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Condair DL Series Installation Manual

Adiabatic air humidification system
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READ AND SAVE THESE INSTRUCTIONS
INSTALLATION MANUAL
Adiabatic air humidification system
Condair DL II
Humidification and Evaporative Cooling

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  • Page 1 READ AND SAVE THESE INSTRUCTIONS INSTALLATION MANUAL Adiabatic air humidification system Condair DL II Humidification and Evaporative Cooling...
  • Page 2 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 authorized by Condair Ltd.

  • Page 3: Table Of Contents

    Overview water installation 4.8.2 Notes on water installation Electrical installation 4.9.1 Notes on electrical installation 4.9.2 Wiring diagram Condair DL 4.10 Wiring plan Condair DL 4.10.1 Electrical connections between central unit and control unit 4.10.1.1 Wiring diagram central unit - control unit 4.10.1.2...

  • Page 4: Introduction

    We thank you for having purchased the adiabatic air humidification system Condair DL. The humidification system Condair DL incorporates the latest technical ad van ces and meets all recog- nized safety standards. Nevertheless, improper use of the humidification system Condair DL may result in danger to the user or third parties and/or impairment of material assets.
  • Page 5 If the documentation gets mislaid, please contact your Condair representative. Language versions This installation manual is available in various languages. Please contact your Condair representative for information. Introduction...

  • Page 6: For Your Safety

    For safety and warranty reasons any action beyond the scope of this manual must be carried out only by qualified personnel authorized by the manufacturer. It is assumed that all persons working with the humidification system Condair DL are familiar and comply with the appropriate regulations on work safety and the prevention of accidents.
  • Page 7 CAUTION! In order that the Condair DL does not remain in the error status unnoticed for a longer period of time in the event of a malfunction, errors must be signaled via a remote error indication (e.g. via the error relay of the remote operating and fault indication board or via the network via BACnet or Modbus).

  • Page 8: Important Notes

    Check packing slip to ensure all parts has been delivered. All material shortages are to be reported to your Condair supplier within 48 hours after receipt of the goods. Condair assumes no responsibility for any material shortages beyond this period.

  • Page 9: Product Designation

    The product designation and the most important unit data are found on the rating plate fixed on the right side of the control unit and the central unit (see example below): Device type Serial number Manufacturing date month/year Condair Group AG, Gwattstrasse 17, 8808 Pfäffikon SZ, Switzerland Type: Condair DL Serial-No: XXXXXXX 03.16...

  • Page 10: Mounting And Installation Work

    Touching live parts may cause severe injury or danger to life. Prevention: The control unit of the Condair DL 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 all unit covers are relocated properly locked.

  • Page 11: Installation Overview

    4 - Mounting the central unit --> see Section 4.6 5 - Mounting the control unit --> see Section 4.7 6 - Water installation --> see Section 4.8 7 - Electrical installation --> see Section 4.9 Fig. 1: Installation overview Condair DL Mounting and installation work...

  • Page 12: Installation Of The Humidification Unit

    For safety reasons the Condair DL must be installed only in rooms provided with a floor drain. If for some reason the Condair DL must be installed in a location without floor drain, it is mandatory to provide a water tub with drain below the central unit and the duct wall feed throughs and/or water sensors in the room/water tub to safely interrupt water supply in case of a leak.
  • Page 13 (min. 500) 3.94" Heater (100) Slope min. 2° to center drain * Larger distance according to prior agreement with Condair possible 23.62" - 35.43" 600 - 900 * Top view min. 19.69" (min. 500) Inspection door (mandatory, if there is no...
  • Page 14 Side view min. 19.69" (min. 500) 3.94" Heater (100) Slope min. 2° to center drain 23.62" - 35.43" 600 - 900 Top view min. 19.69" (min. 500) Inspection door before the min. 15.75" 13.19" nozzle grid (mandatory) Inspection door after (min.

  • Page 15: Mounting The Post-Evaporation Unit

    4.3.2 Mounting the post-evaporation unit 4.3.2.1 Overview frame constructions post-evaporation unit The following figure shows an overview of the frame constructions of the post-evaporation unit depending on the air duct/AHU size. Mounting and installation work...

  • Page 16: Mounting Procedure Post-Evaporation Unit

    4.3.2.2 Mounting procedure post-evaporation unit 1. Marking the positions of the fastening elements inside the duct/AHU: • Mark the position of the topmost fastening holes (or welding studs) for the fastening of the lateral supports of the post-evaporation unit "A", the nozzle system "C" and the fastening profiles for the lateral sealing plates "B"...
  • Page 17 2. Mount the base plate: Note: this step must be carried out only on systems equipped with a droplet separator. • Attach the base plate to the tub ledge behind the post evaporation unit using the self-tapping screws 6.3 x 25 mm. Note: Make sure the base plate is flush with the duct walls on each side.
  • Page 18 3. Mount the lateral supports of the post-evaporation unit to the duct walls: • Align the lateral supports with the "TOP" labeled mounting bracket on top with an identical distance to the duct ceiling (target measure "a": 2.56" (65 mm), admissible range: 0...3.54" (0...90 mm)) and with a distance "b"...
  • Page 19 4. Mounting the fastening profiles for the upper sealing plates: Important: if only one fastening profile is used in the duct width, the fasting profile must be centrically aligned to the duct width in a distance of 2.95" (75 mm) to the lateral supports, then fixed to the duct ceiling using appropriate self-tapping screws.
  • Page 20 5. Mounting the fastening profiles for the lateral sealing plates: • If not done already with the drilling template in step 1, mark the position of the lateral fastening profiles for the lateral sealing plates on both sides of the duct. Distance between fastening profiles and post-evaporation supports 10.04"...
  • Page 21 6. Mount the cross members: Note: This step must be carried out only on air ducts /AHU's with a width >82.68" (>2100 mm). • For air ducts/AHU's with a width >82.68" (>2100 mm) the cross members are supplied in sec- tions and must be bolted together on site.
  • Page 22 7. Mount the vertical support(s): Note: This step must be carried out only on air ducts /AHU's with a width 82.68" (>2100 mm). 7a. Assembling the vertical support(s): Note: This step must be carried out only on air ducts /AHU's with a height 78.74" (>2000 mm). For air ducts/AHU's with a height 78.74"...
  • Page 23 Note: for stability reasons some or all vertical supports (depending on the height and the width of the AHU/air duct) are fixed with special leg supports to the duct floor and duct ceiling (see overview frame constructions of the post-evaporation unit in Section 4.3.2.1).
  • Page 24 7c. Mount the vertical support(s) and the top and bottom leg supports: Note: this step must be carried out only on air ducts /AHU's with a width >177.17" (>4500 mm). Fig. 13: Mounting the middle vertical support and the top and bottom leg supports Mounting and installation work...
  • Page 25 Note: in the duct section where the leg supports are fixed to the duct/AHU floor (or tub) and the duct ceiling a reinforcement traverse may be installed where required. However, make sure the lower leg support does not stand in the water during operation. On ducts/AHU's with a tub divided in longitudinal direction the leg supports may also be fixed to the tub partitionment if a sufficient load bearing capacity is assured.
  • Page 26 Important! If your system has no service door behind the post-evaporation unit, now place the droplet separator elements in the duct, just behind the frame construction. 8. Mounting the diagonal stiffeners (see also frame construction overviews in Fig. Note: this step must be carried out only on air ducts /AHU's with a width 82.68" (>2100 mm). •...
  • Page 27 Fig. 14: Mounting the diagonal stiffeners 9. Mounting the droplet separator elements: Note: this step must be carried out only if your system is equipped with a droplet separator. On systems with a width up to 82.68" (2100) mm the supplied cross members must be mounted prior to the installation of the droplet separator.
  • Page 28 • Fix the two upper brackets at the appropriate position to all droplet separator elements as shown below using the thread plates and the M6 x 20 mm hexagon socket screws supplied. Important! Tighten the screws by hand only to a point at which the brackets can still be moved. Fig.
  • Page 29 • From the back, hang all droplet separator elements to the topmost cross member. Fix the lower brackets to the droplet separator elements using the thread plates and the M6 x 20 mm hexa- gon socket screws supplied (tighten the screws by hand only to allow later adjustment of the brackets).
  • Page 30 Mounting the lateral sealing plates: • Start on the bottom shift the lateral sealing plates with the slightly bent surface behind the fas- tening profiles. Important! Make sure the sealing plates on top of each other covers and overlaps the subjacent sealing plates in order to ensure that no water can flow behind the subjacent sealing plates.
  • Page 31 11. Inserting ceramic support profiles: • Insert the ceramic support profiles into the lowest row of holders. Make sure the support profiles are inserted such that the slots on each side of the support profiles rest on the holder. Fig. 19: Inserting ceramic support profiles Mounting and installation work...
  • Page 32 12. Mounting the tub rubber sealing: • Fix tub rubber sealing with the clips to the ceramic support profiles as shown below (longer part of the clip is on the side of the rubber sealing). Cut rubber sealing on both sides of the duct to the appropriate length.
  • Page 33 13. Inserting ceramic carrier profiles: • Insert the ceramic carrier profiles into holders. Make sure the carrier profiles are inserted such that the slots on each side of the carrier profile rest on the holders. Fig. 21: Inserting ceramic carrier profiles Mounting and installation work...
  • Page 34 14. Mount the ceramic plates: WARNING! Risk of injury The ceramic plates of the post-evaporation unit are porous and have partial sharp edges. You may injure your hands on this sharp edges or may injure your eyes by splintering ce- ramic parts when handling the ceramic plates.
  • Page 35 15. Mount the upper sealing plates: • Starting on one side push the upper sealing plates underneath the fastening profiles until the they touch the ceramic plates of the topmost row. • Carefully shift the very right and the very left sealing plate against the lateral sealing plates without pushing them away.

  • Page 36: Mounting The Nozzle System

    4.3.3 Mounting the nozzle system 4.3.3.1 Overview frame constructions nozzle system The following figure shows an overview of the frame constructions of the nozzle system depending on the air duct/AHU size. 181.10" (4600) 17.72" (450) 17.72" 82.68" 82.72" 165.35" 165.39" 177.17"...

  • Page 37: Mounting Procedure Nozzle System

    4.3.3.2 Mounting procedure nozzle system 1. Mount the lateral supports of the nozzle system to the duct walls: • Align the lateral supports with the "TOP" labeled mounting bracket on top with an identical distance to the duct ceiling (target measure "a": 2.56" (65 mm), admissible range: 0...3.54" (0...90 mm) and with a distance "d"...
  • Page 38 2. Mount the cross members: Note: this step must be carried out only on systems with more than one nozzle grid in the width. • On systems with more than one nozzle grid in the width the cross members are supplied in sec- tions and must be bolted together on site.
  • Page 39 3. Mount the vertical support(s): Note: this step must be carried out only on systems with more than one nozzle grid in the width. 3a. Assembling the vertical support(s): Note: this step must be carried out only, if the vertical supports are supplied in sections due to plant-specific reasons.
  • Page 40 3b. Mount the vertical support(s) Note: for stability reasons the middle vertical support for ducts with a width >177.17" (>4500 mm) is fixed with a special leg support to the duct floor and an angle bracket to the duct ceiling. Please refer to step "3c" for mounting the leg support and the angle bracket. •...
  • Page 41 3c. Mount the middle vertical support and the top and bottom leg supports: Note: this step must be carried out only on air ducts /AHU's with a width >177.17" (>4500 mm). Fig. 29: Mounting the bottom leg support and the angle bracket to the middle vertical support Mounting and installation work...
  • Page 42 Note: in the duct section where the leg support is fixed to the duct/AHU floor (or tub) a reinforcement traverse may be installed where required. However, make sure the leg support does not stand in the water during operation. On ducts/AHU's with a tub divided in longitudinal direction the leg support may also be fixed to the tub partitionment if a sufficient load bearing capacity is assured.
  • Page 43 4. Mount the nozzle grid(s): • Hang up nozzle grid into the holders, then push nozzle grid downwards until it comes to a stop. Repeat step for additional nozzle grid(s) if necessary. Fig. 30: Mounting the nozzle grid(s) Mounting and installation work...
  • Page 44 5. Mount housing feed throughs: • Mark the required number of feed through holes (vertically or horizontally) on the duct wall using the drilling template supplied (7 steps: 3 feed through holes / 15 steps: 4 feed through holes / 31 steps: 5 feed through holes).
  • Page 45 6. Connect spray circuits to the housing feed throughs: • Interconnect the spray circuits of the different nozzle grids (if more than on grid is present). Interconnect spray circuits with same color only. Important: Make sure the spray circuit lines have a minimum constant downslope of 2 % to the housing feed throughs.

  • Page 46: Positioning And Mounting The Control Unit And Central Unit Mounting Rack

    Positioning and mounting the control unit and central unit mounting rack Positioning the mounting rack – The mounting rack is designed for floor-mounting in interior spaces. Make sure that the floor surface on which the mounting rack is to be mounted, offers a sufficient high load-bearing capacity and stability, and is suitable for the installation.
  • Page 47 Assembling and fixing the mounting rack to the floor 1. Assemble the rack stands (1), mounting plates (4 and 5) and the brace (9) with the hexagon socket screws and washers supplied as shown in 34. Tighten all screws. Fig. Note: mounting plate (5) may be mounted in three different heights.
  • Page 48 " . 1 3 ( 7 4 . 7 " i n . . 7 " i n . 10 hex-head screws ø0.24"x 3.15" (ø6 x 80 mm) 11 Washer 12 Dowel ø0.4" x 2.36" (ø10 mm x 60 mm) .

  • Page 49: Converting The Spray Circuit Outlets From Left To Right

    Converting the spray circuit outlets from left to right Ex factory the central unit is delivered with spray circuit outlets on the left side. If, for site specific reasons the spray circuit outlets must be on the right unit side the spray circuits can repositioned as follows: 1.
  • Page 50 7 Steps with double stage Y5 (red) Y6 (blue) Y7 (yellow) Y7 (yellow) Y6 (blue) Y5 (red) 15 Steps Y5 (red) Y6 (blue) Y7 (yellow) Y8 (green) Y8 (green) Y7 (yellow) Y6 (blue) Y5 (red) 15 Steps with double stage Y5 (red) Y6 (blue) Y7 (yellow)
  • Page 51 31 Steps Y5 (red) Y6 (blue) Y7 (yellow) Y8 (green) Y9 (grey) Y9 (grey) Y8 (green) Y7 (yellow) Y6 (blue) Y5 (red) 31 Steps with double stage Y5 (red) Y6 (blue) Y7 (yellow) Y8 (green) Y9 (grey) Y9 (grey) Y8 (green) Y7 (yellow) Y6 (blue) Y5 (red)

  • Page 52: Mounting The Central Unit To The Mounting Rack

    Mounting the central unit to the mounting rack Open Closed position position Open Closed position position Central unit Weight with pump: approx. 119.05 lbs (54 kg) Weight without pump: approx. 77.16 lbs (35 kg) Admissible ambient condition: – Ambient temperature: 41 ... 104 °F (5 ... 40 °C) –...

  • Page 53: Mounting The Control Unit To The Mounting Rack

    Mounting the control unit to the mounting rack Electrical isolator Open Closed position position Control unit Electrical isolator The electrical isolator (by others) can be mounted to the mounting rack as shown. Open Closed position position Control unit Weight control unit: approx..33.07 lbs (15 kg) Admissible ambient condition: –...

  • Page 54: Water Installation

    Water installation 4.8.1 Overview water installation Central unit Spray circuit connectors 0.39" (ø10 mm) arranged on the left or the right side of the central unit Spray circuit lines (constant downslope Spray circuit connectors on AHU (min. 2%) to central unit) Spray circuit 5 "Y9": grey Spray circuit 4 "Y8": green RO water connector ø0.47"...

  • Page 55: Notes On Water Installation

    – Use the supplied black plastic hoses ø0.39"/0.31" (ø10/8 mm) and ø0.47"/0.35" (ø12/9 mm) only. For hygienic reasons do not use other hoses (except products supplied by your Condair distributor). CAUTION! Fully demineralized water is aggressive. For this reason, the entire water system must contain fully demineralized water resistant material only (e.g.
  • Page 56 If the length of the water supply line between the water conditioning unit and the central unit of the Condair DL exceeds 65.62 ft (20 m), the supply line must be equipped with a suitable pressure damper (overflow valve, surge tank, etc.). Furthermore, the supply line must be properly fastened according to the regulations –...

  • Page 57: Electrical Installation

    Touching live parts may cause severe injury or danger to life. Prevention: The control unit of the Condair DL 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 all unit covers are relocated properly locked.

  • Page 58: Wiring Diagram Condair Dl

    4.9.2 Wiring diagram Condair DL Mounting and installation work...

  • Page 59: Wiring Plan Condair Dl

    4.10 Wiring plan Condair DL Mounting and installation work...

  • Page 60: Electrical Connections Between Central Unit And Control Unit

    4.10.1 Electrical connections between central unit and control unit 4.10.1.1 Wiring diagram central unit - control unit Control unit Driver Control board board 24V E (6.3 AT) (630 mAT) 24V E Smartcard D– Battery D– 24V IC 24/10 V 24V E Enable Legend Driver board...

  • Page 61: Installation Work Central Unit - Control Unit

    4.10.1.2 Installation work central unit - control unit Connecting the motor cable (MC) to the frequency converter (type A only) Danger of electric shock! The frequency converter in the control unit of systems with booster pump contains capacitors. These can remain charged with a potentially deadly voltage for a certain period of time after the control unit has been disconnected from the power supply.
  • Page 62 Connecting the cable harness "CH1" (Pressure sensors) Ex factory the cable harness "CH1" (Pressure sensors) is connected inside central unit to the corresponding pressure sensors. On site the terminal connector of the cable harness must be connected to the appropriate terminal (X10) on the driver board inside the control unit.
  • Page 63 Connecting the cable harness "CH2" (Valves) Ex factory the cable harness "CH2" (Valves) is connected inside central unit to the corresponding valves. On site the terminal connectors of the cable harness must be connected to the appropriate terminals (X3 to X6) on the driver board inside the control unit.
  • Page 64 Connecting the cable harness "CH3" (silver ionization "Ag+" and conductivity sensor "Lf") the cable harness "CH4" (optional temperature sensor) Ex factory the cable harness "CH3" (silver ionization "Ag+" and conductivity sensor "Lf") and the cable har- ness "CH4" (optional temperature sensor "Temp") are connected inside central unit to the silver ionization car- tridge, to the conductivity sensor and to the temperature sensor (optional).

  • Page 65: External Electrical Connections

    Jumper for activating the terminating resistor for Modbus Ventilaton interlock RTU or BACnet MS/TP communication via the RS485 High limit humidistat interface "X3". Jumper must be connected, if Condair DL Air flow monitor is the last device in the network. L1 L2...

  • Page 66: Installation Work External Connections

    4.10.2.2 Installation work external connections Connecting the external safety loop The potential-free contacts of external moni t or ing devic- es (e.g. ventilation interlock, safety high limit humidistat, air flow monitor, etc.) are connected in series (safety loop "K1") to the terminals "SC1" and "SC2" of the terminal block "X1"...
  • Page 67 This relay is activated when the set service interval has expired. – "Running" (Terminal 7 and 8): This relay closes as soon as the Condair DL hu- midifies. – "Unit on" (Terminal 9 and 10): This relay closes as soon as the voltage supply to the control unit of the Condair DL is switched on.

  • Page 68: Connecting Options

    DL type B 110-115 VAC / 50...60 Hz or L1, L2 and L1L2 2xPE, for Condair DL type A and type B 200-240 VAC / 50...60 Hz) is to be connected to terminals "XE1" via the the snap ferrite "SF" (supplied) in accordance with the wiring diagram.

  • Page 69: Appendix

    Appendix Dimensional drawing control unit 1.87 (47.5) 2.89 (73.5) 3.76 (95.5) 11.12 (282.5) 8.54 (217) 8.11 13.54 2.64 4.14 4.14 2.64 (206) (344) (67) (105) (105) (67) Fig. 43: Dimensional drawing control unit (Dimensions in mm) Appendix...

  • Page 70: Dimensional Drawing Central Unit

    Dimensional drawing central unit 11.22 (285) 20.83 10.79 4.11 6.30 6.30 4.11 (529) (274) (104.5) (160) (160) (104.5) 1.59 1.63 (40.5) (41.5) 1.91 1.91 19.45 (48.5) (48.5) (494) 3.29 3.29 18.07 (83.5) (83.5) (459) 4.67 4.31 16.69 (118.5) (109.5) (424) 4.67 6.04 15.31...
  • Page 71 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.
  • Page 72 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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