condair FF2 · PDF file1.2 Notes on the installation and ... – if components of the...
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INSTALLATION AND OPERATING INSTRUCTIONS Adiabatic High-Pressure Humidifier 2545099 EN 0902 Condair FF2
Transcript of condair FF2 · PDF file1.2 Notes on the installation and ... – if components of the...
InstallatIon and operatIng InstructIons
adiabatic High-pressure Humidifier
2545
099
en
090
2
condair FF2
Contents
6 Initialcommissioning 36
6.1 ChecklistinitialcommissioningCondairFF2 36
7 Operation 38
7.1 Displayandoperatingelements 38
7.2 Settingtheunitintooperation 39
7.3 Inspectionsduringoperation 40
7.4 Settingtheunitoutofservice 40
8 Maintenanceandreplacementofcomponents 41
8.1 Importantnotesonmaintenance 41
8.2 Maintenanceintervals 42
8.3 Maintenancework 42
8.4 Resettingthemaintenanceindication 43
8.5 Removalofcomponents 448.5.1 Removalandinstallationofspraynozzles 448.5.2 Replacementofpistonpackings 44
8.6 Changingtheoilofthepistonpump 45
9 Troubleshooting 46
9.1 Importantnotesontroubleshooting 46
9.2 Malfunctionwitherrorindication 46
9.3 Resettingtheerrorindication 46
9.4 Malfunctionwithouterrorindication 47
9.5 Replacingthefuseofthecontrolunit 49
10 Productdata 50
10.1 Technicalspecifications/ambientconditions 50
10.2 Declarationofconformity 51
10 Appendix 52
10.1 Diagramh,x 52
11.2 Commissioaningprotocol(copytemplate) 53
1 Introduction 4
1.1 Totheverybeginning 4
1.2 Notesontheinstallationandoperatinginstructions 4
2 Foryoursafety 6
3 OverviewofCondairFF2 8
3.1 CondairFF2systemoverview 83.1.1 Stand-alonesystem
(masterconfiguration) 83.1.2 Compoundsystem
(master-slaveconfiguration) 93.2 Pumpstation 10
3.3 Humidifierunit 12
3.4 Functionaldescription 14
3.5 Scopeofdelivery 17
4 Notesonplanning 18
4.1 Recordofsite-specificdata 18
4.2 Accessoriesandoptions 19
5 Installationworks 20
5.1 Importantnotesoninstallation 20
5.2 Mountingofthenozzleunit 205.2.1 Notesonpositioningand
mountingofthenozzleunit 205.2.2 Mountingthenozzleunit 21
5.3 Mountingthepumpstation 265.3.1 Notesonpositioningand
mountingthepumpstation 265.3.2 Dimensionandweightsofpumpstation 275.3.3 Mountingthepumpstation 285.3.4 Waterinstallation 29
5.4 MountingthecontrolunitFF2Slave 31
5.5 Electricalinstallation 325.5.1 WiringdiagramMasterunits
(stand-aloneunits) 325.5.2 WiringdiagramSlaveunits 335.5.3 Notesonelectricinstallation 34
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LimitationThesubjectoftheseinstallationandoperatinginstructionsisCondairFF2AdiabaticHighPressureHumidifier.Thevariousaccessoriesareonlydescribedinsofarasthisisnecessaryforproperoperationoftheequipment.Furtherinformationonaccessoriescanbeobtainedinthere-spectiveinstructions.
These installation and operating instructions are restricted to the installation,commissioning,operation,servicingandtroubleshootingoftheCondairFF2andismeantforwelltrainedper-sonnelbeingsufficientlyqualifiedfortheirrespectivework.
Theseinstallationandoperatinginstructionsaresupplementedbyvariousseparateitemsofdocu-mentation(installationdrawings,technicalspecifications,etc.).Wherenecessary,appropriatecross-referencesaremadetothesepublicationsintheinstallationandoperatinginstructions.
1 Introduction
WethankyouforhavingpurchasedtheCondairFF2AdiabaticHighPressureHumidifier(“Con-dairFF2”forshort).
The Condair FF2 incorporates the latest technicaladvances and meets all recognized safetystandards.Nevertheless,improperuseoftheCondairFF2mayresultindangertotheuserorthirdpartiesand/orimpairmentofmaterialassets.
Toensureasafe,proper,andeconomicaloperationofthesteamhumidifierCondairFF2,pleaseobserveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallationandoperatinginstructionsaswellastheinstructionsgiveninthemanualsforthecomponentsusedinthehumidificationsystem.
Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyourCondairsupplier.Theywillbegladtoassistyou.
1.2 Notesontheinstallationandoperatinginstructions
1.1 Totheverybeginning
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Symbolsusedinthismanual
CAUTION!Thecatchword“CAUTION”designatesnotesinthisinstallation and operating instructions that, ifinstallationandoperatinginstructions that, ifthat,ifneglected,maycausedamageand/ormalfunctionoftheunitorothermaterialassets.
WARNING!Thecatchword“WARNING”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyanddangernotesinthisinstallationandoperatinginstructionsthat, ifneglected,maycausetoinjurytopersons.
DANGER!Thecatchword“DANGER”usedinconjunctionwiththegeneralcautionsymboldesignatessafetyanddangernotesinthisinstallationandoperatinginstructionsthat,ifneglected,mayleadtosevereinjuryorevendeathofpersons.
SafekeepingPleasesafeguardtheseinstallationandoperatinginstructionsinasafeplace,wheretheycanbeimmediatelyaccessed.Iftheequipmentchangeshands,thedocumentationmustbepassedontothenewoperator.
Ifthedocumentationgetsmislaid,pleasecontactyourCondairsupplier.
LanguageversionsTheseinstallationandoperatinginstructionsareavailableinvariouslanguages.PleasecontactyourCondairsupplierforinformation.
CopyrightprotectionThepresentinstallationandoperatinginstructionsisprotectedundertheCopyrightAct.Passing-onandreproductionofthemanual(orpartthereof)aswellasexploitationandcommunicationofthecontentsareprohibitedwithoutwrittenpermissionbythemanufacturer.Violationofcopyrighttermsissubjecttolegalprosecutionandarisesliabilityforindemnification.
Themanufacturerreservestherighttofullyexploitcommercialpatentrights.
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2 Foryoursafety
GeneralEverypersonworkingwiththeCondairFF2musthavereadandunderstoodthe installationandoperatinginstructionsbeforecarryingoutanywork.Knowingandunderstanding thecontentsof the installationandoperating instructions isabasicrequirementforprotectingthepersonnelagainstanykindofdanger,topreventfaultyoperation,andtooperatetheunitsafelyandcorrectly.
All ideograms, signs and markings applied to the unit must be observed and kept in readablestate.
QualificationofpersonnelAllactionsdescribedinthepresent installationandoperatinginstructions(installation,operation,maintenance,etc.)mustbecarriedoutonlybywelltrainedandsufficientlyqualifiedpersonnelauthorisedbytheowner.Forsafetyandwarrantyreasonsanyactionbeyondthescopeofthismanualsmustbecarriedoutonlybyqualifiedpersonnelauthorisedbythemanufacturer.
ItisassumedthatallpersonsworkingwiththeCondairFF2arefamiliarandcomplywiththeappro-priateregulationsonworksafetyandthepreventionofaccidents.
IntendeduseTheCondairFF2isintendedexclusivelyforhumidificationinventilationsystemswithinthespeci-fiedoperatingconditions(seechapter10“Productspecifications”).AnyothertypeofapplicationwithouttheexpresswrittenconsentofthemanufacturerisconsideredasnotconformingwiththeintendedpurposeandmayleadtotheCondairFF2becomingdangerous.Operationoftheequipmentintheintendedmannerrequiresthatalltheinformationintheseinstal-lationandoperatinginstructionsisobserved(inparticularthesafetyinstructions)
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Dangerthatmayarisefromtheunit
CAUTION! DangerofelectricshockOnemaygetintouchwithlivepartswhenthepumpstation/controlunitisopen.Touchinglivepartsmaycausesevereinjuryordangertolife..Prevention:beforecarryingoutanyworkontheCondairFF2,settheunitoutofoperationasde-scribedinchapter7.4(switchofftheunit,disconnectitfromthemainsandstopthewatersupply)andsecuretheunitagainstinadvertentpower-up.
WARNING!Poorlymaintainedhumidificationsystemsmayendangerhealth.Wheninsufficientlymaintainedharmfulgermscanbuildupintheairductandaffecttheductair.
Prevention:asdescribedinchapter8“Maintenance”,theCondairFF2mustbecleanedinthespecifiedintervalsandthecleaningworkmustbecarriedoutcorrectly.
WARNING!Duringoperationthewatersystemisathighpressure.Inappropriatelyfastenedhosescanbetornoutofthescrewconnectionsduringoperationbythehighpressure.Thereisdangerofinjury,innocircumstancesloosenanyhosesorscrewconnectionsduringoperation.
Prevention:alwayscorrectlytightenthehighpressurehosesandscrewconnectionsanddonotloosenanyhosesorscrewconnectionsduringoperation.BeforecarryingoutanyworkontheCon-dairFF2,settheunitoutofoperationasdescribedinchapter7.4(switchofftheunit,disconnectitfromthemainsandstopthewatersupply)andsecuretheunitagainstinadvertentpower-up.
BehaviourincaseofdangerIfitissuspectedthatsafeoperationisnolongerpossible,thentheCondairFF2shouldimmediatelybeshutdownandsecuredagainstaccidentalpower-upaccordingtochapter7.4(switchoffsystems,disconnectitfromthemainsandstopthewatersupply).Thiscanbethecaseunderthefollowingcircumstances:– ifcomponentsoftheCondairFF2aredamaged,wornorbadlysoiled.– iftheCondairFF2doesnotworkcorrectly.– ifconnectorsandlinesareleaking.– afterlongtimestorageunderunfavourableconditions.– aftertransportationunderunfavourableconditions.
AllpersonsworkingwiththeCondairFF2mustreportanyalterationstotheunitthatmayaffectsafetytotheownerwithoutdelay.
ProhibitedmodificationstotheunitNomodificationsmustbeundertakenontheCondairFF2withouttheexpresswrittenconsentofthemanufacturer.
ForthereplacementofdefectivecomponentsuseexclusivelyoriginalaccessoriesandsparepartsavailablefromyourCondairsupplier.
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2
1
7
4
3
6
5
8
3 OverviewofCondairFF2
Humidifierunitconsistingof:1 StepvalvesY3,Y4andY52 Nozzleunit3 Dropletseparator(optionorproductofothermanufacturer)4 Flushingvalvehighpressuresystem(option)
Pumpstationconsistingof:5 Pumpunit6 Controlunit7 High-pressurepiping8 Floorstand(option)
3.1 CondairFF2systemoverview
3.1.1 Stand-alonesystem(masterconfiguration)
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3.1.2 Compoundsystem(master-slaveconfiguration)
Mastersystemconsistingof:– pumpstation– humidifierunit
Assumingthemaximumpumpcapacityissufficient,thepumpstationofastand-alonesystemmaysupplypressurizedwatertouptothreefurtherFF2systemsbuildingaso-calledmaster-slavecon-figurationasshownbelow.
Slavesystemsconsistingof:– controlunitFF2slave– humidifierunit
Buscable
High-pressurepiping
Slavesystem1
Slavesystem3
Slavesystem2
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3.2 Pumpstation
Overview
1 Oilpan2 Connectorhousingdrain3 Jettingpump4 Pumpmotor5 Flush/reliefconnector6 High-pressureconnector7 Supplyconnector8 Stopvalve9 Pressuretransmitter(workingpressure)10 Supplyvalve11 Pressurereducingvalve12 Waterfilter13 Flushingvalve(supply)
14 Conductivitysensor(option)15 Safetyvalvesupplypressure16 Safetyvalveworkingpressure17 Manometerworkingpressure18 Manometersupplypressure19 Minimumpressureswitch(supplypressure)20 Frequencyconverterpumpmotor21 Driverboard22 Ratingplate23 BMSgateway(optione-LINKSFF2)24 Remoteoperation/faultindicationboard(option)25 Displayandcontrolunitwithcontrol26 Floorstand(option)
678
109
1112
13
1415
5
3
2
1
4
25
26
21
20
19
18
17
16
23
24
22
11
M
Y6
BriefdescriptionofpumpstationThepumpstationconsistsofthecontrolunitandthepumpunitanditissuppliedinahousingreadyforconnection.
Pumpunit:Theoil-lubricatedhighpressurepumpisdirectlymountedtotheelectricmotorandreachesthemaximumcapacityof1’080kg/hatanoperatingpressureof80bar.Assumingthemaximumpumpcapacityissufficient,uptothreefurtherFF2systemsmaybeconnectedtothejettingpumpviathehigh-pressurecircularpiping.
Aminimumpressureswitchcontinuouslymonitorstheminimumsupplypressureandapressuretransmittercontinuouslymonitorstheminimumworkingpressure.Theystoppumpoperationincasetheminimumpressurevaluesdropbelowthelimitforacertaintime.Twosafetyvalvesensurethatthemaximumsupplypressureandthemaximumworkingpressurearenotexceeded.Thepressurereducingvalvemaintainsconstantsupplypressure.
Attheinstallationsite,thesupplylineofdemineralizedwater,thehigh-pressurehoseofthepiping(accessory)andthedrainmustbeconnectedtothejettingpump.
Controlunit:thecontrolunitconsistsofthedisplayandcontrolunit,thedriverboard,thefrequencyconverterforthecontrolofthehighpressurepumpandtheconnectionterminalsforthepowersupply(380...400V/3N~/50-60Hz).Optionallythecontrolunitcanbeequippedwitharemoteoperatingandfaultindicationprint,aconductivitymonitoringandaBMSgateway(e-LINKSFF2)fortheintegrationintoabuildingmanagementsystem(BMS).Thepumpstationiselectricallywiredatthefactory.Attheinstallationsite,thepowersupply,thehumiditycontrollerorhumiditysensor,theremoteoperatingandfaultindication(option),theexternalsafetychainandthestepvalvesmustbeelectricallyconnectedtothecontrolunit.
Stop valve
Supply valve
Pressure reducing valve
Min. pressure switch supply pressure
Manometer supply pressure
Manometer working pressure
Pressure transmitter working pressure
Step valves
Step valvesSlave 1 ... Slave 3
Safety valve working pressure
Safety valve supply “Y2”
Safety valve supply pressure
Water filter
Conductivity sensor (option)
High pressurepump
High pressure piping
Relief valve workingpressure (option)
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3.3 Humidifierunit
1 Supportingstructurenozzleunit2 Nozzlepipes3 Spraynozzle4 High-pressurepipingfrompumpstation5 StepvalveY3(1/7)6 StepvalveY4(2/7)7 StepvalveY5(4/7)8 FlushingvalveY6workingpressure(option)
9 Waterdrainafternozzles10 Siphon(bycustomers,
heightadaptedtoductpressure)11 Opendrainfunnel(bycustomers)12 Dropletseparator(optionorproductof
othermanufacturer)13 Waterdrainafterhumidifierunit
4
5
6
7
8
9
10
11
1
3
2
12
10
13
11
13
NozzleunitThenozzleunitconsistsofseveralnozzlepipes,whichareequippedwiththenecessarynumberofnozzles(system-specific).Theindividualnozzlepipesaredividedintothreedifferentspraycircuits(1/7,2/7and4/7).Thespraycircuitsareconnectedviaahighpressurehosestothecorrespondingstepvalves(eitherdirectlyorviaadistributionblocks).
DropletseparatorTheinstallationofadropletseparatoristhecustomersresponsibility.AnoptionaldropletseparatorisavailablefortheCondairFF2(seeoppositeillustration).Detailedinformationregardingtheoptionaldropletseparatorcanbefoundintheseparatedocumentationtothisproduct.
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M
Y3 (1/7)
Y4 (2/7)
Y5 (4/7)
Y2
5
18
22
2324
2526
2728
P/PI 3a
16211
8
9
13
1514
17
2PI
D3b4
7
6
20
19
1211
10
Y6
380..
.400V
/3N~/
50-6
0Hz
3.4 FunctionaldescriptionEl
emen
tary
dia
gram
ofC
onda
irFF
2(s
tand
-alo
nes
yste
m)
1 Pu
mp st
ation
2 Co
ntrol
unit
3a
Exter
nal P
- or P
I-con
trolle
r3b
Int
erna
l PID
contr
oller
4 Re
mote
oper
ation
/fault
indic
ation
relay
5 Po
wer s
upply
6 Fr
eque
ncy c
onve
rter p
ump m
otor
7 Je
tting p
ump
8 St
op va
lve9
Supp
ly va
lve10
Pr
essu
re re
ducin
g valv
e11
W
ater fi
lter
12
Cond
uctiv
ity se
nsor
13
Safet
y valv
e (su
pply
pres
sure
)14
Mi
n. pr
essu
re sw
itch (
supp
ly pr
essu
re)
15
Pres
sure
tran
smitte
r (wo
rking
pres
sure
)16
Flu
shing
valve
Y2 s
upply
pres
sure
17
Safet
y valv
e (wo
rking
pres
sure
)18
Dr
ain pu
mp st
ation
(by c
ustom
ers)
19
High
-pre
ssur
e pipi
ng20
Flu
shing
valve
Y6 w
orkin
g pre
ssur
e (op
tion)
21
Step
valve
s Y3,
Y4 an
d Y5
22
Duct
drain
s with
siph
on (b
y cus
tomer
s)23
Dr
oplet
sepa
rator
24
Spra
y noz
zles
25
Air fi
lter m
in. F
7 (by
custo
mers)
26
Humi
dity s
enso
r (by
custo
mers)
27
Safet
y hum
idista
t (sa
fety c
hain,
by cu
stome
rs)28
Flo
w mo
nitor
ing de
vice
(safet
y cha
in, by
custo
mers)
Curre
ntW
ater
15
2PI
D3b4
5
Y3 (1/7)
Y4 (2/7)
Y5 (4/7)
22
2324
2526
2728
P/PI 3a
21
20
M
Y3 (1/7)
Y4 (2/7)
Y5 (4/7)
Y2
5
18
22
2324
2526
2728
P/PI 3a
16211
8
9
13
1514
17
2PI
D3b4
7
6
20
19
1211
10
29
Y6Y6
Slav
e 1Sl
ave 2
... S
lave 3
Slav
e 2 ...
Slav
e 3
Mast
er
380..
.400V
/3N~/
50-6
0Hz
230V
/1N~/
50-6
0Hz
Elem
enta
ryd
iagr
amo
fCon
dair
FF2
(mas
ter-
slav
eco
mpo
und
conf
igur
atio
n)
Curre
ntW
ater
Bus
1 Pu
mp st
ation
2 Co
ntrol
unit
3a
Exter
nal P
- or P
I-con
trolle
r3b
Int
erna
l PID
contr
oller
4 Re
mote
oper
ation
/fault
indic
ation
relay
5 Po
wer s
upply
6 Fr
eque
ncy c
onve
rter p
ump m
otor
7 Je
tting p
ump
8 St
op va
lve9
Supp
ly va
lve10
Pr
essu
re re
ducin
g valv
e
11
Wate
r filte
r12
Co
nduc
tivity
sens
or13
Sa
fety v
alve (
supp
ly pr
essu
re)
14
Min.
pres
sure
switc
h (su
pply
pres
sure
)15
Pr
essu
re tr
ansm
itter (
worki
ng pr
essu
re)
16
Flush
ing va
lve Y
2 sup
ply pr
essu
re17
Sa
fety v
alve (
worki
ng pr
essu
re)
18
Drain
pump
stati
on (b
y cus
tomer
s)19
Hi
gh-p
ress
ure p
iping
20
Flush
ing va
lve Y
6 wor
king p
ress
ure
(opti
on)
21
Step
valve
s Y3,
Y4 an
d Y5
22
Duct
drain
s with
siph
on (b
y cus
tomer
s)23
Dr
oplet
sepa
rator
24
Spra
y noz
zles
25
Air fi
lter m
in. F
7 (by
custo
mers)
26
Humi
dity s
enso
r (by
custo
mers)
27
Safet
y hum
idista
t (sa
fety c
hain,
by cu
stome
rs)28
Flo
w mo
nitor
ing de
vice
(safet
y cha
in, by
custo
mers)
29
RJ45
bus c
able
16
GeneralViathestopvalve(8)thefullydemineralizedwater(alsocalledpermeate)isfedfromthereversingosmosissystem(ROsystem)tothepumpstation(1).
Ifthecontrolunit isoperationalandahumidificationrequestispresent,thesupplyvalve(9)andtheflushingvalve(16)opensimultaneouslyandthepumpcircuitisflushed.Afteracertaintimetheflushingvalve(16)closesagain.Ifthesupplypressureiswithintheadmissiblerangethejettingpump(7)startsandbuildsuptherequiredworkingpressure.Thejettingpumpfeedsthewatertothestepvalves(21)viathehigh-pressurepiping(19).One,twoorallthreestepvalvesopen,dependingonthehumidificationrequired(seestepdiagrambelow).
Thedemineralizedwaterthenflowstotherespectivespraynozzles(24)whereitisatomizedintoafineaerosolmistandabsorbedbytheairpassingby.
Adropletseparator(23)(optionorproductofothermanufacturer)downstreammakesurenoaerosolsarecarriedovertotheairpassingby.Wastewaterflowsdownfromthedropletseparatorstotheductdrains(22)andthesiphons.
Ifthereisnohumidificationrequestthepumpautomaticallystopsafterashorttime.
ControlWithstand-alonesystems(masterconfiguration)thecontrolunitisbuiltintothepumpstation.Thecontrolunitfeaturesaseparatepowersupply(380...400V/3N~/50-60Hz),acontrol/humiditysignalinput,connectorsfortheexternalsafetychainandrelayconnectorsfortheremoteoperationandfault indication(option).Inaddition,thecontrolunit incorporatesthefrequencyconverterforthecontrolofthejettingpump.Withcompoundsystems,eachslave isequippedwithaseparatecontrolunit.Eachcontrolunitfeaturesaseparatepowersupply(230V/1N~/50-60Hz),acontrol/humiditysignalinput,connectorsfortheexternalsafetychainandrelayconnectorsfortheremoteoperationandfaultindication(op-tion).Abuscable(29)connectseachslavecontrolunittothecontrolunitofthemastersystemthatcontrolsthejettingpump.
HumidificationThecontrolofthehumidificationsystemisestablishedviaanexternalP/PIcontroller(3a)orthePIDcontrollerbuiltintothecontrolunit(3b).
Asstandardthehumidificationiseffectedwith7-stagesinaccordancewiththefollowingdiagram.Finergradationsarepossible.ContactyourCondairsupplierifnecessary.
000
100
0 1/7
100
00 100
010
2/7
110
3/7
001
4/7
101
5/7
011
6/7
111
7/7
Step1to7
StepvalveY3(1/7)StepvalveY4(2/7)StepvalveY5(4/7)
Demand[%]
Cap
acity
[%]
17
MonitoringofjettingpumpTheminimumsupplyandworkingpressurevaluesarepermanentlymonitored.Thejettingpumpautomaticallystopsifoneofthesevaluesisoutsidetheadmissiblerange.Arespectiveerrormes-sageappearsinthedisplay,theredlamp“Error”lightsup.
Inaddition to theelectronicmonitoring the jettingpump isequippedwith twomechanicalsafetyvalvesforthesupplyandworkingpressure.Thesevalvesopeniftheadmissiblesupplypressureorworkingpressureareexceeded.
Inaddition,thecontrolunitofthepumpstationandthesalvecontrolunitscanbeequippedwitharemoteoperatingandfaultindicationprint.Thusthefollowingoperatingconditionscanbedisplayedovertheappropriaterelays:“Error”,“Humidification”,“Maintenance”and“Uniton”.
3.5 Scopeofdelivery
Thedeliveryincludes:
– Pumpstationcompletewithcontrolunitandbuilt-inPIDcontrollerandoptionalitemsasorderedaccordingchapter4.3.
– Nozzleunitincludingmountingaccessories
– High-pressurehoses(2m,5mor10m)forhigh-pressurepiping
– 3manti-chafespiralhose
– RJ45Buscable (20mor10m,other lengthsavailableon request), forcompoundsystemsonly
– SpecialcabletostepvalvesY3,Y4andY5
– Installationandoperatinginstructions(thedocumentyouarecurrentlyreading)
– Installationdrawingwithmountingdimensions
– Tubingdiagram
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4 Notesonplanning
PriortodesigningandselectingaCondairFF2humidificationsystemthefollowingpreparatorystepsmustbecarriedout:
• Collectingsite-specificdatarequiredforsystemdesign(seechapter4.1)
• Selectingthedesiredoptions(seechapter4.2)
4.1 Recordofsite-specificdata
YourCondairrepresentativeneedsthefollowingdataforpropersystemdesign:
DuctdimensionsWidth(inner) mm _________Height(inner) mm _________Length(inner,min.1300mm) mm _________Wallthicknessofductintheareaofthewatertubingpass-through mm _________
Airvelocityinduct,or m/s _________
airvolumetobehumidifiedperhour m3/h _________
Airpressure(absolute)inhousing-->notmandatorynecessarily Pa _________
StateofsupplyairpriortohumidificationTemperatureT1 °C _________Humidityx1 g/kg/%rh _________
DesiredstateofairafterhumidificationTemperatureT2 °C _________Humidityx2 g/kg/%rh _________
Importantnotes:– IfaparticularsiteistobeequippedwithseveralFF2systemsdeterminetheabovedataforeach
systemseparately.YourCondairrepresentativewillthenevaluatewhethertheparticularsystemsmaybeoperatedinamaster-slavecompoundconfiguration.
– Evaporatingaerosolscoolsdowntheairinsidetheduct(adiabaticcoolingeffect).Toachievethedesiredairtemperaturethesupplyairmustbeheatedpriortohumidification.
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4.2 Accessoriesandoptions
Accessories
Accessory DescriptionHigh-pressurehoseforhigh-pressurepiping
High-pressurehosesforestablishingthehigh-pressurepipingbetweenthehigh-pressureconnectorsofthepump..Hosesof2m,5mor10mlengthavailable (from stock)(fromstock)
Anti-chafespiralhose Theanti-chafespiralhoseprotectsthehigh-pressurehosesinlocationswheretheyaresubjecttogetintouchwitheachotherorwithothersystemcomponents..Length: 3 m:3m
RJ45buscable Thebuscableconnectsthecontrolunitsofamaster-slaveconfiguration..Length: 10 m or 20 m:10mor20m
Options
Option FloorstandforpumpstationFloorstandforpumpstation Floorstandmadeofcorrosionresistantsteel,formounting
thepumpstationataconvenientheightforeasyopera-tion.
Dropletseparator Dropletseparator in frameconstructionmadeofcorro-sionresistantsteelequippedwithcollectormesheswithaspecialbiocidecoating.Withunfavourableflowconditionsand/orhighairspeedintheductadditionallyadeflectionsheetisprovidedfortheoptimizationoftheincidentairflowofthefirstdropletseparator.
Remoteoperatingandfaultindication
Printwithrelaycontactsfortheremoteindicationofthefollowingoperatingconditions:Uniton,Humidification,ErrorandMaintenance.
Conductivitymonitoring Theconductivitymonitoring,consistingoftheconduc-tivitysensorandtheconductivityprint,monitorstheelectricalconductivityofthewaterandoutputsanerrormessageifthelowerlimitvalueisexceeded.
FlushingvalveY6 Flushingvalvefortheautomaticflushingofthehighpressurepipingduringoperation.Theflushingvalveisinstalleddirectlytothestepvalveblock.
e-LINKSFF2 GatewaytoconnecttheCondairFF2toabuildingman-agementsystem.Twoversionsareavailable:BACnet/IPorLonWorks
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QualificationofpersonnelAllinstallationworkmustbeperformedonlybypersonsfamiliarwiththeCondairFF2AdiabaticHighPressureHumidifierandsufficientlyqualifiedforsuchwork.
Allworkconcerningtheelectricinstallationmustbeperformedonlybyadequatelyqualifiedpersonnel(electricianorworkmanwithequivalenttraining).
SafetyForall installationwork theventilationsystem inwhich theCondairFF2willbeinstalled is toberenderedinoperativeandpreventedfromfurtherinadvertentoperation.
ThepumpstationandpossibleSlavecontrolunitsmaybeconnectedtoelectricmainsonlyafterallinstallationworkhasbeencompleted.
GeneralnotesAllstatementsrelatingtothecorrectpositioningandinstallationoftheparticularcomponentsoftheCondairFF2(seechapter5.2and5.3)mustbefollowedandcompliedwith.
WheninstallingcomponentsoftheCondairFF2usethefixingmaterialssuppliedwiththeunit.Iffixingwiththematerialssuppliedisnotpossibleinyourparticularcase,selectamethodoffixingthatisofsimilarstability.Incaseofdoubt,pleasecontactyourCondairsupplier.
5.2 Mountingofthenozzleunit
5.2.1 Notesonpositioningandmountingofthenozzleunit
Thesystem-specificdimensionsforthepositioningofthenozzleunitintheductaretobefoundintheinstallationdocuments,whichareprovidedwithyoursystem.
In addition to the installation instructionsplease observe the following complementary notesonmounting:
– Caution,fullydemineralizedwaterisaggressive!TheCondairFF2systemusesfullydem-ineralizedwater.Allcomponents(duct/monoblock,mountingaccessories,drainline,etc.)inthehumidifierunitareamustbemadeofstainlesssteel(DIN1.4301/AISI304orbetter)orplasticresistanttofullydemineralizedwater.
– Fortheinstallationandmaintenanceofthehumidifierunittheventilationduct/monoblockmustbeequippedwithaviewingwindowandasufficientlylargemaintenanceaccessdoor.
– Inthehumidifierunitareatheventilationduct/monoblockmustbewaterproof.
– Iftheambientairiscoldtheventilationductmustbeisolatedtopreventthehumidifiedairfromcondensatingatthewalls.
– Important!AtthesiteofinstallationanairfiltermeetingtheF7qualityspecificationsorbettermustbeinstalledbeforethehumidifierunit.
5 Installationworks
5.1 Importantnotesoninstallation
21
– Thesectionoftheductholdingthehumidifierunitmustbeequippedwithatubhavingtwowaterdrains,onebeforeandoneafterthedropletseparators.Makesurethewaterinthetubhasunhamperedaccesstothedrains.Eachwaterdrainmustbeconnectedtothesewagesystemseparately,viaasiphon.Forhygienicreasonstheseshouldbeopendrainstothesewagelineofthesite.Important:Theeffectiveheightofthesiphondependsontheductpressure.Theproperlayoutofthedrainingsystemisthecustomer’sduty.
– Theminimumdistanceof0,4mbetweenthehumidifierunitandapossibleheatingunitaswellasthemountingdimensionsaccordingtothesystemdiagrammustbecompliedwith.
– Topreventwaterdropsfrombreakingawayatthedropletseparatorstheairflowtothehumidi-fierunitmustbeuniformwithregardtotheentirediameter.Airrectifiersorperforatedplatesmustbeinstalledbeforethehumidifierunit,asrequired.
– Theadmissibleairvelocityintheductbeforethehumidifierunitis0.5...4.0m/s.
– Ifsilencersareinstalledintheairconditioningunit,makesuretheyareinstalledwithaminimumdistanceof3mbeforeoraftertheCondairFF2.
5.2.2 Mountingthenozzleunit
1. Installingtheverticalmountingrails:markthepositionofthefixingstrapsattheductwall,thendrilltheø3.3mmfixingholes.Important!Makesurethatthefixingholesintheleftandrightductwallareexactlyalignedoppositeeachotherandthattheaxesoftheupperandlowerfixingholesareatrightanglestotheceilingoftheduct.Then,fixtheverticalmountingrailstothewalloftheductwiththefixingstrapsandtheself-tap-pingscrewsprovided.
22
3. Mountingthenozzlepipes:Fixnozzlepipestothepipesupportsusingthefixingstraps,screwsandwashersprovided(positioningof thenozzlepipesaccording to the installationdrawing).Beforetighteningthefixingstraps,makesuretheoutletopeningsof thenozzlesarealignedexactlyhorizontalinflowdirection.
2. Mountingthepipesupports:Fixthepipesupportstotheverticalmountingrailsusingthescrewsandslidingnutsprovided(verticalpositionaccordingtotheinstallationdrawing).Important!Alignoppositepipesupportsexactlyhorizontal.
23
4. Mountingthecentralsupportrail(onlyforductswithawidtha>2m):Fixcentralsupportrailtothenozzlepipesusingthefixingstraps,screws,washersandslidingnutsprovided.Fixlowerandupperanglebrackettothecentralsupportrailusingthescrews,washersandslidingnutsprovided.Finallyfixtheanglebracketstotheductceilingandtheductbottomusingtheself-tappingscrewsprovided(firstdrilltheø3.3mmholes).
5. Mountingthedistributionblocks(systemswithmorethanthreenozzlepipesonly):Fixdistributionblockstotheverticalmountingrailsusingthescrewsandwashersprovided(position-ingaccordingtotheinstallationdrawing).
24
6. Mountingthestepvalveblock:Fixthestepvalveblockattheappropriatepositiontotheductusingtheself-tappingscrewsprovided.Then,drillductpassagesø32.5mmandclose theholes insideandoutsidewith the rubbersleevesprovided.
7. Connectingthehigh-pressurehosestothestepvalveblock:Connect thehigh-pressurehosestothestepvalveblock,thenleadthehosesthroughtherubbersleevesintotheductasshownintheillustrationbelow.
25
8. Connectingthehigh-pressurehosestothespraycircuits:Connectthehigh-pressurehosestotheappropriatedistributionblocksandnozzlepipes(positionofthespraycircuitsaccordingtotheinstallationdrawing).Makesurethehosesarenotkinked(ifnecessary,leadhosesinabowtotheconnector).
1/72/7
4/7
26
Pleaseobservethefollowingnotesonpositioningandmounting:
– Placethepumpstationinawaythat:
– thedistancetothehumidifierunitisasshortaspossible.Note:High-pressurehosesof2m,5mor10mlengthareavailablefromstock.
– itisfreelyaccessibleandthereisenoughspaceforconvenientoperationandmaintenance(min.freespacearoundpumpstation:laterally0.5m,infront0.6m).
– Thepumpstationisdesignedfortheoperationinprotectedroomsandmustthereforenotbeinstalledoutside.
– Donotinstallthepumpstationinexposedlocationsorlocationswithheavydustload.
– Thepumpstationmustbeinstalledonlyinalocationhavingawaterdrainonthefloor.Ifthisisnotpossible,itismandatorytoprovidewatersensorstosafelyinterruptwatersupplyincaseofleakage.Furthermore,chooseasuitablelocationthatpreventsdamagetomaterialassetsincaseofleakage.
– Thepumpstation isdesignedforinstallationonaload-carryingfloororontheoptionalfloorstand.Thepumpstationor the floorstandmustbe fixedwithscrewsto the floor (protectionagainstshiftingandtilting).Caution!Donotinstallthepumpstationtovibratingcomponents.
5.3 Mountingthepumpstation
5.3.1 Notesonpositioningandmountingthepumpstation
27
89577
0
904
662
2583
347,5855
181,5
38
602
24837
6538
min. 500min. 500
min
. 800
404
5.3.2 Dimensionandweightsofpumpstation
alldimensionsinmm
Weightofpumpstation: approx.80kgWeightoffloorstand: approx.6kg
28
5.3.3 Mountingthepumpstation
347,5
855
120
120
347,5
327.5
327.5
120
120
347,5
327.5
327.5
Mountthepumpstationatthedesiredlocationinaccordancewiththefollowingfiguredirectlytothefloor(leftfigure)ormounttheunitontheoptionalfloorstand(rightfigure).
29
Y3Y5
Y4
Y3Y5
Y4
Y6 **
5.3.4 Waterinstallation
Notesonwaterinstallation– Usehosestoconnectthesupplyflushinglineandthetubdraintoanopendrainfunnel(make
suretoinstallthehosescorrectly).
– TheworkingpressureflushingvalveY6(**)ismounteddirectlytothestepvalveblockoftheMasterunit(stand-alonesystem)orthelastSlaveunit(Compoundsystems).Thedrainhoseoftheflushingvalveistobeconnectedtoanopendrainfunnel(makesuretoinstallthehosecorrectly).
– Useonlytheoptionalhigh-pressurehosestoestablishthehigh-pressurepipingbetweenthehigh-pressureconnectionofthepumpstationandthestepvalveblock(orbetweenstepvalveblocksoftheSlaveunits,respectively).Otherhosesmaygetdamagedinoperationandcausesystembreakdown.
Master
Slave 1...3
M20x1.5
ø19 mm hose connector or G 1/2" inside thread
30
– Important!Beforeconnecting,allwaterhosesmustbeflushedwithfullydemineralizedwaterforatleast10minutes.Removethesealingcapsfromtheconnectorsjustshortlybeforeinstallingthehoses.
– Installthehigh-pressurehosesinawaythattheydonotgetintouchwitheachotherorothersystemcomponents.Wherethisisnotpossibleforanyreasonprotectthehigh-pressurehosesusingthesuppliedanti-chafespiralhose.Inthelocationsexposedtochafingwraptheanti-chafespiralhosehelicallyaroundthehigh-pressurehoses(s).
31
5.4 MountingthecontrolunitFF2Slave
1. Unlockandswivelup the transparentcover, thenunlock the twohinges(seedetail “A”)andremovethecover.
2. Undothe6screws,thencarefullyliftthecontrolunitcoveranddisconnectthecablesontheelectronic.
3. Breakoutthe4oblongholesinthebottomoftheunithousingandfixthecontrolunittothewallusing4screws.
4. Connectthevoltagesupply,thecontrolsignal,etc.tothecorrespondingterminalsinthecontrolunitaccordingtheappropriatewiringdiagram(seechapter5.5.2).Important:allcablesmustbeleadintothecontrolunitviathecableglands.
CAUTION!Theelectroniccomponentsinsidethecontrolunitareverysensitivetoelectrostaticdischarge.Whentheunitisopenforinstallationwork,appropriatemeasuresmustbetakentoprotectthesecomponentsagainstdamagecausedbyelectrostaticdischarge(ESDprotection).
Detail“A”
Detail“B”1.
2.
3.
236mm
280mm22
0m
m
306
mm
32
5.5 Electricalinstallation
5.5.1 WiringdiagramMasterunits(stand-aloneunits)
B1 Pressure transmitter 1...10VB2 Active humidity controller or humidity sensorB3 Minimum pressure switch (supply pressure)B4 Conductivity monitoring print (option)B5 Conductivity sensor (option)B6 Temperature sensor motor coilB7 Ventilator interlockF1 Fuse 6.3A, slow-acting (power supply control unit)F2 Fuse 1A, slow-acting (Relay 230V)F3 Fuse 630mA, quick-acting (step valves)F4 Fuse 200mA, quick-acting (analogue entry)F5 Fuse 200mA, quick-acting (24 VDC supply)F6 External fuse 10A, slow-acting (voltage supply 3x400V)H Remote operating and fault indication (option)J Cable bridge (must be removed, if B7 is connected)JP3 Jumper must be set, if Slave unit is connectedK Main contactor
K1 External safety chain (safety humidistat, flow control, ventilator interlock, etc.)
M Motor high-pressure pumpQ External service switch (min. contact clearance 3
mm) or plug-type connector (installation mandatory)S1 Unit switchU Frequency converter pump motorV Ventilator pump motorX Bus connection Master-Slave systemsY1 Supply valveY2 Flushing valve supply pressureY3 Step valve 1/7Y4 Step valve 2/7Y5 Step valve 4/7Y6 Flushing valve working pressure (option)
NN
UV/FanDrain ValveInlet Valve
EnableFC
Y1
Y2
41
2 5
L1 N L1 N
X1
Y3
Y4
X2
L1 L3 NL2
3 x 400V
L1 L3 PENL2
Q
F6
φ
L1 L2 L3
J
F21AT
F3630mAT
RS485 MasterSlave System
X8 X3
U V W B7 T1T2
T5
T6
31
5 Y5NStage 3Stage 2Stage 1
NPump
NHighP
F16.3AT
200mAF
F4F5 X4
X6
X7X9X10X11
Y6
GND +
OptionConductivity
M3~
B6
B4 V
K
B5
B3
B7
S1
U
X
B1
24V5V
Y- +
X
B2
B4 Drive EnableB2 +24VB5 Run forward
GN
DP
ress
GN
DIn
put+
Inpu
t+
+24V
Res
1R
es2
Lev/
TpP
min
.+2
4V
GN
DO
ut F
C+
X5
Fron
t Pan
el
P N P1
L1 N SC
1S
C2
PT1
PT2
H
Err
or
Ser
vice
Ste
am
Uni
t On
K1
JP3
33
5.5.2 WiringdiagramSlaveunits
B2 Active humidity controller or humidity sensorB7 Ventilator interlockF1 Fuse 6.3A, slow-acting (power supply control unit)F2 Fuse 1A, slow-acting (Relay 230V)F3 Fuse 630mA, quick-acting (step valves)F4 Fuse 200mA, quick-acting (analogue entry)F5 Fuse 200mA, quick-acting (24 VDC supply)F6 External fuse 10A, slow-acting (voltage supply 3x400V)H Remote operating and fault indication (option)J Cable bridge (must be removed, if B7 is connected)JP3 Jumper must be set on last if Slave unit
K1 External safety chain (safety humidistat, flow control, ventilator interlock, etc.)
Q External service switch (min. contact clearance 3 mm) or plug-type connector (installation mandatory)
S1 Unit switchX Bus connection Master-Slave systemsY3 Step valve 1/7Y4 Step valve 2/7Y5 Step valve 4/7Y6 Flushing valve working pressure (option)
NN
UV/FanDrain ValveInlet Valve
EnableFC
41
2 5
L1 N L1 N
X1
Y3
Y4
X2
J
F21AT
F3630mAT
RS485 MasterSlave System
X8
31
5 Y5NStage 3Stage 2Stage 1
NPump
NHighP
F16.3AT
200mAF
F4F5
X6
X7X9X10X11
Y6
S1
X
24V5V
Y- +
X
B2G
ND
Pre
ss
GN
DIn
put+
Inpu
t+
+24V
Res
1R
es2
Lev/
TpP
min
.+2
4V
GN
DO
ut F
C+
P N P1
L1 N SC
1S
C2
PT1
PT2
HE
rror
Ser
vice
Ste
am
Uni
t On
L1 PEN230 V
Q
F6
B7
K1
from Master
to next Slave
JP3
34
– Theelectricinstallationmustbecarriedoutaccordingtothewiringdiagramsinchapters5.5.1and5.5.2andtheapplicablelocalregulations.Allinformationgiveninthewiringdiagrammustbefollowedandobserved.
– Allcablesmustbeleadintotheunitviathecableopenings.
– Makesurethecablesdonotscrubonanycomponent.
– Thesupplyvoltagemustcomplywiththevoltageinthecorrespondingwiringdiagram.
TheelectricalinstallationoftheCondairFF2includes:
Installation Master SlavePowersupply Master:380...400V/3N~/50-60Hz Slave:230V/1N~/50-60HzConnectionofpowersupplytoterminalsL1,L2,L3,NandPE(Master)orL1,NandPE(Slave)respectively,accordingtothecorrespondingwiringdiagram.TheserviceswitchQ(disconnectsall3wireswithaminimumcontactclear-anceof3mm)andthefusesF6(max.10A,slow-blow)aremandatory.Cablesectionaccordingtotheapplicablelocalregulations.
CAUTION!Beforeconnectingmakesurethelocalmainsvoltageandfrequencymeetthevaluesstatedontheratingplateofthepumpstation/Slavecontrolunit.
x x
Stepvalves(Y3,Y4andY5)UsethesuppliedcabletoconnectthestepvalvesY3,Y4andY5toterminalsX6accordingthewiringdiagram.Note:Consultthewiringdiagramforthenumberingofwires.Inaddition,thevalvedesignations(Y3...Y5)areimprintedonthecable.Important:exclusivelyusethecableincludedinthedelivery!
x x
Externalcontrollerorhumiditysensor(B1orB2)ConnectexternalcontrollerorhumiditysensortoterminalX2.
Admissiblecontrolsignalsseechapter10.1.Externalsafetychain(K1)Serialconnectionofpotential-freecontactsofexternalmonitoringdevices(safetyhumidistat,flowmonitoringdevice,releaseswitch,etc.)toterminalsSC1andSC2.Important!Ifnomonitoringdevicesareconnectedacablebridge(J)mustbeinstalledtotheterminalsSC1andSC2.
CAUTION!DonotconnectanyexternalvoltagetoterminalsSC1andSC2..
x x
5.5.3 Notesonelectricinstallation
35
Installation Master SlaveRemoteoperationandfaultindication(option)Fourpotential-freerelaycontactsareavailableforremoteoperationandfaultindication.Thefollowingstatesofoperationcanbecommunicatedremotely:– “Error”: Thisrelayisactivatedincaseofmalfunction.– “Humidification”: Thisrelaycloseswhenhumidificationstarts.– “Maintenance”: Thisrelayisactivatedifoneofthepresetmaintenance
countersexpires.– “Uniton”: Thisrelaycloseswhenthecontrolunitispoweredupvia
themainsswitch.Themaximumcontactloadis:250V/5A.Foractuatingrelaysorsmallcontactorsuseappropriateinterferencesuppres-sors.
x x
FlushingvalveY6workingpressure(option)ConnecttheflushingvalveY6accordingtothewiringdiagramtotheterminalsNandHighPoftheterminalblockX7usingthesuppliedcable.
x x
InterconnectionMaster-SlaveMasterandSlave(s)areinterconnectedaccordingtothewiringdiagramsviatheRJ45cableavailableasaccessories.
InadditiontheJumperJP3mustbesetonthedriverboardoftheMasterandthelastSlave.
x x
Note:ThereareseparatedocumentationsavailableforRS485Modbusande-LINKSFF2.
36
6 Initialcommissioning
ItismandatorythattheinitialcommissioningiscarriedoutbyanauthorisedservicetechnicianofyourCondairsupplieraccordingtothefollowingchecklist.Thechecklistmustbefilledoutduringthefirstcommissioningandsignedbythecorrespondingservicetechnician.
6.1 ChecklistinitialcommissioningCondairFF2
Agency:_______________________________ Client:_______________________________Location:______________________________ Date:________________________________Pump: ________________________________ Serialnumber:_________________________Nozzletype:____________________________ Humidificationcapacity:__________________Demandsignal:_________________________ Softwareversion:_______________________
1. Visualinspection
Hosesproperlyfixedandanti-chafespiralhosemounted,wherenecessary?
Connectionshigh-pressurepipingpumpstation-stepvalveblock
Hoseconnectionsintheduct
ConnectionY3tospraycircuit1/7
ConnectionY4tospraycircuit2/7
ConnectionY5tospraycircuit4/7
2. Control/Configuration
AretheelectricinstallationsoftheMasterandtheSlaves(ifavailable)correctlydoneinaccordancewiththeappropriatewiringdiagram?Speciallyobserve:– Arethecablesofthestepvalvescorrectlyconnected?– Isthecontrolsignalcorrectlyconnected?– Istheexternalsafetychainconnected(MasterandSlaves)oristhecablebridgeJ
connectedinstead?– Isthepowersupplycorrectlyconnectedandcorrectlyfused?Withcompoundsystems:IstheterminatingresistorJP3setonthedriverboardoftheMasterandthelastSlave.Arethecontrolunits(MasterandSlave)correctlyconfigured(switchoncontrolunitsandcheckconfiguration).Speciallyobserve:– Isthecontrolsignalcorrectlyconfigured(istheinternalcontrollerdeactivated,ifan
externalcontrollerisconnected)?– IsthenumberofSlaveunitscorrectlyconfiguredinthecontrolunitoftheMaster?– Isthepowerlimitcorrectlyconfigured?
37
3. Pumpstation
Controloftheoillevelinthepump
Flushsupplylineforatleastfor5...10minutes-->thenconnect
Flushhigh-pressurepipingfor5...10minutes
Roomequippedwithfloordrain?
Flushinglineandhousingdrainconnectedandhosessecured?
Flowpressure2...10bar?
Stopvalveopen?
Noleakagesatthepump?
4. Nozzleunit
Nozzlepipestight?
Drainwithinthehumidificationdistancepresentandconnectedviaasiphon?Doestheheightofthesiphoncomplywiththeexpectedductpressure?Sprayangleofthenozzles(min.50°,optimal70°)
Minimumdistancefromthefirstnozzletotheductwallaccurate(nodropformationontheductwall)?Step1/7
Step2/7
Step3/7
Step4/7
Step5/7
Step6/7
Step7/7
5. Dropletseparator
Dropletseparatorcorrectlyinstalled,accordingtotheregulationsofthemanufacturer?
Drainafterthedropletseparatorpresentandconnectedviaasiphon?Doestheheightofthesiphoncomplywiththeexpectedductpressure?Nodropthrowafteratleast1houroffullload(fanandhumidifier)
Remarks: _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Date:_________________________________ Signature: _________________________
38
7 Operation
7.1 Displayandoperatingelements
DisplayandcontrolunitFunction: ConfigurationoftheCondairFF2. Indicationofoperatingparameters. Resetofmaintenancecounter. redLED“Error”Function: TheLED lights in caseof amalfunction of
theunit.Furtheroperationisnotpossibleanylonger.Thetypeofmalfunctionisshowninthedisplay,seechapter9).
TheLEDflashesincaseofatemporarymal-functionoftheunit.Furtheroperationoftheunitisstillpossible.
TheLED flashesalternatelywith thegreenLEDif theexternalsafetychain(ventilationinterlockhastriggered)isopen.Assoonasthesafetychainisclosedagain,theindicationdisappears.
yellowLED“Maintenance”Function: TheLEDlightsifthemaintenanceisdue.
greenLED“Humidification”Function: TheLEDlightsiftheunithumidifies. TheLEDflashesalternatelywiththered
LEDiftheexternalsafetychain(e.g.ven-tilationinterlockhastriggered)isopen.Assoonasthesafetychainisclosedagain,theindicationdisappears.
FlushkeyFunction: Manualflushingofthesupplyline.After
havingpressedtheflushkey,theflushingiscontrolledviathedisplayandcontrolunit.
UnitswitchFunction: Switchestheunitonandoff.Theswitchis
illuminatedwhentheunitisswitchedon.
39
Important!Theproceduredescribedhereafterassumesthatthesystemhasbeeninstalledcorrectlyandinitialcommissioninghasbeencarriedoutdulybyaservicetechnicianofthemanufacturer/distributor.
ProceedasfollowstosettheCondairFF2intooperation:
1. Checkallsystemcomponentsandinstallationsforpossibledamage.
WARNING!
Adamagedsystemorasystemwithdamagedinstallationsmustnotbesetintooperation.
2. Openthestopvalveofthewatersupplyline.
3. Activatetheserviceswitchofthepowersupplylinetothepumpstation,andifpresenttotheSlavecontrolunits.
4. Actuatethepowerswitchofthepumpstation,andifpresentoftheSlavecontrolunits.
Thecontrolcarriesoutasystemtestandthesupplylineisflushed.DuringthetestallthreeLED’slightuptemporarilyandthedisplayshowstheoppositemessage.
7.2 Settingtheunitintooperation
Ifafailureoccursduringthesystemtest,acorrespondingerrormessageisshowninthedisplay.
After the system test the unit is in normal operation mode.The dis-playshowsthestandardoperatingdisplay(firstpageoftheindicationlevel).Note:ThecontentsofthestandardoperatingdisplaydependsontheactualoperatingstatusandontheconfigurationoftheCondairFF2andcandifferfromtheoppositedisplay.
Assoonasahumiditydemandispresent,thesupplyvalveopensandthepumpstarts.Assoonasthenecessaryworkingpressureisreached,onetwoorallthreestepvalvesopendependingonthecurrentdemandandtheCondairFF2humidifies.Note:Ifahumiditydemandispresentbutsincethelast flushingof thesupplylinemorethan1hourhaspassed,thesupplylineisflushedfirstandthenthepumpisstarted.
Note:fordetailedinformationregardingtheoperationofthecontrolunitandthesettingspleaseobservetheinformationgivenintheseparateoperatinginstructionstothecontrolunitFF2.
STARTUP: FF2
INIT MODUL
StandbyFF2
05.01.2009 12.00.00Menu Set
Demand :100%FF2
05.01.2009 12.00.00Menu Set
40
7.3 Inspectionsduringoperation
DuringoperationtheCondairFF2andthehumidificationsystemhavetobeinspectedweekly.Onthisoccasioncheckthefollowing:
• thewholehumidificationsystemforanyleakage.
• thenozzleunitandtheothersystemcomponentsforcorrectfixingandanydamage.
• theelectricinstallationforanydamage.
• theoperatingdisplayforanywarningorerrormessage
Iftheinspectionrevealsanyirregularities(e.g.leakage,errorindication)oranydamagedcomponentstaketheCondairFF2outofoperationasdescribedinchapter7.4.Then,letthedamageormalfunc-tionberesolvedbyaqualifiedspecialistoraservicetechnicianofyourCondairsupplier.
7.4 Settingtheunitoutofservice
Important!ForhygienicreasonswestronglyrecommendtoleavetheCondairFF2onallthetime,eveninperiodswhennohumidificationisrequired.Thiswaythewatercircuitisflushedonaregularschedulethuspreventingtheformationofunwantedmicroorganisms.
ProceedafollowstoputtheCondairFF2outofservice,e.g.formaintenancework:
1. Switchoffthepumpstationand/orallSlavecontrolunits(ifpresent).
2. Shutoffthelinesupplyingdemineralizedwaterfromthereversingosmosissystemanddraintheline,asrequired.
3. Closethestopvalveofthesupplylineandsecureittopreventinadvertentopening.
4. Switchonthepumpstationagainandwaituntilautomaticpressurereliefhastakenplace(approx.1minute),thenswitchthepumpstationoffagain.
5. TurnofftheserviceswitchinthemainssupplylinestothepumpstationandtotheSlavecontrolunits(ifpresent),thensecuretheserviceswitchesagainstinadvertentswitchingon.
6. Hygiene!Letthefanoftheventilationsystemrununtilthehumidifierunitisdry.
7. Incaseyouneedtocarryoutmaintenancework,switchtheventilationunitoffandsecureittopreventinadvertentpowerup(seeinstructionmanualoftheventilationsystem).
41
8 Maintenanceandreplacementofcomponents
QualificationofpersonnelAllmaintenanceworkmustbecarriedoutonlybywellqualifiedandtrainedpersonnelauthorisedbytheowner.MaintenanceandrepairoftheelectricalinstallationoftheCondairFF2mustbecarriedoutonlybyqualifiedpersonnel(e.g.electrician)beingawareofpossibledangerandimplications.
Itistheowner’sresponsibilitytoverifyproperqualificationofthepersonnel.
GeneralnoteTheinstructionsanddetailsformaintenanceworkmustbefollowedandupheld.
Onlythemaintenanceworkdescribedinthisdocumentationmaybecarriedout.
OnlyuseoriginalCondairsparepartstoreplacefaultyparts.
SafetyBeforemaintenanceisinitiated,theCondairFF2mustbetakenoutofoperationinaccord-ancewithinstructionsinchapter7.4andprotectedagainstunintentionalswitchingon.Beforeservicingthehumidificationunit, theventilationsystemmustbesetoutofoperation(consult thedocumentationoftheventilationsystem).
TheCondairFF2mustbecleanedintherequiredintervalsandthecleaningworkhastobecarriedoutcorrectly.
WARNING!Poorlymaintainedhumidificationsystemsmayendangerhealth.Thereforeitismandatorytoobservethespecifiedmaintenanceintervalsandtocarryoutmaintenanceworkinstrictaccordancewiththeinstructions.
8.1 Importantnotesonmaintenance
42
8.2 Maintenanceintervals
Toensuresafe,hygienicandeconomicoperationoftheCondairFF2itscomponentsmustbeperiodi-callymaintained.ForthatpurposetheCondairFF2hasafixedadjustedmaintenancecounter.
W20 Oil changeWARNING
Demand :100%Menu INFO
As soon as the set maintenance interval time has expired, the oppositemaintenancemessageindicatesthatamaintenanceortheoilchangeofthehigh-pressurepumpisdue.Alistoftheworkwhichhastobecarriedoutcanbefoundinchapter8.3.
8.3 Maintenancework
Important:theintervaltimeforthefirstmaintenanceisfixsetto50hoursaftertheinitialcommis-sioning!Afterwards,themaintenanceintervaltimechangesautomaticallyto2000hours.
Systemcomponent WorktobecarriedoutPumpstation Checkwaterfilterandclean,asrequired.
Removeoilfrompumpreplacewithnewoil(oilquality:HD-SAE30motoroilor15W40multigradeoil) (see chapter 8.6).(seechapter8.6)..Iftheoilintheinspectionglassismilkywhite(oilcontainswater)thepistonpackingsmustbereplaced(seechapter8.5.2).8.5.2)..Check jettingpumpand installations for leakage.HavedefectivecomponentsrepairedorreplacedbyaCondairservicetechnicianCheckelectricalconnectionsandwires.Havedefectivecomponentsrepairedorreplacedbyaqualifiedtechnician.
Nozzleunit Checkscrewingofbaseframeforproperfastening.In humidification mode set the nominal humidity value to 100 %andcheckthesprayingangleofthespraynozzles(sprayingcone:optimum70°,50°stilladmissible).Ifthecheckissuccessfulsetthenominalhumiditybacktothecorrectvalue.Removespraynozzles (seechapter8.5.1)andclean them inanultrasonicbath,asrequired.Replacedefectivenozzles.Checkhoses,tubingandconnectionsforpossibleleakage.Fastenscrewingorreplacedefectivecomponents,asrequired.Checknozzlesforproperfastening.Moderatelytighten(torque:ap-prox.4Nm)nozzleswith13mmopen-endwrench,asrequired.
43
Systemcomponent WorktobecarriedoutHumidifierhousing/watertub
Checkwatertub(behindthedropletseparators)fordepositsorac-cumulationofwater.Ifcheckrevealsaconsiderableamountofaccumulatedwater,checkwaterdrainanddropletseparators.Note:Waterdropsandsmallaccumulationsofwaterinthetubbehindthedropletseparatorsarebasicallyinherenttothesystem.Cleanthewatertubandthewetareaofthehumidifierhousing(alsobehindthedropletseparators)withacombinedcleaning/disinfec-tionagent.Thenrinseallcomponentswithhygienicallycleanwater fromthereversingosmosissystemandrubdry.
Dropletseparator Seeseparatedocumentationofthedropletseparator.Checklist“Maintenance” Afterhavingcarriedoutallmaintenancework,fillinthe“Maintenance
checklist”.
Aftercompletingmaintenancework,themaintenanceindication(yellowLEDlights)mustbereset.Note:Ifthemaintenanceindicationisnotresetwithin168hoursanerrormessageistriggered.
Selectthemaintenancemenu:Path:Main menu > User > Password entry: 8808 > Maintenance
Select“Pumpstation”inthemaintenancemenu,thenpressthe<Set>key.
Select“OilChange”,thenpressthe<Set>key.
Theresetdialogueshowsupinthedisplay.Pressthe<Yes>keytoresetthemaintenancecounterandthemaintenancemessage.Note:Pressthe<No>keyifyouwishtoaborttheresetprocedure.
To return to the standard operating display press the <Esc> key severaltimes.
WartungPump station:Set
Esc Set
are you sure? Oil Change
No Yes
Pump stationOil Change :Set
Esc Set
8.4 Resettingthemaintenanceindication
44
8.5 Removalofcomponents
8.5.1 Removalandinstallationofspraynozzles
1. Putthesystemoutofserviceaccordingtochapter7.4andsecureittopreventinadvertentstart-up.
2. Usea13mmopen-endwrenchtoremovethespraynozzle.
3. CheckO-ring,replaceifnecessary.
4. Screwinneworcleanedspraynozzleandmoderatelytighten(torque:4Nm)withopen-endwrench.
8.5.2 Replacementofpistonpackings
Theinstructionsforthereplacementofthepistonpackings,isprovidedwiththesparepartsetoftheappropriatepump.
45
8.6 Changingtheoilofthepistonpump
WARNING!Strictlyfollowalllocalregulationsonenvironmentalprotectionwhenchangingtheoil.Bringtheoldoiltowasteoilcollectingpoint.Innocasedisposeofoilintotheenvironment!
1. Putthesystemoutofserviceaccordingtochapter7.4andsecureittopreventinadvertentstart-up.
2. Openthewasteoilscrew(dependingonthemodelthescrewisonthebottomoronthesideofthepump)usingaopen-endwrenchandlettheoildrainintotheexistingoiltub.Note: If theoil ismilkywhite (oilcontainswater) thepistonpackingsmustbereplaced(seechapter7.5.2).
3. Installthewasteoilscrewandfastenitwiththeopen-endwrench.
4. Carefullyremovetheoiltub,thenemptythetubintoalockablewasteoilcontainer.Correctlydisposeofthewasteoilaccordingtheapplicablelocalregulation.
5. Cleanoiltubandrelocateitunderthepumpagain.
6. Removetheyellow-blackoilfillercapandtopupHD-SAE30motoroilor15W40multigradeoil(approx.0.4l...1.0ldependingonthemodel)untilthelevelisjustinthemiddleoftheinspectionglass(locatedabovethewasteoilscrew).
7. Relocatetheoilfillercap.
46
9 Troubleshooting
Malfunctionsduringoperationareindicatedbyacorrespondingwarningmessage(operationstillpossible,redLEDflashes)orerrormessage(operationnotpossibleanylonger,redLEDlights)inthedisplayofthepumpstationortheSlavecontrolunit.DetailedinformationtheretocanbefoundintheseparateoperatinginstructionsforFF2controlunit.
9.3 Resettingtheerrorindication
Toresettheerrorindication:
Disconnectthepumpstation/Slavecontrolunitfromthemainsforapprox.5seconds,thenreconnectagain.
Note:Ifthefaulthasnotbeeneliminated,theerrorindicationreappearsafterashortwhile.
9.2 Malfunctionwitherrorindication
9.1 Importantnotesontroubleshooting
QualificationofpersonnelHavefaultseliminatedbyadequatelyqualifiedandtrainedpersonnelonly.Malfunctionscausedbytheelectricalinstallationmustberepairedbyauthorizedpersonnel(e.g.electrician)only.RepairworkonthehighpressurepumpmayonlybecarriedoutbyyourCondairrepresenta-tive’sservicetechnician.
SafetyWheneliminatingfaults,theCondairFF2mustbetakenoutofoperation,asdescribedinchapter7.4,andpreventedfromfurtherinadvertentoperation.Makesurethepowersupplytothepumpstation/Slavecontrolunitsiscutoff(testwithvolt-agetester)andthatthestopvalveinthewatersupplylineisclosed.
47
Thefollowingtableprovideserrorsthatdonotissuemessages,notesonthecauseofmalfunctionandinformationonhowtoeliminatethesourceoftrouble.
Error Cause RemedyWaterdepositsintheductsec-tionoutsideofthewatertub
Dropletseparatordefective. Check/Replacedropletsepa-rator
Excessairvelocity(>4m/s) induct.
Reduce air velocity in duct(<4m/s).
Faultylocationofspraynoz-zlesorsprayingcircuitsnotconnectedtoappropriatenozzles.
Checklocationofnozzlesandpiping of spraying circuits ac-cordingtothenozzlediagram.
CondairFF2humidifiesper-manently.
Nominalhumidityvaluetoohigh.
Reduce nominal humidity val-ue.
Ambienthumidityverylow. Nomeasurestobetaken,justwait.
Theinternalcontrollerisactivated,althoughanexternalcontrollerisconnected
Deactivateinternalcontroller.
Maximumhumidificationcapacitynotreached.
Wrongsystemdesign(capacitytoolow).
ContactyourCondairsupplier.
Stepvalve(s)Y3,Y4orY5de-fective.
Checkthefunctionofthestepvalvesbyincreasingthenominalhumidityvalue.Important! Reset the nominalhumidity to the correct valueafterchecking.
Spraynozzlesclogged. Remove nozzles (see chap-ter8.5.1)andcleanorreplacethem
Hosestonozzlepipesareleak-ingordisconnected,ornozzlepipesareleaking.
Checkhoses/nozzlepipesandseal,asrequired
Controlunitisswitchedonbutthedisplayofthecontrolunitdoesnotshowanything.
Serviceswitchinpowersupplylineisoff.
SetserviceswitchinpowersupplylinetoOnposition.
FusesF6of thepowersupplylineblown
HaveanelectricianreplacefusesF6ofthepowersupplyline.
FuseF1ofcontrolunitblown HaveanelectricianreplacefuseF1ofthecontrolunit(seechapter9.5).
Displayorcontrolboarddefec-tive
HaveaCondairservicetechni-cianreplacethedisplayorthecontrolboard.
9.4 Malfunctionwithouterrorindication
48
Error Cause RemedyExcessivefluctuationsofhumiditycontrol.
Faulty electrical connection ofsprayvalvesY3,Y4andY5orsprayingcircuitsnotconnectedtoappropriatenozzles.
Have an electrician connectspray valves Y3, Y4 and Y5correctly(seewiringdiagram).Checkpipingofsprayingcircuitsandrectify,asrequired
Duringahumidificationcyclewaterisflowingviathedrainlineintothefunnelalthoughthereisnoflushing.
FlushingvalveY2(supplyline)soiledordefective.
Haveanexpertcheck/cleanorreplaceflushingvalveY2.
Safetyvalve(supplypressureorworkingpressure)wronglyset,soiledordefective.
Haveanexpertcorrectlysetup,cleanorreplacethesafetyvalves(supplypres-sure:8bar,workingpres-sure:100bar).
49
9.5 Replacingthefuseofthecontrolunit
DANGER!Dangerofelectricshock!Onemaygetintouchwithlivepartswhenthepumpstation/controlunitisopen.Touchinglivepartsmaycausesevereinjuryordangertolife.
Therefore,beforeopeningthepumpstation/controlunit:switchoffthepumpstation/controlunit,disconnectitfromthemainsandprotectitagainstinadvertentswitchingon.
CAUTION!Theelectroniccomponentsinsidethecontrolunitareverysensitivetoelectrostaticdischarge.Whencarryingoutworkontheopenunit,appropriatemeasuresmustbetakentoprotectthesecomponentsagainstdamagecausedbyelectrostaticdischarge(ESDprotection).
Replacementofthecontrolunitfusesmustbecarriedoutbyqualifiedandauthorisedpersonnelonly(e.g.electrician).
Master Slave
Locationofthefuses/Notesonreplacingthefuses
Designation Type RemarksF1 6.3A,slow-acting VoltagesupplycontrolunitF2 1A,slow-acting Relay230VF3 630mA,slow-acting StepvalvesF4 200mA,quick-acting AnalogueinputF5 200mA,quick-acting 24VDCvoltagesupply
F3
F2
F1
F5F4
F3
F2
F1
F4
F5
50
10 Productdata10.1 Technicalspecifications/ambientconditions
Humidifierunitbuilt-inlength min1.3m
Specificationoffilterbeforehumidifier min.F7
Max.supplyairtemperaturebeforehumidifier 50°C
Airvelocity,rangeofuse 0.5...4.0m/s
Lossofpressurewithregardtocross-sectionofduct approx.75PaatwL2.3m/s
Nozzlecapacities(at80barspraypressure) 5kg/h
Effectivehumidificationdistance 0.8...1.3m
Humidificationcapacity 35....1080kg/h
Pumpstation(controlandjettingpump)Dimensionsofpumpstation(HeightxWidthxDepth) 904x662x404mm
Weightofpumpstation max.80kg
Jettingpumpsupplyvoltage 380...400V/3N~/50...60Hz
Activeoutputofjettingpumpmotor 1.5kW / 4.0kW
Currentconsumptionofjettingpumpmotor 1.7...4.3A / 4.4...6.9A
Powerconsumptionofcontrol 60VA
Workingpressureofjettingpump(Standard) 80bar
Oilcapacityofjettingpump(capacitydependingonpumpsize)
approx.0.4l...1.0l
Admissiblesupplywatertemperaturebeforejettingpump 5...35°C
Admissiblewaterpressure(yieldpressure)beforejettingpump 2...10bar
AdmissibleconductivityofwatersuppliedbyROsystem 3...15µS/cmnoadditives,max.100KBE/ml
Controlsignals 0...10VDC,2...10VDC0...5VDC,1...5VDC,0...16VDC,3,2...16VDC,0...20mA,4...20mA
Controlaccuracy upto±4%rh
Watersupplyconnection 19mmhoseconnectororG1/2"insidethread
Flushinglineconnection 19mmhoseconnectororG1/2"insidethread
Tubdrainconnection 19mmhoseconnectororG1/2"insidethread
Connectorhigh-pressurehose M20x1.5(outsidethread)
Admissibleambienttemperature 5...35°C
Admissibleambienthumidity max. 75 %rh, non-condensing
Testcertificates CEapprovalmark
Protectionclassofjettingpump/control IP31
51
10.2 Declarationofconformity
Wedeclareunderoursoleresponsibilitythatthepumpstationusedintheadiabatichigh-pressurehumidifierCondairFF2complywiththefollowingstandards:
– EN292-1
– EN292-2
– EN50081-1(1992)
– EN50082-2(1995)
– EN61000-4-2(1995)
– EN61000-4-3(1996)
– EN61000-4-4(1995)
– EN61000-4-5(1995)
– EN61000-4-6(1996)
– EN61000-4-8(1993)
– EN61000-4-11(1994)
WalterMeier(KlimaInternational)AGPfäffikon,january5,2009
52
10 Appendix10.1 Diagramh,x
53
11.2 Commissioaningprotocol(copytemplate)
Cond
air F
F2
Main
tena
nce r
ecor
d
Unit
type
Seria
l num
ber
Com
miss
ioni
ngSo
ftwar
e ver
sion
Loca
tion
Resp
onsib
leIn
tern
al no
.
Date
Tim
ePe
rmea
t con
duc-
tanc
e�if
poss
ible�
�if p
ossib
le�[µ
S/cm
]
Load
pre
ssur
e be
fore
pum
p [b
ar]
Load
pre
ssur
e af
ter p
ump
[bar
]
Wor
king
hour
s
[h]
Rem
arks
rega
rdin
g th
e main
tena
nce
Signature
Seite
Notes
© Walter Meier (climate International) ltd. 2009, printed in switzerlandtechnical modifications reserved
reg.no. 40002-2
Manufacturer:Walter Meier (climate International) ltd.talstr. 35-37, p.o. Box, cH-8808 pfäffikon (switzerland)phone +41 55 416 61 11, Fax +41 55 416 62 62www.waltermeier.com, [email protected]
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