Condair Esco Series User manual

Steam humidification system
2562350 EN 1009
Condair Esco
INSTALLATION AND OPERATING INSTRUCTIONS

Possible applications for the Condair Esco live steam humidication system
In the proximity of machinery and production processes, op-
timal air humidity is essential. Of course for hospitals, as well
as clinics, laboratories, and the chemical and pharmaceutical
industries, air humidity and hygiene is an absolute necessity.
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.
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
Why humidify with steam?
To humidify the air with water vapour is the most direct, sim-
plest, 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.

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5
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

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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 lat-
est 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.

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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 electri-
cal 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.

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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

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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 conden-
sate drains ensure clean, condensate-free steam.The nozzles, tap-
ping 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.

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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 distribu-
tors 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

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Steam distribution pipes DL40-Esco 5
Type Duct width mm mDkg/hr
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
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)
Diagram for determining the dimension of the Esco 5 steam connection unit with appro-
priate valve size.
Valve admission pressure p1 [bar]
Steam capacity mD [kg]

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2.2.2 Dimension diagram Condair Esco 5 steam connection unit,
rotary disc actuator CA150A / CA150A-S
2.2.3 Dimension diagram Condair Esco 5 steam connection unit,
rotary disc actuator CA75
ø45
A
G 1/2"
143
160
106
G 1/2"
32
50
182
268
ø41
ø84
45°
ø8.5
100
204
ø45
A
G 1/2"
143
160
106
G 1/2"
50 116
268
ø41
ø84
45°
ø8.5
100

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2.3 System Condair Esco 10, 20 and 30
Complete steam connection unit with rotary disk actuator and water separa-
tor for humidiers type DR73 and DL40.
1 Steam connection
2 Strainer
3 Water separator
4 Primary condensate drain connection
5 Ceramic rotary-disk control valve
6 Rotary actuator
7 Connecting ange
8 Secondary condensate drain
9 Steam nozzles
10 Steam distribution pipe
11 Main distribution pipe
12 Condensate return line
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.
72
3
4
6
5
1
8
9
10
1112
8
9
10
12
DR73
DL40

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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 (= col-
lector). 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.

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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.

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• 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 seal-
ing 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-ca-
pacity 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)
Filter cover
CuAl10Ni5Fe4 Stufng box
1.4305 Valve stem
CuZn (T90-10/T90-20)
1.4305 (T90-30)
Valve catch
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)
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

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3 Humidier selection
3.1 The essentials in brief
When tendering or ordering, it should be noted that the steam humidica-
tion 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.
Type DL40
Steam humidication system consisting of: connection unit, electric
rotary actuator, horizontal steam distribution pipe with steam noz-
zles and condensate drain pipe.
Humidication capacity: ....................... kg/hr
Primary steam overpressure: ....................... bar
Humidity inlet/outlet: ....................... g/kg
Air volume: ....................... m
3/hr
Brand Condair Esco
Type .......................
Supplier .......................
Duct width/height in light ........................ mm
Min. inlet air temperature ........................ °C
Max. humidication distance ........................ m
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)

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Tabular overview of standard components and options
Standard Components
Connection unit
for max. steam capacity
see chapter 3.2 and 3.7
Esco 5
up to 127 kg/hr
Esco 10
up to 250 kg/hr
Esco 20
up to 500 kg/hr
Esco 30
up to 1000 kg/hr
Ceramic-
rotary-disk control valve
see chapter 3.2 and 3.7
7 valve sizes
5-1 to 5-7
10 valve sizes
10-1 to 10-10
4 valve sizes
20-1 to 20-4
4 valve sizes
30-1 to 30-4
Steam distribution type
see chapter 3.4 and 3.7
DR73
not
possible
DL40 DR73 DL40 DR73 DL40 DR73 DL40
not
possible
rotary-disk contr. valve actuator
see chapter 3.3
Condair CA75 ● ●
Condair CA150A ●●●●●●
Condair CA150A-S ●●●●●●
Condair P10 ●●●●●●
Options
Mounting set for
insulated ducts/AHU’s
(see chapter 3.5)
●●●●●●
Manometer
see chapter 3.6
Display 0 to 2,5 bar
●1) ●1) ●1) ●1) ●1)
Display 0 to 6,0 bar ●1) ●1) ●1) ●1) ●1)
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

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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-
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.
Note:
The computer dimensioning program will always select the larger valve
size.
Selection diagram for dimensioning the
connection unit Esco 20 with the corre-
sponding valve size.
Selection diagram for dimensioning the
connection unit Esco 30 with the corre-
sponding valve size.
Selection diagram for dimensioning the connection unit Esco 10 with the corre-
sponding valve size.
Humidication capacity mD [kg/hr]
Humidication capacity mD [kg/hr] Humidication capacity mD [kg/hr]
Steam connection unit Esco 20
Valve size
Steam connection unit Esco 10
Steam connection unit Esco 30
Valve size
Valve admission pressure p1 (bar)
Valve size
Valve admission pressure p1 (bar)
Valve admission pressure p1 (bar)

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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 (Con-
dair 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