Condair HP200 VFD, HP100, HP500, HP500 VFD, HP800 Installation And Operation Manual

HP Series

Important: Read and save these instructions. This guide to be left with equipment owner.

Installation and
Operation Manual

Includes installation, operation
maintenance and troubleshooting
information for your HP Series
humidifier

1507183-E| 17 JUN 2016

Thank you for choosing Condair.

INSTALLATION DATE (MM/DD/YYYY)

MODEL #

SERIAL #

CYLINDER #

INSTALLATION DATE (MM/DD/YYYY)

MODEL #

SERIAL #

CYLINDER #

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 does not accept any liability for installations of humidity equipment installed by unqualified personnel
or the use of parts/components/equipment that are not authorized or approved by Condair.

Copyright Notice

Copyright 2019, Condair Ltd. All rights reserved.

Contents

2 Introduction

2 About HP

3 Receiving and Unpacking Equipment

3 Absorption Distances

3 Components

6 Multiple Zones

7 Water Quality

17 Installation

18 Important Notes on Installation

20 Pre-Installation

23 Construction of a Wet Duct Section

24 Pump Module

27 Mounting the Pump Station

28 Water Installation

43 Startup, Operation, and

Maintenance

44 Initial Commissioning and Startup

37 HP High Pressure Atomizing

Humidifier Start-up Checklist

50 Operation

59 Setting the Unit Into Daily

Operation

60 Inspection During Operation

61 Shutting Down the Unit

62 Maintenance

65 Preventative Replacement Parts

69 Troubleshooting

72 Warranty

31 HP Manifolds

37 Mist Eliminator

CAUTION: Servicing

 Disconnect main power before any servicing.

CAUTION: Electrical

CAUTION: Plumbing

 All plumbing work should be done according to local plumbing code.

CAUTION: Installation

 The plumbing and electrical compartments contain high voltage components and

wiring. Access should be limited to authorized personnel only.

 During and following operation of the humidifier, the steam and components in

contact with the steam such as the blower pack, steam lines, steam distributors,
and condensate lines can become hot and can burn if touched.

 Condair does not accept any liability for installations of humidity equipment

installed by unqualified personnel or the use of parts/components/equipment
that are not authorized or approved by Condair.

 All electrical work should be done according to local and national electrical code.
 Electrical connection to be performed by a licensed electrician.

 Plumbing to be performed by a licensed plumber.

 Drain water from humidifier can be very hot. Do not drain to public sink.

 Do not mount on hot surfaces.

 Do not mount in area where freezing can occur.

 Do not mount on vibrating surface.

 Do not mount on floor.

 Regardless of selecting on/off or modulating control method, Condair

humidifiers must have a closed circuit across its on/off security loop control

terminal to operate. Condair highly recommends the use of a duct high limit

humidistat.

1 | HP Series Installation Manual

Introduction

HP (Adiabatic Humidification System)

Congratulations on the purchase of your Condair HP humidification system. This system was
designed to be efficient and reliable, and is manufactured from high quality materials to provide
long trouble free operation. In order for the system to operate as intended it must be installed
properly.

This guide details the design, installation, commissioning, operation, and troubleshooting of the
HP system. Please take the time to familiarize yourself with this guide before beginning to
ensure that the system is installed the way it was designed. This ensures a long and trouble
free life of the humidifier.

About HP (Adiabatic Humidification System)

The HP (High Pressure) system is designed to be installed inside an AHU or duct system to
humidify air to a desired relative humidity. Proper humidity levels have been shown to be
important for health and comfort of occupants. Maintaining proper humidity is also important
for many industrial and manufacturing processes.

The HP system uses a series of nozzles to spray a very fine mist of water droplets into an air
stream. During this process the air absorbs moisture increasing its relative humidity levels. As
the water droplets evaporate, they absorb some energy in the form of heat from the air. This
loss of heat causes the air temperature to drop, resulting in a phenomenon known as adiabatic
cooling.

The HP adiabatic system has 2 effects:

 The relative humidity of the air increases (humidification)

 The temperature of the air falls (adiabatic cooling)

Humidification of the air is the main goal of the HP system. The cooling of the air is secondary
and is frequently beneficial since it is ‘free’ cooling. In cases where air-cooling is un-desired,
preheating of the air is required.

In general a HP system has the following advantages over other humidification technologies:

 Low frequency of maintenance, since there are few moving or expendable parts.

 Replacing components is quick and requires minimal system disassembly.

 A ‘free’ air-cooling benefit from water extracting latent heat from the air.

HP Series Installation Manual | 2

Receiving and Unpacking Equipment

 Check packing slip to ensure ALL material has been delivered.

 All material shortages are to be reported to Condair within 48 hours from receipt of goods.

Condair assumes no responsibility for any material shortages beyond this period.

 Inspect shipping boxes for damage and note on shipping waybill accordingly.

 After unpacking, inspect equipment for damage and if damage is found, notify the shipper

promptly.

All Condair products are shipped on an F.O.B. factory basis. Any and all damage, breakage or
loss claims are to be made directly to the shipping company.

Absorption Distances

An important consideration in the planning of a HP system is the absorption distance, or the
distance it takes for the droplets to evaporate inside the HVAC system. The absorption distance
is relative to the air velocity, temperature, atmospheric pressure, and the amount of water in the
incoming air. In applications where space is limited, such as in an air-handler, precautions
should be taken to prevent the wetting of sensitive components downstream.

Components

Condair Supplied

Condair will supply the following components:

1 High pressure pump skid
2 Valve block assembly and cables
3 Nozzle manifolds and mounting hardware
4 10 ft. of high pressure hose (optional 6.5 ft., 16.5 ft., or 33 ft. of high pressure hose for

piping)

5 10 ft. of anti-chafe spiral hose (optional)
6 Installation manual, installation drawing with mounting dimensions, and tubing diagram.
7 Mist eliminator (optional)
8 Air proving switch (optional)
9 High limit humidistat (optional)
10 Humidistat (optional)

3 | HP Series Installation Manual

Field Supplied

The Installer is responsible for supplying the following:

1 Electrical disconnects
2 All electrical wiring
3 High pressure piping between pump skid and manifolds
4 Flex hose
5 P-traps
6 Drain funnels
7 Wet duct section (drain pans, wall sections, sealants, fasteners)
8 Pump skid vibration dampening
9 Electricity, water, and airflow

HP Series Installation Manual | 4

2

Figure 1: Typical HP System Installation

Humidifier Components:

1 Step Valves MV REG1, MV REG2, and MV REG3
3 Nozzle Manifold
4 Mist Eliminator
5 Flushing Valve MV REG5

Pump Station Components:

6 High Pressure Pump
7 Control Panel, with Touch Screen
8 High Pressure Flexible Hose
9 UV-light system (Option)

Multiple Zones

Oftentimes a single pump package will be used to serve different ducts or zones. In this case
each duct will have its own set of manifolds, valve controller and valve block making it fully

5 | HP Series Installation Manual

independent of the other zones. The pump should be sized to handle the full flow capacity of all

All units must be located at the same elevation.

The maximum length of high pressure piping from the pump station to the last Slave unit must not
exceed 200 ft.

zones combined to ensure reliable operation.

Care must be taken when laying out the piping between the pump and the valve blocks at each
zone to prevent vibration transmission or water hammering effects. The piping should be
securely supported using appropriate cushion clamps (by others) and long straight runs should
be avoided.

Figure 2: Typical Installation with Master/Slave Configuration

HP Series Installation Manual | 6

Water Quality

Quality

Requirement

Water Supply:

Drinking Water Quality / RO Water

Conductivity:

5-1000 μS/cm

Silt Index:

Max. 3.0

KMn04:

Max. 10 mg/l

NTU:

Max. 1.0

Temperature:

Max. 59°F (15°C)

TDS:

Max. 625 mg/l

Fe:

Max. 0.05 mg/l

Mn:

Max. 0.05 mg/l

Hardness (Max.):

Max. 5 gpg (5º dH)

Free Chlorine (Max.):

Max. 1 mg/l

Water used with the Condair HP system must be very pure. Dissolved solids, and impurities
contained in the water will precipitate out when the water evaporates, causing dust and
minerals to be deposited into ducts, and/or the humidified space. Dusting can have adverse
effects on filters, fans, heating and cooling coils, human health, and may promote corrosion and
bacteria growth in ducts.

For this reason only Reverse Osmosis (RO) or De-Ionized (DI) water can be used with a Condair
HP humidification system. DI water is very aggressive, in applications where DI water is used all
components (including wet section of ducting and drains) must be constructed from stainless
steel.

If a water treatment system is required, the Condair HP RO pump station is available and
includes an integrated RO system built directly onto the HP pump skid.

To ensure that the HP nozzles do not become blocked or damaged over time, the following
conditions should also be met:

Table 1 : Water Quality Requirements

7 | HP Series Installation Manual

Component Overview

Pump Station

Figure 3: HP Pump Station

Figure 4: HP Flow Diagram

HP Series Installation Manual | 8

Part Specification

D

Drain

F

Filter 1μ

FR

Water meter (option)

G1

Pressure gauge 0-145 psi (0-10 bar)

G2

Pressure gauge 0-145 psi (0-10 bar)

G3

Pressure gauge 0-1958 or 0- 2320 psi (0-135 or 0-160 bar)

K1

Check Valve

K2

Check Valve

M1

Motor

MV1

Solenoid Valve

MV5

Valve for flushing

MV REG 1

Valve for nozzle strings

MV REG 2

Valve for nozzle strings

MV REG 3

Valve for nozzle strings

P1

High pressure pump

FD

Frequency converter (option)

PT

Pressure transmitter for frequency converter

PS

Pressure switch

R

Pressure reduction valve

T

Thermostat

UV

UV light tube and transformer (option)

V1

Test water tap 1/8”

Pump Station Details

High-pressure pump station.
All components exposed to water are made of corrosion resistant material. The hoses are

drinking water approved high pressure hoses, stainless steel braided or high-pressure hoses in
dimension 1/4" or 3/8”.The system is fitted on a frame and all components are assembled,
tested, and ready to use.

Pump Station: The water-lubricated high pressure stainless steel pump is directly mounted
to the electric motor and operates at a pressure of 435 to 1015 psi (30 - 70 bar).

9 | HP Series Installation Manual

Table 2 : Technical Specifications

HP100

HP200

VFD

HP300

HP500

HP500

VFD

HP800

HP800

VFD

HP1300

VFD

Capacity, l/h*

120

200

318

528

500

948

800

1300

Weight, kg (lb)

50-65

(110-

143)

50-65

(110-

143)

55-70
(121-

154)

65-80
(143-

176)

55-70
(121-

154)

75-90
(165-

198)

65-80
(143-

176)

75-90
(165-

198)

Dimensions l x w
x h, in

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

25.9 x

19.7 x

51.1

Water supply, bar

1-4

1-4

1-4

1-4

1-4

1-4

1-4

1-4

Sound pressure
level, db(A)

<80

<80

<80

<80

<80

<80

<80

<80

Electrical
connection

220-240 / 380-415 / 3 / 60Hz

Installed effect:
kW – Pump

0.50

0.80

1.1

1.5

1.2

2.2

2.4

3.5

Pipe diameter –
inlet, “RG

3/8

3/8

3/8

3/8

3/8

3/8

3/8

3/8

The pump is protected against dry running by a pressure switch that stops the system if water
pressure drops. The high-pressure pump is protected against overheating by a temperature
circuit that measures the current temperature in the pump.

Control unit: the control unit consists of the touch display and PLC. A power board, for control of
the high pressure pump and connection terminals for power supply. The power board has an
alarm switch (NC).

Optionally the control unit can be equipped with a remote operating and fault indication print, a
conductivity monitoring and a BMS gateway for the integration into a building management
system (BMS).

The pump station is electrically wired at the factory. At the installation site, the power supply,
the humidity controller or humidity sensor, the remote operating and fault indication (option),
the external safety chain and the step valves must be electrically connected to the control unit.

HP Series Installation Manual | 10

Humidifier Unit

Figure 5: HP Humidifier Unit

1 Nozzle manifold mounting rails
2 Nozzle manifold
3 Spray nozzles
4 Flushing valve MV5 working pressure (option)
5 Step valve MV REG3 (4/7)
6 Step valve MV REG2 (2/7)
7 Step valve MV REG1 (1/7)
8 High-pressure hose from pump station
9 Water drain after nozzles
10 Open drain funnel (by others)
11 Mist Eliminator/Droplet Separator (option or by others)
12 Water drain after humidifier unit
13 P-Trap (by others, height adapted to duct pressure)

11 | HP Series Installation Manual

14 Separation element humidifier unit
15 (min. height: 3 cm, sealed towards the duct floor and the duct walls)
16 Drain hose from flush valve MV5

Nozzle Unit

The nozzle unit consists of several nozzle pipes, which are equipped with the necessary number
of nozzles (system-specific). The individual nozzle pipes are divided into three different spray
circuits (1/7, 2/7 and 4/7). The spray circuits are connected via a high pressure hoses to the
corresponding step valves (either directly or via a distribution blocks).

Mist Eliminator

The installation of a mist eliminator is the customers responsibility. An optional Condair
mist eliminator is available for the Condair HP.

Note regarding the Condair mist eliminator: Due to the special surface finish of the mist
eliminator material, the Condair mist eliminator will reach peak performance about 4-8 weeks
after the initial installation (time depending on the water quality).

HP Series Installation Manual | 12

Figure 6: HP System Layout, Stand Alone System

13 | HP Series Installation Manual

Figure 7: HP System Layout, Master/Slave System

HP Series Installation Manual | 14

General

The pump is driven by a 3-phase motor. The pump speed is controlled from 1000 rpm to 3500
rpm by a frequency controller VFD.

The control system consists of a PLC unit, which controls water treatment and adjusts humidity
in the duct. Adjustment is carried out by means of a special proportional regulator, which
activates the necessary number of steps in relation to the current humidity requirement.

A flushing function is included, which ensures hygienic operation and prevents standing water in
the system. If one of the nozzle pipes has been inactive for 30 minutes, the control panel will
trigger a rinse pulse lasting two seconds, this ensures continual water movement within the
system.

The control signal comes from an analogue 0-10 volt signal. It is possible to choose between
two different modes for this signal:

1 Humidity control – The humidity is measured against the relevant input and the control then

calculates how many steps to activate in order to achieve the required level of humidity.

2 Direct capacity - The required capacity is transferred directly from a BMS system.

Hour counters are incorporated into the control unit. One hour counter that indicates the

pump’s running time to be used for setting service intervals, one hour counter for the pump and

one hour counter for each of the steps, which summarizes the period of time where each step is
active.

Control

With stand-alone systems (master configuration) the control unit is built into the pump station.
The control unit features a separate power supply, a control/humidity signal input, connectors
for the external safety chain and relay connectors for the remote operation and fault indication
(option). In addition, the control unit incorporates the frequency converter for the control of the
high pressure pump.
With master/slave systems, each slave is equipped with a separate control unit. Each control
unit features a separate power supply, a control/humidity signal input, connectors for the
external safety chain and relay connectors for the remote operation and fault indication
(option). A bus cable connects each slave control unit to the control unit of the master system
which controls the high pressure pump.

Humidification

The control of the humidification system is established via an external P/PI controller, or the PID
controller built into the control unit.

As standard, the HP features 7-Stage valve control as outlined in the figure below. An additional
step valve is available as an option, and increases the total number of stages to 15.

15 | HP Series Installation Manual

Figure 8: 7-Stage Valve Control

Monitoring of high pressure pump

The supply pressure and pump temperature are continuously monitored. The HP pump
automatically stops if one of these values is outside the admissible range. A respective error
message appears in the display.

In addition, the control unit of the pump station and the salve control units can be equipped
with a remote operating and fault indication board. Thus the following operating conditions can

be displayed over the appropriate relays: “Error”, “Humidification”, “Maintenance” and “Unit
on”.

HP Series Installation Manual | 16

Installation

17 | HP Series Installation Manual

Important Notes on Installation

Qualification of personnel

All installation work must be performed only by persons familiar with the Condair HP Adiabatic
High Pressure Humidifier and sufficiently qualified for such work.

All work concerning the electric installation must be performed only by adequately qualified
personnel (electrician or workman with equivalent training).

Safety

For all installation work, the ventilation system in which the Condair HP will be installed is to be
rendered inoperative and prevented from further inadvertent operation.

The pump station and possible Slave control units may be connected to electric mains only after
all installation work has been completed.

General notes

All statements relating to the correct positioning and installation of the particular components of
the Condair HP must be followed and complied with.

When installing components of the Condair HP, use the mounting hardware supplied with the
unit. If the mounting hardware cannot be used in your particular case, select a method of fixing
that provides equivalent support. For questions on concerns, please contact your Condair
supplier.

HP Series Installation Manual | 18

Scope of Delivery

Included Components

 Pump station complete with control unit and built-in PID controller and optional items as

ordered

 Nozzle unit including hoses, 3xstep valves / 1xflush valve and mounting accessories

 High-pressure hose (9.8ft. / 3 m) for high-pressure piping between pump station and step

valves

 Hose feed through, 3 pc. for single walled duct’s

 Special cable to step valves REG1, REG2, REG3

 Alarm switch (NC)

 Installation and operating instructions (the document you are currently reading)

 Installation drawing with mounting dimensions

 Tubing diagram

19 | HP Series Installation Manual

Pre-Installation

Prior to beginning installation of the HP system, the required tools should be obtained, and all
contractor-supplied parts (indicated as parts “By Others” throughout this manual) should be
gathered.

Required Tools

In order to assemble an HP system the following tools and supplies are required:

1 Hammer
2 Socket Set, common imperial and sizes
3 Box-end wrenches – various sizes
4 Pipe Bender
5 Screwdriver Set, including standard flathead and Phillips
6 Caulking
7 Caulking Gun
8 Metal Snips
9 Hacksaw
10 Plumbing Tape

Required Components

The following components must also be supplied to complete the installation:

1 Electrical Disconnect Switches

 Disconnect switches must be supplied to isolate the humidifier for maintenance and in the

case of emergency. If the control panel and disconnect is to be located outdoors, NEMA
rated disconnect switches should be used per national and local codes.

2 Sizing High Pressure Stainless Steel Tubing

 Stainless steel piping must be supplied for distances between the HP pump module and the

HP manifolds. These distances should be kept to a minimum to minimize pressure losses
and maximize system performance, however it is important to avoid over-sizing the lines.
For most installations a 1/2” line is appropriate. Stainless Steel Pipe Fittings

 Stainless steel compression fittings are required for all high-pressure line connections.

When using swage type fittings to connect feed lines together, use fittings of the same
material as the feel lines. Never use a brass compression fitting on a stainless steel tube,
as the brass will not properly hold the harder stainless steel pipe.

 Follow manufacturer’s instructions when installing fittings.

 Recommended tube material: 304L stainless steel tube, ½” Outside Diameter, 0.049” Wall

thickness

 Recommended fittings: 316 stainless steel, ½”, double ferrule compression connections.

HP Series Installation Manual | 20

3 Reinforced Flexible Hose

 The HP pump module features a modern high precision pump. Despite this some degree of

vibration is unavoidable when the system is operating. Vibration effects can be further
amplified by long lengths of solid piping and can be transmitted over distances. To avoid
this, reinforced flexible hose is recommended between the pump outlet and the feed piping,
as well as between the feed piping and the valve block. The lengths of reinforce flexible
hose used at these points should be at least 2ft (61 cm). This will dampen vibrations
transmitted from the pump and air-handler / ducting.

 A length (9.8 ft. / 3m) of high pressure hose is supplied with each unit for piping between

the pump station and step valves.

 Additional hose can be purchased from Condair. Hoses provided by others are not

recommended.

 Care must be taken when using reinforced flexible hose. It must not be allowed to sag

unduly, vibrate excessively, be bent around a radius of less than 2” (50 mm), or come into
contact with sharp edges. Always leave some extra line when going around corners and
making bends. Avoid twisting and kinking the lines while un-spooling and installing. When
supporting the hose, keep in mind that thermoplastic hose has a tendency to return to
position it was supplied in.

4 Pipe Supports and Fasteners

 The installer must also supply support for feed piping. When selecting brackets, pipe

strapping, and various other supports, ensure that local and national plumbing codes are
followed. The use of heavy-duty vibration control clamps is strongly recommended. For long
runs, ensure that there is no more than 5 feet between supports.

 Various fasteners may be required to complete the installation of the HP system. These

should be sized to adequately support any anticipated loads. Follow local codes for
installing pipe hangers and bolts.

 Recommended supports: Stauff® Cushion Clamps or equivalent

5 Primary Wiring for Pump Module

 Appropriate primary wiring is required for connection to the pumps. Refer to the

specification labels on the pump and valve controllers for voltages and currents. Follow
local and national codes for wiring.

6 Vibration Isolation

 The pump skid will generate some degree of vibrations by its nature. It is recommended

that the pump skid be installed on a vibration-damping mat or vibration isolators to reduce
vibrations and noise.

21 | HP Series Installation Manual

Construction of a Wet Duct Section

General

The section of ductwork that the HP manifolds are installed to be in needs to be capable of
handling excess water that is not absorbed by the air. Condair requires that a wet section be
installed in the duct. The wet section should be as long as expected wetting distance. In most
cases Condair recommends the wet section extend 1.5 feet upstream and 6 feet downstream
of the HP manifolds.

A wet duct section consists of; a double walled plenum, drain pan, and drains. All material used
in the wet section should be made of stainless steel. All seams should be sealed properly with
caulking to prevent leaks.

Double Walled Plenum

A stainless steel liner should be secured to the existing wall. The objective of this is to cover any
exposed insulation, seams, and any existing ducting materials that may not be corrosion
resistant or suited for constant exposure to water. The liner should cover both sides and ceiling
of the plenum. All seams should be caulked and sealed to prevent leakage.

Drain Pan

A stainless steel drain pan should be installed on the floor of the duct. This pan should slope
downwards in the direction of airflow from the HP manifolds to end of the wet section. The
drain pan should terminate with a drain connected to a “P” trap. The “P” trap should be at least
2 inches taller (center to center) that the duct static pressure, and should drain to an open
funnel drain.

For systems up to 750 lb/s per hour a 1” diameter drain should be used. For larger systems a
2” diameter drain, or multiple 1” diameter drains should be used.

HP systems must NOT drain onto a roof. Building damage could result. Any drain lines routed
outdoors must be insulated and heat traced to protect from freezing.

Ensure that all traps are primed by filling them with water.

Mist Elimination

In some cases, the HP system will need to be installed in tight spaces or where water sensitive
equipment is present a short distance downstream. In these cases a mist eliminator is
required. The mist eliminator will be located immediately after the drain in the wet section. A
second drain will be then installed immediately after the mist eliminator.

Air Handler Installations

In many cases the HP system is installed in an air handler upstream of the cooling coil. Many
air handlers include a wet section around the cooling coil as a standard offering. These cooling
coils also function as natural mist eliminators and thus an additional mist eliminator may not be
required. Consult the air handler manufacturer for further information.

The above is not true for a heating coil; most heating coils are not designed to be wetted. If
installing upstream of a heating coil a mist eliminator must be used.

HP Series Installation Manual | 22

Pump Module

Running the pump on any voltage other than what is listed on the spec label can cause
serious equipment damage and may ignite a fire.

Please follow these guidelines for positioning and mounting of the pump module:

Place the pump station in a way that:

 The distance to the humidifier unit is as short as possible.

Note: High-pressure hoses in lengths of 9.8 ft. (3m), 16.4 ft. (5m) or 32.8 ft. (10m) length are
available.

 It is freely accessible and there is enough space for convenient operation and maintenance

(min. clearance around pump station: Side clearance 1.6 ft. (0.5 m), front side/back side
clearance 2.6 ft. (0.8 m)).

 The pump station is designed for the operation in protected and dry rooms, and must

therefore not be installed outside.

 Do not install the pump station in exposed locations or locations with heavy dust load.
 The pump station must be installed only in a location having a water drain on the floor. If this

is not possible, it is mandatory to provide water sensors to safely interrupt water supply in case
of leakage. Furthermore, choose a suitable location that prevents damage to material assets in
case of leakage.

 The pump station is designed for installation on a load-carrying floor.
 Do not install the pump station on vibrating surfaces or components.

23 | HP Series Installation Manual

Dimensions and Weights of Pump Station

Pump Station

Dimensions [in]

Weight [lb]

A B C

HP 100 (200 VFD)

19.7

26.0

51.2

110 – 143

HP 300 (500 VFD)

19.7

26.0

51.2

121 – 154

HP 500 (800VFD)

19.7

26.0

51.2

143

HP 800 (1300VFD)

19.7

26.0

51.2

165

Figure 9: Pump Station Dimensions and Required Clearances

Table 3 : Pump Station Dimensions and Weights

HP Series Installation Manual | 24

Mounting the Pump Station

Install the HP pumps station in the desired location, directly on the floor or in a tray.

The pump station must be placed in a location with an accessible floor drain to prevent flooding
in case of a leak.

Ensure that the pump station is mounted level using the four adjustable supports (see figure
below)

Figure 10: Front View – HP 100-300 Pump Station

25 | HP Series Installation Manual

Water Installation

Before connecting water lines, all water lines must be flushed with fully demineralized water
for at least 10 min. Remove the sealing caps from the connections just before installing the
hoses.

Figure 11: Water Connections

HP Series Installation Manual | 26

Connecting Water Supply Hose

The high pressure hose between the high pressure pump and high pressure manifold must
not be installed before bleeding of the high pressure pump has been done. See page 42:
Initial Commissioning and Start-Up

Water Supply Requirements: 14.5 – 58.0 PSI (1 – 5 bar)

Water Volume: Min. humidification capacity x 2 l/hr.

Water Quality: See Water Quality on page 7.

Figure 13: Water Supply Connection

1 Connect water supply hose to the supply connection (RG ¾” inside thread) using the gasket

provided.

Connecting High Pressure Hoses

1 Connect the high pressure hoses between the pump station and the valve block(s) using the

high pressure hoses supplied.

2 Use only the high pressure hoses provided to connect the pump station, high pressure

manifold and step valve block (or between step valve blocks of the Salve units). Hoses by
others may fail or become damaged during operation and prevent the system from
operating.

3 Install the high pressure hoses ensuring that they do not touch each other or other system

components. Where this is not possible, use anti-chafe spiral hose or similar to protect the
hoses from damage.

27 | HP Series Installation Manual

Connecting Drain Line to the Working Pressure Flushing Valve (MV5)

Electrical installation should be carried out by a licensed electrician. Touching live parts
may cause severe injury or even death.

The electronic components inside the control unit are very sensitive to electrostatic
discharge. When carrying out work on the open unit, appropriate measures must be taken
to protect these components against damage caused by electrostatic discharge (ESD
Protection.

The working pressure flushing valve MV5 is mounted directly to the step valve block of the
Master unit (stand-alone system) or the last Slave unit (master/slave configuration).

1 Connect the drain hose to the flushing valve connection using the drain hose supplied.
2 Lead the drain hose down to an open funnel with a constant down-slope.
3 Fix drain hose in its position to prevent movement during operation.

Electrical Installation

 The wiring diagram can be found inside the control unit of electrical cabinet.

Note: The Condair HP is equipped with a 3-Phase monitoring relay for detection of incorrect
phase sequence, total and partial phase loss. Instructions can be found on a sticker inside
the electrical cabinet.

 The electrical installation (power supply, humidity control) must be installed according to the

wiring diagram supplied with the unit and the local/national electrical code. All information
given in the wiring diagrams must be followed.

 All cables must be lead into the control unit via the cable openings using the cable glands.

 Make sure the cables do not come touch any other components.

 The supply voltage must match the voltage indicated in the wiring diagram.

HP Series Installation Manual | 28

HP Manifolds

Installation of the HP Manifolds

The system specific dimensions for the positioning of the manifold can be found in the
installation documents which are provided with your system.

In addition to the installation instructions, please ensure the following when installing the HP
manifolds:

 In order to allow for proper maintenance of the manifold, the ventilation duct must be

equipped with a viewing window and a maintenance access door.

 The manifold must be installed in a full wet section with two drains: one before and one

after the mist eliminator. See page 23 for wet section requirements.

 If the ambient air is cold, the ventilation duct must be isolated to prevent the humidified air

from condensing on the walls.

 An air filter with min. MERV 13 (F7) or better must be installed upstream of the manifold.
 A stainless steel drain pan should be installed on the floor of the duct. This pan should

slope downwards in the direction of airflow from the HP manifolds to end of the wet section.

The drain pan should terminate with a drain connected to a “P” trap. The “P” trap should be at

least 2 inches taller (center to center) that the duct static pressure, and should drain to an open
funnel drain.

 The minimum distance between the nozzle manifold and a heating element must not be less

than 16 inches.

 The duct velocity before the humidifier must be within 100 – 787 fpm.

29 | HP Series Installation Manual

Mounting the Nozzle Supports

Figure 14: Vertical Mounting Fixture Location

1 Install the vertical mounting fixtures by marking the position of the top brackets on the

ceiling of the duct (1/5 of the duct width from each side). Drill 1/8” (ø3.3) fixing holes (self-
tapping screws) or 15/64” (ø6 mm) (nuts and bolts).

Make sure that the fixing holes on the left and right of the duct ceiling are aligned.

2 Fix the top brackets to the ceiling of the duct with self-tapping screws or bolts provided.

Figure 15: Top Bracket Installation

HP Series Installation Manual | 30

Figure 16: Installation of Pipe Supports

3 Install one of the pipe supports to each of the top brackets using the nuts and bolts

provided. Hand tighten.

Figure 17: Installation of Pipe Supports

4 Install one of the pipe supports to each of the bottom brackets using the nuts and bolts

provided. Hand tighten.

Do not remove the film from the adhesive pad underneath the bottom bracket.

5 Bolt the two pipe fixtures together as shown in Fig. 17. Adjust the length such that the

bottom bracket can slide up and down. Hand tighten.

31 | HP Series Installation Manual

6 Use a level to adjust the fixture both sideways and back/forth so that the pipe fixture is

exactly vertical in all directions.

7 Now mark the position of the bottom bracket using a scratch pin or similar, to draw around

it. Clean the bottom of the duct thoroughly underneath the bottom bracket using a
degreaser.

8 Remove the film from the adhesive pad, and press the bottom bracket in place.
9 Check that the fixture is still vertical in all directions.
10 Tighten all bolts. The pipe fixture is now in place.

Mounting the Nozzle Pipes

Figure 18: Installation of Rubber Ferrules

1 Refer to the supplied drawing for the position of each of the nozzle pipes.
2 Install the nozzle pipes first by fixing the pipes to the vertical pipe fixtures using the clamps

and rubber ferrules provided as shown in figure 18.

3 The rubber ferrules are first pushed on to the nozzle pipes, the flat side/opening facing away

from the nozzles.

Ensure that the pipe outlets are aligned horizontally in the direction of flow.

Note: The clamps and rubber ferrules both comes in two different widths, the broad ones are
used where two pipe fixture rods overlap (on taller units).

HP Series Installation Manual | 32

Figure 19: Installation of Nozzle Pipes and Clamps

4 Once the ferrules are installed, push the nozzle pipes firmly into the grooves of the pipe

fixtures and install the clamps as shown in Fig. 19.

Mounting the Step Valve Block

Figure 20: Installation of Step Valve Block

1 Mount the step valve block outside of the duct near the nozzle manifolds using the self-

tapping screws or bolts provided.

33 | HP Series Installation Manual

2 Drill 3 x ø1-1/4” (3xø32 mm) duct penetrations and seal the holes on the inside and outside

with the rubber sleeves provided.

3 Connect the high-pressure hoses to the step valve block, then lead the hoses through the

rubber sleeves into the duct.

4 Connect the high-pressure hoses to the appropriate distribution blocks and nozzle pipes as

indicated in the supplied drawing.

Hand tighten the hose screw connections, then tighten the screw connections 1-1/4 turns
further using an open-end wrench. Check screw connections for leaks during operation. If the
screw connections are leaking, retighten them. Do not over tighten the screw connections.

Make sure the hoses are not kinked (if necessary, lead hoses in a bow to the connector).
Maintain the following minimum bend radius:

– for hoses DN6 = 4 in. (100 mm)

– for hoses DN8 = 5 in. (130 mm)

– for hoses DN10 = 7 in. (180 mm)

Figure 21: Hose Connections

HP Series Installation Manual | 34

Mist Eliminator

Mounting the Condair HP Mist Eliminator

General

The Condair Mist Eliminator is a single bank water droplet removal system installed at a pre­defined distance from the water entry point. The highly humidified air is to come into contact
with the Mist Eliminator and any un-absorbed droplets of water are removed from the air
stream. The collected water accumulates on the media then descends downward towards the
bottom of the Mist Eliminator. During this process much of the collected water is absorbed into
passing air while any remaining water is funneled to one of two drains via a pre-installed drain
pan. See Figure 22: Mist Eliminator Overview.

The Mist Eliminator is available in standard sizes ranging from 4ft high x 4ft wide to 12ft high x
20ft wide with 4ft increments between. If a duct size does not fall under one of our standard
sizes simply order the next larger size then cut to fit.

The drain pan is to be installed at the bottom of the plenum to remove the water collected by
the Mist Eliminator. The height of the drain pan should be not be any less than 3 inches
(7.5cm) and should extend past the filter bank 8 inches (20.3cm). A drain with trap before and
after the Mist Eliminator is required, shown in
Figure : For this the duct’s static pressure must be known. The drain traps must be 2 inches
larger than the duct’s static pressure. Ensure that the drain trap is filled with water prior
commissioning a high-pressure system.

35 | HP Series Installation Manual

Figure 22: Mist Eliminator Overview

Installation of Mounting Angles

Figure 23: Drainage and Drains

Figure 24: Mounting Angles

Measure the duct height and width.

Height = _________

Width = _________

The mounting angles are to completely surround the duct. Mark the duct floor with a line a

minimum of 8” from the end of the drain pan and perpendicular to the ducts airflow. Now

continue the lineup vertically up the walls and finally across the ducts ceiling.

Each angle measures 95.5 inches. Enough length of angle is supplied to cover the perimeter of
the duct but they must be cut to fit. Over-lapping joints slightly is recommended for the floor
angles only as they should be sealed along the entire length of angle with appropriate caulking
to prevent free air flow through the drain pan. Angles may have to be cut in half to make-up two
4ft lengths. When securing the mounting angles to the duct place the side with circular holes
against the duct and the bent edge along the marked line.

Orient the mounting angle as shown in Detail A in
Figure 24: Mounting Angles. Using field supplied self-taping screws attach the mounting angle
to the duct via the round mounting holes. A screw every 18 inches is recommended.

HP Series Installation Manual | 36

Installation of Mounting Channels

Duct Width

Mounting Position

Number of Channels

4ft - 8ft

Middle

1

8ft - 12ft

Offset 2ft from middle

2

12ft - 16ft

Middle

3

16ft - 20ft

Offset 2ft from middle

4

Before installing the mounting channel or channels the starting mounting point needs to be
determined using the duct width. If the duct width is 4ft or less then there is no need for a
mounting channel, continue to the next step.

Table 4. Mounting Channel Locations

Once the mounting location is determined the mounting channel(s) are ready to be cut to fit,
keeping in mind that drain pans are not level and lengths may vary. From the starting point,
each additional mounting channel is placed at 4ft centers. In the figure below a typical 4ft x 8ft
installation is shown with the mounting angle surrounding the perimeter and a mounting
channel installed vertically at the center point of the duct.

In Figure 26: Large Duct Mounting Channel Locations, a 6ft high x 10ft wide mist eliminator
frame is shown. Notice how the mounting channel placement is offset from the center.

Installations between 8ft x 12ft to 16ft x 20ft may involve the removal of excess material.
Excess material is removed equally from both sides of the frame not from the middle.

To secure the mounting channel in place use the factory supplied ½ inch self-threading screws.
Use the center row of slotted holes to attach the mounting channel to the mounting angle.
Place one screw at the top and one at the bottom making sure that the mounting channel is
level or square to the ceiling, this will help for mounting the wire mesh. See Figure 27:
Mounting Channel Installation.

If the duct height greater than 8 feet a channel extension is needed in order to link 2 mounting
channels together. The extension slides inside the mounting channel. Use 4 ½ inch factory
supplied screws for each mounting channel as shown in Figure 28: Mounting Channel Extension
Kit.

37 | HP Series Installation Manual

Figure 25: Mounting Channel Location

Figure 26: Large Duct Mounting Channel Locations

Figure 27: Mounting Channel Installation

Figure 28: Mounting Channel Extension Kit

HP Series Installation Manual | 38

Installing 1 inch Screws/Studs

In the final step of this instruction Media Clamping Strips are used to secure the media to the
frame. In this step the screws used to fasten the Media Clamping Strip to the finished assembly
must be installed. Each Media Clamping Strip requires 3 screws evenly spaced. Clamping
strips are 46 inches in length upon arrival from the factory however if the Clamping Strip is cut
to fit the duct size it will still require 3 screws evenly spaced to properly secure it. After each
screw is installed use the factory supplied nuts to lock them in place.

Figure 29: 1 Inch Screw / Stud Installation

Installation of Wire Mesh

The 4ft wide Wire Mesh can now be cut to length (duct height or top mounting stud to bottom
mounting studs.) To fasten the Wire Mesh to the assembly use the factory supplied self­threading ½ inch screws starting from the top angle and middle channels working out and
down. Be sure to install the wire mesh square when first fastened otherwise it will not align
properly at the opposing end. Notch around screws previously installed for best results.

Figure 30: Mesh Installation

39 | HP Series Installation Manual

Media Installation

The recommended way to install the media is taking the entire roll and securing its leading edge
to the top of the assembly by working the 1inch screws/studs though the media, see Figure 31:
Mesh Installation. Then carefully rolling it downward until it reaches the bottom of the duct. Cut
the media at the bottom of the assembly to fit. Once cut, go back and work the rest of the
screws through the media. If the recommended method cannot be followed, use a flat, clean
surface to pre-cut the media. Be sure to cut the media with precision so not to be short on the
final section of the assembly.

Figure 31: Mesh Installation

Media Clamping Strip Installation

The final step is to secure all components of the assembly using the media clamping strip.
Place the strips so the 1 inch screw/studs pass through the slotted holes on the media
clamping strip then fasten a factory supplied nut to hold the assembly in place. See Figure 32:
Clamping Strip Installation.

Figure 32: Clamping Strip Installation

HP Series Installation Manual | 40

Start-up, Operation, &
Maintenance

41 | HP Series Installation Manual

Initial Commissioning and Start-Up

Initial commissioning must be completed by an authorized service technician from your

Installing the Membrane and Preparing Unit for Flush

This section describes initial step-by-step commissioning of the unit. The procedure described
here after assumes that the system has been installed correctly in accordance with the
information in sections above.

local Condair supplier.

1 Unscrew the filter housing using spanner part number 104.570.

When fitting the water filter, wear sterile gloves to keep the filter bacteria-free.

Figure 33: Removing Filter Housing

2 Bleeding the filter.

a. Remove the bleeding screw on top of the filter.

b. Slowly open the water supply and fill the filter.

c. Refit the bleeding screw.

HP Series Installation Manual | 42

Figure 34: Bleeding Screw

3 Remove the protective plug from the high-pressure hose (from the REG valve block) and put

the open end of the hose to a drain. Fix the hose in this position so it cannot move.

43 | HP Series Installation Manual

Figure 35: Protective Plug

4 Bleeding of the HP Pump

a. The high pressure hose should already be disconnected and lead to a drain (Step 3

above).

b. Start the system by increasing the set point on the humidity controller.
c. Flush through the pump for a minimum of 20 seconds.
d. Turn off the system and reconnect the high-pressure hose to the REG valve block.

Figure 36: Reconnecting High Pressure Hose

They system is now ready for operation. As soon as a humidity demand is present, the supply
valve will open and the HP pump will start.

When the necessary pressure is reached, one, two, or all three step valves will open depending
on the current humidity demand.

HP Series Installation Manual | 44

HP High Pressure Atomizing Humidifier Start-Up Check List

Hoses properly fixed and anti-chafe spiral hose mounted where necessary?



Connections: High-pressure pumping station – Step Valve Block



Hose connections in the duct



Connection MV REG1 to spray circuit 1/7



Connection MV REG2 to spray circuit 2/7



Connection MV REG3 to spray circuit 4/7



Connection MV5 flush valve to drain



Are the electrical connections for the Master and Slave units (if available) done
correctly in accordance with the appropriate wiring diagram?

 Are the step valve cables wired correctly?
 Is the control signal wired correctly?
 Is the external safety loop wired correctly (Master and Slaves) or is a jumper

installed?

 Is the power supply wired correctly and correctly fused?



The check list below must be filled out during the first commissioning and signed by the
corresponding service technician.

Client:_____________________________________________________________________

Location:____________________________ Date: ________________________________

Pump Model: _________________________ Pump Voltage: _________________________

Nozzle Type: _________________________ Humidifier Serial #:______________________

Humidification Capacity: _______________ Demand Signal: ________________________

Software Version: _____________________ Tag / Zones Served:______________________

1 Visual Inspection

2 Control/Configuration

45 | HP Series Installation Manual

Are the control units (Master and Slave) correctly configured (Power up control units

and check configuration).

 Is the control signal correctly configured (is the internal controller deactivated, if an

external controller is connected)?

 Is the number of Slave units correctly configured in the control unit of the Master?
 Is the power limit correctly configured?



3 Pump Station

Flush supply line for a min. 5-10 minutes before connecting



Flush high-pressure piping for 5-10 minutes



Room equipped with floor drain?



Flushing line and housing drain connected and hoses secured?



Flow pressure of 30 – 145 psi (2-10 bar)



Manual shut off valve on main water supply open?



No leaks at the pump?



Nozzle pipes tight?



Drain within the humidification distance present and connected with a P-trap? Is the
P-trap the correct height based on the duct static pressure?


Spray angle of the nozzles (Min. 50°, Optimal 70°)



Minimum distance from the first nozzle to the duct wall is correct (no droplet
formation on the duct wall)?


Step 1/7



Step 2/7



4 Nozzle Unit

HP Series Installation Manual | 46

Step 3/7



Step 4/7



Step 5/7



Step 6/7



Step 7/7



5 Mist Eliminator

Mist eliminator installed correctly according the installation manual?



Drain after the mist eliminator present and connected with a P-trap? Is the P-trap the
correct height based on the duct static pressure?


No droplet carry over after at least 1 hour of full output (fan and humidifier)



Notes:
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
__________________________________________________________________________

Installed by:___________________________________________________________________
(Company Name and Business Address)

Inspected by:__________________________________________________________________
(Company Name and Business Address)

Signed: _____________________________ Date: _____________________________

47 | HP Series Installation Manual

Operation

Touch Screen

Figure 37: Normal Operating Screen

The screen is equipped with four F keys. Each of the keys is used to navigate between the

different screens. When these are used, the individual key’s function is indicated in the

description directly above the key.

The actual touch screen can be operated by gently tapping a finger or a fingernail against the

required “buttons” on the screen. If you want to change a numerical value, press the relevant

number key. This will make a numerical keyboard appear on which the new value can be
entered. Remember to enter any comma that may be needed. In case you make an incorrect
entry, this can be deleted by means of the Backspace button. Once a new value has been
entered, press Enter at the bottom right of the image using the numerical keyboard.

HP Series Installation Manual | 48

Protection Against Unwanted Changes

On the display, the control unit settings are protected against unwanted changes by means of
passwords.

The different user groups have different passwords and different rights.

1 User – no password – can read operational information and alarms.
2 User 1 – password 1234 – as above + changes of set points.
3 Technician – password 197 – as above + changes of operational parameters and choice of

membrane rinse.

4 Master – password xxxx – as above + option choices, reset to factory settings.

Additionally, there are areas of the screen that are protected by extra passwords, to which only
Condair technicians have access.

When a password is required in order to change parameters, a screen will appear where the
password can be entered. Change to numerical keyboard by means of the keys 0-9. Once the
password has been entered, the system will remain unlocked at the relevant level for five
minutes.

Alarm Display

This page shows alarms and operational messages. The alarm display contains information
about when an alarm was triggered and when it was reset. The page shows active alarms and
previous alarms. Please note that the system does not have a backup memory, which means
that previous alarms will be lost in case of power failure.

 Max Hygrostat (high limit) – Max Hygrostat has dropped out because the humidity is too

high. The system has stopped and must be restarted once the humidity level has dropped.

 Water Pressure Too Low – The water pressure of the water inlet to pump is too low.

 Sensor Error – The signal from one of the humidity sensors is outside the expected range of

20-80% RH. In order to ensure that it will be possible to start in very dry surroundings, the
20% limit is reduced to 5% RH for the first 10 minutes after the system is switched on. If an
alarm is triggered, only the affected sections will be stopped.

 High Pressure Too Low – The high pressure in the hoses is too low, (default <40 bar / 580

psi) the system is stopped and must be restarted using the reset button.

 High Pressure Too High – The pressure in the hoses is too high, (default >80 bar / 1160 psi)

the system is stopped and must be restarted using the reset button.

49 | HP Series Installation Manual

 Emptying Tank – Water Too Hot – The water is too hot (above 40°C / 104°F). The tank will

be emptied to start level and filled with cold water. The pump will continue to run.

 Stop – Pump Too Hot – The water is too hot – above 50°C (122°C). The system has

stopped and must be restarted once the temperature has dropped.

 Tank Full – The water level in the tank is too high:

o Lower the water level and reset the system
o Check that the inlet valve closes tightly when the system is idle.

 Thermo Relay Error – The protective motor switch for the high pressure pump is disengaged.

Engage the relay and try restarting.

Message Display

 Water Level Below Start Level - The water level in the container is too low for the pump to

start. Once an adequate level has been reached, the system will start automatically.

 Pump Will Start Automatically After Delay – The pump has been set on pause, e.g. after

disinfection. The pump will start automatically after the expiry of the set time.

HP Series Installation Manual | 50

Screens

The start page provides access to pages and
choice of functions:

 Selection of language
 General selections
 Calibration of screen
 Setting of clock
 Display software version and administration of

passwords

Once these choices have been made, press OK
to continue.

Choose whether membrane rinse is to be used.

Select – Requires a chose to be made

Membrane Flush – Run rinse of RO membranes
(Takes at least 35 min.)

Normal Operation – Run normal operation

Choose between the different functions and
options.

Please note that some options require hardware
changes to the pump station.

Analog Mode

Humidity Controlled Capacity

Direct Controlled Capacity

Register Mode

3 Valves – 7 Step

4 Valves – 15 Step

5 Valves – 31 Step

RO Options

No EC Monitoring

EC Monitoring

EC Monitoring + RV/CO2

EC Monitoring + MB + CO2

Start Page – Basic Settings

51 | HP Series Installation Manual

Setting of the clock and date.

Once settings have been chosen, press F3.

HP Series Installation Manual | 52

Operation and Alarm Page

Normal operation page:

The current image depends on the choice of
control mode.

If humidity controlled capacity has been selected,
the current humidity and the required set point
are displayed.

If directly controlled capacity has been selected,
the current capacity is displayed in %.

In both cases, the pump’s temperature and the

current capacity in liters per hour are shown.

In case an alarm or message is triggered, a bar
will appear across the screen showing the
message.

The menu page and alarm page can be reached
via the buttons on the screen.

53 | HP Series Installation Manual

Alarms and User Messages

All alarms and operational messages are shown
with the time at which they occurred and the
time when the alarm stopped.

Please note that the alarm log will be reset after
a power cut.

Menu for the pages where the different
parameters can be changed.

Parameter Change Menu

HP Series Installation Manual | 54

Settings For Control Parameters

Parameters for control settings.

Enter the flow values for the individual nozzle
strings as liters per hour.

PRO – Used for control with humidification
signals. A lower value here will give a more
aggressive adjustment.

Reg.Up/Reg.Down – Indicates the regulation rate
in seconds.

Section parameters for sensor scaling:

HIE – Highest electrical signal

LOE – Lowest electrical signal

HI – Reading at HIE

LO – Reading at LOE

55 | HP Series Installation Manual

Pump

Hour counter for the pump and for each
section, which show the total running time.

Pump alarm settings.

These values should be changed by
Condair Technicians only.

Settings for the High Pressure Guard

These values should be changed by
Condair Technicians only.

HP Series Installation Manual | 56

Setting the Unit into Daily Operation

A damaged system or system with damaged installations must not be set into operation.

The procedure described here after assumes that the system has been installed correctly in
accordance with the information in sections above and initial commissioning has been carried
out by a service technician from the manufacturer/manufacturers’ representative.

Proceed as follows to set the Condair HP into operation:

1 Check all system components and installations for possible damage.

2 Open manual shut off valve on the water supply line.
3 Activate the service switch of the power supply line to the pump station, and to the Slave

control units (if applicable).

4 Activate the power switch of the pump station, and to the Slave control units (if applicable).
5 The touch screen will now start up and show the basic setup screen. They system will carry

out a system test and flush the system.

6 If a failure occurs during the system test, a corresponding error message will be shown on

the display.

Figure 38: Main Setup Screen

7 Press F4/Home on the display and the controller will show the normal operating screen.

57 | HP Series Installation Manual

8 As soon as a humidity demand is present, the supply valve will open and the HP pump will

start.

Figure 39: Normal Operating Screen

9 Detailed information regarding the operation of the control unit and the settings can be

found on pg. 48.

Inspections During Operation

During operation, the Condair HP and the humidification system have to be inspected weekly.
On occasion, check the following:

 The whole humidification system for any leaks.

 The nozzle manifold and other system components for any damage.

 The electrical installation for any damage.

 The operating display for any warning or error messages.

 If the inspection reveals any irregularities (e.g. leakage, error indication) or any damaged

components, take the Condair HP out of operation as described in the section below.
The necessary corrections or fixes must be completed by a qualified specialist or service
technician from your Condair supplier.

HP Series Installation Manual | 58

Shutting Down the Unit

in periods when no humidification is required. This ensures that the water circuit is flushed
on a regular schedule thus preventing standing water within the system.

For hygienic reasons, it is highly recommended to leave the Condair HP on all the time, even

Proceed as follows to shut down the unit for maintenance:

1 Switch off the pump station and/or all Slave control units (if applicable).
2 Close the manual shut off valve of the water supply line and secure it to prevent inadvertent

opening.

3 Open the test tab on the discharge manifold to relive pressure in the system.
4 Turn off the service switch on the main power supply lines to the pump station and to the

Slave control units (if applicable). Then secure the service switches against inadvertent
opening.

5 Let the fan of the ventilation system continue to run until the humidifier section is

completely dry to prevent standing water.

6 Power down the ventilation unit and secure it to prevent inadvertent power up.

59 | HP Series Installation Manual

Maintenance

Poorly maintained humidification systems may endanger health. Therefore it is mandatory to
follow the specified maintenance intervals and to carry out maintenance work in strict
accordance with the instructions.

Important Notes on Maintenance

Qualification of Personnel – All maintenance work must be carried out by qualified and trained
personnel authorized by the owner.

Maintenance and repair of the electrical installation must be carried out by a certified
electrician.

It is the owners responsibility to verify proper qualifications of the personnel.

General Note

The instructions and details for maintenance work must be followed and complied with.

Only the maintenance work described in this document may be carried out.

Only the use of original Condair spare parts are permitted.

HP Series Installation Manual | 60

Maintenance Intervals

Work to be Carried Out

After the first

50 hr.

Monthly or

every 500 hr.

Every 200 hr.

Every 4000 hr.

Pump Station

x

x
Check electrical connections and wires. Have defective
components repaired or replaced by a qualified technician.

x

x
Overhaul or replace PAH pump *(every 8000 hr.)

*

Nozzle Unit

Check mounting of base frame for proper fastening. Tighten loose
screws as required.

x

Check nozzles for proper fastening. Moderately tighten (torque:
approx. 1.5 ft.lb. (2.1 Nm)).

x

Check hoses, tubing, and connections for possible leaks. Tighten
connections or replace defective components as required.

x

In humidification mode, set the nominal humidity value to 100%
and check spraying angle of the nozzles (spraying cone: optimum
70°, 50° acceptable). If the spray angle is acceptable, set the
nominal humidity back to the correct value. Clean/Replace nozzles
with unacceptable spray patterns.

x

Check nozzles for scaling. Remove spray nozzles (see pg. 66) and
clean them in an ultrasonic bath as required. Replace defective
nozzles.

x

Clean nozzle unit (base frame, nozzle pipes, hoses, etc.) with a
combined cleaning and disinfectant agent. Then rinse all
components with water from the system and then dry components.

x

In order ensure safe, hygienic and economic operation of the Condair HP, components must be
periodically checked and maintained according to the table below. The maintenance intervals
and maintenance work stated below are guidelines only. Depending on the system specific
conditions (quality of the supply air, the water, etc.), the maintenance intervals may be reduced.

Table 5: Maintenance

Check high pressure pump and installations for leakage. Have
defective components repaired or replaced by a Condair
service technician.

61 | HP Series Installation Manual

Mist Eliminator

Check mist eliminator (Condair and third-party products) for

x

X**

Maintain mist eliminator (third-party product)

According to

manufacturer

Wet Section / Drain Pan

Check drains.

x

Check drain pan (behind mist eliminator) for deposits or
accumulation of water. If inspection reveals a considerable amount
of accumulated water, check water drain and mist eliminators.
Note: Water drops and a small accumulation of water in the pan
behind the droplet separators are inherent to the system.

x
Clean the drain pan and the entire wet section (including behind
the mist eliminator) with a combined cleaning and disinfecting
agent. Then rinse all components with water from the system and
then dry all components.

x

possible damage. Repair or replace defective components.

Clean Condair mist eliminator. Un-mount the boxes and clean all
components including the base frame inside the duct with a
combined cleaning and disinfecting agent. Then rinse all
components with water from the system and then dry components.

* Maintenance interval for PAH pump: Every 8000 hr.

** Maintenance indication: Droplets appear downstream from the mist eliminator (when
system active)

After completing the maintenance work, fill in the maintenance checklist and sign it. Reset
possible maintenance indications. The appropriate personnel is fully liable for any maintenance
work not carried out.

HP Series Installation Manual | 62

Preventative Replacement Parts

Description

Part
Number

HP 100

HP 300

HP 500

HP 800

Technical
Life Time

Service

B

Service

C

Service

D

Service

E

Every
(1/2)
Year

Every
(1st)
Year

Every
(2nd)
Year

Every
(4th)
Year

Water Filter

Filter 1 micron
20"

1bcde

1bcde

6 months

Change

Change

Change

Change

Filter 1 micron 9
7/8"

1bcde

1bcde

6 months

Change

Change

Change

Change

O-ring for water
filter

1de

1de

1de

1de

24 months

Check

Check

Change

Change
Air filter

Sterile breather
filter 0.2μ

1cde

1cde

1cde

1cde

12 months

Check

Change

Change

Change
Carbon Filter (if installed)

Filter, 20”

activated carbon

3 months

Change

Change

Change

Change

Filter, activated
carbon, 50L

6 months

Change

Change

Change

Change
Water Softener (if installed)

AQA Total Refill
1500-4500 E/XP
(Change by
400m3)

400m3 /

12 months

Check

Change

Change

Change

AQA Total Refill
5600 E/XP
(Change by
600m3)

600m3 /

12 months

Check

Change

Change

Change

Service kit,
Kinetico
30/2030 ­60/2060

24 months

Check

Check

Change

Change
Kinetico ion
exchange
substance

48 months

Check

Check

Check

Check

Table 6: Replacements

63 | HP Series Installation Manual

Hardness test kit

12 months

Check

Check

Check

Check

UV Filter (if installed)

12W SQ-PA/2
Bulb

1cde

12 months

Check

Change

Change

Change

19W S2Q-PA/2
Bulb

1cde

1cde

12 months

Check

Change

Change

Change

26W S5Q-PA/2
Bulb

1cde

12 months

Check

Change

Change

Change
Quartz UV System (if installed)

12W QS-212
Quartz

1e 48 months

Check

Check

Check

Change

19W QS-330
Quartz

1e

1e 48 months

Check

Check

Check

Change

26W QS-463
Quartz

1e

48 months

Check

Check

Check

Change
Bacteria/Sterile Filter (if installed)

10” Bacterial

filter

6 months

Change

Change

Change

Change

O-ring for filter
housing

24 months

Change

Change
Electrical Control System

PLC backup
battery

1e

1e

1e

1e

12 months

Check

Check

Change

Relay, print frame
relay

1cde

1cde

1cde

1cde

12 months

Change

Change

Change

Contactor,
230VAC 9A –
S00

1e

1e

1e

1e

48 months

Check

Check

Change
Glow lamp for
start/reset

1de

1de

1de

1de

24 months

Check

Check

Change

Change
PAH Pump (Max 8000 hr.)

Service kit PAH 2

1de 8000 hr. /
24 months

Check

Check

Overhaul

Overha
ul

HP Series Installation Manual | 64

Service kit PAH
4/6.3

1de

1de 8000 hr. /
24 months

Check

Check

Overhaul

Overha
ul

Service kit PAH
10/12.5

1de

8000 hr. /
24 months

Check

Check

Overhaul

Overha
ul

PAH Coupling

Service kit
coupling PAH 2/4

48 months

Check

Check

Service kit
coupling PAH 6.3

48 months

Check

Check

Service kit
coupling PAH
10/12.5

48 months

Check

Check

Pressure Gauge

0-160 Bar Gauge

Check

Check

Check

Check

0-10 Bar Gauge

Check

Check

Check

Check

Section Valve

Armature Kit, NC

48 months

Check

Check

Check

Armature Kit, NO

48 months

Check

Check

Check

Piston Kit NO/NC

48 months

Check

Check

Check

Pilot nozzle 1.0
mm

48 months

Check

Check

Check

Pilot nozzle 1.4
mm

48 months

Check

Check

Check
Valve for Co2 (if installed)

Solenoid valve

24 months

Check

Change

Change

Humidity Sensor

HST-010
humidity sensor

+/- 10%

Check

Check

Check

Check
Filter for Sensor

48 months

Check

Check

Check

Check

CC Converter, 4­20mA

Check

Check

Check

Check
Max Hygrostat

+/- 10%

Check

Check

Check

Check

Pressure Regulator

65 | HP Series Installation Manual

Pressure
regulator service
kit

1cde

1cde

1cde

1cde

12 months

Overhaul

Overhaul

Overha
ul
On/Off Valve

On/off valve

1e

1e

1e

1e

48 months

Check

Check

Check

Change

Check Valve at Manifold

Check valve 1/4"

24 months

Check

Check

Overhaul

Overha
ul

Check valve 3/8"

24 months

Check

Check

Overhaul

Overha
ul

Nozzles

Nozzle ML 2.5
Stainless

5% yearly

Check

Check

Check

Check

Nozzle ML 4.5
Stainless

5% yearly

Check

Check

Check

Check

Nozzle ML 1.5
Stainless

5% yearly

Check

Check

Check

Check
Nozzle filter, 25 μ

12 months

Check

Change

Change

Change

Disinfection

Barfry D50/500
4% 1L

Use for
service

Use for
service

Use for
service

Use for
service

Use for
service

Hydrogenperoxid
e 3% 1L

Use for
service

Use for
service

Use for
service

Use for
service

Use for
service

Water Sample

BQ Water
analysis incl.
materials

Use for
service

Use for
service

Use for
service

Use for
service

Use for
service

HP Series Installation Manual | 66

Maintenance Indications

The Condair HP RO as fixed adjusted maintenance counters. See pg. 56 for menu
access.

Removal of Components

Removal/Installation of Spray Nozzles

1 Put the system out of service (see section: Shutting Down the Unit) and secure it to prevent

inadvertent start-up.

2 Use the nozzle key to remove the spray nozzle.
3 Check the O-ring for damage. Replace if necessary.
4 Screw in the new or cleaned spray nozzle and tighten (torque: 1.5 ft.lb. (2.1 Nm)) using the

nozzle key.

Figure 40: Removal/Installation of Spray Nozzle

Disassembling and Assembling Mist Eliminator Boxes for Cleaning

1 Put the system out of service (see section: Shutting Down the Unit) and secure it to prevent

inadvertent start-up.

2 Undo retaining clips, then remove upper and lateral rubber seals.
3 Remove the connection plates on the lower or upper side of the mist eliminator boxes, then

unhinge the boxes.

4 Undo the screws of the box frame and remove the separator profiles
5 The assembly of the mist eliminator boxes follows the reverse sequence. When assembling

the mist eliminator profiles and the profile retainers, ensure that the profile retainers point to
the bottom when the box is installed and the separator profiles are correctly mounted (see fig.

38).

67 | HP Series Installation Manual

Troubleshooting

HP Series Installation Manual | 68

Important Notes on Troubleshooting

Qualification of Personnel – Have faults eliminated by adequately qualified and trained
personnel only. Malfunctions caused by the electrical installation must be repaired by
authorized personnel (e.g. electrician) only.

Repair work on the high pressure pump may only be carried out by your Condair
representative’s service technician.

Safety – When eliminating faults, the Condair HP must be taken out of operation (see section:
Shutting Down the Unit) and prevented from inadvertent operation.

Make sure the power supply to the pump station and slave control units is cut off (test with
voltage tester) and that the manual shutoff valve in the water supply line is closed.

Error Indication

Malfunctions during operation are indicated by a corresponding warning message on the display
of the pump station or Slave control unit (if available). See pg. 80 for detailed error information.

Resetting the Error Indication

To reset the error indication, press the reset button underneath the touch screen.

Note: if the fault has not been eliminated, the error indication will reappear after a short while.

Safety Equipment

Pressure Switch - The control unit is equipped with a blocking function from the pressure switch,
which is located on the inlet side of the RO pump, and ensures that the pump stops if the water

pressure disappears. If the water pressure drops to below the pressure switch’s shift pressure,

the screen will display an alarm text. Restart by pressing ‘Alarm reset’.

Humidity High Limit (Max. Hygrostat) - It is possible to connect a humidity high limit to the
control cabinet. If humidity levels rise to a value that exceeds the value set on the high limit, the
system will stop and the alarm lamp will light up. The system will not restart until the alarm is
acknowledged by pressing ‘Alarm reset’. If this function is not required, the input will short­circuit on the terminal block.

High Pressure Measuring – In order to ensure that the system runs with the correct high
pressure, all pumps with a VFD controller are equipped with a Pressure Guard. If the pressure is
too low or too high, the system will trigger an alarm.

High Pressure Measuring – The high-pressure pump is protected against overheating by a
temperature circuit that measures the current temperature in the pump. – The temperature
limits can be set individually.

1 If the temperature exceeds 30°C (86°F), the control unit will initially attempt cooling by

starting the water treatment system and filling up the tank with cold water. If this makes the
temperature drop to below 30°C (86°F), this function will reset and everything will continue
unchanged. While the tank is being filled, the high-pressure pump will continue to operate
and will not be affected.

69 | HP Series Installation Manual

2 If instead the temperature continues to rise to above 40°C (104°F), the pump will stop and

start emptying the tank of overheated water and produce new water in the tank. During this
process, the pump will remain idle with the alarm text displayed (until the start level has
been reached). The pump will start automatically once the start level has been reached.

3 If the temperature exceeds 50°C (122°F), the pump will stop immediately and must be

reactivated via the reset button once the temperature has dropped again.

HP Series Installation Manual | 70

Problem

Cause / Solution

Recommendations

Water droplets in the duct
section downstream from
mist eliminator

Mist eliminator defective.

Check/Replace mist eliminator.

Excess air velocity (>787 fpm)
in the duct

Reduce air velocity in the duct (<787 fpm).

Fault location of spray nozzles
or spraying circuits not conned
to appropriate nozzles.

Check location of nozzles and piping of spraying
circuits according to the supplied nozzle diagram.
Relocate nozzles and/or connecting hoses as
required.

Condair HP runs continuously

Nominal humidity value to high

Reduce set-point humidity value.

Ambient humidity very low

No measures to be taken, just wait.

The internal controller is
activated, although an external
controller is connected

Deactivate internal controller.

Maximum humidification
capacity not reached

Wrong system design (capacity
too low)

Step Valve(s) REG1, REG2,
REG3 defective

Check the function of the step valve by increasing
the set-point humidity value.

Remember to reset the set-point humidity value to
the correct value after checking.

Spray nozzles clogged.

Remove and replace nozzles.

Hoses to nozzle pipes are
leaking or disconnected, or
nozzle pipes are leaking.

Check hoses/nozzle pipes and seal as required.

Control unit is switched on
but the display on the
control unit does not show
anything

Service switch on the main
power supply line is off

Set service switch on the main power supply to the
On position.

Fuses of the main power
supply line blown

Have an electrician replace fuses on the main
power supply line.

Fuse of the control unit blown

Have an electrician replace fuse on the control
unit.

Display or control board
defective

Excessive fluctuations in
humidity control

Faulty electrical connections of
the spray valves Y3,Y4, and Y5
or spraying circuits not
connected to appropriate
nozzles.

Have an electrician connect spray valves REG1,
REG2, REG3 correctly (see wiring diagram). Check
piping of spraying circuits and correct if required.

Danger of electrical shock: When replacing the fuse on the control unit, ensure that the switch on
the pump station/slave unit is off and disconnected from the main power supply

Table 7: Troubleshooting

Contact your Condair supplier.

Have a Condair service technician replace
the display or control board.

71 | HP Series Installation Manual

Warranty

Condair Inc. and/or Condair Ltd. (hereinafter collectively referred to as THE COMPANY), warrant for a
period of two years after installation or 30 months from manufacturer’s ship date, whichever date is
earlier, that THE COMPANY’s manufactured and assembled products, not otherwise expressly
warranted, are free from defects in material and workmanship. No warranty is made against corrosion,
deterioration, or suitability of substituted materials used as a result of compliance with government
regulations.

THE COMPANY’s obligations and liabilities under this warranty are limited to furnishing replacement
parts to the customer, F.O.B. THE COMPANY’s factory, providing the defective part(s) is returned freight

prepaid by the customer. Parts used for repairs are warranted for the balance of the term of the
warranty on the original humidifier or 90 days, whichever is longer.

The warranties set forth herein are in lieu of all other warranties expressed or implied by law. No
liability whatsoever shall be attached to THE COMPANY until said products have been paid for in full
and then said liability shall be limited to the original purchase price for the product. Any further
warranty must be in writing, signed by an officer of THE COMPANY.

THE COMPANY’s limited warranty on accessories, not of the companies manufacture, such as controls,

humidistats, pumps, etc. is limited to the warranty of the original equipment manufacturer from date of
original shipment of humidifier.

THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict
accordance with a copy of the catalog and installation manual in effect at the date of purchase and by
a contractor approved by THE COMPANY to install such equipment.

THE COMPANY makes no warranty and assumes no liability whatsoever for consequential damage or
damage resulting directly from misapplication, incorrect sizing or lack of proper maintenance of the
equipment.

THE COMPANY makes no warranty and assumes no liability whatsoever for damage resulting from
freezing of the humidifier, supply lines, drain lines, or steam distribution systems.

THE COMPANY retains the right to change the design, specification and performance criteria of its
products without notice or obligation.

HP Series Installation Manual | 72

U.S.A.

2700 90th St.
Sturtevant, WI 53177

835 Commerce Park Dr.
Ogdensburg, NY 13669-2209

CANADA

2740 Fenton Road
Ottawa, Ontario K1T 3T7

TEL: 1.866.NORTEC1
EMAIL: [e-mail]
WEBSITE: www.condair.com