Condair DL User manual

INSTALLATION MANUAL
Adiabatic air humidification system
Condair DL
2577868 EN 1502
Humidication and Evaporative Cooling

Thank you for choosing Condair
Installation date (MM/DD/YYYY):
Commissioning date (MM/DD/YYYY):
Site:
Model:
Serial number:
Manufacturer
Condair Ltd.
Talstrasse 35-37, CH-8808 Pfäfkon
Ph. [phone], Fax [phone]
[e-mail], www.condair.com
Proprietary Notice
This document and the information disclosed herein are proprietary data of Condair Ltd. Neither this document, nor
the information contained herein shall be reproduced, used, or disclosed to others without the written authorization
of Condair Ltd., except to the extent required for installation or maintenance of recipient's equipment.
Liability Notice
Condair 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.
Copyright Notice
Copyright 2014, Condair Ltd. All rights reserved.
Technical modications reserved

3Contents
Contents
1 Introduction 4
1.1 To the very beginning 4
1.2 Notes on the installation manual 4
2 For your safety 6
3 Important notes on installation 8
3.1 Delivery 8
3.2 Storing/Transportation/Packaging 8
3.3 Product designation 9
4 Installation 10
4.1 Installation overview 10
4.2 Installation of the humidication unit 11
4.2.1 Positioning of the humidication unit 11
4.2.2 Mounting the post-evaporation unit 13
4.2.3 Mounting the nozzle system 26
4.3 Positioning and mounting the central unit 32
4.4 Positioning and mounting the control unit 34
4.5 Water installation 36
4.5.1 Overview water installation 36
4.5.2 Notes on water installation 37
4.6 Electrical installation 39
4.6.1 Notes on electrical installation 39
4.6.2 Wiring diagram Condair DL 40
4.6.3 Electrical connections between central unit and control unit 41
4.6.3.1 Wiring diagram central unit - control unit 41
4.6.3.2 Installation work central unit - control unit 42
4.6.4 External electrical connections 45
4.6.4.1 Wiring diagram external electrical connections 45
4.6.4.2 Installation work external connections 46
4.6.5 Connecting options 48

4Introduction
1 Introduction
1.1 To the very beginning
We thank you for having purchased the adiabatic air humidication system Condair DL.
The adiabatic air humidication system Condair DL incorporates the latest technical ad van ces and meets
all recognized safety standards. Nevertheless, improper use of the adiabatic air humidication system
Condair DL may result in danger to the user or third parties and/or impairment of material assets.
To ensure a safe, proper, and economical operation of the adiabatic air humidication system Condair
DL, please observe and comply with all information and safety instructions contained in the present
documentation as well as in the separate documentations of the components installed in the humidi-
cation system.
If you have questions which are not or insufciently answered in this documentation, please contact your
Condair representative. They will be glad to assist you.
1.2 Notes on the installation manual
Limitation
The subject of this installation manual is the adiabatic air humidication system Condair DL in
its different versions. The various options and accessories are only described insofar as is necessary
for proper operation of the equipment. Further information on options and accessories can be obtained
in the respective instructions.
This installation manual is restricted to the installation of the adiabatic air humidication system Cond-
air DL and is meant for well trained personnel being sufciently qualied for their respective work.
This installation manual is supplemented by various separate items of documentation (operation manual,
spare parts list, etc.), which are included in the delivery as well. Where necessary, appropriate cross-
references are made to these publications in the installation manual.

5Introduction
Symbols used in this manual
CAUTION!
The catchword “CAUTION” used in conjunction with the caution symbol in the circle designates notes
in this installation manual that, if neglected, may cause damage and/or malfunction of the unit or
other material assets.
WARNING!
The catchword “WARNING” used in conjunction with the general caution symbol designates safety
and danger notes in this installation manual that, if neglected, may cause injury to persons.
DANGER!
The catchword “DANGER” used in conjunction with the general caution symbol designates safety and
danger notes in this installation manual that, if neglected, may lead to severe injury or even death
of persons.
Safekeeping
Please safeguard this installation manual in a safe place, where it can be immediately accessed. If the
equipment changes hands, the documentation must be passed on to the new operator.
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.

6For your safety
2 For your safety
General
Every person working with the adiabatic air humidication system Condair DL must have read and under-
stood this installation manual and the operation manual of the Condair DL before carrying out any work.
Knowing and understanding the contents of the installation manual and the operation manual is a basic
requirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to
operate the unit safely and correctly.
All ideograms, signs and markings applied to the components of the adiabatic humidication system
Condair DL must be observed and kept in readable state.
Qualication of personnel
All installation work described in this installation manual may only be carried out by specialists who
are well trained and adequately qualied and are authorized by the customer.
For safety and warranty reasons any action beyond the scope of this manual must be carried out only
by qualied personnel authorised by the manufacturer.
It is assumed that all persons working with the adiabatic air humidication system Condair DL are familiar
and comply with the appropriate regulations on work safety and the prevention of accidents.
Intended use
The adiabatic air humidication system Condair DL is intended exclusively for air humidication in
AHU's or air ducts within the specied operating conditions (see operation manual of the adiabatic
air humidication system Condair DL). Any other type of application, without the written consent of the
manufacturer, is considered as not conforming with the intended purpose and may lead to the adiabatic
air humidication system Condair DL becoming dangerous.
Operation of the equipment in the intended manner requires that all the information contained in this
installation manual are observed (in particular the safety instructions).
Danger that may arise from the adiabatic air humidication system Condair DL
DANGER!
Danger of electric shock!
The control unit of the adiabatic air humidication system Condair DL is mains powered. Live
parts may be exposed when the control unit is open. Touching live parts may cause severe
injury or danger to life.
Prevention: The control unit 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 com-
ponents have been locked properly.

7For your safety
Preventing unsafe operation
All persons working with the adiabatic air humidication system Condair DL are obliged to report any
alterations to the unit that may affect safety to the owner without delay and to secure such systems
against accidental power-up.
Prohibited modications to the unit
No modications must be undertaken on the adiabatic air humidication system Condair DL without
the express written consent of the manufacturer.

8Important notes on installation
3 Important notes on installation
3.1 Delivery
After receiving:
– Inspect shipping boxes for damage.
Any damages of the shipping boxes must be reported to the shipping company.
– 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.
– Unpack the parts/components and check for any damage.
If parts/components are damaged, notify the shipping company immediately.
– Check whether the components are suitable for installation on your site according to the model key
stated on the type plate (refer to model key in the operation manual).
3.2 Storing/Transportation/Packaging
Storing
Until installation store the system components in its original packaging in a protected area meeting the
following requirements:
– Room temperature: 5 ... 40 °C
– Room humidity: 10 ... 75 %rh
Transportation
For optimum protection always transport the unit in the original packaging and use an appropriate lifting/
transporting device.
WARNING!
It is the customer's responsibility to ensure that operators are trained in handling heavy goods and to
enforce the relevant lifting regulations.
Packaging
Keep the original packaging of the components for later use.
In case you wish to dispose of the packaging, observe the local regulations on waste disposal. Please
recycle packaging where possible.

9Important notes on installation
3.3 Product designation
The product designation and the most important unit data are found on the rating plate xed on the right
side of the control unit.
Notes regarding the rating plate and the product key can be found in the operation manual of the Con-
dair DL.

10 Installation
4 Installation
1 - Mounting the post evaporation unit --> see chapter 4.2 – Installation of the humidication unit
2 - Mounting the nozzle system --> see chapter 4.4 – Positioning and mounting the control unit
3 - Mounting the control unit --> see chapter 4.4 – Positioning and mounting the control unit
4 - Mounting the central unit --> see chapter 4.3 – Positioning and mounting the central unit
5 - Water installation --> see chapter 4.5 – Water installation
6 - Electrical installation --> see chapter 4.6 – Electrical installation
Abb. 1: Installation overview Condair DL
4.1 Installation overview
1
2
3
6
5
Air ow direction
Humidity sensor /
Humidity controller **
Post-evaporation unit
Nozzle system
Electrical isolator
Control unit
** by client
Drain hose
Open tundish with
drain trap **
Test valve **
Water lter **
Shut-off valve **
RO water supply
Central unit
min. 3 m

11Installation
4.2 Installation of the humidication unit
4.2.1 Positioning of the humidication unit
Usually, the design and dimensioning of the ventilation duct/AHU as well as the location of the humidi-
cation system Condair DL inside the duct are determined, recorded and set compulsory when planning
the entire system. Prior to installation, however, make sure the following criteria have been taken into
consideration:
– For safety reasons the Condair DL must be installed only in rooms provided with a oor
drain. If for some reason the Condair DL must be installed in a location without oor 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 leakage.
– In the area of the humidication unit the ventilation duct/AHU must be waterproof.
– Caution, fully demineralised water is aggressive! For this reason, all components located close
to the humidication unit (duct/AHU, fastening material, drain pipe, etc.) must be made of corrosion-
proof steel (minimum requirements according to DIN 1.4301) or plastic.
– For installation and maintenance of the humidication unit a inspection window and a sufciently
large maintenance door must be available in the duct/AHU.
Important: inspection windows must be constructed in such a manner that they can be cov-
ered, so that no light can fall into the duct section where the humidication unit is installed
(reduction of the growth of microorganisms)
– Important! An air lter must be installed at the air inlet of the humidication unit. The lter
must meet the quality standards F7 (EU7) or better.
– In case of low ambient temperature the duct must be insulated to prevent the moist air from condens-
ing inside the duct.
– If the system is equipped with a heater, make sure it is at least 0.5 m away from the humidication
unit.
– In order to avoid drops seeping over the ceramic elements, an even air ow over the full cross
section of the post-evaporation unit must be guaranteed. If necessary, rectiers or perforated plates
must be installed on the building side before the humidier.
If the air velocity in the duct before the post-evaporation unit (in relation to the humidication ef-
ciency) exceeds 3.0 m/s, booster elements must be installed.

12 Installation
– For control and maintenance purposes we recommend to provide the duct/AHU with an additional
inspection door after the post-evaporation unit.
– The section of the duct holding the humidication unit must be equipped with a sloping tub
having drains before and after the post-evaporation unit (pass-through tub), or with a drain
before the separation as well as drains before and after the post-evaporation unit (separated
tubs). Each drain must be connected separately to the waste water system via a siphon. For
hygienic reasons connect the drain pipes with an open outlet to the waste water system of
the building.
Note: The effective height of the siphon drain depends on the duct pressure. Correct dimensioning
of the siphon drain is the customer’s responsibility.
Abb. 2: Positioning of the humidication unit (dimensions in mm)
min. 40 min. 400
min. 400 360 min. 400
+
600 - 900
100
+
min. 500
min. 500
Side view
heater
slope min. 2°
to center drain
Top view
door
door

13Installation
4.2.2 Mounting the 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 proles for
the lateral sealing plates “B” on both duct walls using the drilling template supplied.
• Mark the position of the outmost fastening holes (or welding studs) for the fastening of the left-
most and rightmost fastening proles for the upper sealing plates “D” on duct ceiling using the
drilling template supplied.
Note: For marking the fastening holes (or welding studs) “D” the drilling template must be bent
90° on the indicated position.
Abb. 3: Positioning of the fastening elements (side view)
b
a a
CBA
D
780 mm +120/-180 mm
275 mm
min.
100 mm
(75 mm)
40 mm 40 mm40 mm
65 mm 65 mm
Lateral support
nozzle system
Fastening prole
for lateral sealing plates
Fastening prole
for upper sealing
plates
Lateral support
post-evaporation unit
Air ow direction
Drilling template

14 Installation
2. 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 dis-
tance to the duct ceiling (target measure ”a”: 65 mm, admissible range: 0...90 mm) and with
a distance “b” of 100 mm to the intersection of the AHU, then x them via the topmost fastening
hole to the duct wall using a self-tapping screw 6.3 x 25 mm (do not tighten the screw yet).
Important: to be able to mount the optional booster the distance of 100 mm to the intersection
of the AHU must be maintained.
• Align both supports at right angles to the duct ceiling and check the distance to the duct ceiling
once more (the distance must be identical for both supports). Then, x both supports approx.
every 30 cm with a self-tapping screw 6.3 x 25 mm to the duct walls.
Note: evenly allocate the self-tapping screws over the entire length of the supports.
• This step must be carried out only on ducts with a height >2100 mm where the supports consist
of several proles: x the additional supports ush and in line with the upper support approx.
every 30 cm with self-tapping screws 6.3 x 25 mm to the duct walls.
Note: evenly allocate the self-tapping screws over the entire length of the supports.
Abb. 4: Mount the lateral supports
a= target measure 65 mm (admissible range 0...90 mm)
b= min. 100 mm
a
b
a
b
TOP
TOP
65 mm
min.
100 mm
min.
100 mm
65 mm
30 mm
30 mm

15Installation
3. Mounting the fastening proles for the upper sealing plates:
• If not done already in step 1, mark the position of the outmost fastening holes for the fastening of
the leftmost and rightmost fastening proles for the upper sealing plates “D” on the duct ceiling
using the bended drilling template.
• Fix both fastening proles to the duct ceiling via the marked hole using a self-tapping screw 6.3 x
25 mm. Then, align both fastening proles to each other using a cord. When aligned, x the two
fastening proles to the duct ceiling using self-tapping screws 6.3 x 25 mm.
• Fix the remaining fastening proles evenly allocated over the duct with and ush to the rst
mounted fastening proles to the duct ceiling using self-tapping screws 6.3 x 25 mm.
Abb. 5: Mounting the fastening proles for the upper sealing plates
75 mm
75 mm
75 mm
75 mm
75 mm
40 mm

16 Installation
4. Mounting the fastening proles for the lateral sealing plates:
• If not done already with the drilling template in step 1, mark the position of the lateral fastening
proles for the lateral sealing plates on both sides of the duct. Distance between fastening proles
and post-evaporation supports 275 mm.
• Fix fastening proles with a distance of 275 mm to the post-evaporation supports and right-angled
to the duct ceiling to the duct wall using self-tapping screws 6.3 x 25 mm. Do not tighten the
screws yet.
Note: Make sure the lateral fastening proles are evenly allocated over the duct height and in
line one below the other and that the lowest proles are ush with the bottom of the duct and
the topmost proles are ush with the duct ceiling.
Abb. 6: Mounting the fastening proles for the lateral sealing plates
275 mm
40 mm
275 mm
275 mm
40 mm

17Installation
5. Mount the cross members:
Note: This step must be carried out only on air ducts /AHU's with a width >1650 mm.
• For air ducts/AHU's with a width >2000 mm the cross members are supplied in sections and
must be bolted together on site. Proceed as follows: Undo the screw connections on the cross
members overlapping. Arrange cross member sections and x them together using the screws
M6 x 16 mm and nuts removed right before. Exactly align cross member sections and fasten the
screw connections. Then, x the reinforcement plates at the overlapping to the cross members
as shown below using four screws M6 x 16 and nuts, align plates and fasten the screw connec-
tions.
• Slightly loosen the four screw connections, with which the mounting plates are attached on both
sides to the cross members, so the mounting plates can be moved.
• From behind (view in air ow direction) hang up the cross members at the appropriate vertical
position to the lateral supports of the post-evaporation unit, then push the cross members down-
wards until they come to a stop. Now, fasten all screw connections of the mounting plates.
Abb. 7: Mount the cross members
Support
Mounting plate
Cross member
Reinforcement plate

18 Installation
6. Mount the vertical support(s):
Note: This step must be carried out only on air ducts /AHU's with a width >1650 mm.
• For air ducts/AHU's with a height >2000 mm the vertical supports are supplied in sections and
must be bolted together on site. Proceed as follows: Undo the screw connections on the vertical
supports overlapping. Arrange vertical support sections and x them together using the screws
M6 x 16 mm and nuts removed right before. Exactly align vertical support sections and fasten
the screw connections.
• Fix angle bracket(s) (for xing the vertical support to the duct ceiling) to the vertical support(s)
using two screws M6 x 16 mm and nuts. If necessary, remove the corresponding screw connec-
tion on the vertical support(s) rst.
Important: Fix angle bracket in such a manner that the distance between the leg of the angle
bracket and the upper edge of the vertical support has the same distance as the upper edge of
the two lateral supports have to the duct ceiling (see step 1).
Abb. 8: Mounting the vertical support
a

19Installation
• Mark horizontal position(s) of the vertical support(s) on the cross members (one vertical sup-
port is always in the middle of the duct, several vertical supports must be evenly allocated over
the duct width). From the front (view in air ow direction) attach the vertical support(s) with the
angle bracket on top to the cross members, then shift upwards until it comes to a stop and x
the vertical support(s) four screws M6 x 16 mm and nuts to the cross members. Slightly fasten
the screw connections only.
• Check distance between upper edge of the vertical support(s) and the duct ceiling as well as
the vertical alignment of the vertical support(s) by measuring the distance between the vertical
support(s) and the duct walls on top and on the bottom.
Important: The distance between the upper edge of the vertical support(s) to the duct ceiling
must be identical to the distance between the upper edge of the two lateral supports of the post-
evaporation unit to the duct ceiling. If necessary, align vertical support(s) horizontally and vertically.
• Fix angle bracket of the vertical support(s) with two self-tapping screws 6.3 x 25 mm to the duct
ceiling (see detail top left in g. 8).
• Check dimensions again an realign if necessary. Then, tighten all screw connections.

20 Installation
7. Mounting the lateral sealing plates:
• Start on the bottom shift the lateral sealing plates with the slightly bent surface behind the fasten-
ing proles. Make sure the sealing plates on top of each other covers and overlaps the subjacent
sealing plate. Slightly tighten the self-tapping screws of the appropriate fastening prole after
the sealing plates have been positioned to ensure that the sealing plates do not slip downwards
but can still be moved.
• Evenly allocate the overlapping of the sealing plates over the duct height. Shift the topmost seal-
ing plate ush to the duct ceiling and the lowest sealing plate ush to the duct oor, then tighten
all self-tapping screws on the fastening proles.
Abb. 9: Mounting the lateral sealing plates