2577872 EN 1412 READ AND SAVE THESE INSTRUCTIONS INSTALLATION MANUAL Adiabatic air humidification/air cooling system Condair ME Control Humidification and Evaporative Cooling
Thank you for choosing Condair Installation date (MM/DD/YYYY): Commissioning date (MM/DD/YYYY): Location ref.: Model: Serial number: Manufacturer Condair Plc Artex Avenue, Rustington, Littlehampton, West Sussex. BN16 3LN (UK) TEL: +44(0)1903 850 200 FAX: +44(0)1903 850 345 www.condair.co.uk Proprietary Notice This document and the information disclosed herein are proprietary data of Condair Plc.
Contents 1 1.1 1.2 Introduction General Notes on the installation manual 4 4 4 2 For your safety 6 3 3.1 3.2 3.3 3.4 Important notes on installation Delivery Storing/Transportation/Packaging Product designation / Which model do you have UL approved installation 8 8 8 9 9 4 4.1 4.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.6 4.6.1 4.6.2 4.6.
1 Introduction 1.1 General We thank you for having purchased the Condair ME Control Evaporative Humidifier and Cooler (Condair ME Control for short). The Condair ME Control incorporates the latest technical advances and meets all recognized safety standards. Nevertheless, improper use of the Condair ME Control may result in danger to the user or third parties and/or impairment of material assets.
Symbols used in this manual CAUTION! The catchword “CAUTION” used in conjunction with the caution symbol in the circle designates notes in this installation 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 installation manual that, if neglected, may cause injury to persons.
2 For your safety General Every person working with the Condair ME Control must have read and understood the installation manual and the operation manual of the Condair ME Control before carrying out any work. Knowing and understanding the contents of the installation manual and the operation manual is a basic requirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the unit safely and correctly.
Correct lifting and handling Lifting or handling of components must only be carried out by trained and qualified personnel. Ensure that the lifting operation has been properly planned and risk assessed, and that all equipment has been checked by a skilled and competent Health & Safety representative. It is the customer's responsibility to ensure that operators are trained in handling heavy goods and to enforce the relevant lifting regulations.
3 Important notes on installation 3.1 Delivery After receiving: 3.2 – Inspect shipping boxes for damage. Any damages to the shipping boxes must be reported to the shipping company. – Check packing slip to ensure all parts has been delivered. All material shortages are to be reported to your Condair representative within 48 hours after receipt of the goods. Condair assumes no responsibility for any material shortages beyond this period. – Unpack the parts/components and check for any damage.
3.3 Product designation / Which model do you have The product designation and the most important unit data are found on the rating plate fixed to the evaporative module and the control unit. Information regarding the rating plate and the product key can be found in the operation manual of the Condair ME Control. 3.
4 Installation 4.1 Installation overviews 4.1.1 Typical installation Condair ME Control (internal installation) Control unit 4 1 Electrical isolator Evaporative module Hydraulic module 2 5 Water supply line Air flow direction 3 Drain vent AHU drain Water drain line 1 - Mounting the evaporative module --> see chapter 4.2 – Mounting the evaporative module 2 - Mounting the hydraulic module --> see chapter 4.3 – Mounting the hydraulic module 3 - Water installation --> see chapter 4.
4.1.2 Typical installation Condair ME Control (external installation) Control unit 4 Electrical isolator 1 Evaporative module 5 Hydraulic module Water supply line 2 Pressure equalisation Air flow direction 3 AHU drain Drain vent Water drain line 1 - Mounting the evaporative module --> see chapter 4.2 – Mounting the evaporative module 2 - Mounting the hydraulic module --> see chapter 4.3 – Mounting the hydraulic module 3 - Water installation --> see chapter 4.
4.2 Mounting the evaporative module 4.2.1 Notes on positioning the evaporative module The design and dimensioning of the AHU/air duct as well as the location of the evaporative module inside the duct are determined, recorded and set compulsory when planning the entire system. Prior to installation, however, make sure the following criteria have been taken into consideration: 12 – The AHU/air duct floor must be designed with a loading capacity capable of supporting the evaporative module’s weight.
– For inspection, commissioning and maintenance we recommend a minimum free space of 600 mm (24") before and after the evaporative module. Air flow direction a 395 mm / 15.6" Recommended service access Recommended service access 600 mm / 24" 600 mm / 24" (min. 200 mm / 7.9") Dimension “a”: ME Control (internal mounting): ME Control (external mounting): 272 mm (10.7") 111 mm (4.4") Fig.
4.2.2 Installation procedure evaporative module 1. Mounting the tank upstands to the tank: • Mounting the tank upstands supplied by Condair: fix tank upstands to the tank as shown in the figure below using the nuts (M8, AF: 13 mm) and washers supplied. Do not tighten the nuts. Fig.
2. Mounting the tank: • Insert the tank into the AHU/air duct. WARNING! Use an appropriate lifting device or handle the tank with the help of another person to position it inside the duct. It is the customer's responsibility to ensure that operators are trained in handling heavy goods and to enforce the relevant lifting regulations. • Align the tank to the centre of the duct and perpendicular to the duct walls. When aligned fix tank upstands to the duct floor.
3. Fix frame to the tank: • Fix the vertical supports to the tank using the nyloc nuts (M6, AF: 10 mm) and M6 washers. Then, align the vertical supports exactly vertical using a level and tighten the nuts. • Fix the cross member to the vertical supports using the nyloc nuts (M6, AF: 10 mm) and M6 washers. Then, tighten the nuts. Fig.
4. Fix cross member of frame to AHU/duct ceiling: • Fix the cross member to the AHU/duct ceiling using appropriate fixings. Before tightening the screws align the vertical supports exactly vertical using a level. Fig.
5. Mount the blanking plates on the air inlet side (blanking plates available as option): • Starting on each duct side on the bottom fix the side blanking plates to the duct wall using appropriate fixings. Before fixing make sure the side blanking plates are aligned exactly vertical and the free end of the blanking plates touches the middle of the corresponding vertical support. • Starting on one side fix the upper blanking plates to the duct ceiling using appropriate fixings.
6. Mounting the cross bar: • Put the cross bar on the corresponding cross bar bracket with a distance of “A” to the vertical support (see table below). Type evaporative cassette (according to rating plate) Dimension A (nominal) F75 100 mm (4") F85 150 mm (6") F95 200 mm (8") P85 200 mm (8") P95 300 mm (12") A Note: On larger systems the supplied crossbar support(s) must be installed as shown to prevent bending of the cross bar! Fig.
7. Mount optional submerged UV, if applicable: If your system is equipped with the submerged UV mount UV bulb assembly to the cross bar and the junction box to the tank in accordance with the separate manual for this option. 8. Mount distribution head assembly to the topmost evaporative cassettes: • This step must only be carried out on evaporative cassettes with glass fibre media: mount the appropriate distribution cassettes onto the corresponding evaporative cassettes.
9. Mount evaporative cassettes: Note: to avoid damage to the evaporative cassettes during transit, we recommend that the evaporative cassettes are fitted on site. • Before installing the evaporative cassettes sweep the interior of the tank. • Starting with the tallest evaporative cassettes on the bottom hook the cassettes into the vertical supports. Make sure the overlying cassettes slip properly into each other. 1 Fig.
10. Mount the droplet separator cassettes (this step must only be carried out, if your system is equipped with a droplet separator): Note: to avoid damage to the droplet seperator cassettes during transit, we recommend that the droplet seperator cassettes are fitted on site. • Starting with the tallest droplet separator cassettes on the bottom, riveting the banks of the droplet separator cassettes together using ø 3.2 mm (0.13") blind rivets.
• Hook the lower separator brackets into the cross bar. • Then, starting on one side mount one separator bank after the other, align it and secure it with the upper separator brackets. Make sure separator metalwork slots into evaporator cassettes. Fig.
4.3 Mounting the hydraulic module The mounting procedure of the hydraulic module depends on whether or not the hydraulic module is mounted internal or external to the duct. 4.3.1 Mounting the hydraulic module (internal installation) 1. Apply silicone free grease (e.g. gasket grease) onto the surface of the tank connector and onto the surface of the rubber sealing inside the connector of the hydraulic module. 2.
Mounting the hydraulic module (external installation) Clearances to be observed MINIMUM 25 mm (0.98") CLEARANCE TYP. DETAIL A HYDRAULIC MOUNTING BRACKET 150 mm (5.91") 156.83 mm (6.17") 110 mm (4.33") 110.5 mm (4.35") 173.17 mm (6.82") 110.5 mm (4.35") Ø80 mm (3.15") HOLE MINIMUM CLEARANCE OF 300 mm (11.81") REQUIRED 325 mm (12.80") 310 mm (12.
Mounting procedure 1. Mark position of the hole for the drain pipe feed through on the AHU/duct wall. Important: when mounted the drain pipe must have a downslope of 1 to max. 2 % towards the AHU/duct wall. 2. Drill hole ø55 mm (2.2") for the drain pipe into AHU/duct wall. 3. Lead drain pipe ø54 mm (2.125") through the wall feed through and connect it to the tank using the elbow union (supplied as part of the external installation kit). 4. Cut drain pipe to length.
4.4 Water installation 4.4.1 Notes on water installation The layout of the water piping (distribution, supply and drain water piping) depends on the system version. Refer to the corresponding chapter for detailed information and observe the following installation notes. – Notes on distribution piping – The distribution piping is to be carried out according to the figures found in chapter 4.4.2 – Water installation (internal installation) and 4.4.
– – – Notes on water supply – The water supply is to be carried out according to the figures found in chapter 4.4.2 – Water installation (internal installation) and 4.4.3 – Water installation (external installation) and the applicable local regulations for water installations. The indicated connection specifications must be observed. The installation material must be supplied by the customer.
4.4.2 Water installation (internal installation) Stages (box rows) Connection layout distribution hoses 2 1 2 1 3 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 5 4 2 1 3 5 4 2 1 3 5 2 4 5 Distribution hoses ø15 mm (0.625") constant slope (no sagging) 3 5 4 Water supply push-fit connector ø15 mm (0.625") 5 2...5 bar Feed throughs (supplied) Shut-off valve (supplied) Drain pipe ø28 mm (1.125") with constant downslope 1...
4.4.3 Water installation (external installation) Stages (box rows) Connection layout distribution hoses 2 1 2 1 3 2 1 3 4 2 1 3 4 2 1 3 4 2 1 3 5 4 2 1 3 5 Distribution hoses ø15 mm (0.625") constant slope (no sagging) 2 4 5 3 5 Feed through (supplied) 4 5 4 2 1 3 5 Pressure equalisation pipe (mandatory, not supplied) Shut-off valve (supplied) 2...5 bar Drain pipe vent (mandatory, not supplied), highest point of vent tube must be above max.
4.5 Mounting the control unit 4.5.1 Notes on positioning the control unit Please observe the following notes when positioning the Condair ME control unit: – The control unit can be mounted directly outside to the AHU/air duct or to a wall or stand (not supplied). – The control unit should ideally be positioned as close to the evaporative module as possible for ease of servicing and maintenance. Note: the hydraulic module of Condair ME Controls is equipped with a 5 m (16.
4.5.2 Mounting the control unit 5 31 ") .4 2 (1 450 (17.7") 300 (11.8") .5 52 1") (2. 0 21 ) 3" (8. .5 52 ") 1 (2. 64.5 (2.5") Important: if multiple systems have been supplied to a site, ensure that the serial number on the control panel corresponds to the serial number marked on the evaporative module. Fig. 19: Mounting the control unit of Condair ME Controls Mounting procedure: 1. Mark the attachment points for the upper and lower wall support at the desired position with the help of a level.
4.6 Electrical installation 4.6.1 Notes on electrical installation DANGER! Risk of electric shock! The control unit contains live mains voltage. Live parts may be exposed when the control unit is open. Touching live parts may cause severe injury or danger to life. Prevention: The control unit must be isolated from the mains before commencing any installation work. WARNING! The electronic components inside the control unit are very sensitive to electrostatic discharge.
– All cables from the hydraulic module mounted inside the AHU/air duct must be lead via appropriate cable gland(s) out of the AHU/air duct. – Ensure cables are secured in such a way that the insulation is not damaged by sharp edges and so that they do not create a trip hazard. – Observe and maintain maximum cable length and required cross section per wire according to local regulations. – The mains supply voltage must match the respective voltage stated on the rating plate.
D.PUMP D.LVL UV F3 PE L N 100...240 V/1~/50..60 Hz F4 SUPPLY L N N L1 S3 Q A A B B X5 T1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 K2 X19 S1 PMC-24V100W1AA X4 T2 PMC-24V100W1AA B4 F2 (630 mAT) X12 X11 X3 X20 X10 X4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Fig. 21: Wiring diagram Condair ME Control B6 M1 U.V. L N N L1 H1 PE N/GND L/24V P F1 (1 AT) GND 24V P X9 T3 PMC-24V100W1AA B1 B2 B3 K1 X1 X2 SF J2 J3 min.
Legend wiring diagram Condair ME Control A1 Driver board A2 Control board B1 Ventilation interlock B2 Max. humidity monitor B3 Air flow monitor B4 Temperature and conductivity measuring B5 Sensor temperature and conductivity measuring B6 Level sensor dosing pump (option) B7 Demand or humidity/temperature signal B8 External On/Off switch (external enable) B9 Air temperature monitoring duct (option) BAT Backup battery (CR2032, 3V) CS Current sensor (UV lamp) D.LVL Terminal level switch dosing liquid tank D.
Installation work Note: for the connection of the available options please refer to the installation and operation manual of the corresponding option. Control signal (Y) Note: the control settings must be done via the control software of the Condair ME Control. Please refer to the operation manual of the Condair ME Control.
24/10V TMP HUM GND 24V E Enable 24 V - voltage supply X16 JP5: 10V JP4: 24V Temperature sensor – T 24 V Control unit Y TEMP B7 A temperature sensor is to be connected to the contacts “TMP” (+) and “GND” (–) of the terminal block “X16” on the driver board. The admissible signal values can be found in the technical data table in the operation manual. The connecting cable must either be fed through the rectangular cable feed through or a free cable gland into the control unit.
External safety circuit To guarantee the safety of the humidification/cooling system, monitoring the operation by means of a safety circuit “K1” is an absolute requirement. X1 SC1 SC2 J2 Control unit K1 To accomplish this, the potential-free contacts of external monitoring devices (e.g. ventilation interlock “B1”, safety high limit humidistat “B2”, airflow monitor “B3”, etc.
Connecting the 14-core inter-connecting cable from the hydraulic module 1 2 3 4 5 6 7 8 9 10 11 12 13 14 X4 Level Sensor 1 GND Pumps 4&5, Drain & Sensor GND Pumps 1,2&3 VCC Pumps 1,2&3 VCC Pumps 4&5 Signal Pump 4 Signal Pump 2 Signal Pump 1 Signal Pump 3 Signal Pump 5 Signal Drain Pump VCC Drain&Inlet Valve GND Drain Valve GND Inlet Valve 1 2 3 4 5 6 7 8 9 10 11 12 13 14 The 14-core inter-connecting cable “K2” from the hydraulic module is to be connected according to the wiring diagram to the terminals
Mains voltage supply CAUTION! Before connecting the mains voltage supply, make sure the voltage indicated on the rating plate meets the local line voltage. Otherwise, do not connect the control unit. F3 L N SUPPLY Control unit F4 PE L N 100...240 V/1~/50..60 Hz Q Connect mains voltage supply 100...240 V/1~/50...60 Hz in accordance with the wiring diagram, to the terminal block “SUPPLY” in the control unit.
5 Appendix 5.1 Inlet water quality requirements Condair Plc recommends that the Condair ME must be connected to a clean, wholesome (drinking water quality) mains water supply. For areas of hard water and to minimise scale build up the water supply may be treated by a reverse osmosis system (RO). Reverse Osmosis For Condair ME systems supplied with RO water it is recommended that the system is operated within the following parameters.
Parameter Content in supply water Concern Sodium - No specific concerns Total organic carbon - No specific concerns Turbidity < 5 NTU No specific concerns Colony count 22°C < 1000 cfu/ml Indicator of contaminated water supply Coliform bacteria < 10 cfu/100 ml Indicator of poor water quality Legionella bacteria < 50 cfu/1000 ml Risk of Legionella Pseudomonas species < 10 cfu/100 ml Indicator of slime forming potential Controlled Substances DANGER! Many of the following controlled subs
CONSULTING, SALES AND SERVICE: Condair Plc Artex Avenue, Rustington, Littlehampton, West Sussex. BN16 3LN (UK) TEL: +44(0)1903 850 200 FAX: +44(0)1903 850 345 www.condair.co.
