Condair Esco 10, Esco 5, Esco 20, Esco 30 Installation And Operating Instructions Manual

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Condair Esco

Steam humidiﬁcation system

INSTALLATION AND OPERATING INSTRUCTIONS

2562350 EN 1009

Possible applications for the Condair Esco live steam humidication system

In the proximity of machinery and production processes, optimal 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.

In storage rooms, where organic matter like sh, vegetables

or tobacco is kept for longer periods of time, optimal air humid-

ity will prevent undesired drying and preserve the freshness. It improves the health and well-being of people, animals and

plants, especially during the heating season. Condair Esco’s

steam air humidication system satises these requirements

to a high degree.

Why humidify with steam?

To humidify the air with water vapour is the most direct, simplest, and safest method. Humidity contained in air is called

water vapour. To humidify the air means increasing its water vapour content. The Condair Esco steam humidication system raises the lacking humidity to the proper, optimal value without

any undesired side-effects.

Using steam to humidify the air...

• is indisputably the most hygienic method (sterile)

• causes no disturbing odours

• hardly affects the temperature of the air (isothermal)

• prevents waterborne mineral deposits from accumulating in

air ducts and rooms

• allows optimal control of the air humidity

• requires minimal maintenance

Contents

1 Important notes 6

1.1 Correct use for intended purpose 6

1.2 Safety instructions 7

1.3 Notes on the installation and operating instructions 8

1.4 Warranty/liability 8

2 The Humidier 9

2.1 Steam humidication system Condair Esco 9

2.2 System Condair Esco 5 10

2.3 System Condair Esco 10, 20 and 30 13

2.4 Function 14

2.5 Connection unit 15

3 Humidier selection 17

3.1 The essentials in brief 17

3.2 Connection unit and ceramic rotary-disk control valve 19

3.3 Rotary control valve actuator 20

3.4 Steam distribution 24

3.6 Manometer 28

3.7 Condair Esco stainless steel 29

4 Hints for the consulting engineer and the HVAC technician 36

4.1 The use of steam in air humidication 36

4.2 Installation instructions 37

4.3 Using the humidication distance diagrams 37

4.4 Installation in systems or ducts 43

4.5 Dimension diagrams 45

4.6 Dimensions diagrams for installation 47

4.7 Connection diagrams for actuators 50

5 Hints for the heating engineer 52

5.1 Connecting the steam supply pipe 52

5.2 Installing the steam pipes 52

5.3 Schematic diagram 56

5.4 Connections to be prepared by customer 57

6 Initial start-up 58

7 Maintenance 59

8 Trouble-shouting guide 60

9 Vaporisation / condensation 61

9.1 Terminology and denitions 61

10 Work sheet DR73 / DL40 63

1 Important notes

Please read this chapter carefully. It contains important information, which must be observed for safe, correct, and economic operation of the steam humidication system Condair Esco.

1.1 Correct use for intended purpose

Steam humidication systems Condair Esco are intended exclusively for indirect humidication via steam distribution pipe in a ventilation duct. For

applications in process technology systems, please consult the supplier. Any other type of application is considered as not conforming with the intended purpose. The supplier cannot be made liable for any damage resulting

from improper use. The user bears full responsibility.

Correct use for intended purpose further includes:

• Observation of the instructions, regulations and notes contained in the

present installation and operating instructions for the steam humidica- tion system Condair Esco.

• These installation and operating instructions contain all information required for planning a humidication project which utilises the steam humidication system Condair Esco. In addition, it contains all informa-

tion necessary to install such a system.

• The installation and operating instructions are intended for use by engi-

neers, planning personnel and system constructors entrusted with the

design of humidication systems. It is assumed, that these persons have a good understanding of the ventilation and humidication technology.

• The steam humidication system Condair Esco incorporates the latest technical advances and meets all recognised safety regulations (manufacturer’s statement). Ignorance of appliance-specic qualities or improper use, however, can result in danger to the user or third parties and/or impairment of the system and other material values.

• The notes in the installation and operating instructions concerning the planning /layout of a humidication system, and the installation details for the steam humidication system Condair Esco must be observed

and followed without fail.

The following points must be observed in addition to these installation and

operating instructions:

• All local safety regulations concerning the use of pressurised steam

systems.

• All local safety regulations concerning the use of mains-supplied electrical equipment.

• All instructions and warnings in the publications for the products used in conjunction with the steam humidication system Condair Esco.

• All safety regulations concerning the system in which the steam humidication system Condair Esco is tted.

• All instructions and warnings provided on the steam humidication

system Condair Esco.

• All local sanitary regulations.

The well organised world-wide Condair distributor network provides service at all times by qualied technicians. Please contact your supplier if you have any queries concerning the steam humidication system Condair Esco or humidication technology in general.

1.2 Safety instructions

• The steam humidication system Condair Esco must only be installed, operated and serviced by persons familiar with this product and sufciently qualied for the task. The customer must ensure that the installa-

tion and operating instructions are supplemented by internal instructions

with respect to supervisory and notication liability, work organisation, personnel qualication, etc.

• Persons unfamiliar with the operating instructions must neither operate nor service the steam humidication system Condair Esco. The user of this steam humidication system is responsible for preventing any unauthorised persons from operating this humidier.

• Without proper qualications, no operations may be carried out for which the consequences are not known. In case of doubt, the supervisor or

the supplier must be contacted.

• Original Condair accessories and options from your supplier must be used exclusively for installation of the steam humidication system Condair Esco.

• Without the written consent of the supplier, no attachments or modi- cations must be made to steam humidication systems Condair Esco,

accessories, and options.

• Original Condair spare parts from your supplier must be used exclusively for service and maintenance of the steam humidication system Condair

Esco.

• Do not remove the anges from the steam connection units.

1.3 Notes on the installation and operating instructions

Limitation

Comments in the present installation and operating instructions “Steam

Humidication System Condair Esco” are limited to details:

• on the proper planning of systems

• on the proper installation

• on the proper commissioning procedure

• on the proper operation and maintenance

• on service and trouble-shooting

Safekeeping

Keep these installation and operating instructions in a safe place where it is

always available. If applicable, it must be passed on to subsequent users.

If this documentation is misplaced, please contact your supplier.

Language versions

Contact your supplier if you require another language version of your instal-

lation and operating instructions.

1.4 Warranty/liability

Warranty entitlements expire, and no liability is assumed for damages caused by:

• improper installation or application contrary to the intended purpose

• installation of modications which were not approved by Condair

• improper maintenance by unqualied personnel

• using spare parts and accessories other than original Condair ones

2 The Humidier

2.1 Steam humidication system Condair Esco

Wherever existing steam is employed for humidication, the steam humidi- cation systems Condair Esco, DR73 and DL40 prove to be outstanding.

The precisely controlled steam mass ow is evenly distributed into the air current, void of any condensate spray. Steam humidication

systems Condair Esco, type DR73 and DL40 operate very reliably. They are compact, easily installed, and thanks to computerised layout, permit a system-optimised humidication distance. The absolutely steam-tight rotary-disk control valve prevents temperature energy losses in the closed position.

• Safe operation

Strainers, water separators, as well as primary and secondary condensate drains ensure clean, condensate-free steam. The nozzles, tapping the steam at the centre of the distribution pipe, render the jacket

heating unnecessary, because accumulating condensate is drained via

secondary steam trap.

• Compact

Strainer, water separator, steam trap, rotary-disk control valve and rotary actuator form a compact unit, requiring little space.

• Easy to install

Combining all important parts into one compact unit, averts the need

for expensive additional installations and prevents sealing problems

during installation.

2.2 System Condair Esco 5

Small, compact valve-unit with integrated ceramic rotary-disk valve and

mounted steam connection ange. 1/2"-female thread for the steam supply

pipe. Designed for the connection to DL40 standard single-steam distributors 5/023 - 5/178.

Technical specications:

Max. steam capacity 127 kg/hr (with p1 = 4 bar) Valve admission pressure p1 0.2...4.0 bar Valve-sizes 5/1...5/7

Accessory:

Primary, thermostatic steam trap including 1/2"-connection tting; execution complete stainless steel. The thermostatic steam trap immediately adjusts

to changing operation terms and it deaerates automatically. Condensate is

removed with a supercooling of 4 K.

Actuators:

The following actuators can be mounted:

1) electrical rotary disk actuators CA75, CA150A, CA150A-S

2) pneumatic actuator type P10

Options:

• Strainer, delivered loose (installation recommended)

• Mounting set for insulated ducts

• Adaptors for the mounting of other electrical rotary actuators

• Positioner XSP31 with mounting kit to pneumatic actuator P10

Steam distribution pipes DL40-Esco 5

Type Duct width mm m 5/023 275 - 424 16 5/038 425 - 524 27 5/048 525 - 624 32 5/058 625 - 724 41 5/068 725 - 924 50 5/088 925 - 1224 62 5/118 1225 - 1524 94 5/148 1525 - 1824 118 5/178 1825 - 2124 127

Valve size diagram Condair Esco 5

kg/hr

Valve admission pressure p1 [bar]

Diagram for determining the dimension of the Esco 5 steam connection unit with appro-

priate valve size.

2.2.1 Material specications Condair Esco 5

Version Standard

Valve-body, ange GGG40

Valve-disks SIC

Drive shaft 1.4305 (AISI 304)

Live spindle CuZn

Compression spring 1.4401 (AISI 316L)

Flat packing PTFE

O-ring seals EPDM/PTFE

Fittings galvanised steel

Tooth-and locking plates 1.4110

Double nipple for primary steam trap 1.4404 (AISI 316L)

Primary steam trap, thermal 1.4301

Strainer SF12:

Housing GGG40

Screen 1.4301 (AISI 304)

Steam capacity mD [kg]

2.2.2 Dimension diagram Condair Esco 5 steam connection unit,

ø45

G 1/2"

143

160

106

G 1/2"

182

268

ø41

ø84

45°

ø8.5

100

204

ø45

G 1/2"

143

160

106

G 1/2"

50 116

268

ø41

ø84

45°

ø8.5

100

rotary disc actuator CA150A / CA150A-S

2.2.3 Dimension diagram Condair Esco 5 steam connection unit, rotary disc actuator CA75

2.3 System Condair Esco 10, 20 and 30

Complete steam connection unit with rotary disk actuator and water separator for humidiers type DR73 and DL40.

DR73

DL40

1112

1 Steam connection

2 Strainer

3 Water separator 4 Primary condensate drain connection

5 Ceramic rotary-disk control valve

6 Rotary actuator

Type DR73 and DL40, of the steam humidication 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. The nozzles, tapping the steam at the centre of the distribution pipe,

render the jacket heating unnecessary, because accumulating condensate is drained via secondary steam trap. Operational reliability and compact, easy-to-install design characterise this steam humidication system.

7 Connecting ange 8 Secondary condensate drain 9 Steam nozzles

10 Steam distribution pipe

11 Main distribution pipe 12 Condensate return line

2.4 Function

On the inlet side, the steam humidication systems Condair Esco DR73 and

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 oat). Thus, the humidier

is operable any time. The steam distributor, however, remains cold and does not heat the air current; no energy is wasted.

With the ceramic rotary-disk control valve open, the steam passes through

the strainer into the water separator. As a result of the multiple steam de-

ection in the water separator, the condensate, carried along, is reliably eliminated and drained via primary condensate drain.

In the DR73 type, the dried steam exits the water separator through the

ceramic rotary-disk control valve to ow via main distribution pipe into the

vertically arranged secondary pipes. The hot, dry steam is tapped at the centre of the steam distribution pipes and discharged under pressure on both sides, by means of special nozzles, at an angle to the air current.

Condensate, accumulating in the vertical pipes, slides along the inside of the pipe down into the horizontally attached main distribution pipe (= collector). This spaciously designed pipe is drained by way of an externally

mounted thermal secondary condensate drain.

In the DL40 type, the steam is directly routed into the steam distribution pipe, tapped at the centre of it and discharged under pressure, by means of special nozzles, into or against the air current. Condensate, accumulating

along the inside of the pipe, is drained via condensate return line by way of

an externally mounted thermal secondary condensate drain.

Any condensate accumulating during system start-up is immediately drained

by the primary steam trap. The pre-dried steam is led via control valve into

the distribution system, where it is taken from the dry center of the pipe

and introduced uniformly into the volume ow by means of the differential

pressure. Thanks to this dependable system, there is no need for a start-up

protection and jacket heating.

Condensate-related backpressure is an impossibility in both lines of prod-

ucts even in a pressureless state, because the steam distributor pipe is drained via condensate return line with inherent down gradient.

2.5 Connection unit

• Steam connection

Connection to the steam supply is made from the top by means of a

standard ange.

• Strainer

The strainer is located inside the connection unit at an angle of 90 degrees to the steam inlet. Its unique design results in a uniform ow

of steam, at a signicantly reduced velocity, through the entire screen area into the water separator. If required, the threaded connection facilitates cleaning the screen.

• Water separator

The water separator removes the condensate droplets carried along by the steam entering through the strainer. The droplets slide down the inner wall of the water separator into the primary condensate drain. The

dried steam ows to the ceramic rotary-disk control valve.

• Steam trap

The steam humidication systems Condair Esco DR73 and DL40 both

utilise a primary and a secondary condensate drain. The primary

condensate drain consists of a spheric oat that adapts to pressure

and capacity uctuations and continuously drains the condensate from the steam connection unit (alternatively a drain with a bell-shaped oat may be used instead).

The secondary condensate drain empties the condensate accumulating in the steam distribution pipes. This thermal steam trap is maintenance-

free.

• Ceramic rotary-disk control valve

The humidier control valve consists of two SiC (silicon carbide) ceramic disks, pressing against each other. One of them is xed, while the other

one is rotating. It is distinguished by the following features:

• Compact design: The control valve is integrated into the connection

unit.

• Tightness: With the ceramic rotary-disk control valve closed, no steam can pass into the humidication section. Thus, the tightly sealing valve prevents undesired formation of condensate and damage, caused by off-periods (corrosion etc.).

• Beyond the opening point of the valve the characteristic curve of

the control valve is linear for the entire regulating range.

• Rotary control valve actuators: One standardised rotary control valve actuator with emergency function for all valve bodies. A second rotary actuator (without emergency function) is available for low-capacity humidiers.

Specications:

Primary steam pressure range PN6 connection unit: 0.2....4.0 bar

(Pressure values are generally expressed in bar overpressure)

Max. primary steam temperature: 152 °C

Leak rate of SiC ceramic rotary-disk control valve: 0.0001%

Standard Version

GGG 40 Valve body/water separator/ange

SIC Ceramic rotary-disk control valve

1.4301 (AISI 304) Strainer

GG20 (T90-20/T90-30)

1.4301 (T90-10)

CuAl10Ni5Fe4 Stufng box

1.4305 Valve stem

CuZn (T90-10/T90-20)

1.4305 (T90-30)

1.4401 (AISI 316L) Compression spring

PTFE Flat-packing

CuZn Bearing

CuZn Threaded joint for primary condensate drain

GGG 40 Primary condensate drain (spheric oat drain)

Filter cover

Valve catch

EPDM / PTFE-FEP O-ring seals

CuZn Manometer

GGG 40 Coupling piece to actuator

1.4301 Complete steam distribution system DR73 and DL40

1.4305 Steam nozzles

3 Humidier selection

3.1 The essentials in brief

When tendering or ordering, it should be noted that the steam humidication system Condair Esco, type DR73 and DL40 consists of the following

components (*=optional):

1. Connection unit

2. Ceramic rotary-disk control valve

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 humidication systems Condair Esco, type

DR73 and DL40:

Primary steam pressure (for live steam): 0,2...4,0 bar

Primary steam temperature: 104...152 °C

Max. ambient temperature: 50 °C

Max. ambient humidity: 98 % r.h.

Text for tendering

Steam humidication system Condair Esco

Steam humidier for connection to an existing steam supply, consisting of:

• Connection unit with anged connection, steam-tight ceramic rotary-disk control valve, strainer, separation chamber and

primary spheric oat steam trap

• Steam distribution pipe, with steam nozzles, for a uniform discharge of live steam into air current throughout the entire length of the pipe, and thermal secondary condensate drain

• Electric rotary actuator for connection to all commercially available humidity controllers

Type DR73

Steam humidication system consisting of: connection unit, electric rotary actuator, horizontal main distribution pipe with condensate drain pipe, and vertically arranged secondary pipes with steam nozzles.

Humidication capacity: ....................... kg/hr

Primary steam overpressure: ....................... bar

Humidity inlet/outlet: ....................... g/kg

Air volume: ....................... m

Type DL40

Steam humidication system consisting of: connection unit, electric rotary actuator, horizontal steam distribution pipe with steam nozzles and condensate drain pipe.

Duct width/height in light ........................ mm

Min. inlet air temperature ........................ °C

Max. humidication distance ........................ m

/hr

Brand Condair Esco

Type .......................

Supplier .......................

Accessories, optional

• Manometer mounted to connection unit, for steam pressure 0 - 2.5 bar

• Manometer mounted to connection unit, for steam pressure 0 - 6.0 bar

• Mounting set for insulated ducts / AHU’s

• Coupling pieces for multiple piping (only type DL40)

Tabular overview of standard components and options

Connection unit

for max. steam capacity see chapter 3.2 and 3.7

Ceramicrotary-disk control valve

see chapter 3.2 and 3.7

Steam distribution type

see chapter 3.4 and 3.7

rotary-disk contr. valve actuator

Standard Components

see chapter 3.3 Condair CA75

Condair CA150A

Condair CA150A-S

Condair P10

Mounting set for insulated ducts/AHU’s

(see chapter 3.5)

Manometer

see chapter 3.6 Display 0 to 2,5 bar

Esco 5

up to 127 kg/hr

7 valve sizes

5-1 to 5-7

DR73

not

possible

Esco 10

up to 250 kg/hr

10 valve sizes

10-1 to 10-10

DL40 DR73 DL40 DR73 DL40 DR73 DL40

● ●

● ● ● ● ● ●

● 1) ● 1) ● 1) ● 1) ● 1)

Esco 20

up to 500 kg/hr

4 valve sizes

20-1 to 20-4

Esco 30

up to 1000 kg/hr

4 valve sizes

30-1 to 30-4

not

possible

Display 0 to 6,0 bar

Options

Coupling pieces for multiple piping

see chapter 3.4.2 2 x steam distrib. pipe type 10/. 3 x steam distrib. pipe type 10/.

1)retrotable

● 1) ● 1) ● 1) ● 1) ● 1)

●

3.2 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cation capacity and steam pressure

Example:

– Required humidication capacity: 100 kg/hr – Available steam pressure: 1.5 bar

The intersection of the two “search lines” for the connection unit is lo-

Steam connection unit Esco 20

Valve size

Valve admission pressure p1 (bar)

Humidication capacity mD [kg/hr]

cated in the Esco 10 diagram between the characteristic curves 10/7 and 10/8.

– Esco 10 with valve size 10/7 provides 76 kg/hr

– Esco 10 with valve size 10/8 provides 120 kg/hr

The HVAC engineer will select one of the two possible valves: a) the Esco 10-10/7, if it is permissible for the “comfort” humidication

to be somewhat lower, in favour of optimal controllability during the remainder of the operating time.

b) the Esco 10-10/8, if the humidity requirements were calculated

rather tightly, or if a certain application in process technology requires the max. steam capacity.

With the rotary control valve actuator CA150A, the steam output can be limited to the actual system requirement. Without this limitation, the

steam boiler output must be dimensioned to correspond with the max.

steam capacity of the ceramic rotary-disk control valve.

Selection diagram for dimensioning the connection unit Esco 20 with the corre- sponding valve size.

Steam connection unit Esco 30

Valve size

Valve admission pressure p1 (bar)

Note:

The computer dimensioning program will always select the larger valve

size.

Steam connection unit Esco 10

Valve size

Humidication capacity mD [kg/hr]

Selection diagram for dimensioning the connection unit Esco 30 with the corre- sponding valve size.

Valve admission pressure p1 (bar)

Selection diagram for dimensioning the connection unit Esco 10 with the corre- sponding valve size.

Humidication capacity mD [kg/hr]

3.3 Rotary control valve actuator

The steam humidication 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). By using special adapter parts, other commercially available rotary control valve actuators can be employed as well.

ATTENTION/IMPORTANT

Rotary control valve actuators without spring-loaded return device (Condair CA75 or other makes) require additional on-site safety installations,

in case the control voltage is lost (emergency stand-by voltage, auxiliary valve with automatic shut-off function). To prevent malfunction of the valve,

all electrical connections of the rotary actuators must be properly wired to the connector box.

Electric rotary control valve actuator

Condair CA150A and CA150A-S

Version:

Actuator housing: ground and cover plate made of metal with ultrasonic

welded plastic housing, emergency function by means of spring-loaded

return device, suitable for direct attachment to all Esco connection units. In addition, type CA150A-S comes with an adjustable and a xed auxiliary switch. They are used to signal rotation angles of 10° or 10...90° respec-

tively.

The regulating range of the electric rotary control valve acutators starts at a control signal of 2 VDC. However, because the ceramic rotary disks overlap in their closed state (to ensure absolute tightness), the valve starts opening at a signal value of 3 VDC.

Specications:

CA150A CA150A-S

Supply voltage 24 VDC or 24 VAC / 50/60 Hz / Power consumption 7 VA

Emergency function by spring-loaded return device if supply voltage fails

Control signal Y Y1: 0-10 VDC

Input impedance Y1: 100 kΩ (0,1 mA)

Operating range Y1: 2-10 VDC

Measuring voltage U 2-10 VDC (max. 0,5 mA)

Torque / run time 20 Nm / motor: 150 s, spring return: 20 s

Auxiliary switch potential free none 2 x EPU 1mA...3(0.5)A

Protection class / System of protection III (extra-low safety voltage), CE / IP 54 (drip-proof)

Position indicator mechanical

max. permissible steam temperature 152 °C

Ambient temperature -30 ... +50 °C

Ambient humidity classe D in accordance with DIN 40040

Weight 2100 g

Electric rotary control valve actuator

Condair CA75 without emergency function

Version:

Actuator housing made of plastic, without emergency function, with electrically limited 90° rotation angle, suitable only for direct attachment to connection units Esco 5 and Esco 10. Ideal for using in conjunction

with low-capacity humidiers to supplement humidication. Since the rotary control valve actuator Condair CA75 does not incor- porate an emergency function, the responsibility for using it lies with

the planning engineer. He must decide on the necessary safety measures

in case of power loss, e.g. shut-off valve with spring-loaded return actuator, connected in series, or an emergency stand-by voltage supply.

Specications:

CA75

Supply voltage 24 VDC or 24 VAC / 50/60 Hz / Power consumption 2 VA

Control signal Y 0-10 VDC

Input impedance 100 kΩ (0,1 mA)

Operating range 2-10 VDC

Measuring voltage U 2-10 VDC (max. 0,5 mA)

Torque / run time 5 Nm / motor: 150 s

Auxiliary switch potential free none

Protection class III (extra-low safety voltage), CE / IP 54

Position indicator mechanical

max. permissible steam temperature 152 °C

Ambient temperature -30 ... +50 °C

Ambient humidity Class D in accordance with DIN 40040

Weight 480 g

Adaptor for mounting rotary control valve actuators of different

makes

The steam humidication 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.

Adaptors are currently available for the following third-party electric rotary

actuators: – Sauter ASF 123 SF 122 – Siemens GCA 161.1E

– Joventa DM 1.1 F-R

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.

Housing is of olive-yellow, self-extinguishing, glass-bre-reinforced plastic; membrane of silicon; drive spindle of stainless steel; compressed-air connection RP 1/8“, female thread.

Pneumatic actuator P10 for Esco 5

Pneumatic actuator P10 for Esco 10 Pneumatic actuator P10 for Esco 10

stainless steel version

Pneumatic actuator P10 for Esco 20 Pneumatic actuator P10 for Esco 20

stainless steel version

Pneumatic actuator P10 for Esco 30

Technical specications:

Control pressure: 0...1.2 bar Max. pressure: 1.5 bar Working pressure range: 0.3...0.9 bar Actuating power: 100 N Stroke: 63 mm

Running time for 100% stroke: 7 s Air consumption for 100% stroke: 0.5 I

Permissible ambient temperature: -10...70 °C

Degree of protection: IP 20

Accessory: Pneumatic positioner XSP31 for actuator type P10

Used to convert a continuous positioning signal y into the dened position of the pneumatic actuator P10.

The positioners capabilities:

– increases the positional accuracy

– divides up the positioning range, (e.g. sequence)

– increases the positional speed.

Execution:

Housing of light alloy; with two diaphragm cells and integrated pressure adjuster for setting the zero-point; double-armed lever for matching the unit to the type of drive and for setting the control span; control element of

plastic, measuring connection M4 for the output pressure, compressed-air

connection RP 1/8“ female thread. Complete with assembly material.

If the pneumatic positioner for the valve unit is ordered together with the P10 actuator, these units are assembled and pe-adjusted at the factory.

Technical specications:

Supply pressure: 1.3 ±0.1 bar Max. control pressure: 1.4 bar

Adjustment range: 0.2...1.0 bar Linearity: 1 % 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 P10 Positioner (optional)

Condair Esco 5 1 1

Condair Esco 10 1 1

Condair Esco 10, stainless steel version 1 1

Condair Esco 20 2 1

Condair Esco 20, stainless steel version 2 1

Condair Esco 30 2 1

3.4 Steam distribution

The steam humidication 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 humidication zone. Can be connected to the steam con-

nection units Esco 10 and Esco 20.

With optionally available coupling pieces, multiple piping is possible

with two or three steam distribution pipes arranged on top of, or next to each other.

– Type DR73

Ideally suited for large fresh-air portions and high duct or system cross-sections. Vertical steam distribution pipes, with integrated

nozzles, guarantee the shortest possible humidication distance, thanks to computer aided customised system design. Can be connected to all steam connection units.

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

is why the unit designation is comprised of the following components:

Example-type

Type

for steam distribution

Pipe type (installation type)

see chapter 3.4.1

Amount of distribution pipes

see chapter 3.4.1

Size of the connection unit

see chapter 3.2

Valve size

see chapter 3.2

DR73 - A4.10-5

• Pipe type (installation type)

There is a choice of the following types:

Type A (Type JA)

for installation in horizontal ducts or units without ground clearance Type DR73 - A Type DR73 - JA* from 488 kg/hr Type DR73-J2A* from 2 x 488 kg/hr

(with 2 connection units Esco 30)

Type A

Type B (Type JB)

for installation in horizontal ducts or units with ground clearance Type DR73 - B Type DR73 - JB* from 488 kg/hr Type DR73 - J2B* from 2x 488 kg/hr

(with 2 connection units Esco 30)

Type B

* Dimension diagrams for types DR73-J.. up on request

Table 1

Determining the number of steam distribution pipes in dependence of the

duct height b, the air velocity w and the humidication capacity mD.

• 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-

cation distance. To calculate a cost-optimised system that selects the steam distribution pipes, based on a given humidication distance, is

possible only with the computer program.

Number of steam distribution pipes

Air velocity w [m/s] Humidication capacity m

Tabelle 2

Determining the number of steam distribution pipes in dependence of the

air velocity w and the duct width a

Duct height b [mm]

[kg/hr]

Airvelocity w (m/s)

1 - 1,9 800 1100 900 1550 1000 2000 1100 2450 1200 2900 1300 3350 2 - 2,9 700 1000 800 1450 900 1900 1000 2350 1100 2800 1200 3250 3 - 3,9 600 900 700 1300 800 1700 900 2100 900 2500 1100 2900 4 - 4,9 500 800 600 1200 700 1600 800 2000 800 2400 1000 2800 5 - 7,4 400 700 500 1050 600 1400 700 1750 700 2100 900 2450

7,5 - 9,9 300 600 400 950 500 1300 600 1650 600 2000 800 2350

Airvelocity w (m/s)

1 - 1,9 1400 3800 1500 4250 1600 4700 1700 5150 1800 5600 1900 6000 2 - 2,9 1300 3700 1400 4150 1500 4600 1600 5050 1700 5500 1800 5950 3 - 3,9 1200 3300 1300 3700 1400 4100 1500 4500 1600 4900 1700 5300 4 - 4,9 1100 3200 1200 3600 1300 4000 1400 4400 1500 4800 1600 5200 5 - 7,4 1000 2800 1100 3150 1200 3500 1300 3850 1400 4200 1500 4550

7,5 - 9,9 900 2700 1000 3050 1100 3400 1200 3750 1300 4100 1400 4450

Duct width

a (mm)

min. max. min. max. min. max. min. max. min. max. min. max.

Duct width

a (mm)

min. max. min. max. min. max. min. max. min. max. min. max.

Duct width

a (mm)

Duct width

a (mm)

Number of steam distribution pipes

Duct width

a (mm)

Number of steam distribution pipes

Duct width

a (mm)

Duct width

a (mm)

Duct width

a (mm)

Duct width

a (mm)

Duct width

a (mm)

Duct width

a (mm)

Duct width

a (mm)

* Minimum duct height per type:

Type min. height

in mm A 600 B 400 JA 800 JB 800

Example: From Table 1 = 3 (3 steam distribution pipes) Duct height b = 1000 mm From Table 2 = 4 (4 steam distribution pipes)

Duct width a = 1700 mm

Humidication capacity mD = 120 kg/hr If the number of secondary pipes, calculated

Air velocity w = 7 m/s from the two tables, does not coincide, always select the higher number.

Type DR73 - ...4.20 ➔ Size of the connection unit in accordance with chap. 3.2

Result:

* Note: Number of vertical pipes for J-types have to be divisible with two.

3.4.2 Type DL40

The steam humidication 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 connection units Esco 10 or Esco 20. The unit designation is comprised of the following components:

– Pipe type

Initially, the pipe types are selected on the basis of the air duct width. It must then be noted, that there is a maximum steam capacity that can be accommodated by a given length.

– Multiple coupling pieces

Where it is required by the system and permitted by the available space, dual or triple piping is possible with steam distribution pipes arranged on top of, or next to each other. The connection units Esco 10 and Esco 20 are available with the matching coupling pieces, for a standard pipe spacing of 300 mm, 600 mm and 900 mm.

For dimension diagrams refer to chap. 4.6.2.

Example-type

Type

for steam distribution

Installation type

1=single piping 2=dual piping 3=triple piping

see chapter 3.4.2

Pipe type

see chapter 3.4.2

Size of

connection unit

see chapter 3.2

Valve size

see chapter 3.2

DL40-1-10/118-10-3

Steam-

Connection

unit

[size]

Pipe

for

type

DL40

10/023 10/038 10/048 10/058

10/068 10/088

10/118 10/148

10/178 10/208

10/238 10/268

10/298 10/328

10/358 10/388

20/058 20/088

20/118 20/488

20/178 20/208

20/238 20/268

20/298 20/328 20/358 20/388

Duct

width

[mm]

250-399 400-499 500-599 600-699

700-899

900-1199

1200-1499 1500-1799

1800-2099 2100-2399

2400-2699 2700-2999

3000-3299 3000-3599

3600-3899 3900-4299

600-899

900-1199

1200-1499 1500-1799

1800-2099 2100-2399

2400-2699 2700-2999

3000-3299 3300-3599 3600-3899 3900-4299

max.

steam

capacity

[kg/hr]

16 27 32 41

50 62

118

142 187

214 241

250 250

41 62

118

142 187

214 241

268 295 322 349

3.5 Mounting set for insulated ducts and AHU’s

There are distance-sleeves available to put through the insulation in order to x and stabilize the steam connection units on the devices, (see picture). The tublets are delivered with length of 45 or 75 mm and can be easily

cutted on site to the needed insulation thickness, according to the wall thickness of the duct/ahu. For detailed information to the mounting set please see separate brochure

“Condair Esco installation instructions”.

3.6 Manometer

– Pressure display 0 - 2,5 bar

for valve admission pressure 0,2 - 1,5 bar

– Pressure display 0 - 6,0 bar

for valve admission pressure 1,5 - 4,0 bar

For information on retrotting individual components refer to the tabular

overview in chapter 3.1.

All connection units Esco 10 - 30 may optionally be equipped with a ma- nometer. This allows monitoring of the valve admission pressure during

operation. The selection of the appropriate manometer depends on the valve admission pressure:

3.7 Condair Esco stainless steel

Condair Esco DL40 and DR73 steam humidiers 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. The steam is supplied to the valve in cycles. The condensate

produced when starting the system is therefore separated at the steam drier and taken to the spheric oat primary trap. This ensures that only dry

steam ows through the valve. The steam inlet is anged and is of welded

design tested for strength.

Electrical rotary drives or a pneumatic actuator from the existing range can be tted as required.

The steam connection units are supplied complete and ready for installation.

• steam capacity: maximum 500 kg/hr with

• steam overpressure: maximum 4.0 bars

The valve characteristic of the integrated ceramic rotary-disk valve cor-

responds to the performance of the Condair Esco 10 and Esco 20 steam connection unit (see selection diagram for Esco 10 or Esco 20 in chap-

ter 3.2).

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.

DL40 Single piping

DL40 Double piping

DR73 Multiple piping

Primary steam trap

Standard: Spheric oat condensate drain with stainless steel connector

0...4.0 bar or bell-shaped condensate drain with screw-type connector 0...1.5 bar or 1.5...4.0 bar

Optional: For steam capacities less than 100 kg/hr, a thermostatic pri-

mary steam trap can be used.

Tabular overview of Condair Esco stainless steel:

Standard components and options Esco 10 and Esco 20

Steam connection unit

for max. steam capacity

see chapter 3.2

Ceramic rotary disk control valve

see chapter 3.2

Steam distribution type

see chapter 3.4

Rotary control valve actuator

see chapter 3.3

Standard components

Condair CA75

Condair CA150A

Condair CA150A-S

Condair P10

Mounting set for insulated ducts/AHU’s

see chapter 3.5

Manometer

Display 0 to 2,5 bar

Display 0 to 6 bar

Coupling pieces for

Options

Multiple piping

see chapters 3.4.2 and 4.6.2 2 x steam distribution pipe

Typ 10/.

3 x steam distribution pipe

Typ 10/.

Esco 10

up to 250 kg/hr

stainless steel

10 valve sizes

10-1 to 10-10

DR73 DL40 DR73 DL40

●

● ● ● ●

● 1) ● 1) ● 1) ● 1)

●

Esco 20

up to 500 kg/hr

stainless steel

4 valve sizes

20-1 to 20-4

●

The robust industrial Bourdon tube pressure gauge with display

– 0...2.5 bar

– 0...6.0 bar

1) retrotable

Material specication of the stainless steel components

DIN-W-No.:

1.4301/1.4305 Steam connection unit (welded design)

1.4301 Steam inlet ange

1.4301 Flange for steam distribution systems

SIC 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 O-rings

PTFE Flat packing

1.4301 Nuts

1.4305 Cylindrical pins

1.4301 Bell-shaped primary oat trap

1.4571 Connection screwing to spheric oat drain

1.4305 Thermostatic primary and secondary steam trap

1.4305 Connection screwing to secondary steam trap

1.4571 Manometer

1.4301 Steam distribution system DR73 and DL40

Specication:

Steam connection ange for steam distribution systems, Flange

ø9

ø45

ø84

45°

ø13

ø9

ø13

ø61

ø104

100

45°

ø9

ø13

ø45

ø84

130

45°

ø9

ø13

ø61

ø104

140

45°

measurements

DR73

– Condair Esco 10

stainless steel

DL40

– Condair Esco 5 – Condair Esco 10

stainless steel

DR73

– Condair Esco 20

stainless steel

DL40

– Condair Esco 20

stainless steel

P-actuator

100206200

406

120

DN32/PN16

284

356

G 1/2"

245

170

ø140

ø45

245

200

G 1/2"

170

70 204

120

DN32/PN16

401

133

160

8.5

45°

32 182

ø140

ø45

245

200

G 1/2"

170

70 116

120

DN32/PN16

401

133

160

8.5

45°

Condair Esco 10 stainless steel

Dimension diagrams

Actuator

CA150A / CA150A-S

Condair Esco 10 stainless steel

Actuator

CA75

Condair Esco 10 stainless steel

514

173

257.5

G 1/2"

282

DN50/PN16

182.5

82.5

139.5

160

284

568

341

148

ø61

ø165

491

173

257.5

G 1/2"

282

DN50/PN16

182.5

82.5 204

139.5

160

32 182

104

45°

P-actuator Condair Esco20 stainless steel

Actuator CA150A / CA150A-S Condair Esco 20 stainless steel

4 Hints for the consulting engineer and the HVAC technician

4.1 The use of steam in air humidication

To use steam from an existing steam boiler system, for the humidication

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. Because steam is removed from the existing

network, different operating conditions from those usually encountered

are often created in the boiler house. This subject deserves a few remarks

from actual practice.

– Feed-water conditioning

The capacity of the feed-water conditioning system must be adjusted to the future steam withdrawal rate. Furthermore, it is necessary to ensure trouble-free operation by carrying out regular maintenance.

Feed-water additives must not be allowed to exceed the values for

permissible concentration in the room air. One must also keep in mind the possibility of odours being created by feed-water additives or by contamination of the steam.

– Feed-water pump

The pump capacity must be suited for the additional steam withdrawal.

– Steam generation

All steam boilers that permit efcient steam withdrawal, from a suf-

ciently large steam chamber, are suitable. Continuous ow heaters and ash steam boilers are, as a rule, unsuitable.

– Boiler ushing

The continuous withdrawal of steam for air humidication raises the concentration of residues. Periodic and adequate ushing is the

only way to avoid steam odour.

– Heat content of the steam

Does air humidication with steam affect the temperature of an air-

conditioned room? The purpose of humidication is to increase the water vapour content

of the air. While the heat content of water vapour, contained in the air, is

approx. 2550 kJ/kg, that of introduced steam usually amounts to about 2675 kJ/kg. The result is only a slight increase of the air temperature

of approx. 0.1 °C, based on a specic humidication rate of 1 g per kg of

air. This hardly results in an additional temperature increase, except perhaps by heat radiation.

– How “dry” does the steam have to be for air humidication?

The task of a steam humidier is to introduce condensate-free, “dry” water vapour, from the existing steam supply, into the air, at a rate

which is controlled by the required humidity. This effectively prevents corrosion , growth of bacteria and algae, and the development of odours

in air ducts. Drop collectors and drainage facilities are unnecessary

(see chapter 4.4).

4.2 Installation instructions

0°

10°

20°

30°

40°

t [°C]

0 5 10 15 20 25 30

X [g/kg]

h [kJ/ kg]

100 %

90 %

80 %

70 %

60 %

50 %

40 %

30 %

20 %

10 %

On the theory of humidication

The air’s ability to absorb water vapour is dependent upon the prevailing

conditions of the air. It can be determined from the h-x diagram as the difference between the saturated condition x x1 before humidication. Standard practice in air conditioning is to

always maintain a certain safety margin between the air condition x2, after humidication, and the saturated condition xS (=100% relative

humidity), to avoid the risk of condensation in the ducts. This danger

is reinforced further by the following factors:

• Supply-air temperature uctuations prior to humidication, because

• Humidity control system is not consistently adjusting to less than full

• Restricting factors (e.g. contaminated air lters) may greatly reduce

and the water vapour content

with lowering temperature, the state of saturation xS may drop below

the computed value for the state of saturation x2 (humidication based on humidier performance),

capacity requirements during transitional periods.

the operating air volume.

• When air ducts pass through cooler rooms, not xS at room temperature

is relevant, but rather at the duct’s inner wall temperature, which might drop below the dew point.

These obvious physical relationships in air conditioning technology express

why condensation may occur in air ducts. Air will always absorb humidity, offered in the form of water vapour, but not beyond the limit set by

the saturated condition.

4.3 Using the humidication distance diagrams

Please pay close attention to the following diagrams, and strictly observe the distances to downstream obstacles, when using the steam humidication

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.

However, the exact calculation of the guaranteed humidication distance, for the steam distribution system DR73, is only possible by means

of the computer dimensioning software.

4.3.1 Type DR73

D C D

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; accordingly, the humidication distances to a downstream obstacle or the

measuring point are also short.

As depicted in illustration 1, the arrangement and distribution of the steam outlet openings of the distribution pipe DR73 is identical to that of

a spray nozzle air humidier. Furthermore, compared to most commercial

steam humidiers, the steam pipes are spaced considerably closer, so the max. steam mass ow per meter of distribution pipe is substantially

reduced.

To compute the humidication distances BN, BF or BS to the respective obstacles and BM to the measuring point (in accordance with illustrations 2-5), and the “terminology of the humidication distance”, the aforementioned optimal steam distribution and the following values are essential:

• Air velocity w

• Humidity x1 before humidier

• Humidity increase ∆x

• Air temperature t before humidication

• Type of downstream obstacle and measuring point

Max. spacing between steam distribution pipes and steam nozzles, and max. steam capacity in kg/hr per meter of distribution pipe

W C max D E mD max. [m/s] [mm] [mm] [mm] [kg/hr · lfm]

1 450 400 150 30 2 425 350 150 35 3 400 300 150 40 4 390 270 150 45 5 385 200 150

W = air velocity

D, E = distance from wall

C max. = max. distance between distribution pipes

max. = max. steam capacity in kg/hr

per meter of distribution pipe

Figure 1

In the humidication distance diagram 1, empirically calculated standard values, based on lab tests, are used to express the humidication 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,

(N), which causes wetting of the lters (F, S) when the relative humidity is

increased accordingly.

The maximum steam mass ow -the most important prerequisite for determining the humidication distance- is based on the steam pipe dimensioning on page 26.

Figure 2 Installation upstream of fan

Downstream obstacle: fan

Figure 4 Installation downstream of fan in duct

Downstream obstacle: bend

Example for operation with outside air:

Air velocity w = 3 m/s

Air temperature before humidier

t = 13°C

Humidity increase ∆x = 6 g/kg Closest obstacle: ne lter F

Figure 3 Installation downstream of fan

Downstream obstacles: silencer + ne lter

Figure 5 Duct installation

Downstream obstacle: particle lter

Terminology of the humidication distance

Mist zone

Result:

Humidication distance (from diagram): B

≅ 2,3 m

Normal obstacles

Fine lters

Particle lters

Measuring point

Humidity increase ∆x [g/kg]

Humidication distance - diagrams 1

Diagram for calculating the distance to a downstream obstacle in fresh

air operation, x1 = 1 g/kg

S = particle lter (Q, R, S)

F = ne lter (C)

N = normal obstacles (bend,

fan, air heater, silencer,

etc.)

Humidication distance BN / BF / BS in [m] according to downstream

obstacle

min. air

temperature t

[°C]

min.

Type of downstream obstacle at varying air temperatures t [°C] before steam distribution

pipe DR73

air velocity t w [m/s]

Humidication distance BN / BF / BS in [m] according to downstream

obstacle

min. air

temperature

[°C]

min.

Humidity increase ∆x [g/kg]

Diagram for calculating the distance to a downstream obstacle in circu-

lating air operation, x1 = 4 g/kg

S = particle lter (Q, R, S)

F = ne lter (C)

N = normal obstacles (bend,

fan, air heater, silencer,

etc.)

Type of downstream obstacle at varying air temperatures t [°C] before steam distribution

pipe DR73

air velocity t w [m/s]

Location of the humidity sensor

to calculate the measuring point distance

Using the diagram below, the humidication 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 obstacles presents two totally different physical problems:

At the measuring point, the measured value must correspond to the humidity mean value and occasional uctuations, caused by turbulence, must not exceed a certain value.

As regards the obstacles, a distance must be observed which guarantees that no water droplets, temporarily formed past the discharge point (mist zone), collide with the obstacle only to be eliminated as condensate.

Example:

Air velocity w = 3,5 m/s Humidity increase ∆x = 4,5 g/kg Humidic. distance (from diagram) to measuring point BM ≅ 6,4 m

This diagram is only to be used in conjunction with the steam distribution

system type DR73.

Humidication distances B

measuring points located in duct humidity control systems. They are meant to be recommendations for installing companies and control specialists.

Humidication distance BM [m]

(Distance from measuring point to distribution pipe DR73)

, computed from this diagram, are valid only for

∆x [g/kg]

Humidity increase

w [m/s] air velocity

in duct or system

4.3.2 Type DL40

From the following humidication distance diagram 2, the extension factor as compared to type DR73 can be found and with its help the required humidication distance to the downstream obstacles determined. If this turns out to be too long, the steam humidication system Condair Esco DR73 is to be chosen in order to avoid the formation of condensate.

Humidication distance diagram 2

Diagram for determining the distance to a downstream obstacle in circulat-

ing air operation, x1 = 1 g/kg

Example:

Humidity increase ∆x = 5 g/kg Steam distribution pipe L = 1,8 m Air velocity w = 3 m/s Actual steam mass ow mD = 108 kg/hr Duct height/width = 0,9/1,9 m Air temperature = 19 °C

Calculation:

The air velocity w determines the rated load per meter of steam distri bution pipe (40 kg/hr). The actual load per meter of steam distribution pipe is calculated from:

mD (108 kg/hr)

= 60 kg/hr per meter

L (1,8 m)

Continuation from this intersection in the diagram is self explanatory. Applying the same parameters, the humidication distance is now calculated from dia-

gram 1 (type DR73) and the two results multi-

plied with each other:

Humidication distance from Humidication distance diagram 1: 0,75 m

Extension factor from Humidication distance diagram 2: 1,8

▼ Load per meter of distribution pipe in kg/hr

air velocity w

in duct [m/s]

Total steam mass ow [kg/hr]

Duct ratio (height/width)

Humidication distance DL40:

0,75 m x 1,8 = 1,35 m

Extension factor

4.4 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 humidication system Condair Esco, we guarantee a drop-free humidication. An oversupply, however, from the humidier, a clogged secondary condensate drain, or a malfunctioning controller or control valve are all it takes to feed water or a water/steam mixture into the steam distribution pipe. It will always be an advantage,

therefore, to protect your system from water damage by installing either a sealed section of duct or a drip pan with drain. To allow operational checks and inspections of the humidication sec-

tion, at any time, we recommend to install an inspection cover, inspection glass or a service opening past the distribution pipe.

Important: The humidiers have to be mounted in a horizontal way.

Procedure:

– Type DR73

Systems without ground clearance (A-type):

1. Provide openings (round holes) in duct (see chap. 4.6.1).

2. From the duct side, slide the main distribution pipe through the prepared openings.

Systems with ground clearance (B-type):

1. Provide a round hole in the duct bottom for each distribution pipe.

2. Attach the main distribution pipe with xing plates.

Continued procedure for all unit types DR73

3. Mount the connection unit with connecting ange to the side of the duct (do not damage O-rings).

4. Carefully (without damaging O-rings) insert the clean steam distribution pipes into the sleeves of the main distribution pipe. To improve sliding,

slightly moisten O-rings with water. Never use oil or grease.

Adjust the distribution pipes in such a manner that the steam nozzles

are faced crosswise to the air ow.

5. Use the bolts to secure the distribution pipes.

6. Install the steam and condensate connections. Make sure that the

condensate line has a down slope of approx. 0.5 - 1% .

– Type DL40

1. Provide openings (round holes) in duct.

2. From the duct side, slide the steam distribution pipe through the prepared openings. Make sure not to damage the steam pipe ends.

3. Mount the connection unit with connecting ange to the side of the duct. Make sure not to damage O-rings. To improve sliding, slightly

moisten O-rings with water. Never use oil or grease.

4. Secure the distribution pipe with the bolt.

5. Install the steam and condensate connections. Make sure that the

condensate line has a down slope of approx. 0.5 - 1%.

4.5 Dimension diagrams

160 A

N O M

G 1/2"

D E 75

4.5.1 Steam connection unit

4.5.2 Rotary actuator

Steam connection unit Esco 10 Esco 10 Rotary actuator CA75 CA150A/ CA150A-S

A 417 424 B 159 159

C 121 121 D 85 85 E 74 74 F 81 81 G 205 205 H 143.5 143.5 I 132 132 K 116 182 L (Flange) DN32/PN16 M 66 98 N 125 125 O 210 210

Esco 10, 20 and 30

CA150A, CA150A-S and CA75

Side view steam connection unit with valve actuator

all dimensions in mm

Steam connection unit Esco 20 Esco 30 Rotary actuator CA150A/ CA150A/ CA150A-S CA150A-S

A 514 619 B 214 254

C 157 223 D 113.5 154 E 100 100 F 112 148 G 236 272 H 189 261 I 172 195 K 182 182 L (Flange) DN50/PN16 DN80/PN16 M 98 98 N 132 187 O 315 350

all dimensions in mm

Top view steam connection unit with valve actuator

4.5.3 Pneumatic actuator P10

ø84

ø8.5

ø41

45°

356

284

100272

167

G 1/2"

105

143

100

4xø8.5

ø41

G 1/2"

100

356

284

ø88

4xø13.5

568

284

A 100

140

G 1/2"

4xø9

ø59.5

120

Esco 20 Esco 30

Condair Esco 5

Condair Esco 10

View

Condair Esco 20 and Condair Esco 30

View

100

120

4xø8.5

4xø9

140

4xø13.5

ø41

ø59.5

ø88

Steam connection unit Esco 10, Esco 20 and Esco 30

with pneumatic actuator

Esco 10 Esco 20 Esco 30

P 288 338 422

B 159 214 254

L DN32/PN16 DN50/PN16 DN80/PN16 G 205 236 272 H 143.5 189 261 A 420 510 617

all dimensions in mm

4.6 Dimensions diagrams for installation

4.6.1 Type DR73

Types A • Side view • Template

Esco 10 Esco 20 Esco 30 Z: 160 170 170

Type B • Side view • Template

Steam connection unit Esco 10 Esco 20 Esco 30

X 220 240 250 X min. 270 280 260

Y 40 60 80

W min. 10 10 20 W max. 30 30 30 V 9 9 13.5

all dimensions in mm

Detailed dimensions for steam distribution pipes DR73 can be requested following order conrmation.

4.6.2 Type DL40

X Y

F E

Pipe length X Y

• Position of the steam nozzles

• Coupling piece for multiple piping

The manufacturer recommends, mostly for uninsulated ducts and AHU's, to insulate the multiple couplings on site, or to install a silencer inside the duct, in order to reduce any noise that might occur.

Note: A special collector with built-in silencer is available from your Condair distributor on request.

230 - 380 mm 80 mm 60 mm

580 - 1180 mm 110 mm 90 mm

1480-3880 mm 150 mm 130 mm

min. 20 mm

Dimensions for multiple piping

Esco 10 Esco 10 Esco 20

CA75 CA150A

A ø = 1 1/4“ (ø=42)

B 300/600/900

C 60/80/100 80/100/120

D 135/155/175 155/175/195

E 604/624/644 574/594/614 679/699/719

F 160 160

all dimensions in mm

4xø9

ø59.5

120

100

4xø8.5

ø41

Esco 10 Esco 20

Side view • Template

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:

4.7 Connection diagrams for actuators

0...10 VDC

CA150A

AC 24V 50/60 Hz DC 24V

Y1U

1 2 3 5

Y U

CA150A-S

Y1U

1 2 3 5

Y U

S1 S2 S3

5°

S4 S5 S6

25°...85°

S1 S2 S3 S4 S5 S6

4.7.1 Electric rotary actuator CA150A and CA150A S

Safety position “ZU” currentless (Emergency function by means of spring- loaded return device)

on site installation by client!

Connector box

Supply

AC 24 V 50/60 Hz DC 24 V

0...10 V Control signal

Input resistance: 100 kΩ (0,1 mA)

Working range: 2...10 VDC

Connector box

Wiring diagram CA150A/CA150A-S: Lead 1: Ground AC 24 V / DC 24 V– Lead 2: Phase AC 24 V / DC 24 V+

Lead 3: Control signal Y1 0...10 VDC

Lead 5: Measuring voltage U 2...10 VDC

S1/S2/S3 Ancillary switch 10° (safety position “ZU”) S4/S5/S6 Ancillary switch 10°...90° adjustable

Spring-loaded return device

Specications - CA150A: Supply voltage AC 24 V / DC 24 V Dimensioning: 7 VA Power consumption: 5 W when winding up the spring

3 W in standby position Function: continuous Control signal Y1: 0...10 VDC Working range Y1: 2...10 VDC

Measuring voltage U: 2...10 VDC

Torque: 20 Nm

Running time: Motor 150 s

Spring return 20 s

Type CA150A-S with ancillary switch: Specications same as CA150A Ancillary switch: 2xEPU 1 mA...3(0.5)A

Switching points: 10° xed, 10°...90° adjustable

Caution: This is a functional diagram. The installation has to be carried out in accordance with local regulations. To prevent malfunction of the valve, all electrical connections of the rotary actuators must be properly wired to the connector box.

Note: The regulating range of the electric rotary control valve acutators starts at a control signal of 2 VDC. However, because the ceramic rotary disks overlap in their closed state (to ensure absolute tightness), the valve starts opening at a signal value of 3 VDC.

4.7.2 Electric rotary actuator CA75

measuring voltage

4.7.3 Positioner XSP 31 for pneumatic actuator P10

5 Hints for the heating engineer

5.1 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 humidier. A shut-off valve (provided by customer) is installed preceding the humidier. A steam pressure gauge (manometer) may also be provided.

Longer steam supply lines require appropriate draining!

Diagram for dimensioning the steam supply pipe

Steam overpressure p [bar]

5.2 Installing the steam pipes

Insulation:

Always insulate steam pipes to prevent condensation.

Down gradient:

Always install steam pipes with a down gradient in the ow direc-

tion.

Steam tapping pipes:

Steam mass ow in m

[kg/hr] at velocity of 25 m/s

Always tap steam from the top of the pipe.

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

Key:

= Shut-off valve

= Condensate drain

= Compensators

= Control valve

= Drain

Always drain ascending pipes at the lowest point..

Deviations

Always drain by-passes.

Control valves

Always drain control valves on the primary side.

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. (3) without transversal piping may be drained in backward direction towards the steam vessel (against the ow direction of the steam in this exceptional case).

Ascending pipes longer than 6 m (4) must be drained at their lowest

point.

All supply lines to the humidier at the customer’s facility require appropriate draining at their lowest point.

2. General example

11 11

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 ttings have to be insulated. 5 Install steam dryer (wet steam erodes the pipes) 6 Install lines at a downslope of 1:100 in ow direction

7 Use T-pieces for drains

8 Provide a drain every 20 to 40 m

9 Design the steam distributor as large as possible

10 The steam distributor requires a drain 11 Install a dirt pan to improve operational reliability

12 Install a pressure gauge for monitoring the steam pressure 13 Tapping of steam must always take place on the upper side of the steam

line

14 Provide compensators for line expansion 15 Design an appropriate array of sliding and xed points

16 Install drains at the lowest point of all steam lines

17 Provide a drain at the end of the steam line

Before commissioning: thoroughly rinse the entire system, open valves

and connectors, clean, and blow out dirt at the lowest points of the line.

5.3 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.

S = secondary condensate drain:

The secondary condensate must be able to ow without any re-

strictions.

Primary and secondary condensate must be drained separately (unequal pressure).

5.4 Connections to be prepared by customer

Steam distribution pipes, type DR73 and DL40 can be connected to steam

boilers, steam converters or existing steam supplies. The supply overpressure (live steam) should be as consistent as possible and be between 0.2

and 4.0 bar. Steam supply and condensate pipes are to be installed using suitable material. All gaskets, sealing material, threaded connections, and insulating material must be able to withstand temperatures of up to 152 °C,

depending on the pressure. A shut-off valve is to be installed in the steam

supply pipe.

The humidier steam supply pipe is to be connected always to the top of a main supply pipe or steam generator with large steam volume. Installa-

tions of steam and condensate networks are to incorporate latest technical

advances. Attention is to be paid to assure complete drainage during full

capacity, less than full capacity and standstill.

Steam supply pipes, to be installed by the customer, must be connected to the Esco connection unit. Optimally arranged, it combines strainer, separa-

tion chamber, control valve and manometer (optional). This arrangement ensures contamination-free, dried steam at the inlet side of the control valve,

which is thus protected from erosion. Condensate, accumulating from the steam supply pipe and the connection unit, is continually drained prior to

reaching the control valve.

All condensate pipes, to be installed by the customer, are directly connected

to the condensate drains and, with a slight down gradient (0.5-1 %), routed via siphon (steam trap) to a funnel or oor drain.

One steam connection, two condensate pipes, and the simple installation procedure, result in minimal installation costs at a maximum steam hu-

midication quality. To avoid drainage problems, caused by a high steam volume or valve admission pressure, the condensate from the primary and

secondary steam traps must be drained separately. This means, the two

condensate drain pipes must not be merged before the funnel.

Post-vaporization: Upon draining of the conduit system through the con-

densate drains, post-vaporization may occur at the end of the condensate line which can be recognized by a continuous steam plume. Post-vapor-

ization occurs when the condensate pressure drops to the ambient pressure, and by the large gradient between the condensate temperature and

the ambient temperature. Post-vaporization is normal and should not be

confused with steam loss caused by problems in the condensate drain.

Caution! In closed locations the steam caused by post-vaporization may have some undesired side effects. In such cases post-vaporization must be suppressed by taking appropriate measures (siphons, cooling section, etc.).

6 Initial start-up

1. Make sure the steam supply and condensate pipes are properly connected.

2. Slowly open the shut-off valve, examine the entire steam supply pipe to the control valve for leaks, and monitor the manometer for the required

steam pressure. 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 humidication system Condair Esco DR73 and DL40 as well as the attached valve actuator into operation, refer to the guidelines provided by the control and installation rms. Operation may be initiated only by an appropriately trained control specialist or service

technician.

5. Testing the system behaviour in case of voltage loss ➯ The steam discharge from the steam distribution pipes must be interrupted. When using actuators without emergency function, the interruption of steam

discharge from the pipes, in case of voltage loss, must be guaranteed

by some other on-site safety device. Without this on-site safety de-

vice, steam discharge from the steam pipes cannot be interrupted. The

manufacturer cannot be held responsible for any water damages

resulting from this.

7 Maintenance

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

The strainer must be cleaned whenever necessary.

The attached rotary control valve actuators CA75, CA150A and CA150A-S

are maintenance-free. For other actuators, the operating and mainte-nance instructions of the appropriate supplier are applicable.

Primary and secondary condensate drains are maintenance-free. However, clogging can also occur within the connections or in the condensate

network.

In case of problems with the condensate drainage, consult the troubleshooting guide.

The condition for a perfect functioning during a long time is:

Application of dry steam, which does not contain any mineral salt, such as chloride, sulphate, sulde and ammonia. (see note VdTÜV 1453, edition 4/83; Editor: Union of the associations of technical observation e.V., Essen).

8 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

• Defective or interrupted control line to safety devices (system interlock)

• High-limit humidistat placed in wrong location

• Ceramic rotary-disk control valve in closed position

• Defective rotary control valve actuator or Ceramic rotary-disk control valve is jammed

• Control voltage or pressure loss

Malfunctioning steam supply

• Shut off valve in steam supply pipe closed (Check manometer)

• Steam supply pipe clogged by dirt

• Safety shut off valve closed

Ceramic rotary-disk control valve is not closing, excessive humidication

• Actuator mounted incorrectly

• Humidistat defective or improperly set

• Defective controller

• Defective rotary control valve actuator (voltage available)

• Ceramic rotary-disk control valve is jammed

• Pressure spring has lost its resilience

• Loss of control voltage; actuator (without emergency function) does not close valve

Water is discharged from the steam distribution pipes

• Steam supply pipe not insulated

• Steam supply pipe not properly drained

• Steam supply pipe connected incorrectly to the main pipe (bottom or side instead of on top)

• Incorrect primary pressure resulting in incorrect secondary pressure after the valve

(p2 > 0.15 bar) or improperly dimensioned ceramic rotary-disk control valve

• Oversupplied or overstressed steam generator (water is forced along)

• Malfunctioning steam distribution pipe drainage (clogged or defective condensate drain)

• Excessive back pressure in condensate drain pipe (secondary condensate drained under pressure)

• Primary and secondary condensate drains are joined together

• Condensate line is routed too high (static back pressure)

• Main distribution pipe is not installed horizontally

9 Vaporisation / condensation

9.1 Terminology and denitions

• 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:

• Steam pressure of the liquid

• Ambient pressure

• Temperature

• Substance

• Saturated vapour pressure

The saturated vapour pressure is that value, which is characterised by the balance between the ambient pressure and the vapour pressure of a liquid.

Once the equilibrium is reached, vaporisation of the liquid takes place;

this is called saturated steam.

The steam pressure of a liquid is temperature-dependent so that the pressure equilibrium, at which evaporation begins, is characterised for each substance by a temperature pressure curve. This curve is called saturated steam curve.

• Saturated steam

Steam that reaches the saturated steam pressure but is not separated

from the liquid phase, interacts with the liquid, i.e. the amount of water that vaporises equals the amount of steam that condenses. Steam, in such an interactive state, is called saturated steam.

Most important characteristic:

Saturated steam is not compressible (a part of it would condense in the process).

• Wet steam

When saturated steam cools down (e.g. by heat loss) part of it con-

denses, and the share of water droplets in the steam increases. This is called wet steam.

• Superheated steam

Steam, which is separated from the liquid and heated up, is called

superheated steam.

Most important characteristic: Superheated steam is compressible.

• Vaporisation heat

100

t [°C]

Q [kJ]

h' I

Vaporisation heat equals the transformation energy required to vaporise a liquid. In order to compare different substances, the specic vaporisation heat (transformation energy per measuring unit kJ/kg) is observed. From the diagram for water (see below) it can be seen, that the temperature (at sea level) remains constant at a 100 °C. Any additional heat is used for vaporising; this heat is called vaporisation heat.

Key:

Q = Thermal energy

t = Temperature

h’ = Heat content water h” = Heat content steam

ID = Vaporisation heat

• Enthalpy

Enthalpy equals the latent energy of a substance.

In steam, the enthalpy equals the heat content, which is the heat required for vaporisation plus the latent energy which already existed before the vaporisation.

Enthalpy is expressed per measuring unit (kJ/kg)

• Condensation

Condensation is understood to be the transition of saturated steam into

the liquid state.

Condensation occurs when a certain pressure or temperature change takes place. Gas does not condense outside the saturated steam

range (e.g. superheated steam cannot be condensed by a pressure increase).

• Condensate

Condensate equals water which originates from condensed steam. The

temperature of the condensate is the same as that of the steam.

• Condensation heat

Energy, which was used to vaporise, is released again when condensation takes place; it is referred to as condensation heat. Condensation

heat is utilised in many instances, e.g. in dehydration processes.

10 Work sheet DR73 / DL40

Work sheet

Position

System designation

Amount (humidier)

max. humidication capacity mD

Steam overpressure (valve admission pressure) p1

Humidity before humidication x1

Humidity after humidication x2

Humidity increase ∆x

Inner duct width a / wall thickness

Inner duct height b / wall thickness

Installation in (G = Unit / K = Duct)

Air volume ow

Air mass ow

min. air velocity

min. air temperature t1 (before distributor pipe)

DR73 DL40

pcs.

kg/hr

bar

g/kg

mm / / / /

m3/hr

kg/hr

m/s

°C

Existing humidication distance Downstram obstacle

Actual humidication distance B

Steam distributor pipe

Number of steam distributor pipes

Steam connection unit

Steam connection DN 32 / PN 16

Control valve (according to diagram)

Valve actuator

Options

Manometer

Dual coupling

Triple coupling

Mounting set for insulated ducts/AHU’s

m/... / / / /

Type

pcs.

Esco

Type

pcs.

Type

xxxxxxxxxx xxxxxxxxxx

Type

xxxxxxxxxx xxxxxxxxxx

pcs.

Total price per system:

Notes

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. 35-37, P.O. Box, CH-8808 Pfäﬃkon (Switzerland) Phone +41 55 416 61 11, Fax +41 55 416 62 62 www.waltermeier.com, international.climate@waltermeier.com

Condair Esco 10, Esco 5, Esco 20, Esco 30 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Important notes

1.1 Correct use for intended purpose

1.2 Safety instructions

1.3 Notes on the installation and operating instructions

1.4 Warranty/liability

2.2 System Condair Esco 5

2.3 System Condair Esco 10, 20 and 30

2.4 Function

2.5 Connection unit

3.1 The essentials in brief

3.2 Connection unit and ceramic rotary-disk control valve

3.3 Rotary control valve actuator

3.4 Steam distribution

3.6 Manometer

3.7 Condair Esco stainless steel

4 Hints for the consulting engineer and the HVAC technician

4.2 Installation instructions

4.4 Installation in systems or ducts

4.5 Dimension diagrams

4.6 Dimensions diagrams for installation

4.7 Connection diagrams for actuators

5 Hints for the heating engineer

5.1 Connecting the steam supply pipe

5.2 Installing the steam pipes

5.3 Schematic diagram

5.4 Connections to be prepared by customer

6 Initial start-up

7 Maintenance

8 Trouble-shouting guide

9 Vaporisation / condensation

10 Work sheet DR73 / DL40