Condair DL Series User manual

2603657-A EN 2207

Air Humidication and Evaporative Cooling

SERVICE MANUAL

Adiabatic humidification system

Condair DL II

For internal use only!

READ AND SAVE THESE INSTRUCTIONS

Contact

Condair Ltd.

2740 Fenton Road, Ottawa, Ontario K1T3T7

TEL: 1.866.667.8321, FAX: 613.822.7964

EMAIL: na.info@condair.com, WEBSITE: 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 or maintenance of recipient's equipment.

Liability Notice

Condair Ltd. does not accept any liability due to incorrect installation or operation of the equipment or due to the

use of parts/components/equipment that are not authorized by Condair Ltd.

Technical modications reserved

3Contents

Contents

1 Introduction 5

2 For your safety 6

3 Initial commissioning of the Condair DL 8

3.1 Requirements 8

3.2 First steps after installing the water supply and drain 8

3.3 Quick check electrical installation 13

3.4 Setup table for silver ionization capacity counter 14

3.5 Final check of control unit (with "0948") 15

3.6 Testing the options 15

4 Calculation of the nozzle output 16

4.1 Nozzle specications 16

4.2 Calculations 16

4.2.1 Calculations for systems with pump 16

4.2.2 Calculations for systems without pump 17

4.3 Spray circuit assignment and spray circuit capacities 18

5 Frequency converter (FC) 19

5.1 Diagram of frequency converter (see also wiring plan DL) 19

5.2 Programming the frequency converter 20

5.3 Buttons on the frequency converter and its operation: 21

5.3.1 Programming or data check 21

5.3.2 Procedure for activating the speed display instead of current or frequency 22

5.4 Programming instructions for adapters with SD card (1) 22

5.4.1 Programming steps 23

6 Motors 24

7 Pump 25

7.1 Pump marking 25

7.2 Starting point of pumps 25

8 Overview central units 27

9 Valve block 35

9.1 Valve block – 7 Steps 35

9.2 Valve block – 15 Steps 36

9.3 Valve block – 31 Steps 37

9.4 Valve block – 3 Steps 38

10 Integrated Controller IC 2.0 39

10.1 Software update 39

4Contents

11 Engineering settings 41

11.1 Settings in the "Engineering" submenu 41

11.1.1 Settings in the "Operating Mode" submenu 41

11.1.2 Settings in the "Flushing" submenu 42

11.1.3 Settings in the "Conductivity Flush" submenu 43

11.1.4 Settings in the "Conductivity" submenu 44

11.1.5 Settings in the "Temperature" submenu 46

11.1.6 Settings in the "Step Control" submenu 47

11.1.7 Settings in the "Frequency Converter" submenu 50

11.1.8 Settings in the "Water Inlet" submenu 52

11.1.9 Settings in the "Ag-Ion" submenu 53

11.1.10 Settings in the "Countdown" submenu 54

11.1.11 Settings in the "Reset Conguration" submenu 54

11.2 Settings in the "Hardware Options" submenu 55

11.2.1 Settings in the "Leak Monitoring" submenu 55

11.2.2 Settings in the "Disinfection Pump" submenu 56

11.2.3 Settings in the "Ext. Pipe Flush" submenu 57

11.2.4 Settings in the "Air Cleaning" submenu 57

11.2.5 Settings in the "Auxiliary Outlet" submenu 58

11.3 Settings in the "Features" submenu 59

11.3.1 Settings in the "Softstart" submenu 59

11.3.2 Settings in the "Converter" submenu 61

11.3.3 Settings in the "Pre-Wet" submenu 62

11.4 Functions and settings in the "Maintenance" submenu 63

11.4.1 Functions in the "Reset" submenu 63

11.4.2 Settings in the "Settings" submenu 64

11.4.3 Settings in the "Disinfection Timer" submenu 64

11.4.4 Functions in the "Histories" submenu 65

11.4.5 Functions in the "Diagnostics" submenu 65

11.4.5.1 Settings in the "Manual Demand" submenu 66

11.4.5.2 Display functions in the "Input Diagnostics" submenu 67

11.4.5.3 Functions in the "Output Diagnostics" submenu 68

11.4.5.4 Functions in the "RFI Diagnostics" submenu 69

12 Start sequence diagram 70

13 Hydraulic and electrical diagram 71

13.1 Hydraulic diagram 71

13.2 Wiring plan Condair DL 72

13.3 Wiring diagram Condair DL 73

14 Overview of variants 74

15 Checklist for commissioning 75

5Introduction

1 Introduction

This service manual is aimed at trained Condair service technicians and requires good knowledge of

the Condair DL. In addition, it is prerequisite that the service technician is aware of the installation and

operating instructions of the Condair DL and is familiar with the hazards involved in handling the device.

This service manual contains the following information:

– Description of initial commissioning

– Description of engineering level settings of the Condair DL control unit

– Description and fault diagnosis of the frequency converter

Symbols used in this manual

CAUTION!

The catchword "CAUTION" used in conjunction with the general caution symbol designates notes in

this service manual that, if neglected, may cause damage and/or malfunction of the unit or other

material assets.

WARNING!

The catchword "WARNING" used in conjunction with the general caution symbol designates safety

and danger notes in this service manual that, if neglected, may cause injury to persons.

DANGER!

The catchword "DANGER" used in conjunction with the general caution symbol designates safety

and danger notes in this documentation that, if neglected, may lead to severe injury or even death

of persons.

6For your safety

2 For your safety

General

The service technicians working with the Condair DL must have read and understood this service manual

as well as the installation and operating instructions of the Condair DL before carrying out any work.

Knowing and understanding the contents of the Condair DL service manual and the installation and

operating instructions is a basic requirement for protecting personnel against any kind of danger, to

prevent faulty operation, and to operate the unit safely and correctly.

Qualication of personnel

All work described in this service manual may only be carried out by specically trained Condair

service technicians.

It is assumed that all service technicians working with the Condair DL are familiar and comply with the

appropriate regulations on work safety and the prevention of accidents.

Danger that may arise from the adiabatic humidication system Condair DL

DANGER!

Risk of electric shock

The control unit of the adiabatic humidication system Condair DL is operated with mains volt-

age. Live parts may be exposed when the control unit is open. Touching live parts may cause

severe injury or danger to life.

Prevention: Before carrying out any work on the Condair DL humidication system, disconnect the con-

trol unit from the mains using the electrical isolator and secure the electrical isolator against inadvertent

power-up (Wait at least another 10 minutes before starting work on the frequency converter or motor)

WARNING!

Health risk because of inadequate hygiene

Improperly operated or poorly maintained adiabatic humidication systems may endanger

health. Improper operation or poor maintenance can lead to the proliferation of pathogenic

germs (such as Legionella, which cause Legionnaires' disease) in the water system and in

the area of the humidication unit of the humidication system Condair DL, which may also

escape into the surrounding air.

Note:

Improper changes to the engineering level parameters can lead to system malfunction.

Depending on the circumstances, fully hygienic operation cannot be ensured, such as when:

– Conductivity limits are increased

– Flushing intervals are increased

– Maintenance intervals are increased

– Flushing times are reduced

– The silver ionization current is reduced

– Spray circuit capacities are entered incorrectly

If there is any doubt, do not change any of the parameters.

7For your safety

DANGER!

Risk of electric shock

The frequency converter in the control unit of systems with booster pump contains capacitors.

These can remain charged with a potentially deadly voltage for a certain period of time after

the control unit has been disconnected from the power supply!

Prevention: Wait at least 10 minutes after disconnecting the power supply. Then make sure the ap-

propriate contacts on the frequency converter and the terminals on the pump motor are free of voltage

before starting any work on these components!

8Initial commissioning of the Condair DL

3 Initial commissioning of the Condair DL

3.1 Requirements

For the rst commissioning it is assumed that the components of the adiabatic humidication system

Condair DL (control unit, central unit and humidication unit) are correctly installed and connected and

that the installations have been checked for correct workmanship.

Before you continue with the steps in Section 3.2.

1. Remove the lter cartridge(s) from the lter housing(s) in the water supply line.

2. Disconnect the water supply line on the central unit, run it into a drain and rinse the line for at least

10 minutes to prevent the system from becoming contaminated by standing water or contamination

by chips and rust particles.

3. Then reinstall the lter cartridge(s) and connect the water supply line to the central unit.

3.2 First steps after installing the water supply and drain

1. Make sure that the control unit of the Condair DL is disconnected from the power supply via the

electrical isolator and that it is secured against being switched on unintentionally.

2. Remove the front covers of the control and central unit.

3. Open the motor terminal box in the central unit and check the position of the cable shielding braid

in the stainless-steel cable gland.

The EMC cable glands on the motor terminal box and on the housing of the control unit (below the

frequency converter, see Fig. 1 and Fig. 2) are used for contacting the shielding braid. The stripped

parts of the motor cable must be positioned in such a way that the shield can be contacted easily

through the steel spring inside the cable gland. The shielding braid must not touch a conductor under

any circumstances! Make sure that the stripping is only in the EMC cable gland area; it must not

protrude too far into the terminal box.

Fig. 1: Motor terminal box with stainless

steel EMC cable glands

Fig. 2: Motor cable with an exposed shield-

ing braid

4. If not already connected, connect the motor cable to the motor.

Note: The motor runs with 3x230V and must be congured for a delta circuit:

– Strand 1 = L1 = U

– Strand 2 = L2 = V

– Strand 3 = L3 = W

9Initial commissioning of the Condair DL

5. If the motor cable needs to be connected to the frequency converter, it is connected as follows:

Strand numbers:

1 = U

2 = V

3 = W

Warning: If a different order is chosen, the pump will run in the wrong direction!

6. Two separate protective earth conductors must be guided to the terminals into the inner part of

the control unit. There is a danger of electric shock on the motor or sheet metal part due to the dis-

charge current of the lter at the frequency converter if the protective earth conductor is missing!

Please observe the safety instructions in the operating instructions.

Earth conductors (PE)

Fig. 3: Two separate protective earth conductors

7. Connect the mains supply cable, if not already connected:

• Route the mains supply cable via an electrical isolator or provide a socket so that the device can

be isolated from the mains in all poles.

– Socket for DL type A and B: 200-240 VAC / 15 A slow acting fuse

– Socket for DL type B only: 100-115 VAC / 15 A slow acting fuse

Fig. 4: Electrical isolator (provided by customer)

• Route the mains supply cable through the cable gland and inside the control unit, wind 1x around

the snap ferrite (one loop).

Note: If it is not possible to wind a loop with the stiff wires at hand, two snap ferrite cores can

be xed one after the other to the mains supply (without a loop, route cable through directly)

Then connect to terminals as follows:

– Terminals: L1, L2 and PE for DL type A and B with 200-240 VAC

– Terminals: L1, N and PE for DL type B with 100-115 VAC

Fig. 5: Snap ferrite core for better EMC

8. If not already connected: Connect the control signal, safety loop, and enable, see wiring diagram

afxed to the inside of the cover or in the Condair installation manual!

9. Reattach and lock the front covers of the control and central unit.

10 Initial commissioning of the Condair DL

10. Switch on the electrical isolator (see Fig. 4) and the on/off switch on the right side of the control unit

housing. Then, open the shut-off valve in the water supply line.

Wait until the controller starts up.

11. If the warning message W50 "Out of Commissioning" is displayed after switching on the control

unit, access the menu with the engineering password "0948". Then, select "Menu > Password:

0948 > Maintenance > Reset > Commissioning Reset" submenu and conrm the message after

having ushed the external water supply line. The warning message W50 "Out of Commissioning"

also appears if the control unit has been disconnected from the mains for more than 48 hours (see

also Section 11.4.1).

12. Under "Menu > Password: 0948 > Maintenance > Settings" set the "Humidication" function to "Off"

so that there is no unexpected humidication.

13. Press the "Manual Functions" button in the home screen and then trigger the ushing function (see

Fig. 6) in order that the inlet valve opens, and the system is vented.

Flush the central unit with the ushing function 2 times for at least 5 min.

09/01/2021DL

07:00 pm

Manual Functions

Flushing

Ceramic Wash Over

09/01/2021DL

07:00 pm

Home

Next Maintenance

1685 hr

Demand

Standby

09/01/2021DL

07:00 pm

Flushing

Manual Functions

Back Continue

09/01/2021DL

07:00 pm

Flushing

60 %

In Progress

Cancel

12 3 4

Fig. 6: Triggering a system ushing

14. Access the menu with the engineering password "0948".

15. Access "Output Diagnostics" under "Menu > Maintenance > Diagnostics".

16. Select <Y1 Inlet Valve> parameter and open the inlet valve Y1. The system will be ushed via the

drain valve Y10 (open without current)! Water must be visible or audible at the drain downstream of

the water jet pump.

17. If still open, close the safety loop to trigger the spray valves.

18. After the ushing select <Y10 Drain Valve> parameter and close the drain valve Y10.

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