Condair GC 130 Operation And Maintenance Manual Download Page 2

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Summary of Contents for GC 130

Page 1: ...OPERATION AND MAINTENANCE MANUAL Gas fired Steam Humidifier Condair GS Series xxxxxxx_A_EN_1905_Condair GS_OM Humidification and Evaporative Cooling ...

Page 2: ...duced used or disclosed to others without the written authorization of Condair Group AG except to the extent required for installation operation or maintenance of the customer s equipment Liability Notice Condair GroupAG does not accept any liability due to incorrect installation maintenance or operation of the equip ment or due to the use of parts components equipment that are not authorized by C...

Page 3: ...n Menu 21 4 2 6 2 Service Menu 35 4 2 6 3 Setpoint 37 4 2 6 4 Administrator Menu 38 4 3 Software Configuration 39 4 3 1 Configuring the Control Software 39 4 3 2 Configuring for Multi Unit Operation 40 5 Operation 41 5 1 General 41 5 2 Operating Procedures 41 5 2 1 Filling the System 41 5 2 2 Ignition Safety Shutoff Test 41 5 2 3 Starting the Humidifier 42 5 2 4 Remote Monitoring 43 5 2 5 Inspecti...

Page 4: ... Valves and Drain Pump 54 6 5 6 Cleaning the Burner Assembly 55 6 5 7 Replacing Backup Battery 57 6 5 8 Replacing Internal Fuse 57 6 5 9 Resetting Service Reminder 58 6 5 10 Installing Software Updates 58 7 Fault Isolation 59 7 1 General 59 7 2 Fault Indication 59 7 3 General Troubleshooting 59 7 4 Warning and Fault List 60 7 5 Resetting Fault Status 66 8 Decommissioning 67 8 1 General 67 8 2 Remo...

Page 5: ...f 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 wi...

Page 6: ... 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 ...

Page 7: ...team distributor within specified operating conditions refer to Operating Data on page 68 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 i...

Page 8: ...midi fier 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 WARN...

Page 9: ...e behind toxic residue Rinse all parts thor oughly with clean tap water after cleaning WARNING Risk of fire DO NOT clean the sacrificial anode with any chemicals The anode can react with acids to create flammable hydrogen gas CAUTION Risk of damage to the humidifier components or injury DO NOT over torque the bolts Ensure the proper order of torquing is followed Failure to do so may cause damage t...

Page 10: ...t parts and accessories available through your Condair representative The location of the various safety labels on the Condair GS humidifier is shown below 1 2 3 4 Figure 1 Safety Labels 1 Label gas safety warning 2 Label keep cabinet closed warning 3 Label general safety warning 4 Label specification ...

Page 11: ...up in a Main Extension configuration using Condair s Linkup system to satisfy large humidification needs The Condair GS humidifier comes in two housing styles compact 23 45 kg h and full size 65 260 kg h Refer to Figure 2 5 4 3 2 1 Figure 2 Condair GS Series Humidifiers 1 GS 23 45 compact housing 2 GS 65 full size housing 3 GS 90 130 full size housing 4 GS 195 full size housing 5 GS 260 full size ...

Page 12: ...tional Description 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 a...

Page 13: ...ters the bottom of the tank The float chamber is connected to the top and bottom of the tank to monitor water levels with reference to the low operational pressure inside the tank The float chamber and its control board consists of two magnetic floats one is a backup that measure the water level These levels correspond to 3 LEDs on a display panel and are monitored by the control software Water Le...

Page 14: ...e return duct high limit in the supply duct 3 Duct return air 4 Duct supply air 5 Humidistat On Off high limit external security loop 6 Drain line condensate with trap 7 Funnel ar gap with optional trap 8 Supply line gas 9 Nalve manual gas shutoff 10 Fitting union 11 Trap sediment 12 Filter water 13 Valve water shutoff 14 Supply line water 15 Fitting union 16 Switch disconnect electrical fused ded...

Page 15: ...ions Element Description Touchscreen display Allows the user to monitor or control the Condair GS humidifier Refer to Control Software on page 15 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 operat ing status of the humidifier Green indicates that the Condair GS humidifier is operating normal...

Page 16: ... is generating steam Stopped The humidifier is stopped because a condition with a Fault status is active Disabled The Condair GS humidifier is disabled by the BMS building management system Safety Loop One or more contacts in the external security loop is open so the humidifier has stopped producing steam Idle The humidifier is in standby mode no humidity demand Idle Drain The humidifier has been ...

Page 17: ...able 5 on page 17 shows mainte nance 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 list of current faults warnings can be accessed directly from this field to view additional details The general maintenance reminders and alarm messages display...

Page 18: ...e the control software refer to Software Settings Tab on page 39 for details Driver Board A B Version shows the current version of the driver board Graph shows you a trend data Export Trend Data sends the data to a connected USB drive Timer Tab On Off Timers allow you to enable or disable the On Off timer function to permit disabling of steam production during specified days and times Configuratio...

Page 19: ... unit will not produce steam Manual Capacity shows the capacity limitation value as a per centage of the maximum capacity of the unit Select the field to set a fixed maximum output capacity 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 Setpoint Channel 1 shows the current fixed humidi...

Page 20: ... FTBD Time shows the time of day when a full tank blowdown will occur Refer to the Water Management Tab on page 22 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 24 for more details Idle Mode allows you to set the idle function of the humidifier when it is i...

Page 21: ...Unit Operation Tab on page 28 General Menu on page 30 Basic Tab on page 30 Time Date Tab on page 30 Communications Menu on page 31 Remote Enable Tab on page 31 IP Parameters Tab on page 31 BMS Timeout Tab on page 32 Modbus Parameters Tab on page 32 BACnet Parameters Tab on page 32 Remote Fault Board on page 34 Service Menu on page 35 Humidifier Service Tab on page 35 General Service Tab on page 35...

Page 22: ...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 system is working properly Options On or Off Factory setting On Float Check Time allows you to set the time of day when the float check function will occur Blowdown Rate allows you to set the rate as a percentage of actual steam producti...

Page 23: ... Blowdown Settings on page 49 for addi tional details Setting range 1 200 hr Factory setting 100 hr Fill Correction 1 allows you to adjust all the parameters for the high volume fill valve s to compensate for valve tolerances as well as site specific conditions CAUTION Do not adjust this value unless instructed to do so by a Condair representative Setting range 0 1 10 0 Factory setting 1 0 Fill Co...

Page 24: ...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...

Page 25: ...the general control mode for the incoming control signal Options Demand signal from an external controller RH P uses the internal proportional controller to interpret the sensed humidity into a demand RH PI uses the internal 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 Limiter Mode...

Page 26: ...not adjust this value unless instructed to do so by a Condair representative Setting range 6 65 Factory setting 15 ITime Channel 1 allows you to set the integral time for error cor rections by the internal P PI controller CAUTION Do not adjust this value unless instructed to do so by a Condair representative Setting range 1 60 minutes Factory setting 5 minutes Setpoint Channel 2 allows you to set ...

Page 27: ...f 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 v...

Page 28: ...gs in this tab and the next are only avail able 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 6 Factory setting 1 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 humidifi...

Page 29: ...hout com munication 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 perce...

Page 30: ...anish Dutch Danish Finnish Swedish Polish Czech 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 touch screen display Setting range 1 black 100 white Factor...

Page 31: ... will revert to Fixed assignment Fixed manually configure the network ad dress 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 de...

Page 32: ...owing 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 ...

Page 33: ... 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 ad dress for the humidifier Setting range 128 254 Factory setting 128 Foreign Device When Foreign Device is ON BBMD IP Port IP Address and Re Register Time appears A foreign device will need...

Page 34: ...rvice output on any system warning including system notifica tions prior to completing automated corrective actions ex fill time out If Service is selected the RFB will activate the service output only for service warnings Options Warning Service Factory setting Warning Safety Loop when enabled the remote fault board will activate the service relay upon the security loop opening Options Yes No Fac...

Page 35: ... 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 Riskofsevereburnsfromcontactwithhotsteam 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 Service Interval allows you to set the time interval between scheduled ...

Page 36: ... your Condair representative allows you to reset the service history A warning message is dis played asking you to confirm the reset All previously recorded service history is erased Export History allows you to send your fault and service history to a USB device Diagnostics Tab Input Diagnostics allows you to access the Input Diagnostics menu and view the following tabs which show the current sta...

Page 37: ...ll Valve 1 and 2 Secondary Fill Valve 1 and 2 Drain Pump Fan On Ignition Mod 1 4 Freeze Valve Blower PWM Blower RPM 1 and 2 Relay Diagnostics allows you to access the Relay Diagnostics menu to en able or disable 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 Remote Fau...

Page 38: ...res 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 Yes Software Updates Tab Software Update allows you to update the control softwar...

Page 39: ...ed from the factory to suit your site specific require ments but this can be modified as needed This section provides the necessary instructions to recon figure the control software 4 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 I...

Page 40: ... 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 cylind...

Page 41: ...ty 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 hu...

Page 42: ...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 13 Upon successful completion of the tests the combustion sequence starts refer to Combustion on page 12 Depending on the system demand the blower s ...

Page 43: ...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 mount ings and are fastened securely Check for leaks in the exhaust vent Check that there are no obstruc...

Page 44: ...y contain steam or hot water 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 contro...

Page 45: ... 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 8 Wait for the unit to cool down to a safe temperature before performing any maintenance inside the plumbing cabinet 5 2 9 Restarting After Shutdown Restart the Condair GS humidifier as...

Page 46: ...tment or servicing The combustion chamber and heat exchanger 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 ...

Page 47: ...he Secondary Heat exchanger on page 52 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 51 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 53 Inspect the hoses fill valve and drain pump for blockage X X Ch...

Page 48: ...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 c...

Page 49: ...down rate for the hard ness level of the feed water b Then refer to Table 12 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 11 and make a note of the recommended maximum FTBD interval value for the hardness...

Page 50: ...emovable 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 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 Instal...

Page 51: ...allation ofAccess Panels on page 50 and remove all covers 3 Disconnect the fill hose from the drain fitting 4 Remove and discard the tank gasket Condair does NOT recommend reusing the tank gasket 5 Use a soft bristled or plastic brush or scraper not wire brush not metal to remove all scale build up on the inside surfaces of the tank the outside of the primary heat exchanger coils and inside of the...

Page 52: ... 1 Gasket 2 M6 nut 3 9 N m 35 in lb 3 Insulation 4 Tank door 5 M6x22hexheadscrew 2 3N m 20in lb 6 Heat exchanger coils 7 Tank 8 Sacrificial anode 6 5 3 Cleaning the Secondary Heat exchanger Clean the secondary heat exchanger and condensate trap CS model only as follows Refer to Figure 11 1 Drain the tank and shut down the humidifier as described in Shutting Down on page 45 2 Remove the side panel ...

Page 53: ... follows Refer to Figure 12 1 Shut down the humidifier as described in Shutting Down on page 45 and remove the side panel refer to Removal and Installation of Access Panels on page 50 2 Remove hoses from the float chamber and remove the float chamber by pulling on the rear tab and lifting the float chamber upwards 3 Openthefloatchamberandcarefullyremovethetwofloats Makeanoteoftheorientationofthefl...

Page 54: ...lation of Access Panels on page 50 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 ro...

Page 55: ... valve 9 Drain pump adapter 10 Drain pump 24 V 11 Drain pump cover 12 O ring x2 13 Dual fill valve 14 Strainer 6 5 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 14 1 Shut down the humidifier Remove the plumbing cabinet doo...

Page 56: ...k nut M5 x4 1 2 N m 10 in lb 8 M6x12 hex head x9 0 5 N m 4 in lb 9 M6x10 socket cap x15 10 Spark igniter 11 Burner 12 Burner gasket 13 Burner blower gasket 14 M4 Nut x2 6 Visually inspect the matting 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 If the matting is clogged DO NOT use a scraper to rem...

Page 57: ... 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 2 3 1 Figure 15 Backup Battery and Fuse Replacement 1 Board integrated cont...

Page 58: ... 50 and swing the front panel open 3 Carefully insert the USB memory stick into the USB port The maximum length of the memory stick should not exceed 75 mm 3 in 4 Close the front panel and install the door panel 5 Remove the lock and tag from the external disconnect switch and restore power to the humidifier 6 Set the On Off button to the On position 7 When the Home screen appears select the Menu ...

Page 59: ... 16 Figure 16 Fault History Screens In addition the Service relay in the remote fault board can also be set up to indicate that a service warn ing or a system warning notification is active 7 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 compone...

Page 60: ...en manually limited Check adjust Manual Capacity if necessary Humidifier displays warning or fault message The control software has detected an abnormal condition Refer to Warning and Fault List on page 60 7 4 Warning and Fault List Table 14 shows the list of warning and fault messages triggered by the control software in the humidi fier and the corrective actions The warning code escalates to a f...

Page 61: ...ll 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 51 W28 E28 Maintenance Due Warning Maintenance Due Fault on fault 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...

Page 62: ...mance Fix the problem before restarting the unit Back pressure 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 n...

Page 63: ...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 51 Defective temp...

Page 64: ...m 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 igniti...

Page 65: ...ith another relay on the board to verify that it is working Replace if necessary 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 51 E146 Blower Not Operating The identified blower is not operati...

Page 66: ...take vent and air intake terminal for blockages 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 Pressure tubes not connected or loose wiring Check the pressure tube connections are attached securely Check the wiring b...

Page 67: ...own on page 45 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 in the Installation Manual 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 t...

Page 68: ...5 CS 10 9 10 9 163 5 163 5 13 195 GS 195 12 3 12 3 184 5 184 5 13 195 GS 260 CS 10 9 10 9 218 0 218 0 13 260 GS 260 12 3 12 3 246 0 246 0 13 260 9 2 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 Off 2 5 20 VDC On Digital inputs via Modbus BACnet IP MST...

Page 69: ...ressure regulated 3 0 8 0 bar 207 550 kPa Flow rate 10 L min for GS 23 130 20 L min for 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 230 V 1 50 Hz Pn max in kW In max in A Cable cross sec...

Page 70: ......

Page 71: ...warranty must be in writing signed by an officer of THE COMPANY THE COMPANY s parts or materials that are considered consumables including but not limited to cylinders filters nozzles membranes media gaskets O rings etc are NOT covered by the warranty THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict accordance with a copy of the catalog and install...

Page 72: ...Condair Group AG Talstrasse 35 37 8808 Pfäffikon SZ Switzerland Tel 41 55 416 61 11 Fax 41 55 416 62 62 info condair com www condair group com CONSULTING SALES AND SERVICE ...

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