Condair GS Series Installation, Operation And Maintenance Manual
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Condair GS Series Installation, Operation And Maintenance Manual

Outdoor gas-fired steam humidifier
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INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Outdoor gas-fired steam humidifier
Condair GS
Series II
Humidification and Evaporative Cooling

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  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL Outdoor gas-fired steam humidifier Condair GS Series II Humidification and Evaporative Cooling...
  • Page 2 DANGER! Fire or explosion hazard! If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. DO NOT store or use gasoline or other flammable va­ pors and liquids in the vicinity of this or any other appliance.
  • Page 3 Condair Ltd., except to the extent required for installation or maintenance of recipient's equipment. Liability Notice Condair Ltd. does not accept any liability due to incorrect installation or operation of the equipment or due to the use of parts/components/equipment that are not authorised by Condair Ltd..

  • Page 4: Table Of Contents

    Contents Introduction Before You Start! Notes on the Installation, Operation and Maintenance manual For your safety Receiving and Storage Inspection Storage and Transportation Product Overview Model Overview Model Designation Electrical Functional Description Options Accessories Mounting and Installation Work Safety Notes on Mounting and Installation Work Installation Overview Unit Fitting 5.3.1...
  • Page 5 10.4 Weights 10.5 Dimensions 10.5.1 Dimensions Condair GS 50 OC / GS 100 OC / GS 150 OC 10.5.2 Dimensions Condair GS 200 OC / GS 300 OC 10.5.3 Dimensions Condair GS 450 OC / GS 600 OC 2604697-A_EN_2211_Condair GS Outdoor_IOM...

  • Page 6: Introduction

    Notes on the Installation, Operation and Maintenance manual Limitation The subject of this manual is the Condair GS outdoor steam humidifier in its different versions. It is intended as a supplement to the Condair GS indoor manuals (installation manual and operation manual).
  • Page 7 If the equipment is moved to another location, make sure that the manual is passed on to the new user. If the manual is lost or misplaced, contact your Condair representative for a replacement copy. Language versions This installation, operation and maintenance manual is available in other languages. Please contact your Condair representative for information.

  • Page 8: For Your Safety

    For your safety General Every person, who is in charge of any work on the Condair GS must have read and understood this installation, operation and maintenance manual as well as the Condair GS indoor manuals before car- rying out any work.
  • Page 9 DANGER! Risk of fire or explosion! The Condair GS outdoor steam humidifier is a gas­fired humidifier. Improper operation and maintenance as well as incorrect settings and unauthorized alteration can cause carbon monoxide poisoning, explosion, fire or other hazards that can cause serious injury, death or property damage.
  • Page 10 Never use the manual drain valve until the unit has cooled down. Use the manual drain valve to verify that the tank is empty before removing the tank cover. Drain the tank as described in the Condair GS indoor operation manual.
  • Page 11 Preventing Unsafe Operation All persons working with the Condair GS outdoor steam humidifier must report any alterations to the unit that may affect safety to the owner without delay. If it is suspected that safe operation is no longer possible, the Condair GS outdoor steam humidifier should immediately be shut down and secured against accidental power­up according to Condair GS indoor operation manual.

  • Page 12: Receiving And Storage

    Receiving and Storage Inspection All Condair products are shipped F.O.B at the factory. All damage, breakage or loss claims are the re- sponsibility of the shipping company. After receiving the shipment, inspect the goods as follows: – Inspect the shipping boxes for damage. Report any shipping box damages to the shipping company without delay.
  • Page 13 WARNING! It is the customer's responsibility to ensure that operators are trained in handling heavy goods and that the operators comply with the appropriate regulations on work safety and the prevention of accidents. Packaging If the packaging needs to be disposed of, observe local regulations on waste disposal. Recycle packag- ing where possible.

  • Page 14: Product Overview

    All other features of the Condair GS outdoor steam humidifier are similar to the Condair GS indoor units. Refer to the respective Condair GS indoor humidifier manuals for details.

  • Page 15: Model Designation

    Model Designation The specification label on the right side of the Condair GS shows the model number, the serial number and the nominal values of the device (position of the specification label see Fig. OGDENSBURG , N.Y. OTTAWA, ONT. SERIAL NUMBER...
  • Page 16 Humidifier Components GS 50-150 units, top CS/NX model, bottom MT model) front, side and top panels removed in the figure for clarity Note: On Condair GS OC 150 CS/NX models the blower is located above the burner. Product Overview 2604697-A_EN_2211_Condair GS Outdoor_IOM...
  • Page 17 Legend Gas inlet Flue gas vent Steam outlet 12 Dual fill valve Combustion air inlet 13 Secondary heat-exchanger (CS/NX models only) Burner 14 Water supply hose Tank door 15 Flue gas condensate trap (CS/NX models only) Blower 16 Remote fault board Drain pump with drain valve 17 Control board Level control unit...
  • Page 18 Fig. 4: Humidifier Components GS 200-600 units, top CS/NX model, bottom MT model) front, side and top panels removed in the figure for clarity Product Overview 2604697-A_EN_2211_Condair GS Outdoor_IOM...
  • Page 19 Legend Gas inlet Flue gas vent Steam outlet 12 Dual fill valve Combustion air inlet 13 Secondary heat-exchanger (CS/NX models only) Burner 14 Water supply hose Tank door 15 Flue gas condensate hose (CS/NX models only) Blower 16 Remote fault board Drain pump with drain valve 17 Control board Level control unit...

  • Page 20: Electrical

    Table 1: Components installed by models Quantity Component GS 50/100 GS 150 GS 200/300 GS 450 GS 600 Primary heat-exchanger Secondary heat-exchanger Water tank Burner Blower Gas valve Ignition control module Spark-igniter and flame sensor Dual fill valve – – Quad fill valve –...

  • Page 21: Functional Description

    Functional Description Powering up the unit When power is supplied to the humidifier for start-up, the humidifier checks the state of two thermo- stats before proceeding to normal operation. The first thermostat activates the internal heaters. If the temperature is too low, the heaters will automatically engage, and will switch off once the appropriate temperature reached.
  • Page 22 On initial start-up, the dual fill valve fills the tank and the level control unit. A start-up test monitors the water level as the tank and level control unit fills, and ensures proper functioning of the unit. Note: A fault message "Float Level" may appear at any time. This indicates an invalid combination of readings from the control software (for example, if L5 and L1 LEDs activate at the same time).

  • Page 23: Options

    Options Table 3 shows the list of options for the Condair GS Outdoor Humidifier. Contact your local Condair representative for details. Table 3: Condair GS Outdoor Humidifier Options Option Application Natural gas or Propane Factory-installed gas valve for using either natural gas or propane in the humidifier.

  • Page 24: Mounting And Installation Work

    DANGER! Risk of electric shock! The Condair GS is mains powered. Live parts may be exposed when the unit is open. Touching live parts may cause severe injury or even death. Prevention: The Condair GS must be connected to the mains only after all mounting and installation work has been completed, all installations have been checked for correct workmanship and the access panels are installed and properly locked.

  • Page 25: Installation Overview

    Water drain line (supplied by others) Flue gas condensate drain (CS/NX models only, supplied by others) Extract air duct * for Condair accessories, refer to Help, or contact your local Condair sales representative. 2604697-A_EN_2211_Condair GS Outdoor_IOM Mounting and Installation Work...

  • Page 26: Unit Fitting

    Unit Fitting 5.3.1 Humidifier Location To ensure proper functioning of the Condair GS outdoor steam humidifier and to obtain optimum efficiency, the following points must be considered and observed when choosing the location for the humidifier: – The Condair GS outdoor steam humidifier must be mounted only outside of buildings where the flue gases can escape freely.
  • Page 27 – Make sure in the place of location of the Condair GS outdoor steam humidifier the supply of clean fresh air is provided. The unit must be placed at least 118.1" (3 m) away from any mechanical exhaust outlet. CAUTION! Operation of the humidifier with unclean air can lead to safety problems and reduce the output of the unit.

  • Page 28: Dimensions And Weights

    5.3.2 Dimensions and Weights See also dimensional drawings in Section 10.5. Table 5: Overall dimensions and weights Condair GS CS/NX OC Demensions in inches (mm) Weights in lbs (kg) Model Height Height with Width Depth Operating Roof curb roof curb GS 50 CS/NX OC 68.1 (1729)

  • Page 29: Removing The Humidifier From The Shipping Pallet

    5.3.3 Removing the Humidifier from the Shipping Pallet Fig. 7: Removing the humidifier from the shipping pallet 1. Remove cardboard protection from the humidifier. 2. Remove flue gas pipe, storm collar and rain cap which are placed on top of the humidifier. 3.

  • Page 30: Mounting The Humidifier

    5.3.4 Mounting the Humidifier 5.3.4.1 Mounting the Humidifier on a Concrete Curb 1. At the place of installation make a curb (foundation) according to the following drawing. Make sure the top of the curb is level in all directions. CAUTION! Make sure the curb and the place of installation are solid enough to structurally support the entire weight of the humidifier when in operation.
  • Page 31 2. Cut out the hole in the roof for routing the water piping and the electrical wiring into the unit (dimen- sions see above). 3. Attach an appropriate 4-strand hanger with shackles to the lifting lugs in the base of the unit. Lift the unit onto the curb and fix it to the curb with appropriate fixing material according to local codes.

  • Page 32: 5.3.4.2 Mounting The Humidifier On The Optional Roof Curb

    5.3.4.2 Mounting the Humidifier on the Optional Roof Curb 1. Assemble the optional roof curb stand according to the instructions supplied with the roof curb. 2. Place the roof curb at the desired position to the floor/roof and attach it to the floor/roof with appro- priate fixing materials.

  • Page 33: Mounting Checklist

    5.3.5 Mounting Checklist After mounting the humidifier, check the following: … Unit mounted in an outdoor environment where it is not exposed to severe weather, or where the- temperature drops below -4 °F (-20 °C) for "moderate climate package"; -40 °F (-40 °C) for "cold climate package", or where strong winds may cause the unit to fall.

  • Page 34: Flue Gas Installation

    Flue Gas Installation WARNING! Warning! Since the regulations for the installation of flueing systems differ from country to country, the relevant local regulations must be adhered to without reservation. All work concerning the flue pipe installation must be performed only by adequately qualified per­ sonnel.

  • Page 35: Notes On Flue Gas Installation

    Make sure the rain cap is at least 24" (60 cm) above any ridge within 10 ft (3 m) of the humidifier. Note: if the flue gas venting needs to be longer for any reason please contact your Condair repre- sentative.

  • Page 36: Steam Installation

    Overview Steam Installation Optional steam connection Fig. 11: Overview Steam Installation Steam outlet humidifier (steam outlet diameter see Steam distributor (Condair accessory) Table Worm gear hose clamp (supplied) Condensate drain line with trap Hose cuff (supplied) Open funnel with trap connected to building water water system...

  • Page 37: Notes On Steam Installation

    11.8" (300 mm) straight up above steam outlet before any radius. Refer to the Condair GS indoor installation manual for best practice of steam and condensate line rout- ing, radius and connection details, as well as sizing and materials.

  • Page 38: Water Installation

    30...80 psi (207…552 kPa) 33.8...59 °F (1...15 °C) - ideal, recommended min. 2" 33.8...77 °F (1...25 °C) - full admissible range (min. ø45 mm) Fig. 12: Overview water installation (Condair GS 150 CS unit shown) Mounting and Installation Work 2604697-A_EN_2211_Condair GS Outdoor_IOM...

  • Page 39: Notes On Water Installation

    (DI), with a flow rate of 2.6 gal/min (10 l/min) for GS 50-150 unit or 5.3 gal/min (20 l/ min) for Condair GS 200-600 units. The water quality must meet the require- ments as listed in...
  • Page 40 38. The hose must be rated to 212 °F (100 °C). – For Condair GS CS/NX 200-600 units: Install a trap with a min. height of 3.6 " (92 mm) in the flue gas condensate line before the condensate neutralization device.

  • Page 41: Water Installation Checklist

    … Condensate hose rated for 212 °F (100 °C)? … Condensate trap installed in the flue gas condensate drain line before the condensate neutraliza- tion device (Condair GS CS/NX 200-600 units only)? … Condensate trap inside/outside unit filled with water? …...

  • Page 42: Gas Installation

    Gas Installation 5.8.1 Overview Gas Installation Fig. 13: Overview Gas installation Gas supply connection Test port (supplied by others) – GS 50 OC to GS 150 OC: 3/4" NPT Sediment trap (supplied by others) – GS 200 OC to GS 600 OC: 1 1/4" NPT Note: Installation essential in the case of the use of steel Union fitting (supplied by others) gas pipes...

  • Page 43: Notes On Gas Installation

    5.8.2 Notes on Gas Installation The gas supply installation must be carried out in accordance with Fig. 13 on page 42 and the ap- plicable national and local codes for gas supply installations. In addition, the following requirements must be satisfied: –...

  • Page 44: Gas Leakage Test

    5.8.3 Gas Leakage Test DANGER! Risk of explosion or fire! Prevention: NEVER use an open flame to check for gas leaks (Risk of injury, death or property dam- age). Use a commercial soap solution or a gas sniffer to check for leaks. CAUTION! Risk of damage to the gas pressure regulating valve! Prevention: Before performing the leakage test described below, close the manual gas shutoff valve...

  • Page 45: Electrical Installations

    DANGER! Risk of electric shock! The Condair GS is mains powered. Live parts may be exposed when the unit is open. Touching live parts may cause severe injury or even death. Prevention: The Condair GS must be connected to the mains only after all mounting and installation work has been completed, all installations have been checked for correct workmanship and the access panels are installed and properly locked.

  • Page 46: Wiring Diagrams

    Continued on Continued on next wiring diagram next wiring diagram next wiring diagram next wiring diagram Fig. 14: Wiring Diagram Condair GS 50 OC - GS 600 OC (reference document 2584161, revision G) Mounting and Installation Work 2604697-A_EN_2211_Condair GS Outdoor_IOM...
  • Page 47 Supplementary Wiring Diagram Condair GS 450 OC ­ GS 600 OC Fig. 15 shows the supplementary wiring diagram for the Condair GS 450 OC - GS 600 OC. The con- nections are carried over from Fig. 14 on page Continued from...
  • Page 48 GR/Y - Green & Yellow GR/Y GR/Y Continued on Internal Wiring diagram Fig. 16: Supplementary wiring diagram 120V/1ph Voltage Supply for Condair GS 50 OC - GS 600 OC (reference document 2604624, revision A) Mounting and Installation Work 2604697-A_EN_2211_Condair GS Outdoor_IOM...
  • Page 49 GR/Y - Green & Yellow GR/Y Continued on Internal Wiring diagram Fig. 17: Supplementary wiring diagram 208V/3ph Voltage Supply for Condair GS 50 OC - GS 600 OC (reference document 2604625, revision A) 2604697-A_EN_2211_Condair GS Outdoor_IOM Mounting and Installation Work...

  • Page 50: Electrical Connections Checklist

    … All wiring done according to the wiring diagrams and instructions in this manual as well as the cor- responding wiring diagrams (controls) the Condair GS indoor installation manual? … Power cable properly grounded through the ground lug inside the electric cabinet? …...

  • Page 51: Operation

    Operation General The Condair GS outdoor steam humidifier must only be operated by personnel who is adequately quali- fied, well trained and are authorized by the customer. Observe all safety precautions described in and in the Condair GS indoor op- Section 2 on page 8 eration manual.

  • Page 52: Operating The Unit

    If any irregularities (leakages, fault messages or damaged components) are found, shut down the Condair GS outdoor steam humidifier before carrying out any work – refer to the Condair GS indoor operation manual. Contact your Condair representative if assistance is required.

  • Page 53: Maintenance

    During cold weather, all maintenance on the unit must be performed in a heated service tent. The maintenance items discussed in this section are in addition to those listed in the Condair GS indoor operation and maintenance manual. Refer to the Condair GS indoor operation and maintenance manual for other maintenance requirements.

  • Page 54: Cleaning The Heater(S)

    Cleaning the Heater(s) Fig. 18: Cleaning the heaters Proceed as follows to clean the heater(s): 1. Open the service panel on the plumbing side. 2. Use a vacuum cleaner or compressed air to remove all dirt and pollen from the heater(s) and fan(s). 3.

  • Page 55: Cleaning The Circulation Air Intake And Air Outlet

    Cleaning the Circulation Air Intake and Air Outlet Fig. 19: Cleaning the circulation air intake and air outlet Proceed as follows to clean the circulation air intake and air outlet: 1. Undo 5 screws and remove the circulation air intake shroud assembly. 2.

  • Page 56: Cleaning The Combustion Air Intake

    Cleaning the Combustion Air Intake Fig. 20: Cleaning the combustion air intake Proceed as follows to clean the heater(s) and fans(s): 1. Undo 5 screws and remove the combustion air intake shroud. 2. Vacuum the mesh screen (must not be removed), the intake shroud and the intake port. 3.

  • Page 57: Cleaning The Inside Of The Outdoor Unit

    Cleaning the Inside of the Outdoor Unit Fig. 21: Cleaning the inside of the outdoor unit Proceed as follows to clean the inside of the outdoor unit: 1. Open the service panels on the burner and on the plumbing side. 2.

  • Page 58: Fault Isolation

    Troubleshooting the Condair GS humidifier may require personnel to access the inside of the control cabinet in the humidifier which may expose personnel and equipment to the hazards. Make sure that the Condair GS humidifier is shut down properly as described in Condair GS II operation manual, and observe all safety precautions described in...

  • Page 59: Decommissioning Of The Condair Gs

    Remove the Condair GS outdoor steam humidifier from service (for disposal or long-term storage) as follows: 1. Drain the tank, and shut down the humidifier as described in the Condair GS indoor operation manual. Follow all safety precautions. 2. Close the gas supply and disconnect the gas connection to the humidifier.

  • Page 60: Product Specifications

    Product specifications 10.1 Performance Data Power consumption at Power consumption at Manifold Min./Max. Steam minimum demand maximum demand Model Pressure Capacity BTUh (kW) BTUh (kW) in H O (Pa) lb/hr (kg/h) Natural gas Propane Natural gas Propane GS 50 CS 12,400 (3.6) 12,400 (3.6) 62,000 (18.2)

  • Page 61: Gas Consumption At Maximum Power

    10.2 Gas Consumption at Maximum Power Gas consumption at maximum demand Power consumption at maximum demand gal/hr (m Model BTUh (kW) Natural gas Propane GS 50 CS 62,000 (18.2) GS 50 NX 65,000 (19.0) GS 50 MT 70,000 (20.5) GS 100 CS 124,000 (36.4) GS 100 NX 120,000 (35.2)

  • Page 62: Operating Data

    86 °F (30 °C) Backpressure steam line Maximum permissible backpressure (duct 6 in H O (1.49 kPa) for Condair GS 50-150 OC) static pressure and line backpressure) 10 in H O (2.49 kPa) - Condair GS 200-600 OC) Gas operating pressure Natural gas 4.5-10.0 in H...

  • Page 63: Weights

    208V/3ph wye/60Hz 2 x 1200W 16.0 3.54 IP Rating IP55 for all units 10.4 Weights For the weights of the Condair GS humidifier models refer to Table 5 on page 28 Table 6 on page 2604697-A_EN_2211_Condair GS Outdoor_IOM Product specifications...

  • Page 64: Dimensions

    33.58" (853) 34.53" (877) Fig. 22: Dimensions Condair GS 50 OC / GS 100 OC / GS 150 OC (Dimensions in mm (inch)) Roof curb optional. The humidifier may also be installed onto an appropriate concrete curb according local guidelines.

  • Page 65: 10.5.2 Dimensions Condair Gs 200 Oc / Gs 300 Oc

    Optional Roof Curb 36.69" (932) 43.43" (1103) 44.37" (1127) Fig. 23: Dimensions Condair GS 200 OC / GS 300 OC Roof curb optional. The humidifier may also be installed onto an appropriate concrete curb according local guidelines. 2604697-A_EN_2211_Condair GS Outdoor_IOM...

  • Page 66: 10.5.3 Dimensions Condair Gs 450 Oc / Gs 600 Oc

    Optional Roof Curb 36.69" (932) 69.52" (1766) 70.43" (1789) Fig. 24: Dimensions Condair GS 450 OC / GS 600 OC Roof curb optional. The humidifier may also be installed onto an appropriate concrete curb according local guidelines. Product specifications 2604697-A_EN_2211_Condair GS Outdoor_IOM...
  • Page 67 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 ear- lier, that THE COMPANY’s manufactured and assembled products, not otherwise expressly warranted (with the exception of the cylinder), are free from defects in material and workmanship.
  • Page 68 CONSULTING, SALES AND SERVICE: U.S.A. 835 Commerce Park Drive Ogdensburg, New York 13669 CANADA 2740 Fenton Road Ottawa, Ontario K1T 3T7 TEL: 1.866.667.8321 FAX: 613.822.7964 EMAIL: na.info@condair.com WEBSITE: www.condair.com...

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