated after 15 seconds. The
sequence is repeated upto a maximum of three times, after which the ignition control module(s) locks out
and the fault message "Ignition Fail" appears. If a flame is sensed by the flame sensor(s), the gas valve(s)
remains open and combustion continues. The gas valve(s) continues to maintain a constant air-to-gas
ratio independent of the blower speed or external conditions.
On the CS model, the hot flue gases pass through the primary heat-exchanger then the secondary heatexchanger, where it is cooled further before it exits through the exhaust vent. The heat recovered by the
secondary heat-exchanger is used to warm up the feed water. On the standard-efficiency model, the hot
flue gases pass through the primary heat-exchanger and exit through the exhaust vent.
Water Management
The Condair GS humidifier is equipped with a combination fill box and unique float chamber water
level monitoring device. Two magnetic floats (one is a backup) measure five different water levels in
the humidifier for proper operation. The float chamber and its control board are located away from the
boiling action to increase reading accuracy and reduce mineral build-up. The fill box is connected to
the tank through four hoses. One hose connects to the bottom of the tank, and is used as the primary
means to fill the tank. A second hose routes water through the secondary heat-exchanger into the tank
(on CS model only). The third hose from the float chamber to the tank is used to monitor the water level
in the tank. The fourth connection is above water level to ensure equalization of air pressure between
the tank and float chamber. The fill box also includes an internal 25 mm air gap to isolate the water in
the tank from the water supply, as well as a vacuum breaker to prevent siphoning. The float chamber
has five distinct levels which are monitored by the control software – high water level L5 (yellow LED),
middle level L3 (green LED), low water level L1 (red LED) and two intermediate levels L4 (green and
yellow LEDs) and L2 (green and red LEDs).
On initial start-up, the dual fill valves fill the tank as well as the float chamber. The water level reaches
the backup float first, then the main float. During start-up, if the backup and main floats do not read
the same water level within 10 seconds of each other, the fault message "Float Level" appears, and the
humidifier shuts down. As water fills the float chamber and reaches the L1 level, the control software
performs a series of tests to verify the dual fill valves and drain pump function properly. During the tests,
the dual fill valves continue to fill the tank until the water level reaches the L5 level, then the drain pump
energizes to lower the water level to just below the L1 level. As the water level in the tank rises, if the
float readings are inconsistent, the warning message "Float Inconsistent" appears and escalates to the fault
message "Float Inconsistent Fault" if three consecutive inconsistencies occur. As the tests continue, if the
water level does not rise to the L5 level, the fault message "Fill Check Fault" appears. Likewise, if the level
does not drop just below the L1 level, the fault message "Drain Check" appears. When the tests are completed successfully, the dual fill valves energize again to fill the float chamber to the L3 level or L4 level.
If a demand signal is present, the humidifier then begins the combustion sequence. The drain pump
and dual fill valves maintain the water level between the L2 and L5 levels. On the CS model, the micropump(s) runs periodically to cycle water through the secondary heat-exchanger(s) into the tank. During
steam production, the control software activates a drain sequence every 24 hours (adjustable to time of
day) to verify that the floats and drain pump function properly.
8
Product Overview
2583700_A_EN_1606
Condair GS
1
8
2
3
4
6
7
5
9
12
13
10
14
11
15
16
17
11
Figure 4: Condair GS General System Overview
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Condair GS
Vent, air intake – connected to exterior (optional connection)
Steam line (rigid pipe)
Vent, exhaust
Valve, manual gas shutoff
Supply line, gas
Adapter, steam hose (accessory)
Hose, steam
Distributor, steam
Duct
Drain line, condensate (with trap)
Funnel, air gap (with trap)
Filter, water
Valve, water shutoff
Supply line, water
Cables, power and control signal
Drain line
Drain line, condensate (CS model only)
2583700_A_EN_1606
Product Overview
9
4
Commissioning
4.1
General
The Condair GS humidifier must be commissioned and operated only by personnel who are well qualified
and properly trained to commission the Condair humidifier. It is the customer's responsibility to verify
the qualifications of personnel.
4.2
Commissioning
The unit must always be commissioned for the first time by a service technican from your Condair representative, or by personnel who are well trained and authorized by the customer.
The steps are in the following order:
1. Verify the site requirements have been satisfied.
2. Inspect the humidifier mounting.
3. Inspect the gas supply connection.
4. Inspect the electrical connections, and check for correct voltage.
5. Inspect the water and drain connections.
6. Inspect the steam and condensate line installations.
7. Inspect the combustion air installation.
8. Inspect the exhaust vent installation.
9. Flush the water supply and drain lines.
10.Configure the controls and the Condair GS humidifier.
11. Conduct performance tests, including control and monitoring devices.
12.Fill out the commissioning protocol documents.
10
Commissioning
2583700_A_EN_1606
Condair GS
5
Operator Interface
5.1
Controls
The operator interface in the Condair GS humidifier is located on the front of the unit – refer to Figure 5.
It consists of a touchscreen display with a LED status indicator, and an On/Off switch. Refer to Table 2
for a description of each of these elements.
1
2
3
Figure 5: Condair GS Operator Interface
1
2
3
Display, touchscreen
Status indicator, LED
Switch, On/Off
DANGER!
Risk of electric shock!
The control cabinet in the Condair GS humidifier has live voltage. Turning off the unit at the
On/Off switch does not shut off power to the control cabinet, which still has live voltage.
Touching live parts may cause severe injury or even death.
Prevention: Shut down the humidifier properly as described in "Shutting Down" on page 49 before accessing the control cabinet in the humidifier.
Table 2: Operator Interface Element Functions
Condair GS
Element
Description
Touchscreen display
Allows the user to monitor or control the Condair GS humidifier. Refer to "Control Software" on
page 12 for details of the software interface.
LED status indicator
The status LED is a multi-function LED, which lights up in different colours depending on the
operating status of the humidifier.
Green: indicates that the Condair GS humidifier is operating normally and humidifying.
Flashing Green: indicates that the Condair GS humidifier is in standby mode.
Yellow: indicates that a warning condition is present, or the humidifier is due for maintenance.
Red: indicates that a fault condition is present, and humidification is stopped.
On/Off switch
Allows the user to turn the Condair GS humidifier on or off.
2583700_A_EN_1606
Operator Interface
11
5.2
Control Software
The control software runs in the background and controls all the functions of the Condair GS humidifier.
The user interacts with the control software through the screens on the touchscreen display. Details of
the screens are described in the following sections.
Note: The screens shown in this chapter are for representation purposes only, and may differ from what
is displayed on your humidifier.
5.2.1
Home Screen
When the Condair GS humidifier is turned on, it starts initializing and performs system checks. When
initialization and system checks are completed successfully, it goes into the normal operating mode.
The Home screen then appears on the touchscreen display.
The major elements of the Home screen are shown in Figure 6.
1
10
2
3
9
4
8
7
6
5
Figure 6: Home Screen Elements
1
2
3
4
5
6
7
8
9
10
12
Date and time, Current
Operating status message – refer to "Operating Status" on page 14 for details.
Humidity control information – shows the type of control signal and the steam output requested.
Service/Warning/Fault status message – refer to "Maintenance and Fault Status" on page 15 for details.
Button, <Help> – access technical support help information. Refer to "Help" on page 15 for details.
Button, <Drain> – manually initiate the drain function. Refer to "Manually Initiate Tank Draining" on page 46 for details.
Button, <About> – access the system information. Refer to "System Information" on page 16 for details.
Button, <Main Menu> – access the Main menu. Refer to "Main Menu" on page 20 for details.
Visual indication, current steam output level
Model number, Condair humidifier
Operator Interface
2583700_A_EN_1606
Condair GS
5.2.2
General Navigational Elements
Figure 7 show the general navigational elements/features of the screens on the touchscreen display.
1
2
3
4
5
6
8
7
9
11
12
10
14
13
Figure 7: General Navigational Elements and Features
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Condair GS
Button, <Return> – cancel and return to previous menu level.
Current menu/sub-menu selection
Button, <Previous Tab> – return to the previous tab in the current menu/sub-menu selection.
Button, <Next Tab> – continue/go to the current/next tab in the menu/sub-menu selection.
Tab, Current
Icon, additional information – access additional information.
Button, <Move Cursor Left> – move the cursor to the left on the display.
Button, <Delete> – delete the entry.
Button, <Move Cursor Right> – move the cursor to the right on the display.
Keypad, alpha-numeric
Button, <Increase> – increase the setpoint value.
Button, <Decrease> – decrease the setpoint value.
Button, <Help> – access context-sensitive help.
Button, <Confirm> – confirm the change/selection. Changes will not be stored if this button is not pressed.
2583700_A_EN_1606
Operator Interface
13
5.2.3
Operating Status
The operating status area of the Home screen (refer to Figure 6 on page 12) shows the current operating
status message and an associated status icon. The messages are described in Table 3, and the status
icons are described in Table 4.
Table 3: Operating Status Descriptions
Message
Description
Idle
The humidifier is in standby mode (no humidity demand).
Standby Drain
The humidifier has been in standby mode for a number of hours. The Idle Drain Time has
elapsed and the Idle Drain function is active – the humidifier is being drained. The humidifier
will automatically refill when it receives a valid humidity demand signal.
Humidifying
The humidifier is generating steam.
Keep Warm
The humidifier is in standby mode, and the Keep Warm function is activated.
Disabled
The Condair GS humidifier is disabled by the BMS (building management system).
Stopped
The humidifier is stopped because a condition with a "Fault" status is active.
Safety Chain Open
One or more contacts in the external security loop is open, so the humidifier has stopped
producing steam.
Warning
A condition with a "Warning" status is active. In addition, the message "Warning" is shown
in the maintenance/fault status area of the Home screen. The humidifier will continue to
produce steam when there is a demand (unless the warning relates to a control signal).
Fault
A condition with a "Fault" status is active. The humidifier is stopped. In addition, the message
"Fault" is shown in the maintenance/fault status area of the Home screen.
Table 4: Status Icon Descriptions
Icon
Description
The icon appears to the left of the operating status message or the maintenance/fault message when the system is working normally.
The icon appears to the left of the maintenance/fault status message when a maintenance
reminder or a condition with a "Warning" status is active. The humidifier will continue to produce steam when there is a demand (unless the warning relates to a control signal).
The icon shown appears to the left of the maintenance/fault status message when a condition with a "Fault" status is active. The humidifier stops producing steam.
14
Operator Interface
2583700_A_EN_1606
Condair GS
5.2.4
Maintenance and Fault Status
The Service/Warning/Fault status area of the Home screen (refer to Figure 6 on page 12) shows maintenance reminders, warning and fault status messages along with associated status icons. This field also
allows access to the "Service Menu". When a maintenance reminder, warning or fault status message is
active, the Fault History list can be accessed directly from this field to view additional details.
The general maintenance reminders and alarm messages displayed in this area are described in Table 5,
and the status icons are described in Table 4. Refer to "Condair GS Warning and Fault List" on page 68 for a
detailed list of warning and fault messages.
Table 5: Maintenance/Fault Status Descriptions
5.2.5
Message
Description
Service info
No faults conditions present.
Maint. Warning
This maintenance reminder appears when the Service Interval time set in the control software
has elapsed. The unit can continue to operate for another 200 hours, after which a corresponding fault message appears and the unit stops operating.
Perform the required scheduled maintenance, then reset the service reminder in the Service
menu. Refer to "Maintenance Procedures" on page 53.
Warning
A condition with a "Warning" status is active. Depending on the warning condition, the
Condair GS humidifier will continue to produce steam when there is a demand (unless the
warning relates to a control signal).
In addition, the status LED turns yellow in colour.
Fault
A condition with a "Fault" status is active. Depending on the fault condition, the Condair GS
humidifier will not produce steam until the fault condition is cleared.
In addition, the status LED turns red in colour.
Help
Touch the <Help> button on the Home screen (refer to Figure 6 on page 12) to view your local technical
support help details.
Condair GS
2583700_A_EN_1606
Operator Interface
15
5.2.6
System Information
Select the <About> button on the Home screen (refer to Figure 6 on page 12) to view the system information for your Condair GS humidifier. The tab structure for this selection is shown below.
About >
"General Tab" on page 16
"Humidifier Status Tab" on page 16
"Operational Status Tab" on page 17
"Control Status Tab" on page 17
"Optional Settings Tab" on page 18
"Networking Settings Tab" on page 19
General Tab
–– Humidifier Model: shows the model number, which is
also shown on the specification label (on the right side of
the humidifier).
–– Humidifier Capacity: shows the current setting of the humidifier's steam output capacity. Select the field to modify
the setting, Refer to"Miscellaneous Tab" on page 26 for other
details.
–– Software Version: shows the current version of the control software. Select the field to update the control software
– refer to "Software Settings Tab" on page 40 for details.
Humidifier Status Tab
–– Serial Number: shows the serial number, which is also
shown on the specification label.
–– Linkup Type: shows the current operating mode of the
humidifier in the Linkup chain. Select the field to choose
a different mode – "Series", "Parallel" or "Independent".
Refer to Linkup Type for more details.
16
Operator Interface
2583700_A_EN_1606
Condair GS
Operational Status Tab
–– Output: shows the current actual steam output level of the
humidifier.
–– Weighted Hours: shows the number of operating hours
on the unit weighted at 100% output.
–– Service Hours: shows the service interval.
–– Average Demand: shows the time-averaged demand on
the system.
–– Est(imated) Days to Service: shows the number of days
before the unit is due for service.
–– Run Time: shows the current accumulated number of
hours the humidifier has been producing steam since
startup.
Control Status Tab
–– Safety Loop: shows the current status of the On/Off devices in the safety loop. If the loop is open, the unit will not
produce steam.
–– Blower Pack: shows the current status of the remotemounted blower pack(s) connected to the unit. If the input
signal is open, the unit will not generate steam.
–– Channel 1: shows the input signal for Channel 1. If configured for demand control, it represents the demand. If
configured for RH(P/PI), it represents sensed humidity.
Refer to Control Mode Ch 1.
–– Setpoint Channel 1: shows the current fixed humidity
setpoint value for the unit. Select the field to adjust the
setpoint value. Refer to "PI Control Parameters Tab" on page 26
for more details.
Note: This field appears only if Control Mode is set to "RH P"
or "RH PI".
Condair GS
2583700_A_EN_1606
Operator Interface
17
Control Status Tab, continued...
–– Channel 2: shows the input signal for Channel 2. If configured for demand control, it represents the demand. If
configured for RH(P/PI), it represents sensed humidity.
Note: This field appears only if the Control Channels is set to
"Dual".
–– Setpoint Channel 2: shows the high limit setpoint value
for the unit. Select the field to adjust the value.
Note: This field appears only if Control Mode is set to "RH P"
or "RH PI", and Control Channels is set to "Dual".
–– Demand: shows the calculated demand for the unit as a
percentage of its maximum capacity.
Optional Settings Tab
–– Manual Capacity: shows the capacity limitation value as
a percentage of the maximum capacity of the unit. Select
the field to set a fixed maximum output capacity. Refer to
"Miscellaneous Tab" on page 26 for more details.
–– Blowdown Rate: shows the rate at which the tank is partially drained, as a percentage of actual steam production.
Refer to the "Water Management Tab" on page 21 for more
details.
–– Drain Cool: shows the configuration setting of the drain
cool function. Select the field to choose a different mode –
"Off", "On" or "Smart". Refer to the "Water Management Tab" on
page 21 for more details.
–– FTBD (Full Tank Blowdown): shows the configuration setting of the full tank blowdown function. Select the
field to enable or disable the function. Refer to the "Water
Management Tab" on page 21 for more details.
18
Operator Interface
2583700_A_EN_1606
Condair GS
Optional Settings Tab, continued...
–– FTBD Time: shows the time of day when a full tank
blowdown will occur. Refer to the "Water Management Tab" on
page 21 for more details.
–– FTBD Interval: shows how often a full tank blowdown will
occur. Refer to the "Water Management Tab" on page 21 for
more details.
–– Time Proportioning: shows the configuration setting of
the time proportioning function. Select the field to enable or disable the function. Refer to the "Operation Tab" on
page 22 for more details.
–– Float Check: shows the configuration setting of the float
check function. Select the field to enable or disable the
function. Refer to the "Operation Tab" on page 22 for more
details.
Networking Settings Tab
Note: The BACnet parameters shown below appear only if BACnet is enabled.
–– BACnet: shows the BACnet communications protocol running on the humidifier – BACnet/IP or BACnet MSTP.
–– Node ID: shows the node ID assigned to the humidifier
over the BACnet/IP protocol.
–– BACnet MSTP MAC: shows the MAC address assigned
to the humidifier.
–– IP Address: shows the IP address assigned to the
humidifier.
Condair GS
2583700_A_EN_1606
Operator Interface
19
5.2.7
Main Menu
Select the <Main Menu> button on the Home screen to view the Main menu. The Main menu and its
contents are password-protected. Refer to Figure 8. Enter the password "8808" to access the Main menu.
8
8
0
8
Figure 8: Main Menu Access
To access the Configuration menu and its features, refer to "Configuration Menu" on page 21.
To access the Service menu and its features, refer to "Service Menu" on page 35.
To access the Administrator menu and its features, refer to "Administrator Menu" on page 40.
The structure of the Main menu and its sub-menus is shown in Table 6.
Table 6: Main Menu Structure
"Main Menu" on
page 20 >
"Configuration Menu" on
page 21 >
"Features Menu" on
page 21 >
"Water Management Tab" on page 21
"Control Settings Menu"
on page 24 >
"Basic Tab" on page 24
"Operation Tab" on page 22
"Miscellaneous Tab" on page 26
"PI Control Parameters Tab" on page 26
"RH Alerts Tab" on page 27
"Communication Tab" on page 28
"Multi-Unit Operation Tab" on page 28
"General Menu" on
page 30 >
"Basic Tab" on page 30
"Communications Menu"
on page 31 >
"Remote Enable Tab" on page 31
"Time Date Tab" on page 30
"IP Parameters Tab" on page 31
"BMS Timeout Tab" on page 32
"Modbus Parameters Tab" on page 33
"BACnet Parameters Tab" on page 33
"Service Menu" on
page 35 >
"Startup Code Tab" on page 35
"Humidifier Service Tab" on page 35
"General Service Tab" on page 36
"Fault/Service History Tab" on page 36
"Diagnostics Tab" on
page 37 >
"Administrator Menu" on
page 40 >
20
Operator Interface
Input Diagnostics
Output Diagnostics
"Password Setting Tab" on page 40
"Software Settings Tab" on page 40
2583700_A_EN_1606
Condair GS
5.2.7.1 Configuration Menu
The Configuration menu lets you configure the operation of the Condair GS humidifier. The menu and
sub-menu items are discussed below. Refer to Table 6 on page 20 for the menu structure.
Features Menu
Each tab under the Features menu is discussed below.
Water Management Tab
–– Blowdown Rate: allows you to set the rate (as a percentage of actual steam production) at which the tank is
drained. Refer to "Adjusting Blowdown Settings" on page 52 for
additional details.
Setting range:
1-100%
Factory setting:
25%
–– Drain Cool: allows you to enable or disable the drain
water cooling function that is used to cool down the drain
water before it is discharged.
Options:
On – enable the function.
Off – disable the function.
Smart – drain water cooling happens
only if the tank is hot.
Factory setting:
Off
–– DWC (Drain Water Cooling) Source: allows you to select
the water source used in drain water cooling.
Options:
Internal – use the fill valve in the
unit to supply water for drain water
cooling.
Factory setting:
Internal
Condair GS
2583700_A_EN_1606
Operator Interface
21
Water Management Tab, continued...
–– FTBD (Full Tank Blowdown): allows you to enable or
disable the full tank blowdown function. Depending on the
water quality, this function can be used to extend operational life and service intervals by reducing mineral buildup in the tank. When enabled, the FTBD function performs
a full drain of the tank when the weighted runtime hours
exceed the FTBD Interval. When blowdown is completed, the
tank is refilled and the unit resumes normal operation.
Options:
On or Off
Factory setting:
On
–– FTBD Time: allows you to set the time of day when a full
tank blowdown will occur.
–– FTBD Interval: allows you to set the frequency of full tank
blowdowns in weighted hours (equivalent to a unit operating at 100% output). Refer to "Adjusting Blowdown Settings" on
page 52 for additional details.
Setting range:
1-100 hr
Factory setting:
72 hr
Operation Tab
–– Idle Mode: allows you to set the idle function of the humidifier when it is in standby mode.
Options:
Idle Only – the humidifier waits indefinitely for a demand signal.
Idle Drain – the tank is drained
after Idle Drain Time elapses without
demand.
Keep Warm – the water in the tank is
kept warm while in standby mode.
Factory setting:
Idle Only
–– Idle Drain Time: allows you to set the time duration the
humidifier stays in standby mode without a demand, after
which the humidifier carries out the function specified in
Idle Mode.
Setting range:
1-100 hours
Factory setting:
72 hours
22
Operator Interface
2583700_A_EN_1606
Condair GS
Operation Tab, continued...
–– Time Proportioning: allows you to enable or disable the
time proportioning function, which allows the controller
to operate the burners on a time-proportional sequence
when the system demand is below the minimum output of
a single burner.
Options:
On or Off
Factory setting:
Off
–– Float Check: allows you to enable or disable the float
check function. When enabled, the humidifier performs a
float check at start-up and every 24 hours (without interrupting steam production if humidifier is operating, or in
standby mode), to verify that the float sytem is working
properly. Refer to the description of the float check function
in "Water Management" on page 8.
Options:
On or Off
Factory setting:
Off
–– Float Check Time: allows you to set the time of day when
the float check function will occur.
–– Fill Correction 1: allows you to adjust all the parameters
for the high volume fill valve(s) to compensate for valve
tolerances, as welll as site-specific conditions.
CAUTION! Do not adjust this value unless instructed to
do so by a Condair representative.
Setting range:
Factory setting:
0.1-10.0
1.0
–– Fill Correction 2: allows you to adjust all the parameters
for the low volume fill valve(s) to compensate for valve
tolerances, as welll as site-specific conditions.
CAUTION! Do not adjust this value unless instructed to
do so by a Condair representative.
Setting range:
Factory setting:
0.1-10.0
1.0
–– Drain Correction: allows you to adjust all the parameters
used for draining the tank and blowdowns to compensate
for drain pump flow rates and site-specific conditions.
CAUTION! Do not adjust this value unless instructed to
do so by a Condair representative.
Setting range:
Factory setting:
Condair GS
2583700_A_EN_1606
0.5-1.5
1.0
Operator Interface
23
Operation Tab, continued...
–– Short Cycle: allows you to enable or disable a timer
function that delays steam production until the already
delivered humidity can stabilize in the conditioned environment. This feature prevents the humidifier from flooding
the environment with excess humidity from false humidity
readings.
Options:
On – the humidifier remains in standby mode until the timer elapses even
if there is a new demand signal.
Off – disables the timer function.
Factory setting:
Off
–– Short Cycle Time: allows you to set the time duration that
the unit waits in standby mode before responding to a new
demand signal.
Setting range:
0-300 s
Factory setting:
60 s
Control Settings Menu
Each tab under the Control Settings menu is discussed below. Refer to the structure of the tabs in Table 6
on page 20.
Basic Tab
–– Source: allows you to select the source of incoming control/humidity signal to the humidifier.
Options:
Analog – the control/humidity signals
are from analog sensors or humidistats connected to the humidifier's low
voltage terminal block.
Modbus – the control signal is from
the BMS via the Modbus communication protocol.
BACnet/IP – the control signal is
from the BMS via the BACnet/IP
communication protocol.
BACnet/MSTP – the control signal is
from the BMS via the BACnet/MSTP
communication protocol.
LonWorks – the control signal is from
the BMS via the LonWorks communication protocol.
Factory setting:
Analog
24
Operator Interface
2583700_A_EN_1606
Condair GS
Basic Tab, continued...
–– Control Mode CH 1: allows you to select the general control mode for the incoming control signal.
Options:
Demand – control signal is from an
external controller.
RH P – uses the internal P (proportional) controller to interpret the
sensed humidity into a demand.
RH PI – uses the internal PI (proportional-integral) controller to interpret
the sensed humidity into a demand.
On/Off – control signal is from an
external On/Off humidistat.
Factory setting:
Demand
–– Control Channels: allows you to select one or two control
signals to control the humidifier.
Options:
Single – single control signal.
Dual – two control signals (typically a
control, plus a high limit signal).
Factory setting:
Dual
–– Signal Type Channel 1: allows you to select the signal
type of the incoming control signal. Note: This setting is
ignored if signal Source is not set to "Analog".
Options:
0-5V, 1-5V, 0-10V, 2-10V, 0-20V,
0-16V, 3.2-16V, 0-20mA, 4-20mA
Factory setting:
0-10V
–– Signal Type Channel 2: allows you to select the signal
type for the high limit signal. Note: This setting is ignored if
signal Source is not set to "Analog". Channel 2 applies only
when Control Channels is set to "Dual".
Options:
0-5V, 1-5V, 0-10V, 2-10V, 0-20V,
0-16V, 3.2-16V, 0-20mA, 4-20mA
Factory setting:
0-10V
Condair GS
2583700_A_EN_1606
Operator Interface
25
Miscellaneous Tab
–– Manual Capacity: allows you to set the capacity limitation value as a percentage of the maximum capacity of the
unit.
Setting range:
20-100 %
Factory setting:
100 %
–– Short Cycle: allows you to enable or disable a timer
function that delays steam production until the already
delivered humidity can stabilize in the conditioned environment. This feature prevents the humidifier from flooding
the environment with excess humidity from false humidity
readings.
Options:
On – the humidifier remains in standby mode until the timer elapses even
if there is a new demand signal.
Off – disables the timer function.
Factory setting:
Off
PI Control Parameters Tab
Note: This tab appears only if Control Mode is set to "RH P" or "RH PI".
–– Setpoint Channel 1: allows you to set the humidifier to
operate at a fixed humidity setpoint value.
Setting range:
0-95% RH
Factory setting:
40%
–– Band Channel 1: allows you to set the proportional range
for the internal P/PI controller as a percentage of relative
humidity (% RH) within which the humidifier will modulate
between 0 and 100% output.
CAUTION! Do not adjust this value unless instructed to
do so by a Condair representative.
Setting range:
Factory setting:
6-65%
15%
–– ITime Channel 1: allows you to set the integral time for
error corrections by the internal P/PI controller.
CAUTION! Do not adjust this value unless instructed to
do so by a Condair representative.
Setting range:
Factory setting:
1-60 minutes
5 minutes
–– Setpoint Channel 2: allows you to set the high limit
setpoint value. Note: This setting appears only if Control
Channels is set to "Dual".
Setting range:
0-95% RH
Factory setting:
80%
26
Operator Interface
2583700_A_EN_1606
Condair GS
PI Control Parameters Tab, continued...
–– Band Channel 2: allows you to set the proportional range
for the internal P/PI controller as a percentage of relative
humidity (% RH) within which the humidifier will modulate
between 0 and 100% output. Note: This setting appears
only if Control Channels is set to "Dual".
Setting range:
6-65%
Factory setting:
15%
–– Damp Channel 2: allows you to set the time duration after
which the high limit setpoint value takes control of the
demand signal. Note: This setting appears only if Control
Channels is set to "Dual".
Setting range:
1-60 seconds
Factory setting:
5 seconds
RH Alerts Tab
Note: This tab appears only if Control Mode is set to "RH P" or "RH PI".
–– RH Alerts: allows you to enable or disable the alert function that warns if sensed humidity is too high or too low.
Options:
On – enables the function.
Off – disables the function.
Factory setting:
Off
Note: The following settings are only available if the RH
Alerts function is enabled.
–– RH High: allows you to set the upper limit value of the
humidity sensor signal. The RH High warning message
is triggered when the signal value exceeds this limit.
Setting range: 20-95%
Factory setting: 75%
–– RH Low: allows you to set the lower limit value of the
humidity sensor signal. The RH Low warning message
is triggered when the signal value drops below this
limit.
Setting range: 20-95%
Factory setting: 20%
–– Sensor Min: allows you to set the minimum signal
value of the humidity sensor. If the signal value drops
below this setting, the sensor is assumed to be damaged or disconnected. The RH Signal warning message is triggered when the signal value drops below
this limit, and humidification stops.
Setting range: 1-10%
Factory setting: 5%
Condair GS
2583700_A_EN_1606
Operator Interface
27
Communication Tab
–– BACnet: allows you to enable or disable the BACnet communications protocol used by the BMS. Enabling or disabling BACnet always requires a power cycle of the unit.
Refer to "BACnet Parameters Tab" on page 33 for more details.
Multi-Unit Operation Tab
–– Linkup: allows you to enable or disable the Linkup function, which allows up to four humidifier to connect and
operate together from a single set of control signals. It
also allows you to designate the humidifier to operate as a
"Main" or "Extension" unit.
Options:
Main – designated as the main (master) unit.
Ext 1 – designated as the first extension unit.
Ext 2 – designated as the second
extension unit.
Ext 3 – designated as the third extension unit.
Off – disables Linkup. The humidifier
performs as a single unit.
Factory setting:
Off
Note: The remaining settings in this tab and the next are
only available on the main unit when the Linkup function is
enabled.
–– Linkup Units: allows you to set the number of humidifiers in the Linkup chain.
Setting range: 1-4
Factory setting: 1
28
Operator Interface
2583700_A_EN_1606
Condair GS
Multi-Unit Operation Tab, continued...
–– Linkup Type: allows you to select the mode of operation of the humidifier in the Linkup chain.
Options:
Parallel – the humidity demand (from
a single zone) is distributed evenly
on all humidifiers in the Linkup chain.
Series – the main unit operates to its
maximum capacity, and as demand
increases the extension units generate steam in sequential order. Each
unit scales steam production in small
increments. Series setting maximizes turndown.
Independent – should not be used
for Linkup.
Factory setting: Series
–– Sequence Rotation: allows you to enable or disable
the function that manages the starting order to balance
operating hours of all linked humidifiers. Note: This
setting is available only if Linkup Type is set to "Series".
Options:
On or Off.
Factory setting: On
–– Sequence Interval: allows you to set the time interval
used by the control software to establish a new operating sequence to balance operating hours of linked humidifiers. Note: This setting is available only if Sequence
Rotation is enabled.
Setting range: 24-1000 hours
Factory setting: 24 hours
–– Linkup Timeout: allows you to set the maximum time
limit that the units in the Linkup chain can operate
without communication to each other before a timeout
warning message is generated.
Setting range: 60-120 seconds
Factory setting: 60 seconds
–– Zero Out: shows the percentage value of the system
demand signal at which the unit is switched on.
Setting range: 0-100%
Factory setting: 0%
Note: This setting can only be modified if more than
one unit is physically connected to the Linkup chain.
–– Full Out: shows the percentage value of the system demand signal at which the unit achieves 100%
demand.
Setting range: 0-100%
Factory setting: 100%
Note: This setting can only be modified if more than
one unit is physically connected to the Linkup chain.
Refer to "Configuring for Multi-Unit Operation" on page 42 for setup
procedure.
Condair GS
2583700_A_EN_1606
Operator Interface
29
General Menu
Each tab under the General menu is discussed below. Refer to Table 6 on page 20 for the menu structure.
Basic Tab
–– Date: allows you to set the current date in MM/DD/YYYY
or DD/MM/YYYY format depending on the Date Format
setting.
–– Time: allows you to set the current time in 12-hour or 24hour format depending on the Clock Format setting.
–– Language: allows you to select the language displayed on
the touchscreen display.
Options:
English, German, French, Italian,
Spanish, Dutch, Danish, Finnish,
Swedish, Polish, Czeck, Hungarian,
Russian, Japanese or Chinese
–– Units: allows you to select the units of measurement.
Options:
Imperial or Metric
–– Contrast: allows you to set the contrast level of the touchscreen display.
Setting range:
1 (low) - 31 (high)
Factory setting:
8
–– Brightness: allows you to set the brightness level of the
touchscreen display.
Setting range:
1 (black) - 100 (white)
Factory setting:
52
Time Date Tab
–– Date Format: allows you to select the date format.
Options:
MM/DD/YY or DD/MM/YY
Factory setting:
MM/DD/YY
–– Clock Format: allows you to select the time format.
Options:
12 hour or 24 hour
Factory setting:
12 hour
30
Operator Interface
2583700_A_EN_1606
Condair GS
Communications Menu
Each tab under the Communications menu is discussed below. Refer to Table 6 on page 20 for the menu
structure.
Remote Enable Tab
–– Allow Remote Disable: allows you select whether steam
production by the humidifier can be remotely disabled via
the BMS.
Options:
Yes – remote disable permitted.
No – remote disable not permitted.
Factory setting:
Yes
IP Parameters Tab
The following settings are used only for communications via
the integrated BACnet IP protocol and web pages.
–– IP Type: allows you to select how the IP address settings
are assigned.
Options:
DHCP – automatically acquire network address settings. Note: After
five unsuccessful attempts to acquire
the address, the system will revert to
Fixed assignment.
Fixed – manually configure the network address and settings.
Factory setting:
DHCP
–– IP Address: allows you to manually set the IP address.
Set the IP address only if IP Type is set to "Fixed".
–– Subnet Mask: allows you to manually set the IP subnet
mask for the IP network. Note: Set the subnet mask only if
IP Type is set to "Fixed".
–– Default Gateway: allows you to manually set the default
gateway for the IP network. Note: Set the default gateway
only if IP Type is set to "Fixed".
Condair GS
2583700_A_EN_1606
Operator Interface
31
IP Parameters Tab, continued...
–– Primary DNS: allows you to manually set the primary
DNS (domain name server) for the IP address. Note:
Set the primary DNS only if IP Type is set to "Fixed".
–– Secondary DNS: allows you to manually set the secondary DNS (domain name server) for the IP address.
Note: Set the secondary DNS only if IP Type is set to
"Fixed"
–– MAC Address: displays the MAC (media access control) address for the Condair GS humidifier.
–– Host Name: displays the host name for the
Condair GS humidifier.
BMS Timeout Tab
–– BMS Timeout: allows you to set the maximum time the
humidifier will wait without any communications from the
BMS network before a timeout warning is generated.
Setting range:
1-300 seconds
Factory setting:
300 seconds
32
Operator Interface
2583700_A_EN_1606
Condair GS
Modbus Parameters Tab
–– Modbus: allows you to enable or disable the Modbus
communications protocol. Enabling or disabling Modbus
always requires a power cycle of the unit.
Options:
On or Off
Factory setting:
On
The following settings appear only if Modbus is enabled.
–– Modbus Address: allows you to set the Modbus address of the humidifier on the network.
Setting range: 1-247
Factory setting: 10
–– Parity: allows you to set the parity bit for the data
transfer.
Options:
None, Even or Odd
Factory setting: Even
–– Baudrate: allows you to set the baudrate for the data
transfer.
Options:
110, 300, 600, 1200, 2400, 4800,
9600, 19200, 38400, 57600, 76800
or 115200
Factory setting: 9600
BACnet Parameters Tab
–– BACnet: allows you to enable or disable the BACnet communications protocol. Enabling or disabling BACnet always
requires a power cycle of the unit.
Options:
BACnet/IP – enables BACnet/IP over
the RJ45 (Ethernet) interface.
MSTP – enables BACnet MSTP
over the RS485 interface. Note: The
Condair GS humidifier is a slave-only
BACnet MSTP device.
Off – disables BACnet communications protocol.
Factory setting:
Off
Condair GS
2583700_A_EN_1606
Operator Interface
33
BACnet Parameters Tab, continued...
The following settings appear only if BACnet is set to
"BACnet/IP" or "MSTP". Note: When set to BACnet MSTP
the Condair GS humidifier communicates as a BACnet
slave only. BACnet master functionality requires installation of optional hardware.
–– Device Name: allows you to assign a name to the
humidifier for communications over the BACnet/IP
protocol.
–– Device Description: allows you to enter a description
for the humidifier.
–– Device Location: allows you to enter the location of
the humidifier.
–– Node ID: allows you to assign a node ID to the humidifier for communications over the BACnet/IP protocol.
Setting range: 1-9999999
Factory setting: 1001
–– BACnet IP Port: allows you to assign a IP port number
for the humidifier.
Setting range: 1-65535
Factory setting: 47808
–– BACnet MSTP MAC: allows you to assign a MSTP
MAC address for the humidifier.
Setting range: 128-254
Factory setting: 128
34
Operator Interface
2583700_A_EN_1606
Condair GS
5.2.7.2 Service Menu
The Service menu lets you enter the startup code, reset the service reminder after performing scheduled
maintenance, access the fault and maintenance history lists and perform diagnostics. Refer to Figure 8
on page 20. Refer to Table 6 on page 20 for the menu structure.
Each tab under the Service menu is discussed below. The Service menu can also be accessed from the
maintenance and fault status area on the Home screen – refer to Figure 6 on page 12.
Startup Code Tab
Note: This tab only appears if the humidifier is being operated for the very first time, or the startup code
has been enabled. Contact Condair to request a startup code, then enter it in the field described below.
–– Startup Code: allows you to enter the startup code required to operate the humidifier.
Humidifier Service Tab
–– Drain Tank: allows you to drain the tank. It can take up
to 1 hour to drain the tank using this function. A warning
message is displayed asking you to confirm if you want to
proceed with draining the tank. Refer to "Manually Initiate Tank
Draining" on page 46 for detailed instructions.
Condair GS
2583700_A_EN_1606
Operator Interface
35
General Service Tab
–– Reset Service Reminder: allows you to reset the service
reminder message after performing scheduled maintenance on the unit. A warning message is displayed asking
you to confirm the reset.
CAUTION! Risk of damage to the unit. DO NOT reset the service reminder message unless the required
scheduled maintenance has been performed on the unit.
–– Service Interval: allows you to set the time interval between scheduled maintenance on the unit.
Setting range:
0-3999 h
Factory setting:
1000 h
–– Clean Tank: allows you to flush the tank in preparation for
maintenance. It can take up to 2 hours to flush and drain
the tank using this function. A warning message is displayed asking you to confirm if you want to proceed.
WARNING!
Risk of severe burns from contact with hot steam
vapours or hot water!
DO NOT remove the tank cover until the until has cooled
down to a safe temperature and the tank is fully empty.
–– Disable Burners: allows you to view the Burners tab (not
shown) so you can enable or disable individual burners in
the unit.
–– Burner "n": allows you to enable or disable the individual burner; where "n" represents the burner number
(1 to 4, depending on the number of blowers in the
unit).
Options:
On or Off
Factory setting: On
Fault/Service History Tab
Note: Make sure that date and time are set correctly so that fault and maintenance history events can
be correctly analyzed.
–– Fault History: allows you to view the fault history list.
–– Service History: allows you to view the service history list.
–– Reset Fault History: allows you to reset the fault history.
A warning message is displayed asking you to confirm the
reset. All previously recorded fault history is erased.
–– Reset Service History: allows you to reset the service
history. A warning message is displayed asking you to
confirm the reset. All previously recorded service history is
erased.
36
Operator Interface
2583700_A_EN_1606
Condair GS
Diagnostics Tab
–– Input Diagnostics: allows you to access the Input
Diagnostics menu and view the following tabs which show
the current status of all inputs to the integrated controller,
as well as calculated parameters.
Controls Tab
System Tab
Condair GS
2583700_A_EN_1606
Operator Interface
37
Diagnostics Tab (Input Diagnostics), continued...
Blowers Tab
38
Operator Interface
2583700_A_EN_1606
Condair GS
Diagnostics Tab, continued...
–– Output Diagnostics: allows you to access the Output
Diagnostics menu to enable or disable various system
components, as well as the relays on the remote fault
board. Note: The diagnostic menu will only be displayed
after you acknowledge the warning message that the humidifier will be placed in standby mode.
Output Diagnostics Tab
Remote Relays Tab
Condair GS
2583700_A_EN_1606
Operator Interface
39
5.2.7.3 Administrator Menu
The Administrator menu lets you enable and disable password control, or install updates for the control
software. Refer to Figure 8 on page 20. Refer to Table 6 on page 20 for the menu structure.
Each tab under the Administrator menu is discussed below.
Password Setting Tab
–– Setpoint Password: allows you to enable or disable password control to modify setpoint values when the humidifier is configured to operate on internal RH(P) or RH(PI)
control.
Options:
Yes – requires password to modify
setpoint values.
No – requires no password to modify
setpoint values.
Factory setting:
Yes
–– Main Menu Password: allows you to enable or disable
password control to access the Main menu.
Options:
Yes – requires password to access
the Main menu.
No – requires no password to access
the Main menu.
Factory setting:
No
Software Settings Tab
–– Software Update: allows you to update the control software. A warning message is displayed asking you to
confirm the software updating.
CAUTION! The control software will be corrupted if
updating is interrupted, which may render the humidifier
unusable.
Refer to "Installing Software Updates" on page 64 for detailed
instructions.
–– Restore Factory Defaults: allows you to restore all settings on the unit to factory settings. A warning message is
displayed asking you to confirm if you want to proceed with
restoring the settings.
CAUTION! All current configurations of the unit will be
permanently lost, and replaced with factory settings.
40
Operator Interface
2583700_A_EN_1606
Condair GS
5.3
Software Configuration
The Condair GS humidifier is shipped fully configured from the factory to suit your site-specific requirements, but this can be modified as needed. This section provides the necessary instructions to reconfigure the control software.
5.3.1
Configuring the Control Software
Perform the basic setup of the control software as follows, if necessary:
1. Make sure that all control wiring and jumpers are installed as described in "External Connections"
in the Installation Manual.
2. Set up the following parameters:
•
Source – select the type of control signals to the humidifier ("Analog", "Modbus", "BACnet/IP", etc.,).
Select "Analog" if a sensor/transducer signal or a demand signal from an external P/PI (proportional)/(proportional-integral) controller is wired directly to the humidifier. Otherwise, select
an applicable digital communication protocol from the list. If your humidifier has the optional
Lonworks or BACnet (BTL) module installed, select "Modbus".
•
Control Channels – select the number of control channels.
Select "Dual" if controlling the humidifier with a high limit and a control signal; otherwise set to
"Single".
•
Control Mode CH1 – select the general control mode for the incoming control and high limit signal
("Demand", "RH P", "RH PI", or "On/Off").
Select "Demand" if the control signal is a demand signal from an external controller. Select "RH
P" or "RH PI", as appropriate, if the control signal is from a sensor/transducer. Or select "On/
Off" if the control signal is from an external On/Off humidistat.
•
Signal Type Channel 1 – select the signal type of the incoming control signal if Control Mode is set to
"Demand", "RH P" or "RH PI", and signal Source is set to "Analog".
Select from "0-5V", "1-5V", "0-10V", "2-10V", "0-20V", "0-16V", "3.2-16V", "0-20mA", or "4-20mA",
as appropriate for the external control device connected to Channel 1.
This concludes the basic setup of the control software.
Condair GS
2583700_A_EN_1606
Operator Interface
41
5.3.2
Configuring for Multi-Unit Operation
Set up the control software for multi-unit operation as described below. A maximum of four humidifiers
can be set up in a "Main-Extension" configuration using Condair's Linkup system to satisfy large humidification needs.
IMPORTANT! This procedure should only be used to control multiple humidifiers that are using the
same control signal inputs from the same conditioned environment.
1. Make sure that all wiring and jumpers are installed, as described in "Connecting Multiple Units Using
Linkup" in the Installation Manual.
2. Configure the main humidifier as described above in "Configuring the Control Software".
3. Set Linkup to "Main" on the humidifier that will be designated as Main in the Linkup chain, and set up
the following parameters on it:
•
Linkup Units – select the total number of humidifiers in the Linkup chain. For example, if there is
one main unit and two extension units, then the total number of humidifier in the chain is 3.
•
Linkup Type – select the mode of operation of the humidifiers in the Linkup chain ("Series" or
"Parallel").
•
Sequence Rotation – enable or disable the function that manages the starting order to balance the
operating hours on each steam cylinder. Note: This setting is available only if Linkup Type is set
to "Series".
•
Sequence Interval – set the time interval used by the control software to establish a new operating
sequence to balance the operating hours on the steam cylinders in the Linkup chain.
•
Linkup Timeout – if required, change the maximum time limit that the units in the Linkup chain can
operate without a connection to each other before they generate a Linkup Timeout warning
message.
•
Zero Out – if required, set the percentage value of the system demand signal at which the unit is
switched on.
•
Full Out – if required, set the the percentage value of the system demand signal at which the unit
achieves 100% demand.
4. Set Linkup in each extension humidifier as Ext1, Ext2, ...
Note: Each extension unit must be a unique extension number.
The humidifiers in the Linkup chain are now set up to generate steam upon humidity demand.
42
Operator Interface
2583700_A_EN_1606
Condair GS
6
Operation
6.1
General
Personnel Qualifications
The Condair GS humidifier must only be operated by personnel who are adequately qualified, well trained
and are authorized by the customer.
Safety
Observe all safety precautions described in "For Your Safety".
6.2
Operating Procedures
The procedures described in this section assume that the Condair GS humidifier has been set up properly
and commissioned by a Condair technician or Condair-approved technician.
Before the Condair GS humidifier can initiate combustion, it must be filled with water and the control
software must perform a series of functional and safety tests.
6.2.1
Filling the System
Fill the Condair GS humidifier as follows. The control software also performs the float test to ensure that
the fill system, the water level controls and the drain pump(s) are functioning properly.
1. Close the manual gas shutoff valve in the supply line.
2. Open the shutoff valve in the water supply line.
3. Set the On/Off button on the humidifier to the On position.
The control software then energizes the dual fill valve(s) and starts to fill the tank. When the water
in the float chamber(s) reaches the L1 level (red LED), the control software runs a series of tests on
the fill and drain system as described in "Water Management" on page 8. On successful completion of
the tests, the float chamber is filled to the L3 level (green LED) or L4 level (yellow and green LEDs),
and the humidifier goes into standby mode. This process can take approximately 10-30 minutes
depending on the size of the unit.
4. Set the On/Off button to the Off position, and perform the "Ignition Safety Shutoff Test" described below.
6.2.2
Ignition Safety Shutoff Test
Perform the ignition safety shutoff test as described below:
1. Check that the manual gas shutoff valve in the supply line is still closed.
2. Make sure that the contacts of all devices connected to the external security loop are closed.
3. Set the On/Off button to the On position. The control software runs a series of tests on the fill and
drain system, and on successful completion the humidifier goes into standby mode.
4. Set the demand signal to the humidifier from the building management system (BMS) or humidistat
at 100%.
The control software energizes the blower(s) to initiate the combustion sequence. The blower(s) run
at full capacity for the pre-purge duration to pre-purge the system. The control software then verifies
the proper functioning of the safety systems and the blowers as described in "Combustion" on page 8.
Condair GS
2583700_A_EN_1606
Operation
43
After the safety systems check is completed successfully, the ignition control module(s) is energized.
The spark-igniter(s) attempts to fire up three times to ignite the gas-air mixture. Since the gas supply
is shut off, no flame is detected by the flame sensor(s) and the gas valve(s) is de-energized. The red
LED in the ignition control module(s) flashes to indicate a safety lockout. The fault message "Ignition
Fail" also appears on the touchscreen display after a short delay.
Note: On units with multiple burners, each burner attempts to ignite in sequence. Hence, it is important to wait for all burners to complete its cycle.
The ignition safety shutoff test is successful when no gas flows to the burner(s) when the manual
gas shutoff valve is closed.
5. Power cycle the humidifier to reset the fault condition.
6. Open the manual gas shutoff valve.
6.2.3
Starting the Humidifier
Start the humidifier as follows:
1. Make sure that the tank in the humidifier is filled with water – refer to "Filling the System" on page 43.
2. Make sure that the ignition safety shutdown test is completed – refer to "Ignition Safety Shutoff Test" on
page 43.
3. Check that the shutoff valve in the water supply line is open.
4. Check that the manual gas shutoff valve in the supply line is open
5. On the CS model, make sure that the condensate trap inside the unit is primed properly.
6. Check that the contacts of all devices connected to the external security loop are closed.
7. Make sure that all access panels on the humidifier are installed and fastened securely.
8. Set the On/Off button on the humidifier to the On position.
The control software then energizes the dual fill valve(s) and starts to fill the tank. It then performs
a series of tests to verify the function of the floats, the dual fill valves and the drain pump – refer to
"Water Management" on page 8. Upon successful completion of the tests, the combustion sequence
starts – refer to "Combustion" on page 8.
Depending on the system demand, the blower(s) runs faster or slower to control the input of the
burner(s). The generated heat turns the water in the tank to steam, which is then delivered to the
distribution system.
As the water level in the tank is reduced due to evaporation, the dual fill valves pulse to maintain
water at the proper level. On the CS model only, the micro-pump(s) activates periodically to pump
water through the secondary heat-exchanger(s). The water is then preheated in the secondary heatexchanger(s) before it flows into the tank.
When the humidity demand has been satisfied (demand drops below the minimum %), the gas
valve(s) is de-energized. The blower(s) then performs a post-purge of the combustion chamber(s),
and then shuts off.
If there is no humidity demand, the humidifier goes into standby mode to await the next humidity
demand signal.
44
Operation
2583700_A_EN_1606
Condair GS
6.2.4
Remote Monitoring
The Condair GS humidifier can be monitored remotely through the remote fault board wired to a remote
monitoring system. Table 7 describes the function of each relay when triggered.
Table 7: Remote Relay Function
Remote Relay
Description
Error
The humidifier is stopped due to a fault condition, or may be operable only for a limited period of time.
Service/Warning
Depending on the software configuration, indicates that a service
warning or a system warning/notification is active.
Unit On
The humidifier has power, and the On/Off switch is in the On
position.
The Condair GS humidifier can also be monitored remotely from a laptop or desktop computer using
the ethernet port on the integrated control board. Contact your Condair representative for assistance.
6.2.5
Inspections During Operation
Perform regular inspection of the Condair GS humidifier and the humidification system when it is in
operation. Inspect the following:
…… Check the gas connection for any leaks.
…… Check the water, drain and steam connections for any leakages.
…… If applicable, check the humidifier and other system components have not shifted from their mountings, and are fastened securely.
…… Check for leaks in the exhaust vent. Check that there are no obstructions anywhere in the exhaust
vent, including the exhaust terminal.
…… Keep the area around the air intake in the unit clear of all obstructions. If an air intake vent is used,
check for leaks and obstructions in the vent, including the intake terminal.
…… Check the area around the unit is clear of all insulating and combustible materials.
…… Visually check the electrical wiring for any damage.
…… Check the Home screen on the humidifier for service or system warning messages.
If any irregularities (leakages, fault messages or damaged components) are found, shut down the
Condair GS humidifier before performing service – refer to "Shutting Down" on page 47. Contact your
Condair representative if assistance is required.
Condair GS
2583700_A_EN_1606
Operation
45
6.2.6
Manually Initiate Tank Draining
Figure 9: Drain Screens
During periods of inactivity, such as off-season or periods of low demand, drain the water from the tank.
To drain the tank in the Condair GS humidifier, manually initiate draining as follows. Refer to Figure 9.
1. Select the <Drain> button on the Home screen. If more than one humidifier is connected in a Linkup
chain, select the appropriate tank, then press the check mark.
2. Select the <Yes> button on the confirmation screen. If humidification is in progress, it is interrupted
and the drain pump(s) empties the tank. A progress bar shows the status of the drain cycle.
Select the <Cancel> button at any time to interrupt the drain cycle. If the drain cycle is interrupted
before it is completed, open the manual drain valve and verify that there is still water in the tank.
Close the manual drain valve, then select the <No> button on the next screen to confirm that the
tank has not been emptied fully.
Note: If necessary, set the On/Off switch to the Off position at the end of the drain cycle to prevent
the humidifier from filling the tank again.
WARNING!
Risk of severe burns from contact with hot surfaces, steam or hot water!
The tank may contain steam or hot water at up to 100 °C. Contact with the hot surfaces,
steam vapours or hot water can result in severe burns.
Prevention: Never open the tank until it has been fully drained, and the unit has cooled down
to a safe temperature. Never use the manual drain valve until the unit has cooled down. Use the
manual drain valve to verify that the tank is empty before removing the tank cover.
Note: If the control software/drain valve(s) does not function properly, wait for the unit to cool down
then open the manual drain valve and empty the tank. Close the drain valve after emptying the tank.
6.2.7
Full Tank Blowdown
The control software in the Condair GS humidifier performs a full tank blowdown to reduce the amount
of dissolved minerals accumulated inside the tank. The Drain Cool function in the control software permits
drain water cooling whenever the drain pump runs. Make sure that the function is enabled if drain cooling
is required. The frequency of the blowdown can be set in the control software.
In addition to the software-controlled full tank blowdown, a separate 24 VAC signal connected to pins
"1" and "8" in the low voltage terminal strip can also initiate a full tank blowdown. When a full tank
blowdown is initiated, the tank is drained fully then refilled. Make sure the Drain Cool function is enabled
if drain cooling is required.
46
Operation
2583700_A_EN_1606
Condair GS
6.2.8
Shutting Down
DANGER!
Risk of electric shock!
The control cabinet in the Condair GS humidifier has live voltage. Turning off the unit at the
On/Off switch does not shut off power to the control cabinet, which is still live. Touching live
parts may cause severe injury or even death.
Prevention: Before performing any work inside the humidifier or with the humidification system,
shut down the humidifier properly as described below.
Shut down the Condair GS humidifier as follows for maintenance, or at the end of the season:
1. Set the demand signal to the humidifier from the BMS or the humidistat at 0%. Then allow the burner(s)
to shut off and the blower(s) to perform a post-purge of the combustion chamber(s).
2. Manually initiate draining of the tank. Refer to "Manually Initiate Tank Draining" on page 46.
3. Make a note of any fault code displayed on the Home screen.
Note: At the end of the season, report the fault history to a Condair-certified technician.
Select Service > Fault/Service History tab to access the fault history.
4. Set the On/Off button to the Off position.
5. Close the manual gas shutoff valve in the supply line.
6. Close the shutoff valve in the water supply line.
7. Disconnect the power supply to the humidifier at the external disconnect switch. To prevent accidental
power-up, lockout and tag out according to the established safety practices at your facility.
WARNING!
Risk of severe burns from contact with hot surfaces!
Components of the steam system may reach 100 °C during operation. Contact with the
hot surfaces can result in severe burns.
Prevention: Avoid touching any components in the plumbing cabinet until the unit has cooled
down to a safe temperature.
8. Wait for the unit to cool down to a safe temperature before performing any maintenance inside the
plumbing cabinet.
6.2.9
Restarting After Shutdown
Restart the Condair GS humidifier as follows after it has been shut down for maintenance or at the start
of the season:
DANGER!
Risk of harm to personnel or damage to property.
Operating a damaged or improperly secured humidifier presents a risk of danger to personnel or damage to property.
Prevention: Do not restart a damaged or improperly secured humidifier.
1. Examine the humidifier and other system components for damage. Do not use the applicance if any
part of the humidifier has been under water. Call a qualified service technician to inspect and replace
any part of the control system or gas control that has been under water.
2. Check for loose or damaged electrical connections, and repair if necessary.
Condair GS
2583700_A_EN_1606
Operation
47
3. If applicable, make sure that the humidifier and its components have not shifted from their mountings, and are fastened securely.
4. Make sure that all condensate traps in the exhaust and steam lines are primed properly.
5. Clean any build-up of dirt around the control cabinet, the area around the burner(s). Clean the area
around the air intake inlet to prevent contaminants from being drawn into the combustion chamber.
6. Clean the air intake terminal, if the humidifier is connected to the exterior.
7. Make sure that all access panels on the humidifier are installed and fastened securely. Refer to
"Removal and Installation of Access Panels" on page 53.
8. Remove the lock and tag from the external disconnect switch, and restore power to the humidifier.
9. Open the water and gas supply to the unit.
10.Start up the humidifier as described in "Starting the Humidifier" on page 44.
48
Operation
2583700_A_EN_1606
Condair GS
7
Maintenance
7.1
General
To ensure proper performance and long operating life of the Condair GS humidifier, Condair recommends inspection of the appliance and installation at least once a year by a qualified service person. The
amount and type of maintenance required is generally dependent on how much the humidifier operates.
The Condair GS humidifier monitors the amount of steam produced over time and will indicate when
service is required. All units come with a default service interval of 1000 hours, which can be adjusted
in the control software.
The combustion air blower motors are permanently lubricated and do not require lubrication.
The gas valves in the Condair GS humidifier are negative-pressure-regulated valves. The valves are
factory-set for the correct gas type. The valve setting listed on the product rating plate is shown relative
to atmosphere – this setting will always remain constant. Contact the factory if adjustment is needed.
In general, the burners do not require adjustment or servicing. The combustion chamber and heatexchanger tubes are all fabricated from stainless steel, and do not require internal cleaning.
The exhaust vent connected to the Condair GS humidifier does not require cleaning, but needs to be
inspected regularly for leaks, blockages, sagging and proper condensate removal.
For proper and safe operation of the unit, the area around the air intake in the unit must be kept clear of
all obstructions. If an air intake vent is used, it must be inspected for leaks and obstructions (including
the intake terminal).
Refer to "Mandatory Maintenance Schedule" on page 50 for other maintenance requirements. Also perform
regular inspections when the unit is operating – refer to "Inspections During Operation" on page 45.
IMPORTANT! Damage caused by use of non-approved parts is not covered by warranty. Use only
original Condair replacement parts.
Personnel Qualifications
Maintenance on the Condair GS humidifier must only be performed by well qualified and properly trained
personnel authorized by the customer. It is the customer's responsibility to verify qualifications of the
personnel.
Safety
Make sure that the Condair GS humidifier is shut down properly as described in "Shutting Down" on page 47,
and observe all safety precautions described in "For Your Safety" before performing any maintenance on
the humidifier.
WARNING!
Wiring errors can cause improper and dangerous operation of the humidifier!
Prevention: Tag all wires before disconnecting them. Reconnect all wires correctly after servicing,
and check the unit functions properly.
Condair GS
2583700_A_EN_1606
Maintenance
49
7.2
Mandatory Maintenance Schedule
Table 8 lists the mandatory maintenance schedule for the Condair GS humidifier.
Table 8: Mandatory Maintenance Schedule
Task
30 Days
After
Initial
Start-up
Midseason
End of
Season
(2000 hrs)
Inspect drainage.
X
X
X
Perform a visual check of the drainage system, including the air gap
funnel and drainage into the building drain.
Initiate a manual drain (refer to "Manually Initiate Tank Draining" on
page 46), and visually check that water flows freely through the
drain.
Perform water
analysis.
–
X
X
Perform a water analysis on a semi-annual basis to ensure optimal performance. Refer to "Management of Scale and Chloride Levels" on
page 51.
Inspect tank,
primary heatexchanger coils
and drain fitting
for scale buildup.
X
X
X
Adjust Blowdown Rate and FTBD Interval, as necessary, to reduce scale
build-up.
Inspect secondary heatexchanger (CS
model only) for
blockage.
–
Inspect sacrificial
anode in the
tank.
–
–
X
Inspect the anode for severe corrosion or scale build-up. Scrape off
excess scale – refer to "Cleaning the Tank" on page 55.
Clean the float
chamber.
X
X
X
Make sure that the floats move freely. Clean the float chamber –
refer to "Cleaning the Float Chamber" on page 58.
Inspet the hoses,
fill valve and
drain pump for
blockage.
–
X
X
Check the fill and drain hoses for blockage. Clean the inside of
the hoses – refer to "Cleaning Hoses, Dual Fill Valves and Drain Pump" on
page 59.
Maintenance
Inspect the inside of the tank, and make sure that scale build-up
does not exceed 50 mm. De-scale as required. Refer to "Cleaning the
Tank" on page 55.
X
X
Inspect water flow through the secondary heat-exchanger and make
sure there is not blockage. Clean, if necessary – refer to "Cleaning the
Secondary Heat-exchanger" on page 57.
Inspect the condensate trap connected to the secondary heat-exchanger for blockage. Flush and prime the condensate trap, if necessary – refer to "Cleaning the Secondary Heat-exchanger" on page 57.
Clean the strainer in the dual fill valves – refer to "Cleaning Hoses, Dual
Fill Valves and Drain Pump" on page 59.
Clean the drain pump – refer to "Cleaning Hoses, Dual Fill Valves and Drain
Pump" on page 59.
Remove dust
build-up on the
blower housing.
–
X
X
Use an air gun to remove dust accumulation on the blower housing.
Inspect the
spark-igniter for
oxidation.
–
–
X
Clean the spark-igniter – refer to "Cleaning the Burner Assembly" on
page 61 for details.
Inspect the
exhaust vent and
terminal.
X
X
X
Check that there are no leaks in the exhaust vent, and it is not damaged or corroded excessively. Check the vent is secured properly
and has the proper slope.
Make sure there is no blockage in the exhaust vent including the
exhaust terminal.
When operating in a stable state, make sure that flue temperature
is 135-149 °C for the standard-efficiency model. Flue temperature
should be 49-60 °C for the CS model.
50
Inspect air
intake vent and
terminal.
–
Inspect high
limit switch and
sensor.
X
Maintenance
X
X
Check the air intake vent for leaks, if used.
Make sure there is no blockage in the air intake terminal, if used.
Clean the screen on the elbow at the intake air inlet.
X
X
Visually check that the thermocouple is attached to the exhaust vent,
and the thermocouple wires are connected properly to the switch.
2583700_A_EN_1606
Condair GS
Task
Inspect condensate collection
system.
30 Days
After
Initial
Start-up
Midseason
End of
Season
(2000 hrs)
X
X
X
Maintenance
Check for leaks or blockages in the condensate lines throughout the
steam line and exhaust vent (if applicable).
Make sure that the condensate traps are primed.
If a condensate neutralizer is installed, follow recommendations of the
device manufacturer.
Inspect the
mounting of the
unit.
–
–
X
Check the mounting surface on which the unit is installed is stable,
and the unit is secured properly to the mounting surface.
Inspect overall
condition of the
unit.
–
–
X
Check the unit for obvious signs of deterioration.
Also perform regular inspections when the unit is operating – refer to "Inspections During Operation" on page 45.
7.3
Management of Scale and Chloride Levels
As the humidifier produces steam, minerals dissolved in the water begin to concentrate in the tank over
time. The amount of dissolved minerals and the chloride levels need to be carefully controlled so they
do not affect the efficiency and service life of components. Hardness of water may cause foaming and
contribute to scale build-up in the humidifier tank and float chamber, and chlorides increase the risk
of stress corrosion cracking in stainless steel components of the humidifier. All of these contribute to
reduced efficiency, and increased amount of service and related maintenance costs.
IMPORTANT! Component failures due to water quality outside the recommended ranges (refer to
Table 9) are not covered by warranty.
The Condair GS humidifier periodically drains water from the tank to reduce the concentration of dissolved minerals that accumulate during long-term operation. This is achieved in two ways – through a
partial blowdown and a full tank blowdown (FTBD).
In a partial blowdown, a certain amount of water (determined by the Blowdown Rate setting) is drained
from the tank and replaced with fresh water, thus lowering the concentration levels. In a FTBD, the
entire tank is drained when a certain number of weighted hours (determined by the FTBD Interval setting)
have elapsed, then refilled with fresh water. Weighted hours is defined as the hours equivalent to a unit
operating at 100% output.
The humidifier is shipped with a default Blowdown Rate of 25% for the partial blowdown, and FTBD Interval
of 72 hours for FTBD. These settings ensure that concentration of dissolved minerals is minimized for
all water conditions. However, they can be adjusted in the control software once water conditions are
known for your site – refer to "Adjusting Blowdown Settings" on page 52.
In addition to the software-controlled FTBD, a separate 24 VAC signal connected to pins "1" and "8" in
the low voltage terminal strip can also be used to initiate a full tank blowdown at any time.
Water Quality
The water quality requirements for the Condair GS humidifier are shown in Table 9. Do-it-yourself kits
are available to test hardness in the feed water. You can also contact your local municipality for a water
quality report, or order a Condair water test kit.
Table 9: Water Quality Requirements
Condair GS
Water Type
Hardness
(PPM)
Alkalinity (pH)
Chloride (PPM)
Potable
0-256
5-8
0-50
Treated
0-17
5-8
0-50
2583700_A_EN_1606
Maintenance
51
7.3.1
Adjusting Blowdown Settings
Due to the wide range of water quality in different locations, it is important to adjust blowdown to suit
the local water conditions. Use the following procedure to adjust the blowdown rate and FTBD interval
for the water conditions at your site.
1. Test the quality of the feed water to determine the hardness and the chloride levels.
2. Then set the blowdown rate as follows:
a. Refer to Table 10, and make a note of the recommended minimum blowdown rate for the hardness level of the feed water.
b. Then refer to Table 11, and make a note of the recommended minimum blowdown rate for the
chloride level in the feed water.
c. Set the Blowdown Rate on the Condair GS humidifier to the higher of the two noted values.
3. Set the FTBD interval as follows:
a. Refer to Table 10, and make a note of the recommended maximum FTBD interval value for the
hardness level of the feed water.
b. Refer to Table 11, and make a note of the recommended maximum FTBD interval value for the
chloride level in the feed water.
c. Set the FTBD Interval on the humidifier to the lesser of the two noted values.
4. Once the base settings are set, monitor the water quality and maintenance history periodically, and
adjust the settings accordingly.
Note: Factory tests have shown that increasing the blowdown rate reduces scale build-up, while
reducing the FTBD interval reduces the chloride concentration levels in the tank. The adjusted settings should reflect a balance between reducing concentration levels and minimizing water usage.
Table 10: Blowdown and FTBD Settings Related to Hardness of Water
Feed Water Hardness
(PPM)
Recommended Minimum
Blowdown Rate (%)
Recommended Maximum
FTBD Interval (h)*
0-60
12
72
60-120
25
72
120-180
40
72
180-350
60
48
> 350
Not recommended for the Condair GS humidifier without treatment of the water. Contact your local Condair representative.
* Weighted hours
Table 11: Blowdown and FTBD Settings Related to Chloride Levels
Feed Water
Chloride Levels (PPM)
Recommended Minimum
Blowdown Rate (%)
Recommended Maximum
FTBD Interval (h)*
5
12
72
5-15
25
72
15-25
45
48
25-40
80
24
40-50
100
12
> 50
52
Maintenance
Not recommended for the Condair GS humidifier without treatment of the water. Contact your local Condair representative.
* Weighted hours
2583700_A_EN_1606
Condair GS
7.4
Maintenance Procedures
7.4.1
Removal and Installation of Access Panels
Removal
Remove the door and side panels in the humidifier as follows. Refer to Figure 10 on page 54.
1. Turn the captive screw at the bottom of the door panel (control cabinet/plumbing cabinet) counterclockwise with a screwdriver.
2. Lift up the door panel slightly so that the top tabs clear the notches in the cabinet, then carefully
swing the bottom of the panel up, as shown, and remove the panel.
3. To remove the left/right side panel, remove the screws and slide the panel towards the front of the
unit, so the tabs in the side of the panel clear the notches in the fixed rear panel.
Note: The Condair GS 23/45 humidifier does not have a removable left side panel. To remove the
right side panel, slide the panel towards the front of the humidifier until the tabs at the top rear and
bottom rear of the panel clear the notches in the cabinet, then remove the panel.
Installation
Install the door and side panels in the humidifier as follows. Refer to Figure 10 on page 54.
1. Align and slide the side panel (left/right) towards the rear of the unit, so the tabs in the side of the
panel engage with the notches in the fixed rear panel. Install the screws and fasten the panel securely.
Note: To install the right side panel in the Condair GS 23/45 humidifier, align the tabs at the top rear
and bottom rear of the panel with the notches in the cabinet, then slide the panel towards the rear
of the unit until it is seated properly.
2. Position the door panel (control cabinet/plumbing cabinet) so that the two tabs in the top rear of the
panel align with the notches in the cabinet.
3. Lower the door panel to seat the tabs in the notches, while ensuring that the tabs in the (left/right)
side panel engage with the notches in the side of the door panel. Refer to the detail in the figure.
4. Make sure that the door panel fits flush on the front and the side. Turn the captive screw in the door
panel clockwise to secure the door panel. Check that it is fastened securely.
Condair GS
2583700_A_EN_1606
Maintenance
53
11
1
10
2
3
7
4
5
6
8
9
Figure 10: Access Panels Removal and Installation (GS 65 Shown)
54
1
Screw, (×4) typical
2
3
4
5
6
7
8
9
10
11
Panel, right side
Top tab, door panel
Notch, cabinet
Tab, side panel
Notch, door panel
Screw, captive
Door panel, control cabinet
Door panel, plumbing cabinet
Panel, left side
Panel, fixed rear
Maintenance
2583700_A_EN_1606
Condair GS
7.4.2
Cleaning the Tank
Clean the inside of the tank, the outside of the primary heat-exchanger coils and the drain fitting as follows. Refer to Figure 11 on page 56.
WARNING!
Risk of severe burns from contact with hot surfaces, steam or hot water!
The tank may contain steam or hot water at up to 100 °C. Contact with the hot surfaces,
steam vapours or hot water can result in severe burns.
Prevention: Always drain the tank, and allow the unit to cool down to a safe temperature before
cleaning the tank.
CAUTION!
Risk of damage to the humidifier components!
Do not use solvents, aromatized or halogenized hydrocarbons, or other harsh chemicals for cleaning. Disinfectants may only be used if they do not leave behind toxic residue. Rinse all parts thoroughly with clean tap water after cleaning.
Note: It is not necessary to remove the tank from the unit in order to clean it.
1. Use the Clean Tank function in the control software to flush and drain the tank.
2. Shut down the humidifier as described in "Shutting Down" on page 47.
3. Remove the door panels – refer to "Removal and Installation of Access Panels" on page 53.
4. Disconnect the fill hose from the drain fitting.
5. Remove the four clamps and the tank cover.
6. Remove and discard the tank gasket.
7. Use a soft-bristled brush (not wire brush) or plastic (not metal) scraper to remove all scale build-up
on the inside surfaces of the tank, as well as the outside of the primary heat-exchanger coils and
the inside of the drain fitting. Carefully remove any scale build-up on the surface of the temperature
sensor. Vacuum out the tank. Flush water through the drain fitting to remove any remaining sediment.
8. Rinse the inside of the tank thoroughly with clean tap water.
WARNING!
Risk of fire!
DO NOT clean the sacrificial anode with any chemicals. The anode can react with acids to
create flammable hydrogen gas.
9. Inspect the sacrificial anode on the inside of the tank cover for excessive corrosion or scale build-up.
Use a soft-bristled brush (not wire brush) to remove scale build-up. Replace the anode, if necessary.
10.Install a new tank gasket (Condair does not recommend reusing the tank gasket), and secure the
tank cover to the tank with the four clamps as follows:
a. Install the left side clamp, using just one M8×18 bolt. Torque the bolt to 4.0 N·m.
Note: The order of installation/torquing of the bolts for the tank cover are shown in the hexagonal
symbols in Figure 11 on page 58.
b. Install the right side clamp, using just one M8×18 bolt. Torque the bolt to 4.0 N·m.
c. Torque the remaining bolts in the left and right side clamps to 4.0 N·m, in the order shown.
d. Install the bottom clamp, and torque the two bolts to 4.0 N·m.
e. Install the top clamp, and torque the M6×16 bolt to 5.1 N·m.
f. Torque the M8×18 bolt in the top clamp to 2.3 N·m.
11. Connect the fill hose to the drain fitting and secure it with a clamp.
Condair GS
2583700_A_EN_1606
Maintenance
55
12.Re-start the humidifier – refer to "Restarting After Shutdown" on page 47. The humidifier then fills the tank
and goes through the start-up sequence.
13.Check for any leaks in the tank cover.
1
13
11
12
10
2
9
M6x16
11
9
M8x18
10
3
4
3
5
M8x18
M8x18
5 REF.
8
REF.
2
1
6
M8x18
M8x18
7 REF.
8
5
4
6
M8x18
M8x18
7
M8x18
7
8
M8x18
Figure 11: Cleaning the Tank
1
2
3
4
5
6
7
56
Maintenance
Sensor, temperature
Hose, fill box to tank (main)
Valve, manual shutoff
Fitting, drain
Clamp, right side
Anode, sacrificial
Clamp, bottom
8
9
10
11
12
13
2583700_A_EN_1606
Clamp, left side
Cover, tank
Gasket, tank
Clamp, top
Tank
Coils, primary heat-exchanger
Condair GS
7.4.3
Cleaning the Secondary Heat-exchanger
Clean the secondary heat-exchanger and the condensate trap (CS model only) as follows. Refer to
Figure 12.
WARNING!
Risk of severe burns from contact with hot surfaces!
Components of the unit can be hot to the touch. Contact with the hot surfaces can result in
severe burns.
Prevention: Allow the unit to cool down to a safe temperature before cleaning the components.
CAUTION!
Risk of damage to the humidifier components!
Do not use solvents, aromatized or halogenized hydrocarbons, or other harsh chemicals for cleaning. Disinfectants may only be used if they do not leave behind toxic residue. Rinse all parts thoroughly with clean tap water after cleaning.
5
4
3
1
2
Figure 12: Cleaning Secondary Heat-exchanger (CS Model Only)
1
2
3
Condair GS
Hose, secondary heat-exchanger to tank
Trap, condensate
Heat-exchanger, secondary
4
5
2583700_A_EN_1606
Hose, micro-pump to secondary heat-exchanger
Micro-pump
Maintenance
57
1. Drain the tank, and shut down the humidifier as described in "Shutting Down" on page 47.
2. Remove the side panel – refer to "Removal and Installation of Access Panels" on page 53.
3. Disconnect the two water hoses from the secondary heat-exchanger.
4. Flush the inside of the secondary heat-exchanger with clean tap water.
5. Reconnect the water hoses.
6. Disconnect the condensate trap from the secondary heat-exchanger and flush out any scale build-up.
7. Reconnect the condensate trap, and prime the trap with water.
8. Re-start the humidifier – refer to "Restarting After Shutdown" on page 47.
9. Check for leaks.
7.4.4
Cleaning the Float Chamber
Clean the float chamber in the fill box as follows. Refer to Figure 13.
1
2
3
4
3
5
6
Figure 13: Cleaning Float Chamber
1
2
3
58
Maintenance
Screw (×6)
Sleeve, float
Float (×2)
4
5
6
2583700_A_EN_1606
Cap, end
Gasket
Fill box
Condair GS
CAUTION!
Risk of damage to the humidifier components!
Do not use solvents, aromatized or halogenized hydrocarbons, or other harsh chemicals for cleaning. Disinfectants may only be used if they do not leave behind toxic residue. Rinse all parts thoroughly with clean tap water after cleaning.
1. Shut down the humidifier as described in "Shutting Down" on page 47.
2. Remove the side panel – refer to "Removal and Installation of Access Panels" on page 53.
3. Remove the six screws and the float sleeve.
4. Carefully remove the end cap, and the two floats. Make a note of the orientation of the floats.
5. Use a soft-bristled brush (not wire brush) to remove all scale build-up on the floats, the end cap, the
inside of the float sleeve and the float chamber. Rinse with clean tap water.
6. Visually check each float for cracks or other damage. Place the two floats in a container filled with
clean water, and check that they both have equal buoyancy. If necessary, replace the floats.
IMPORTANT! When assembling the float sleeve, make sure that the floats are in the same orientation as when they was disassembled – opposing poles of the magnet within the floats must
face up.
7. Assemble the float sleeve making sure that the floats are installed correctly. Install the gasket and
the float sleeve and secure it to the fill box with the six screws.
8. Re-start the humidifier – refer to "Restarting After Shutdown" on page 47.
9. Check for leaks.
7.4.5
Cleaning Hoses, Dual Fill Valves and Drain Pump
Clean the fill and drain hoses, the dual fill valves and the drain pump as follows. Refer to Figure 14 on
page 60.
CAUTION!
Risk of damage to the humidifier components!
Do not use solvents, aromatized or halogenized hydrocarbons, or other harsh chemicals for cleaning. Disinfectants may only be used if they do not leave behind toxic residue.
1. Shut down the humidifier as described in "Shutting Down" on page 47.
2. Remove the side panel – refer to "Removal and Installation of Access Panels" on page 53.
3. Loosen the clamps and remove the fill and drain hoses from the humidifier.
4. Carefully remove the strainer in the dual fill valves. Use a soft-bristled brush (not wire brush) and
carefully remove any scale build-up on the strainer in the dual fill valves. Assemble the dual fill valves
after cleaning, taking care not to damage the strainer.
5. Remove the setscrew, and rotate the drain pump assembly to disengage it from the drain fitting.
Rotate and separate the pump cover from the pump housing. Use a soft-bristled brush (not wire
brush) to remove any scale build-up on the inside of the pump cover, impeller, large O-ring and pump
housing. Assemble all drain pump components in reverse order after cleaning. Install the pump assembly in the drain fitting, making sure that the small O-ring is installed in the drain fitting. Secure
the drain pump in place with the setscrew.
6. Use a rubber mallet to knock out any scale build-up in the fill and drain hoses. Rinse the hoses
thoroughly with hot tap water before installing the hoses. Secure the hoses with clamps.
7. Re-start the humidifier – refer to "Restarting After Shutdown" on page 47.
8. Check for leaks.
Condair GS
2583700_A_EN_1606
Maintenance
59
17
16
18
15
14
13
12
11
1
2
10
3
9
7
6
8
4
5
Figure 14: Cleaning Hoses, Dual Fill Valves and Drain Pump
1
2
3
4
5
6
7
8
9
60
Maintenance
Valve, dual fill
Strainer
Hose, drain
Fitting, drain
O-ring
Setscrew
Cover, pump
Housing, pump
Hose, manual drain
10
11
12
13
14
15
16
17
18
2583700_A_EN_1606
Hose, fill box to drain pump
Hose, fill box to tank (main)
Hose, trap
Hose, fill box to tank
Board, float
Fill box
Adapter, fill
Hose, overflow
Hose, inlet
Condair GS
7.4.6
Cleaning the Burner Assembly
The burner(s) in the Condair GS humidifier does not require maintenance. However, if the burner(s)
is not operating properly, clean the burner(s) and spark-igniter as described below. Refer to Figure 15.
WARNING!
Risk of severe injury to personnel, or property damage!
Prevention: Follow proper shutdown procedure before cleaning the burner(s).
1. Shut down the humidifier as described in "Shutting Down" on page 47. Make sure that the tank has
been emptied.
2. Remove the plumbing cabinet door panel.
3. Remove the four M5 nuts that secure the blower tube to the burner assembly.
4. Carefully swing the blower assembly and attached blower tube up to disengage it from the burner
assembly.
5. Disconnect the ignition wire from the spark-igniter.
7
8
1
4
6
3
2
5
Figure 15: Cleaning the Burner Assembly
1
2
3
4
5
Condair GS
Bolt, M6×12, hex-head (qty. 10)
Nut, M5
Tube, blower
Gasket, blower
Spark-igniter
6
7
8
2583700_A_EN_1606
Matting, burner assembly
Gasket, burner – use a new gasket every time the burner
assembly is reassembled
Assembly, burner
Maintenance
61
6. Remove the ten M6×12 hex-head bolts and the burner assembly. Discard the burner gasket.
7. Visually inspect the mating on the inside surface of the burner assembly for hot spots, tears, or any
clogging. If the matting has hot spots or tears, replace the burner assembly.
WARNING!
Risk of personal injury!
Prevention: Wear a safety mask and clean the burner assembly in a well ventilated area.
If the matting is clogged, DO NOT use a scraper to remove the blockage. Use low pressure air at
maximum 35 Pa to clear all blockages without damaging the matting. Blow air in the direction of the
arrow.
8. Visually inspect the spark-igniter for any oxidation. Carefully remove any build-up with emery cloth.
Check the electrode gap is 3 ± 1.5 mm. DO NOT adjust the gap – replace the spark-igniter, if necessary.
9. Assemble the burner assembly in reverse order. Always use a burner gasket.
10.Apply nickel anti-seize lubricant (Loctite® LB 771™ or equivalent) to the ten M6×12 hex-head bolts
before assembly. Wipe off excess lubricant. Torque the bolts to 5.1 N·m.
11. Torque the four M5 nuts to 3.5 N·m.
12.Restart the unit and check that the burner(s) operates properly.
7.4.7
Replacing Backup Battery
DANGER!
Risk of electric shock!
The Condair GS humidifier is mains powered. Live parts may be exposed when the door
panel on the control cabinet is removed. Touching live parts may cause severe injury or even
death.
Prevention: Shut down the unit as described in "Shutting Down" on page 47 before replacing the
backup battery.
CAUTION!
Electrostatic discharge (ESD)!
The electronic components inside the control cabinet in the humidifier are sensitive to electrostatic discharge (ESD).
Prevention: Take appropriate measures to protect the electronic components inside the unit against
damage caused by electrostatic discharge (ESD). Refer to IEC 61340.
Only a qualified service technician authorized by the customer should replace the backup battery on the
integrated control board.
Replace the backup battery on the integrated control board as follows. Refer to Figure 16 on page 63.
1. Remove the door panel on the control cabinet. Swing the front panel open.
2. Replace the backup battery on the integrated control board with a new 3V battery (CR 2032).
3. Close the front panel, and install the door panel, making sure that it is fastened securely.
4. Remove the lock and tag from the external disconnect switch, and restore power to the humidifier.
62
Maintenance
2583700_A_EN_1606
Condair GS
3
2
1
Figure 16: Backup Battery Replacement
1
2
3
7.4.8
Panel, front
Battery – 3V (CR 2032)
Board, integrated control
Resetting Service Reminder
CAUTION!
Risk of damage to equipment!
DO NOT reset the service reminder unless the scheduled maintenance has been performed.
Reset the service reminder in the control software as follows after performing the required scheduled
maintenance:
1. Select the <Main Menu> button on the Home screen, then enter the password to login. Refer to
"Main Menu" on page 20.
2. Select Service > General Service tab > Reset Service Reminder. A reset dialog appears and
prompts you to confirm the reset.
3. Select the <Yes> button on the confirmation screen. The maintenance warning and the service
reminder messages are reset.
Select the <No> button at any time to abort the reset.
Condair GS
2583700_A_EN_1606
Maintenance
63
7.5
Installing Software Updates
All software updates can be downloaded from www.condair.com. Download the file and extract it to a USB
memory stick that has been formatted to 32-bit FAT system. The software update file (ending with .bin)
should be located at the root level on the USB stick.
Note: If software updating is accidentally interrupted, the humidifier will not operate. However, updating
can be resumed by leaving the USB key inserted in the board and power cycling the unit. The integrated
control board will detect that the software was not installed properly, and restart the updating.
Install the updates for the control software as follows:
DANGER!
Risk of electric shock!
The Condair GS humidifier is mains powered. Live parts may be exposed when the door
panel is removed. Touching live parts may cause severe injury or even death.
Prevention: Shut down the humidifier properly at the external disconnect switch before accessing
the integrated control board in the humidifier.
1. Set the On/Off button to the Off position.
2. Disconnect the power supply to the humidifier at the external disconnect switch. To prevent accidental
power-up, lockout and tag out according to the established safety practices at your facility.
3. Remove the door panel on the control cabinet – refer to "Removal and Installation of Access Panels" on
page 53.
4. Swing the front panel open.
5. Carefully insert the USB memory stick into the USB port. The maximum length of the memory stick
should not exceed 75 mm.
6. Close the front panel, and install the door panel.
7. Remove the lock and tag from the external disconnect switch, and restore power to the humidifier.
8. Set the On/Off button to the On position.
9. When the Home screen appears, select the <MAIN Menu> button, then enter the password to login.
CAUTION!
Risk of file corruption!
DO NOT interrupt software updating once it starts. Wait until updating is completed. Corrupted
control software can render the humidifier unusable.
Note: If software updating is accidentally interrupted, the humidifier will not operate. However,
updating can be resumed by leaving the USB key inserted in the board and power cycling the
unit. The integrated control board will detect that the software was not installed properly, and
restart the updating.
10.Select Administrator > Software Settings tab > Software Update to update the control software.
A progress bar shows the status of the updating process. When updating is completed, the Home
screen is displayed.
11. Repeat Step 1 to Step 4, and carefully remove the USB memory stick.
12.Close the front panel. Install the door panel, making sure that it is fastened securely – refer to "Removal
and Installation of Access Panels" on page 53.
13.Repeat Step 7 and Step 8 to power up the humidifier.
64
Maintenance
2583700_A_EN_1606
Condair GS
8
Fault Isolation
8.1
General
Troubleshooting of the Condair GS humidifier must only be performed by well qualified and well trained
personnel. Electrical repairs must only be performed by a licensed electrician authorized by the customer
or by Condair service technicians.
Troubleshooting the Condair GS humidifier may require personnel to access the inside of the control
cabinet in the humidifier which may expose personnel and equipment to the hazards described below.
DANGER!
Risk of electric shock!
The Condair GS humidifier is mains powered. Live parts may be exposed when the access
panels are removed. Touching live parts may cause severe injury or even death.
CAUTION!
Electrostatic discharge (ESD)!
The electronic components inside the control cabinet in the humidifier are sensitive to electrostatic discharge (ESD).
Prevention: Take appropriate measures to protect the electronic components inside the unit against
damage caused by electrostatic discharge (ESD). Refer to ANSI/ESD-S20.20.
8.2
Fault Indication
When a condition that is not normally expected occurs, it is detected by the control software and a warning or fault message is displayed in the Service/Warning/Fault status area of the Home screen (refer to
Figure 6 on page 12). The warning and fault message types are described in Table 12.
Table 12: Maintenance/Fault Status Descriptions
Message Type
Warning
Descriptions
A condition with a "Warning" status is active. Typically, these conditions
are of a temporary nature, or conditions that cannot cause damage to the
system. Depending on the condition, the Condair GS humidifier may be
stopped or remains operable (unless the warning relates to a control signal).
If the cause of the condition clears on its own accord, the warning message
is automatically reset. If the condition becomes worse, a fault message may
be triggered.
When a warning message is active, the status LED turns yellow in color.
Fault
A condition with a "Fault" status is active. Typically, these are conditions which prevent further operation of the humidifier, or conditions that
can cause damage to the system. When a fault condition occurs, the
Condair GS humidifier stops steam production immediately.
When a fault message is active, the status LED turns red in color.
Condair GS
2583700_A_EN_1606
Fault Isolation
65
When a warning/fault condition occurs, select the warning or fault message to view the "Fault/Service History
Tab" on page 36 and additional details. Refer to Figure 17.
Figure 17: Fault History Screens
In addition, the Service relay in the remote fault board can also be set up to indicate that a service warning or a system warning/notification is active.
8.3
General Troubleshooting
Most operational warning/fault conditions are caused by improper installation, or by not adhering to the suggested best practices for installation of the humidifier and system components.
Hence, a full fault diagnosis always requires a thorough examination of the entire system (hose
connections, control systems, etc.).
Table 13 provides general guidelines for troubleshooting the Condair GS humidifier. For detailed troubleshooting information of the auxiliary system components, refer to their product manuals.
The list of Condair GS warning and fault messages, and corrective actions are shown in Table 14 on page 68.
66
Fault Isolation
2583700_A_EN_1606
Condair GS
Humidifier
Table 13: General Troubleshooting – Condair GS Humidifier
Problem
Nothing happens when the
On/Off switch is turned On.
Humidifier will not produce
steam, or does not reach RH
setpoint value.
Probable Cause
Incorrect voltage, or no voltage.
Corrective Action(s)
–– Check the disconnect switch in the supply line.
–– Check the fuse between the transformer and the On/
Off switch.
Step-down transformer not outputting 24 VAC.
–– Check the fuse.
Safety loop is open.
–– Check if the message "Safety Loop" is displayed in
the operating status area of the Home screen.
–– Measure and confirm 24 VAC on the transformer
primary connections. Replace the transformer, if
necessary.
–– Check if there is 24 VAC supply at low voltage terminal strip pin "2".
–– Check that all On/Off devices connected to low voltage terminal strip pins "1" and "2" are wired properly,
and their contacts are closed when they should be.
Humidifier displays warning
or fault message.
Condair GS
Output is limited by the high limit
humidistat signal.
–– Check if the high limit humidistat is installed too
close to the steam distributor. The recommendation
is five times the absorption distance or minimum
3 m. Check the setpoint value for the high limit –
typically set at 80% RH.
No signal on Channel 1.
–– Check voltage between low voltage terminal strip
pins "3" and "4". For a demand signal configuration,
the signal must be 27% of full scale signal for the
humidifier to start. For a transducer signal configuration, the signal must be lower than the setpoint value
for the humidifier to start.
No signal on Channel 2 (on units
with Control Channels set to "Dual").
–– Check voltage between low voltage terminal strip
pins "3" and "5". For a demand signal configuration,
the signal must be 27% of full scale signal for the
humidifier to start. For a transducer signal configuration, the signal must be lower than the setpoint value
for the humidifier to start.
Capacity has been manually
limited.
–– Check/adjust Manual Capacity, if necessary.
The control software has detected an abnormal condition.
–– Refer to "Condair GS Warning and Fault List" on page 68.
2583700_A_EN_1606
Fault Isolation
67
8.4
Condair GS Warning and Fault List
Table 14 shows the list of warning and fault messages triggered by the control software in the Condair GS
humidifier, and the corrective actions. The warning code escalates to a fault code if the alarm condition is not resolved within a certain period of time. After fixing a fault condition, reset the fault status as
described in "Resetting Fault Status" on page 77.
The components of the driver board and the integrated control board referenced in this section are shown
in Figure 18 on page 78 and Figure 19 on page 78.
Table 14: Condair GS Warning and Fault List
Code
Warning
Fault
W01
E01
W06
W07
–
68
Fault Isolation
–
–
E10
Message
Smartcard missing
Main Unit Missing
(or)
Extension Missing
(No Signal Warning)
Ext Fault
CTRLR Fault
(or)
Memory
(or)
CTRLR Reset
Probable Cause
Corrective Action(s)
No communication with the SIM card.
The SIM card may not be seated
properly on the integrated control
board.
Check that the SIM card is seated
properly.
Defective SIM card.
Contact your Condair representative.
No communication between the Extension unit and the Main unit in the
Linkup chain. Operation is interrupted until a signal is received.
The Linkup configuration between
the Main and Extension unit is not set
correctly.
–– Check the Linkup configuration.
The Main unit or Extension unit may
be switched off.
–– Switch on the Main and/or
Extension unit.
Loose connection.
–– Check the connection between
the Main and Extension units.
An Extension unit has a fault condition which was communicated to the
Main unit.
Alarm condition in the Extension
unit(s).
–– Check the Extension unit(s).
Flash memory read/write fault.
–– Contact your Condair
representative.
2583700_A_EN_1606
Condair GS
Code
Warning
Fault
W22
–
Message
Fill Warning
Probable Cause
Corrective Action(s)
The dual fill valves have been active for an extended length of time and the
water level is still zero. The dual fill valves remain activated.
Water supply problems.
–– Make sure that the water supply line is open, and there is
adequate flow and pressure.
Loose wiring, or clogged strainer in
dual fill valves.
–– Check the wiring to the float
board and the dual fill valves.
–– Check the strainer in the dual fill
valves is not clogged – refer to
"Cleaning Hoses, Dual Fill Valves and
Drain Pump" on page 59.
Drain pump running, or manual drain
valve open.
–– Check that the manual drain
valve is closed, and the drain
pump is not running.
Floats may be stuck.
–– Visually check that the different
LEDs on the float board light up
as the water level in the float
chamber changes. If necessary,
clean the float chamber – refer
to "Cleaning the Float Chamber" on
page 58.
Fill valve relay on the driver board
not seated properly, or defective.
CAUTION! Electro-static discharge
damage to board.
–– Check that LED3 (corresponding
to REL4 for the high volume fill
valve) and LED4 (corresponding to REL5 for the low volume
fill valve) on the driver board
light up when the fill valves are
supposed to be energized. If
not, check the relay(s) is seated
properly on the driver board.
–– Swap the relay(s) with another
relay on the board to verify that it
is working. If necessary, replace
the relay.
W28
E28
Maintenance Due
Warning
Maintenance Due
Fault (on fault)
Defective dual fill valves.
–– Check for 24 VAC on the pins
of the dual fill valves. If necessary, replace the dual fill valves.
Reconnect the wires correctly.
Scale build-up in the drain fitting.
–– Clean the drain fitting, as
described in "Cleaning the Tank" on
page 55.
The preset service interval time has elapsed. The unit will continue to run
for 200 hours before a fault message is generated.
The unit will not operate if the warning message escalates to a fault message.
IMPORTANT! Perform the required scheduled maintenance, then reset
the service reminder before restarting the unit.
Unit needs to be serviced.
–– Refer to "Maintenance" on page 49
for maintenance procedures.
–– Reset the service reminder
after performing the required
scheduled maintenance – refer
to "Resetting Service Reminder" on
page 63.
Condair GS
2583700_A_EN_1606
Fault Isolation
69
Code
Warning
Fault
W32
–
Message
RH Signal
Probable Cause
Corrective Action(s)
The RH input is less than 3%. Operation is interrupted until an input higher
than 3% is received.
Loose wiring, faulty sensor.
–– Check the connection between
the sensor and the unit.
–– Swap the sensor with another
sensor and verify that it is working. If necessary, replace the
sensor.
Layout of the humidifier control system may be causing signal interference.
W34
–
Remote Disabled
–– Check that the controls layout
permits accurate readings.
The unit has been disabled remotely by the building management system
(BMS) through Modbus communication. Operation is interrupted until the
unit is enabled again through Modbus or the control software.
Unit disabled by the BMS.
–– Enable the unit through the
BMS.
–– If unit cannot be enabled
remotely, try enabling the unit
through the Modbus setting in the
control software.
W35
–
BMS T/O (timeout)
The maximum wait time without any communications from the BMS has
been exceeded. If the signal Source is set to "Analog", the humidifier will
continue operating; otherwise it stops producing steam until communications with the BMS is re-established.
W42
–
RH High Warning
Sensed humidity is above the RH High value configured in the control software. The unit will remain idle until the sensed RH value drops below the
setpoint value.
Incorrect layout of the humidifier
control system (sensor location too
close to steam distributor or other
sources that affect measurement), or
defective components.
–– Check the humidifier control
system.
Humidifier capacity too large for the
space being humidified.
–– Limit the output capacity of
the humidifier – refer to Manual
Capacity.
–– Adjust the proportional and/or integral
value of the controller.
The RH High value for the sensor
signal may be set too low.
W43
70
Fault Isolation
–
RH Low Warning
–– Adjust the RH High value for the
sensor signal.
Sensed humidity is below the minimum value configured in the control software. The unit should continue operating unless it is in standby mode.
Incorrect layout of the humidifier
control system (sensor location too
close to steam distributor or other
sources that affect measurement), or
defective components.
–– Check the humidifier control
system.
The RH Low value for the sensor
signal may be set too high.
–– Adjust the RH Low value for the
sensor signal.
Unit may be in standby mode.
–– Check the safety loop is
closed, and that all burners are
operational.
2583700_A_EN_1606
Condair GS
Code
Warning
Fault
–
E46
W52
–
Message
Drain Check
Float Inconsistent
Probable Cause
Corrective Action(s)
The drain pump has been active for an extended period of time without
the water level changing in the float chamber. The unit needs to drain for
optimal performance. Fix the problem before restarting the unit.
Backpressure in the drain line may
be causing slow drain.
–– Remove any blockages in the
drainage system.
Loose connection.
–– Check the connections between the float board and the
driver board, as well as the drain
pump.
Floats may be stuck.
–– Visually check that the different
LEDs on the float board light up
as the water level in the float
chamber changes. If necessary,
clean the float chamber – refer
to "Cleaning the Float Chamber" on
page 58.
Drain pump may be clogged.
–– Clean the drain pump – refer to
"Cleaning Hoses, Dual Fill Valves and
Drain Pump" on page 59.
On unit startup the float levels do not rise logically from low water level L1
(red LED) to high water level L5 (yellow LED).
Excess backpressure in the steam
line.
–– Check the steam line.
Float level sensor may be malfunctioning.
–– Inspect all hoses and
connections.
–– Clean the float chamber – refer
to "Cleaning the Float Chamber" on
page 58.
W57
–
Startup Code
Activation code required to use the humidifier.
Activation code missing.
–
E84
Driver Board Fault
–– Contact your Condair
representative.
No communication between the integrated control board and the driver
board.
Communication cable between the
driver board and the integrated
control board
not connected properly.
–– Make sure the RS485 cable is
connected to J15 (RS4851) on
the driver board, and J12 on the
integrated control board.
–– With the unit powered up,
check that LED1 and LED10 on
the driver board are flashing.
Otherwise, contact your Condair
representative.
Unspecified driver board fault.
Condair GS
2583700_A_EN_1606
–– Check that the heartbeat LED10
on the driver board is blinking.
Otherwise, contact your Condair
representative.
Fault Isolation
71
Code
Warning
Fault
–
E138
Message
Over-Temperature
Fault
Probable Cause
Corrective Action(s)
The exhaust or tank safety sensor has exceeded the safety limit. The unit
will not operate when this fault condition is active. Fix the problem first,
then reset the over-temperature switch as described in "Resetting Fault Status"
on page 77.
Unit may be operating with incorrect
water level.
–– Check that the float chamber is
operating properly.
Exhaust vent may be blocked.
–– Make sure that the exhaust vent
is free of obstructions.
Dual fill valves may not be working
properly.
–– Refer to the troubleshooting
procedure for fault code E145.
Thermocouple wire may be damaged.
–– Visualy inspect the thermocouple wire for kinks or other
damage.
Excess scale build-up on the coils of
the primary heat-exchanger.
–– Remove scale build-up – refer to
"Cleaning the Tank" on page 55.
Micro-pump (on CS model) may not
be working.
–– Check the electrical connections, and check for voltage at
the micro-pump when it is expected to be energized. Replace
the micro-pump if defective.
–– If minimum 3 VDC is not
detected when the micro-pump
is expected to be energized,
the pump module on the driver
board may be defective. Contact
your Condair representative for
further assistance.
W139
–
No Burners Available
Temperature of the water supply may
be too high.
–– Check that the temperature of
the water supply. For optimal
performance, temperature must
not exceed 70 °F (21 °C).
Exhaust condensate removal (on
CS model) may be blocked.
–– Check for blockages in the exhaust drain line in the unit.
All burners have been disabled through the control software. No burners are available for operation of the unit. The unit will not respond to a
demand until one or more burners is enabled.
Burners disabled.
–
72
Fault Isolation
E140
Keep Warm Fault
–– Enable the burners in the control
software.
The Keep Warm function is activated, but the tank temperature has not
increased in the allotted time.
Loose connection.
–– Check the tank temperature sensor connection.
Burners may be disabled.
–– Check that no more than one
burner is disabled in the control
software.
Scale build-up on the temperature
sensor.
CAUTION! The tank may be hot to
the touch.
–– Carefully remove scale build-up
on the sensor as described in
"Cleaning the Tank" on page 55.
Defective temperature sensor.
CAUTION! The tank may be hot to
the touch.
–– Check the tank to see if it is hot.
Then check the electrical signal
to the sensor. Replace the sensor, if defective.
2583700_A_EN_1606
Condair GS
Code
Warning
Fault
W141
Message
Probable Cause
Ignition Fail
Corrective Action(s)
The ignition module identified has failed to ignite within the allotted time
(4 minutes). The unit will index to next available burner in the sequence.
Loose wiring, or defective sparkigniter.
–– Visually check the sight port of
problematic burner – check for
a glowing red spark-igniter followed by a flame.
–– Check the spark-igniter connection. If necessary, replace the
spark-igniter.
Gas supply problem.
–– Check the gas supply is open.
–– Check for 24 VAC at the gas
valve.
–– Check the status LED on the
ignition control module – three
flashes of the red LED indicate
problem with the supply, or gas
valve, or a loose connection.
Contact your Condair representative if further assistance is
required.
Faulty ignition control module.
–
E142
No Burners Available
–– Check the status LED on the
ignition control module – a solid
red LED indicates an ignition
control module failure. Replace
the ignition control module, if
necessary.
All burners have experienced an ignition control module failure, and no
burners are available to produce steam. The unit is unsafe to operate with
this fault condition. Fix the problem before restarting the unit.
Gas supply problem.
–– Check the gas supply is open.
–– Check for 24 VAC at the gas
valve.
–– Check the status LED on the
ignition control module – three
flashes of the red LED indicate
problem with the supply, or gas
valve, or a loose connection.
Contact your Condair representative if further assistance is
required.
Loose wiring, or defective sparkigniter.
–– Visually check the sight port of
problematic burner – check for
a glowing red spark-igniter followed by a flame.
–– Check the spark-igniter connection. If necessary, replace the
spark-igniter.
Faulty ignition control module.
Condair GS
2583700_A_EN_1606
–– Check the status LED on the
ignition control module – a solid
red LED indicates an ignition
control module failure. Replace
the ignition control module, if
necessary.
Fault Isolation
73
Code
Warning
Fault
–
E143
Message
Gas Valve Fail
Probable Cause
Corrective Action(s)
The identified gas valve was energized out of sequence, or when it was
not expected to be energized. The unit is unsafe to operate with this fault
condition. Fix the problem before restarting the unit.
Loose connections.
–– Make sure that all onboard electronics are connected according
to the wiring diagram.
–– Check the status LED on the
ignition control module – three
flashes of the red LED indicate
problem with the supply, or gas
valve, or a loose connection.
–– Check connections to all ignition
control modules and gas valves.
Check for 24 VAC at location
labelled "TH" on the ignition
control module.
Faulty gas valve.
–
E144
Float Level
–– Check for voltage at locations
labelled "TH" and "V2" on the
ignition control module after the
blower has completed prepurging the system. If 24 VAC
voltage is detected at "V2" but
not at "TH", replace the gas
valve. Contact Condair to order
a replacement gas valve.
On three consecutive occasions, more than one float level was registering
at the same time. The unit cannot operate without accurate float level reading. Fix the problem before restarting the unit.
Floats may not be working properly.
–– Check the float chamber for
scale build-up, and clean if necessary – refer to "Cleaning the Float
Chamber" on page 58.
–– Check that both floats have
equal bouyancy, as described
in "Cleaning the Float Chamber" on
page 58. Replace the floats, if
necessary.
Faulty float board
–– Examine the float board for
signs of corrosion, splashed
water on it, or other damage.
Replace the float board, if
necessary.
Obstructions in hoses, or hoses
plumbed incorrectly.
–– Check for obstructions in the
hoses.
–– Check that all hoses are
plumbed correctly.
74
Fault Isolation
2583700_A_EN_1606
Condair GS
Code
Warning
Fault
–
E145
Message
Fill Check Fault
Probable Cause
Corrective Action(s)
The dual fill valves have been active for an extended period of time without
the water level rising in the float chamber. The unit will not operate without
an accurate water level reading. Fix the problem before restarting the unit.
Water supply problems.
–– Make sure that the water supply line is open, and there is
adequate flow and pressure.
Loose wiring, or clogged strainer in
dual fill valves.
–– Check the wiring to the float
board and the dual fill valves.
–– Check the strainer in the dual fill
valves is not clogged – refer to
"Cleaning Hoses, Dual Fill Valves and
Drain Pump" on page 59.
Drain pump running, or manual drain
valve open.
–– Visually check that the manual
drain valve is closed, and the
drain pump is not running.
Floats may be stuck.
–– Visually check that the different
LEDs on the float board light up
as the water level in the float
chamber changes. If necessary,
clean the float chamber – refer
to "Cleaning the Float Chamber" on
page 58.
Fill valve relay on the driver board
not seated properly, or defective.
CAUTION! Electro-static discharge
damage to board.
–– Check that LED3 (corresponding
to REL4 for the high volume fill
valve) and LED4 (corresponding to REL5 for the low volume
fill valve) on the driver board
light up when the fill valves are
supposed to be energized. If
not, check the relay(s) is seated
properly on the driver board.
–– Swap the relay(s) with another
relay on the board to verify that it
is working. If necessary, replace
the relay.
Condair GS
Defective dual fill valves.
–– Check for 24 VAC on the pins
of the dual fill valves. If necessary, replace the dual fill valves.
Reconnect the wires correctly.
Scale build-up in the drain fitting.
–– Clean the drain fitting, as
described in "Cleaning the Tank" on
page 55.
2583700_A_EN_1606
Fault Isolation
75
Code
Warning
Fault
–
E146
Message
Blower Not Operating
Probable Cause
Corrective Action(s)
The identified blower is not operating, or registered a value below 500 rpm
while being energized. The unit is unsafe to operate with this fault condition. Fix the problem before restarting the unit.
Loose connections.
–– Check the PWM (pulse width
modulation) and power connection to the blower.
Blower relay on driver board may not
seated properly, or defective.
CAUTION! Electro-static discharge
damage to board.
–– Visually check that LED7 (corresponding to relay REL8 for the
blower) on the driver board lights
up when the blower is supposed
to be energized. If not, check the
relay is seated properly on the
driver board.
–– Swap the relay with another
relay on the board to verify that it
is working. If necessary, replace
the relay.
Blower feedback signal may be
missing.
–– Restart the unit, and check the
blower rpm in Input Diagnostics in
the control software. If the rpm
is low, contact your Condair
representative.
Restrictions at blower, or damaged
blower.
–– Visually inspect the blower and
blower inlet for restrictions.
–– Visually inspect the blower
impeller for damage. Order a replacement blower, if necessary.
Worn out blower.
W147
–
Blower rpm Low
–– The blower speed may decrease
due to wear. The blower is safe
to operate, but the output may
be reduced. Order a replacement blower.
The blower identified is running at a lower rpm than the lead blower by
more than the allowable tolerance. The unit will continue monitoring the
blower rpm and display this warning if the rpm remains low.
Loose connections.
–– Check the PWM and power connection to the blower.
Low voltage.
–– Visually check that LED7 (corresponding to relay REL8 for the
blower) on the driver board lights
up when the blower is supposed
to be energized.
–– Check for 120 VAC on the output side of the blower relay.
W148
–
Blower rpm High
Restrictions at blower, or damaged
blower.
–– Visually inspect the blower and
blower inlet for restrictions.
Worn out blower.
–– The blower speed may decrease
due to wear. The blower is safe
to operate, but the output may
be reduced. Order a replacement blower.
The blower identified is running at a higher rpm than the lead blower by
more than the allowable tolerance. The unit will continue monitoring the
blower rpm and display this warning if the rpm remains high.
Loose connection.
76
Fault Isolation
2583700_A_EN_1606
–– Check the PWM connection to
the blower.
Condair GS
Code
Warning
Fault
W149
E149
Message
Probable Cause
AP Open Warn
Corrective Action(s)
The air proving switch identified has opened while the unit was operating
or during blower start-up. The unit will interrupt operation and retry three
times. After a third attempt a fault message is generated. The unit is unsafe
to operate with this fault condition. Fix the problem before restarting the
unit.
Pressure tubes not connected, or
loose wiring.
–– Check the pressure tube connections are attached securely.
–– Check the wiring between the air
proving switch(es) and connecctor J2 on the driver board. With
demand off and the blower not
operating, check for 12 VAC at
pins 1 and 2 on connector J2.
8.5
Defective air proving switch.
–– Check that the air proving switch
remains closed during operation
of the blower. Check for suction
in the pressure tubes. If the air
proving switch does not close, it
may be defective and must be
replaced.
Blockage in the air intake vent or air
intake terminal.
–– Visually inspect the air intake
vent and air intake terminal for
blockages.
Exhaust condensate removal (on
CS model) may be blocked.
–– Check for blockages in the exhaust drain line in the unit.
Resetting Fault Status
With the exception of the over-temperature fault (see below), the following procedure should be used to
reset all other fault conditions including the ignition control module safety lockout.
Reset the "Fault" status as follows:
1. Correct the cause of the problem.
2. Set the On/Off button to the Off position.
3. Wait approximately for 5 seconds, then set the On/Off button to the On position.
If the alarm condition has been eliminated, the fault message is automatically reset; otherwise the
fault message reappears after a short while.
Resetting Over-Temperature Fault
Reset the over-temperature "Fault" status as follows:
1. Correct the cause of the problem.
2. Wait for the unit to cool down.
3. Press the reset button on the over-temperture switch.
Condair GS
2583700_A_EN_1606
Fault Isolation
77
8.6
Driver Board Layout
Figure 18 shows the components of the driver board that are referenced in "Condair GS Warning and Fault List"
on page 68 of this manual.
4
U7
C67
D3
C2
C61
C74
R2
R1
R62
U8
U11
R96
C58
C72
D11
D32
D53
C51
R17 C17 R10
TP25
L3
R71
TP4
C83
REL1
D7
D4
C73
R85
C80
TP3
C71
R56
R65
R69
TP32
TP7
D18
R93
R64
D8
6
C79
R3
R13 R53
R9 R16
R97
C9
2
C82
C81
C5
JP1
C57
C3
ZD4
3
1
C16
D49
R20 R54
ZD3
ZD2
D5
U4
2
D2
TP1 R5
R7
L1
R75
LED3
S1
C4
IGNITION2
TP2
R72
Fa
D6
C7
LED6
REL4
D46
D9
R6
R8
R34
D1
C6
TP29
REL7
D24
R29
J6
1
R76
U9
R35
R30
LED12
D38
R73
C64
3
LED4
TP10
R98
C59
1
D47
REL2
C68
REL8
LED7 D50
REL5
EXT1
R95
R24
TP13
C25
IGNITION1
REL6
C65
R94
C78
D36
C46
R68
J5
TP14
R77
R74
D40
A/P SWITCH
C23
C24
D25
R60
C36
J2
TP15
C62 TP28
TP27
C55
R23
R66
TP23
REL9
LED8 D51
LED5
J18
J4
C49
C69
3
C66
3
1
D48
TP16
L2
D39
U12
C12
R25
D52
R78
D22
R32
C30
U5
LED9
D15
C26
U10
C47
C10
U1
C27
R86
REL3
R21
TP8
D19
LED10
XT1
C70
REL10
C21
C18
R18
JP2
D41
R88
R14
R11
D37
C48
1
TP12
R26
R87
TP5
C75
D12
LED1
U3
LED11
TP17
C29
C20
24V
TP24
DIGI_INPUTS
R45
R46
TP11 C28
PMP_FRE_DRN_BLOWER
R41
6
R42
2
10V
8
R51
R33
C32 R27
R61
C50
C45
2
J10
U2
J14
C35
R67
R59
D44
D42
D20
C76
TP21
TP18
TP22
C33 C31
C13
C34
24Vout
6
C43
R47
U6
RS485-1 J13
R89
R91
J15
1
R19
R49
T1
TP19
C19
C11
RS485-2
5
R50 R52
R12
TP6
D13
U13
C52
J16
1
J3
T2
TP20
R90
7
TP33
U14
R92
1
D28
R39
C41
2
R37
C37
R43
1
D30
D23
3
D29
R40
C42
R55
1
C38 R38
C44
R48
C39
C15
R63
C77
TP9
R22
3
R44
Fb
R15
C22
C14
1
D31
C40
D16
D10
C8
D17
R31
Fc
LED2
R82
TP30
D43
C53
C54
J1
1
FLOAT
5
1
J7
PWM1
4
1
J8
PWM2
4
1
J17
FILL_1_2_3
5
1
J11
EXT1
4
1
J9
NTC
2
1
J12
POWER SUPPLY
GS Driver 2580143
4
Figure 18: Condair GS Driver Board Layout
8.7
Integrated Control Board Layout
J15
J2
RFB
Figure 19 shows the components of the integrated control board that are referenced in "Condair GS Warning
and Fault List" on page 68 of this manual.
–
+
GND
–
+
GND
–
+
GND
GND
TD
RD
GND
5V
3.3 V
24 V
JP4
JP8
J12
J14
J19
JP7
JP11
CR2032
Battery
J23
SIM Card
J21
J16
J10
USB
Linkup
J6
ETHERNET
Modbus/ BACnet MSTP
ACC.
J3
Comm. Port
J22
LED
J17
J18
Display
Display
Figure 19: Condair Integrated Control Board Layout
78
Fault Isolation
2583700_A_EN_1606
Condair GS
6
7
8
9
CONTROL SIGNAL
CONNECTIONS
PRIMARY VOLTAGE
CONNECTION
NO
COM
NO
COM
NC
NO
COM
NC
NO
COM
FTBD
5
EXT. VENT
4
+10 VDC
3
GND
2
CH 1
1
CH 2
GND
Legend:
Wire Colours
R - Red
W - White
Bk - Black
Bl - Blue
Br - Brown
O - Orange
Y - Yellow
Gr - Green
Gr/Y - Green & Yellow
24 VAC
Wiring Diagrams
Security Loop
L
R
R
R
Y
Gr/Y
Y
R
Unit ON Steam Service
INTERNAL
Y
N
EXTERNAL
EXTERNAL
Low voltage
terminal strip
Gr/Y
9
Error
INTERNAL
Remote Fault PCB
W
Bk
On/Off
Switch
2
Transformer
6.25 A
120 V
24 V
S
1
R
Gr/Y
4
Float Board
3
Tank
Temp
2-Burner
Units Only
Micro
Pump2
Micro
Pump1
M
M
Stack
Hi-Limit
J1
Gr
Bk
W
Tank
Hi-Limit
R
Blower
Relay
Bk
R
8
Bk
7
W
Gr R Br W Bk
Fill 1
Fill 2
S
S
Bk
W
Br
R
Gr
R
W
Bk
Gr
R
W
Bk
Gr
Bk
J2
J1
PUMP MODULE
CS Model
(J18 on Driver Board)
J1
J10
Y
R
Gr
R
J7
pwm1
W
J3 J2
J1
Y
R
pwm2
J3
DRIVER
BOARD #1
Bk
JP4
R
Y
J6
JP8
digi inputs
J10
JP11
M
R
R
J14
J11
pmp_fre
drn_blower
ext
R
Bk
24Vout
ntc
J15
JP1
RS485-1
power
a/p
ignition1
ignition2
J2
J5
J6
R
Pressure
Switch
Bk
Bk
J13
J9
R
Linkup
battery
fill 1,2,3
J12
Modbus
JP7
J17
R
Y
4
RFB
ACC
SIM
card
J8
R
Gr/Y
3
Bk
JP2
float
5 1 6 2
R
Bk
R
M
Gr/Y
Drain Valve
(optional)
Drain
Pump
INTEGRATED
CONTROL
BOARD
J12
R
Bk
Gr/Y
J14
Gr/Y
Bk
J16 J15
display
J17
comm port
display
Bk
R
Bk
Gr/Y
J19
J18
LED
J22
J16
RS485-2
USB
ethernet
J23
J21
U U
U U
Bk
Bk
Blower 1
Gr/Y
Gr PS Bk PWM
GND
W
HS out
R
PS +
1
Gr/Y
R Bk Br
Ignition
Module 1
Gnd
Spark
Igniter
TH
V1
V2
R Bk Br
TH
V1
V2
Gnd
L1
Gas Valve2
Gas Valve1
Ignition
Module 2
Spark
Igniter
2-Burner
Units Only
M
Gr/Y
L2
Blower 2
L1
Gr PS Bk PWM
GND
W
HS out
R
PS +
1
M
Gr/Y
L2
2-Burner
Units Only
Figure 20: Wiring Diagram - Condair GS 23/45/90
JP4
J6
JP7
JP8
J10
Condair GS
Jumper, for activating the termination resistor for Modbus or BACnet MSTP network
Connector, Modbus (RS485 interface)
Jumper, for activating Modbus or BACnet MSTP communication via connector J6
Termination, Linkup system
Connector, Linkup
2583700_A_EN_1606
Wiring Diagrams
79
6
7
8
9
CONTROL SIGNAL
CONNECTIONS
PRIMARY VOLTAGE
CONNECTION
NO
COM
NO
COM
NC
NO
COM
NC
NO
COM
FTBD
5
EXT. VENT
4
+10 VDC
3
GND
2
CH 1
GND
1
CH 2
24 VAC
Security Loop
Legend:
Wire Colours
R - Red
W - White
Bk - Black
Bl - Blue
Br - Brown
O - Orange
Y - Yellow
Gr - Green
Gr/Y - Green & Yellow
L
R
R
Y
R
Gr/Y
R
Gr/Y
Y
Unit ON Steam Service
INTERNAL
Y
Error
INTERNAL
Remote Fault PCB
W
Bk
On/Off
Switch
Float Board
N
EXTERNAL
EXTERNAL
Low voltage
terminal strip
Transformer
6.25 A
1
4
3
24 V
S
2
R
Gr/Y
Tank
Temp
2-Burner
Units Only
Micro
Pump2
Micro
Pump1
M
M
Stack
Hi-Limit
J1
Gr
Bk
W
Tank
Hi-Limit
R
Blower
Relay
Gr R Br W Bk
Fill 1
Fill 2
S
S
Bk
W
Br
R
Gr
R
W
Bk
Gr
R
W
Bk
Gr
Bk
J2
J1
J10
Y
R
Gr
R
8
Bk
7
5 1 6 2
J7
pwm1
3
4
Bk
JP2
float
R
J1
PUMP MODULE
CS Model
(J18 on Driver Board)
W
RFB
ACC
SIM
card
J3 J2
J1
Y
J8
J3
DRIVER
BOARD #1
R
Bk
JP4
R
Y
R
pwm2
J6
JP8
digi inputs
J10
JP11
fill 1,2,3
M
R
R
J14
J11
pmp_fre
drn_blower
ext
Gr/Y
R
Bk
J12
a/p
ignition1
ignition2
J2
J5
J6
R
R
Bk
R
Drain
Pump
INTEGRATED
CONTROL
BOARD
J12
R
Bk
Gr/Y
J14
Gr/Y
Bk
J16 J15
display
J17
comm port
RS485-1
power
R
Drain Valve
(optional)
display
Bk
R
Bk
Gr/Y
J15
JP1
M
Gr/Y
24Vout
ntc
Pressure
Switch
Bk
Bk
J13
J9
Y
Linkup
battery
J17
R
Modbus
JP7
J16
LED
J22
R
Bk
Gr/Y
RS485-2
J19
J18
USB
ethernet
J23
J21
U U
U U
Bk
Bk
Blower 1
Gr/Y
Gr PS Bk PWM
GND
W
HS out
R
PS +
1
Gr/Y
R Bk Br
Ignition
Module 1
Gnd
Spark
Igniter
TH
V1
V2
R Bk Br
TH
V1
V2
Gnd
L1
Gas Valve2
Gas Valve1
Ignition
Module 2
Spark
Igniter
2-Burner
Units Only
M
Gr/Y
L2
Blower 2
L1
Gr PS Bk PWM
GND
W
HS out
R
PS +
1
M
Gr/Y
L2
2-Burner
Units Only
3 or 4-Burner
Units Only
Continued on
next wiring diagram
A
3 or 4-Burner
Units Only
Continued on
next wiring diagram
B
3 or 4-Burner
Units Only
Continued on
next wiring diagram
C
3 or 4-Burner
Units Only
Continued on
next wiring diagram
D
Figure 21: Wiring Diagram - Condair GS 65/130/195/260
JP4
J6
JP7
JP8
J10
80
Wiring Diagrams
Jumper, for activating the termination resistor for Modbus or BACnet MSTP network.
Connector, Modbus (RS485 interface)
Jumper, for activating Modbus or BACnet MSTP communication via connector J6.
Termination, Linkup system
Connector, Linkup
2583700_A_EN_1606
Condair GS
Figure 22 shows the supplementary wiring diagram for the Condair GS 195/260. Connections are carried
over from Figure 21 on page 80.
Legend:
Wire Colours
R - Red
W - White
Bk - Black
Bl - Blue
Br - Brown
O - Orange
Y - Yellow
Gr - Green
Gr/Y - Green & Yellow
Continued from
previous wiring diagram
C
Continued from
previous wiring diagram
B
Continued from
previous wiring diagram
A
D
4-Burner
Units Only
Micro
Pump4 M
Gr
W
Bk
R
J2
Fill 3
S
Fill 4
S
PUMP MODULE
CS Model
(J18 on Driver Board)
J7
JP2
R
W
Bk
Gr
R
W
Bk
Gr
Bk
J1
J1
float
Micro
Pump3
M
pwm1
J10
Blower 3
J8
L1
pwm2
J3
DRIVER
BOARD #2
R
Bk
digi inputs
Bk PS Gr PWM
GND
W
HS out
R
PS +
1
J17
R
fill 1,2,3
R
Gr/Y
M
L2
J14
J11
pmp_fre
drn_blower
ext
Gr/Y
Blower 4
J13
J9
L1
24Vout
ntc
Y
R
J15
JP1
J12
RS485-1
power
a/p
ignition1
ignition2
J2
J5
J6
Bk PS Gr PWM
GND
W
HS out
R
PS +
1
R
Bk
Gr/Y
J16
RS485-2
M
Gr/Y
L2
R
Bk
R
Bk
Bk
4-Burner
Units Only
Gas Valve4
Gas Valve3
Gr/Y
Gr/Y
Ignition
Module 3
Gnd
Spark
Igniter
TH
V1
V2
R Bk Br
TH
V1
V2
Gnd
R Bk Br
Ignition
Module 4
Spark
Igniter
4-Burner
Units Only
Figure 22: Wiring Diagram - Condair GS 195/260
Sheet 2/2
Condair GS
2583700_A_EN_1606
Wiring Diagrams
81
10
Decommissioning
10.1
General
If the Condair GS humidifier needs to be removed from service (for disposal or long-term storage), strictly
follow all instructions in this chapter.
Personnel Qualifications
Decommissioning of the Condair GS humidifier must only be performed by a qualified service technician
authorized by the customer. It is the customer's responsibility to verify qualifications of the personnel.
Safety
Decommissioning of the Condair GS humidifier will require personnel to access the inside of the control
and plumbing cabinets in the humidifier, which may expose personnel and equipment to the hazards
described below.
DANGER!
Risk of fire or explosion!
The Condair GS is a gas-fired humidifier. Improper decommissioning can cause an explosion, fire or other hazards that can cause serious injury, death or property damage.
Any work on the gas system must only be performed by a qualified installer, service agency or your
local gas supplier.
What to do if You Smell Gas:
DO NOT try to light any appliance.
DO NOT touch any electrical switch.
DO NOT use any phone in the building.
Leave the building immediately.
Call your gas supplier immediately from a location far away from the building with the gas leak.
Follow the gas supplier's instructions.
If you cannot reach your gas supplier, call the fire department.
DANGER!
Risk of electric shock!
The Condair GS humidifier is mains powered. Live parts may be exposed when the access
panels are removed. Touching live parts may cause severe injury or even death.
Prevention: Shut down the unit as described in "Shutting Down" on page 47 before proceeding.
WARNING!
Risk of severe burns from contact with hot water or hot steam vapours!
The water in the tank in the humidifier can be up to 100 °C. Contact with the hot water or hot
steam vapours can result in severe burns.
Prevention: Shut down the unit as described in "Shutting Down" on page 47 and wait for the unit to
cool down before proceeding.
82
Decommissioning
2583700_A_EN_1606
Condair GS
WARNING!
Risk of severe burns from contact with hot surfaces!
Components of the stream system may reach 100 °C during operation. Contact with the hot
surfaces can result in severe burns.
Prevention: Avoid touching any components in the plumbing cabinet until the unit has cooled down
to room temperature.
CAUTION!
Electrostatic discharge (ESD)!
The electronic components inside the control cabinet in the humidifier are sensitive to electrostatic discharge (ESD).
Prevention: Take appropriate measures to protect the electronic components inside the unit against
damage caused by electrostatic discharge (ESD). Refer to IEC 61340.
10.2
Removal from Service for Disposal or Long-term Storage
Remove the Condair GS humidifier from service (for disposal or long-term storage) as follows:
1. Drain the tank, and shut down the humidifier as described in "Shutting Down" on page 47. Follow all
safety precautions.
2. Disconnect the gas connection to the humidifier.
3. Disconnect and remove the power supply to the Condair GS humidifier. Refer to "Wiring Diagrams" on
page 79.
4. Disconnect and remove the control signal inputs to the humidifier.
5. Disconnect the steam and condensate lines, and empty out all fluids.
6. Disconnect the water and drain connections to the humidifier.
7. Disconnect and remove the intake and exhaust vents.
8. Remove the humidifier from its mounting surface.
9. If the Condair GS humidifier is to be put into long-term storage, store the humidifier in its original
packaging inside a protected area that meets the following requirements:
•
Room temperature: 5 to 40 °C
•
Room humidity: 10 to 75% RH
10.If the Condair GS humidifier is to be disposed off, refer to "Disposal/Recycling".
10.3
Disposal/Recycling
The Condair GS humidifier should not be disposed off in domestic waste, and should only be disposed
off in accordance with local regulations at authorized collection facilities.
If you have any questions, contact the appropriate local authorities or your local Condair representative.
Condair GS
2583700_A_EN_1606
Decommissioning
83
11
Product Specifications
11.1
Performance Data
Minimum Input
11.2
Maximum Input
Model
Natural Gas (G20)
(kW)
Propane (G31)
(kW)
Natural Gas (G20)
(kW)
Propane (G31)
(kW)
Min./Max. Steam
Capacity
(kg/h)
GS 23-CS
GS 23
3.6
4.1
3.6
4.1
18.2
20.5
18.2
20.5
4.6-23
4.6-23
GS 45-CS
GS 45
7.3
8.2
7.3
8.2
36.4
41.0
36.4
41.0
9-45
9-45
GS 65-CS
GS 65
10.9
12.3
10.9
12.3
54.5
61.5
54.5
61.5
13-65
13-65
GS 90-CS
GS 90
7.3
8.2
7.3
8.2
72.7
82.0
72.7
82.0
9-90
9-90
GS 130-CS
GS 130
10.9
12.3
10.9
12.3
109.0
123.0
109.0
123.0
13-136
13-136
GS 195-CS
GS 195
10.9
12.3
10.9
12.3
163.5
184.5
163.5
184.5
13-195
13-195
GS 260-CS
GS 260
10.9
12.3
10.9
12.3
218.0
246.0
218.0
246.0
13-260
13-260
Operating Data
Control Signal Input Type:
Active
0-5 VDC, 1-5 VDC, 0-10 VDC, 2-10 VDC, 0-20 VDC, 0-16 VDC, 3.2-16 VDC,
0-20 mADC, 4-20 mADC
Passive
135-10 kΩ ohmic humidity sensor
On/Off control
<2.5 VDC
2.5-20 VDC
Digital inputs (via Modbus, BACnet IP/
MSTP slave)
BACnet IP, BACnet MSTP Slave, Modbus, LonWorks (Option), BACnet MSTP
BTL-Certified (Option), BACnet IP BTL-Certified (Option)
Off
On
Ambient Conditions:
Ambient temperature
5-40 °C
Relative humidity
5-80% (non-condensing)
Combustion Air:
Combustion air maximum temperature
30 °C
Backpressure:
Maximum permissible backpressure
(duct static pressure and line backpressure)
84
Product Specifications
1.49 kPa compact unit
2.49 kPa full-size unit
2583700_A_EN_1606
Condair GS
Gas Operating Pressure:
Natural gas:
H, E, E(S)
G20
1.69-2.49 kPa
L, ELL
G25
1.99-2.99 kPa
HS
G25.1
1.99-2.99 kPa
Lw
G27
1.74-2.29 kPa
Ls
GZ350
1.05-1.59 kPa
G31
2.49-5.73 kPa
Propane:
Water Supply:
Water pressure (regulated)
3.0-8.0 bar
Flow rate
10 L/min for Condair GS 23-130, 20 L/min for Condair GS 195/260
Water temperature
1-15 °C recommended; maximum 25 °C
Water quality
Cold potable water filtered to 5 μm, hardness of 0-256 ppm, pH level between 5-8
and chloride 0-50 ppm.
Drain Water:
Drain water temperature
60 °C maximum
Drainage capacity
20 L/min
Power:
Maximum current draw
11.3
6 A
Size and Weight
Weight
Condair GS
Model
Net
(kg)
Operating
(kg)
GS 23-CS
86.2
154.2
GS 23
79.6
147.4
GS 45-CS
95.3
165.6
GS 45
88.5
158.8
GS 65-CS
145.1
226.8
GS 65
131.5
167.8
GS 90-CS
217.7
351.5
GS 90
199.6
333.4
GS 130-CS
217.7
362.8
GS 130
199.6
344.7
GS 195-CS
362.9
544.3
GS 195
340.2
521.6
GS 260-CS
412.8
703.1
GS 260
383.3
673.6
Size – H × W × D
(mm)
1102 × 598 × 539
1410 × 684 × 705
1410 × 960 × 705
1410 × 1580 × 705
1410 × 1859 × 705
2583700_A_EN_1606
Product Specifications
85
A
Appendix
A.1
Torque Values
Figure A1 shows the hardware in the Condair GS humidifier that MUST be torqued to the values shown
in Table A1 on page A-ii.
1
10
9
8
7
1
6
5
4
2
3
Figure A1: Condair GS Hardware to be Torqued
1
2
3
4
5
Condair GS
Bolt, M6×12, flange-head (qty. 4)
Bolt, M6×14, hex-head (qty. 4)
Bolt, M6×12, hex-head (qty. 4)
Bolt, M8×18, hex-head (qty. 8)
Bolt, M8×18, hex-head (qty. 1)
6
7
8
9
10
2583700_A_EN_1606
Bolt, M6×16, hex-head (qty. 1)
Bolt, M6×12, hex-head (qty. 10)
Bolt, M6×10, socket-head (qty. 14)
Nut, M5, hex-head (qty. 4)
Bolt, M5×16, hex-head (qty. 4)
Appendix-A
i
Table A1: Condair GS Standard Torque Values
Figure A1
Item
Number
Fastener and Location
Quantity
Anti-Seize
Lubricant*
Torque
1
Bolt, M6×12, flange-head,
stainless steel – secondary
heat-exchanger/exhaust flange
bolts
4
–
3.5 N·m
2
Bolt, M6×14, hex-head, stainless steel – primary heat-exchanger bottom flange bolts
4

5.1 N·m
3
Bolt, M6×12, hex-head, stainless steel – drain fitting flange
bolts
4

3.5 N·m
4
Bolt, M8×18, hex-head, stainless steel – tank cover side and
bottom bolts
8
–
4.0 N·m
5
Bolt, M8×18, hex-head, stainless steel – tank cover top bolt
1
–
2.3 N·m
6
Bolt, M6×16, hex-head, stainless steel – tank cover top
bracket bolt
1

5.1 N·m
7
Bolt, M6×12, hex-head, stainless steel – burner flange bolts
10

5.1 N·m
8
Bolt, M6×10, socket-head,
stainless steel – primary heatexchanger top flange bolts
14

5.1 N·m
9
Nut, M5, hex-head, galvanized
steel – blower tube
4
–
3.5 N·m
10
Bolt, M5×16, hex-head, galvanized steel – blower tube
4
–
3.5 N·m
* Apply nickel anti-seize lubricant (Loctite® LB 771™ or equivalent) to fastener.
ii
Appendix-A
2583700_A_EN_1606
Condair GS
Consulting, Sales and Service:
Condair AG
Talstrasse 35-37, CH-8808 Pfäffikon
Tel. +41 55 416 61 11, Fax +41 55 416 62 62
info@condair.com, www.condair.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising