Condair Esco Series Installation And Operating Instructions Manual
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Condair Esco Series Installation And Operating Instructions Manual

Steam humidification system
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Condair Esco
Steam humidification system
INStallatIoN aNd opEratINg INStruCtIoNS

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Summary of Contents for Condair Esco Series

  • Page 1 Condair Esco Steam humidification system INStallatIoN aNd opEratINg INStruCtIoNS...
  • Page 3 Possible applications for the Condair Esco live steam humidification system In the proximity of machinery and production processes, op- timal air humidity is essential. Of course for hospitals, as well as clinics, laboratories, and the chemical and pharmaceutical industries, air humidity and hygiene is an absolute necessity.

  • Page 5: Table Of Contents

    Notes on the installation and operating instructions Warranty/liability The Humidifier Steam humidification system Condair Esco System Condair Esco 5 System Condair Esco 10, 20 and 30 Function Connection unit Humidifier selection The essentials in brief Connection unit and ceramic rotary-disk control valve...

  • Page 6: Important Notes

    These installation and operating instructions contain all information required for planning a humidification project which utilises the steam humidification system Condair Esco. In addition, it contains all informa- tion necessary to install such a system. • installation and operating instructions are...

  • Page 7: Safety Instructions

    Without the written consent of the supplier, no attachments or modi- fications must be made to steam humidification systems Condair Esco, accessories, and options. • Original Condair spare parts from your supplier must be used exclusively for service and maintenance of the steam humidification system Condair Esco. •...

  • Page 8: Notes On The Installation And Operating Instructions

    Warranty entitlements expire, and no liability is assumed for damages caused by: • improper installation or application contrary to the intended purpose • installation of modifications which were not approved by Condair • improper maintenance by unqualified personnel • using spare parts and accessories other than original Condair ones...

  • Page 9: The Humidifier

    The Humidifier Steam humidification system Condair Esco Wherever existing steam is employed for humidification, the steam humidi- fication systems Condair Esco, DR73 DL40 prove to be outstanding. The precisely controlled steam mass flow is evenly distributed into the air current, void of any condensate spray. Steam humidification...
  • Page 10 System Condair Esco 5 Small, compact valve-unit with integrated ceramic rotary-disk valve and mounted steam connection flange. 1/2"-female thread for the steam supply pipe. Designed for the connection to DL40 standard single-steam distribu- tors 5/023 - 5/178. Technical specifications: Max. steam capacity...
  • Page 11 5/118 1225 - 1524 5/148 1525 - 1824 5/178 1825 - 2124 Valve size diagram Condair Esco 5 Steam capacity m [kg] Diagram for determining the dimension of the Esco 5 steam connection unit with appro- priate valve size. 2.2.1...
  • Page 12 2.2.2 Dimension diagram Condair Esco 5 steam connection unit, rotary disc actuator CA150A / CA150A-S G 1/2" 45° G 1/2" 2.2.3 Dimension diagram Condair Esco 5 steam connection unit, rotary disc actuator CA75 G 1/2" 45° G 1/2"...

  • Page 13: System Condair Esco 10, 20 And

    Rotary actuator Condensate return line Type DR73 and DL40, of the steam humidification system Condair Esco, blow precisely controlled, dried steam, uniformly into the air current, void of any condensate spray. Steam distribution takes place via steam distribution pipes with integrated nozzles.

  • Page 14: Function

    Function On the inlet side, the steam humidification systems Condair Esco DR73 DL40 are connected to the live steam supply. The steam on hand, when the ceramic rotary-disk control valve is closed, is continuously drained by means of the primary condensate drain (spheric float).

  • Page 15: Connection Unit

    The droplets slide down the inner wall of the water separator into the primary condensate drain. The dried steam flows to the ceramic rotary-disk control valve. • Steam trap The steam humidification systems Condair Esco DR73 DL40 both utilise a primary and a secondary condensate drain.
  • Page 16 • Ceramic rotary-disk control valve The humidifier control valve consists of two SiC (silicon carbide) ceramic disks, pressing against each other. One of them is fixed, while the other one is rotating. It is distinguished by the following features: • Compact design: The control valve is integrated into the connection unit.

  • Page 17: Humidifier Selection

    3. Rotary control valve actuator 4. Steam distribution system 5. Mounting set for insulated ducts* 6. Manometer* 7. Coupling piece for multiple piping* Operating range for steam humidification systems Condair Esco, type DR73 and DL40: Primary steam pressure (for live steam): 0,2...4,0 bar Primary steam temperature: 104...152 °C...
  • Page 18 3.3 Condair CA75 ● ● Condair CA150A ● ● ● ● ● ● Condair CA150A-S ● ● ● ● ● ● Condair ● ● ● ● ● ● Mounting set for ●...

  • Page 19: Connection Unit And Ceramic Rotary-Disk Control Valve

    Connection unit and ceramic rotary-disk control valve • Connection unit Esco 10, 20 and 30 • Ceramic rotary-disk control valve Characteristic curve for 18 different valve sizes, depending on humidi- fication capacity and steam pressure Example: – Required humidification capacity: 100 kg/hr –...

  • Page 20: Rotary Control Valve Actuator

    Rotary control valve actuator The steam humidification system Condair Esco is supplied with an electric Condair rotary actuator as standard equipment. As desired, the rotary control valve actuator comes either with (CA150A/CA150A-S) or without (CA75) attached spring-loaded return device (emergency function).
  • Page 21 480 g Adaptor for mounting rotary control valve actuators of different makes The steam humidification system Condair Esco can be adapted to any commercially available rotary actuator makes, by using appropriate adap- tor parts and accessories. Before installing different rotary control valve actuators, the supplier must be contacted.
  • Page 22 Pneumatic actuator type P10 for steam connection units Condair Esco 5, 10, 20 and 30 For continuous or on/off control of Condair Esco steam connection units. The actuators are equipped with a mounting panel and delivered completely together with the steam connection units.
  • Page 23 0.2...1.0 bar Linearity: Perm. ambient temperature: 0...70 °C Degree of protection: IP 54 Matrix stroke actuators P10 for Condair Esco steam connection units Type of steam connection unit Pneumatic actuator Positioner (optional) Condair Esco 5 Condair Esco 10 Condair Esco 10,...

  • Page 24: Steam Distribution

    Steam distribution The steam humidification system Condair Esco offers two different types of steam distribution: – Type DL40 Ideally suited for low duct or system cross-sections. The horizontal steam distribution pipe, with integrated nozzles, is especially useful for circulating air systems having a low duct cross-section and an extended humidification zone.
  • Page 25 3.4.1 Type DR73 There are different types of installations for the Condair Esco system DR73, which are explained in more detail below. Each one of these types may have a varying number of distribution pipes and different connection units. This...
  • Page 26 • Determing the number of steam distribution pipes types A, B and J* Notes on the following selection diagrams The following diagrams, used to determine the steam distribution pipes of both systems, are always based upon the shortest possible humidi- fication distance.
  • Page 27 3.4.2 Type DL40 The steam humidification system Condair Esco, type DL40 uses a stand- ardised steam distribution pipe, suitable for all injecting directions. The distribution pipes come in standard lengths and can be connected to con- nection units Esco 10 or Esco 20.

  • Page 28: Manometer

    For detailed information to the mounting set please see separate brochure “Condair Esco installation instructions”. Manometer All connection units Esco 10 - 30 may optionally be equipped with a ma- nometer.

  • Page 29: Condair Esco Stainless Steel

    Condair Esco stainless steel Condair Esco DL40 and DR73 steam humidifiers made entirely from high-grade steel The steam connection unit The rust-protected steam connection unit consists of an amply-dimensioned steam pressure relief compartment, in which a steam drier has been in- tegrated.
  • Page 30 The steam distribution systems The stainless steel steam connection unit has been developed for the connection to the: • DL40 system: Single pipes 10/023...10/388 (see chapter 3.4.2) Double and triple pipes (see chapter 4.6.2) • DR73 system: Short absorption manifolds (see chapter 3.4.2) The delivery of all steam distribution systems includes the stainless steel, thermostatic secondary steam trap.
  • Page 31 Tabular overview of Condair Esco stainless steel: Standard components and options Esco 10 and Esco 20 Steam connection unit Esco 10 Esco 20 for max. steam capacity up to 250 kg/hr up to 500 kg/hr see chapter 3.2 stainless steel...
  • Page 32 Material specification of the stainless steel components Specification: DIN-W-No.: 1.4301/1.4305 Steam connection unit (welded design) 1.4301 Steam inlet flange 1.4301 Flange for steam distribution systems Ceramic rotary disk control valve 1.4301 Live spindle 1.4401 Compression spring 1.4305 Drive shaft PEEK, (free from PTFE, silicone and halogens) Bearing EPDM/PTFE...
  • Page 33 Steam connection flange for steam distribution systems, Flange measurements ø9 ø9 DR73 DL40 – Condair Esco 10 – Condair Esco 5 – Condair Esco 10 stainless steel stainless steel ø9 ø9 DR73 DL40 – Condair Esco 20 – Condair Esco 20...
  • Page 34 Dimension diagrams DN32/PN16 P-actuator Condair Esco 10 stainless steel G 1/2" DN32/PN16 Actuator CA150A / CA150A-S Condair Esco 10 G 1/2" stainless steel DN32/PN16 Actuator CA75 Condair Esco 10 G 1/2" stainless steel...
  • Page 35 DN50/PN16 G 1/2" P-actuator Condair Esco20 stainless steel DN50/PN16 Actuator CA150A / CA150A-S Condair Esco 20 G 1/2" stainless steel...

  • Page 36: Hints For The Consulting Engineer And The Hvac Technician

    Hints for the consulting engineer and the HVAC technician The use of steam in air humidification To use steam from an existing steam boiler system, for the humidification of air, constitutes an actual consumption of energy and steam, whereas with steam heating , only the heat energy of the steam is utilised, and the condensate is recycled.

  • Page 37: Installation Instructions

    Please pay close attention to the following diagrams, and strictly observe the distances to downstream obstacles, when using the steam humidification system Condair Esco. This way only, can you be assured, that the steam is absorbed by the air and no formation of condensate on individual system components takes place.
  • Page 38 4.3.1 Type DR73 The conical discharge of steam at a right angle to the air current, and the variable arrangement of the steam pipes (illustration 1), account for the very high steam resolution achieved with the distribution pipes type DR73. Steam therefore is absorbed by the air after a relatively short distance;...
  • Page 39 In the humidification distance diagram 1, empirically calculated stand- ard values, based on lab tests, are used to express the humidification dis- tances BN, BF or BS to downstream obstacles in dependence of the above mentioned values. The air temperature t, before the distribution pipe, must not fall below the given values t in order to avoid supersaturating the air min,...
  • Page 40 Humidification distance - diagrams 1 Diagram for calculating the distance to a downstream obstacle in fresh air operation, x = 1 g/kg S = particle filter (Q, R, S) Humidity increase ∆x [g/kg] F = fine filter (C) N = normal obstacles (bend, fan, air heater, silencer, etc.) Type of downstream obstacle...
  • Page 41 Location of the humidity sensor to calculate the measuring point distance Using the diagram below, the humidification distance between the steam distribution pipe and the measuring point, in dependence of the air velocity w and the humidity increase ∆x can be determined. Computing the distance to the measuring point or to the downstream ob- stacles presents two totally different physical problems: At the measuring point, the measured value must correspond to the...
  • Page 42 If this turns out to be too long, the steam humidification system Condair Esco DR73 to be chosen in order to avoid the formation of condensate.

  • Page 43: Installation In Systems Or Ducts

    Note: Detailed information on the installation is found in the separate “Condair Esco Installation Instructions”. In principle, when you purchase the steam humidification system Condair Esco, we guarantee a drop-free humidification. An oversupply, however, from the humidifier, a clogged secondary condensate drain, or a malfunction- ing controller or control valve are all it takes to feed water or a water/steam mixture into the steam distribution pipe.
  • Page 44 – Type DL40 1. Provide openings (round holes) in duct. 2. From the duct side, slide the steam distribution pipe through the pre- pared openings. Make sure not to damage the steam pipe ends. 3. Mount the connection unit with connecting flange to the side of the duct.

  • Page 45: Dimension Diagrams

    Dimension diagrams 4.5.1 Steam connection unit Esco 10, 20 and 30 4.5.2 Rotary actuator CA150A, CA150A-S and CA75 Steam connection unit Esco 10 Esco 10 Side view steam connection unit with valve actuator Rotary actuator CA75 CA150A/ CA150A-S 143.5 143.5 (Flange) DN32/PN16 all dimensions in mm...
  • Page 46 4.5.3 Pneumatic actuator P10 Condair Esco 5 G 1/2" View G 1/2" Condair Esco 10 View Condair Esco 20 and Condair Esco 30 View Esco 20 Esco 30...

  • Page 47: Dimensions Diagrams For Installation

    Steam connection unit Esco 10, Esco 20 and Esco 30 with pneumatic actuator Esco 10 Esco 20 Esco 30 DN32/PN16 DN50/PN16 DN80/PN16 143.5 all dimensions in mm Dimensions diagrams for installation 4.6.1 Type DR73 Types A • Side view • Template Esco 10 Esco 20 Esco 30...
  • Page 48 Note: A special collector with built-in silencer is available from your Condair distributor on request. Pipe length...
  • Page 49 Side view • Template Esco 10 Esco 20 Installation for single piping Installation for dual piping Installation for triple piping 1 = min. 200 mm Distance to upstream obstacle for ... Upwind steam discharge: Downwind steam discharge:...

  • Page 50: Connection Diagrams For Actuators

    Connection diagrams for actuators 4.7.1 Electric rotary actuator CA150A and CA150A S AC 24V 50/60 Hz DC 24V Supply Safety position “ZU” currentless AC 24 V 50/60 Hz (Emergency function by means of DC 24 V spring- loaded return device) 0...10 V Control signal Input resistance: 100 kΩ...
  • Page 51 4.7.2 Electric rotary actuator CA75 measuring voltage 4.7.3 Positioner XSP 31 for pneumatic actuator P10...

  • Page 52: Hints For The Heating Engineer

    Hints for the heating engineer Connecting the steam supply pipe The supply pipe should be connected to the top of a perfectly drained main steam pipe and run with a down gradient to the steam humidifier. A shut-off valve (provided by customer) is installed preceding the humidifier. A steam pressure gauge (manometer) may also be provided.
  • Page 53 Suspension Space steam pipe attachments evenly. Steam pipes must be installed without any restrictions. Use compensators or loops to allow for pipe expansion. Ascending pipes Always drain ascending pipes at the lowest point.. Key: Deviations = Shut-off valve = Condensate drain = Compensators = Control valve = Drain...
  • Page 54 Installation examples 1. Short ascending pipes 1 Steam vessel 2 Collector pipe 3 Ascending pipe (length <6 m) 4 Ascending pipe (length >6 m) 5 Consuming point The collector pipe (2) from or to the steam vessel must be oversized by one nominal width unit! Short ascending pipes up to 6 m max.
  • Page 55 2. General example K Steam vessel T Steam dryer V Steam distributor U Consuming point Checklist for the expert 1 Slowly open stop valve of steam collector line 2 Steam line: saturated steam at about 25 m/s 3 Insulation: 30...100 mm 4 Supports and fittings have to be insulated.

  • Page 56: Schematic Diagram

    Schematic diagram When Z is larger than 5 m, the pipe must be drained. P = primary condensate drain: The primary condensate can be drained, even against pressure, via built-in condensate drain. The back pressure must not exceed 50 % of the primary steam pressure.

  • Page 57: Connections To Be Prepared By Customer

    Connections to be prepared by customer Steam distribution pipes, type DR73 DL40 can be connected to steam boilers, steam converters or existing steam supplies. The supply overpres- sure (live steam) should be as consistent as possible and be between 0.2 and 4.0 bar.

  • Page 58: Initial Start-Up

    Retighten leaking connections, and close the shut-off valve again. 3. Insulate the entire steam supply pipe with appropriately heat-resistant material. 4. To put the steam humidification system Condair Esco DR73 DL40 as well as the attached valve actuator into operation, refer to the guide- lines provided by the control and installation firms.

  • Page 59: Maintenance

    Immediately following the initial operation, all screwed connections must be checked for leaks and retightened if necessary. After the steam distribu- tion system Condair Esco has been in operation for one to two weeks, the strainer in the connection unit must be cleaned.

  • Page 60: Trouble-Shouting Guide

    Trouble-shouting guide Error or malfunction and possible cause No steam is discharged from the distribution pipes • Actuator mounted incorrectly • Control or high-limit humidistat set too low • Defective control line between humidistat, controller and rotary control valve actuator •...

  • Page 61: Vaporisation / Condensation

    Vaporisation / condensation Terminology and definitions • Vaporisation Vaporisation is understood to be the transition of a liquid into the gase- ous stage upon reaching the substance’s boiling point. The onset of the boiling process depends on the following parameters: •...
  • Page 62 • Vaporisation heat Vaporisation heat equals the transformation energy required to vapor- ise a liquid. In order to compare different substances, the specific va- porisation heat (transformation energy per measuring unit kJ/kg) is observed. From the diagram for water (see below) it can be seen, that the tempera- ture (at sea level) remains constant at a 100 °C.

  • Page 63: Dr73 Dl40

    Work sheet DR73 DL40 DR73 DL40 Work sheet Position System designation Amount (humidifier) pcs. max. humidification capacity mD kg/hr Steam overpressure (valve admission pressure) p1 Humidity before humidification x1 g/kg Humidity after humidification x2 g/kg Humidity increase ∆x g/kg Inner duct width a / wall thickness Inner duct height b / wall thickness Installation in (G = Unit / K = Duct) Air volume flow...
  • Page 65 Notes...
  • Page 66 Notes...
  • Page 67 © Walter Meier (Climate International) ltd. 2000, printed in Switzerland technical modifications reserved...
  • Page 68 CoNSultINg, SalES aNd SErvICE: JS Humidifiers plc Artex Avenue, Rustington, LITTLEHAMPTON, West Sussex BN16 3LN (United Kingdom) Phone +44 (0)1903 850 200, Fax +44 (0)1903 850 345 www.jshumidifiers.com, sales@jshumidifiers.com Solutions for Indoor Climate reg.No. 40002-2 Manufacturer: Walter Meier (Climate International) ltd. talstr.

This manual is also suitable for:

Esco 10Esco 5Esco 20Esco 30

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