Condair SE series User manual

SE
Series
Engineering
Manual
Includes technical specifications,
guidelines, and options for
selection and application of SETC
B+ Steam Exchange humidifiers
2576599-A | 21 APR 2014
Your guide to selecting and specifying Condair Steam Exchange Humidifiers!

Thank you for choosing Condair.
Proprietary Notice
This document and the information disclosed herein are proprietary data of CONDAIR AG / CONDAIR HUMIDITY
LTD. Neither this document nor the information contained herein shall be reproduced used, or disclosed to
others without the written authorization of CONDAIR AG / CONDAIR HUMIDITY LTD., except to the extent
required for installation or maintenance of recipient’s equipment. All references to the Condair name should be
taken as referring to CONDAIR AG / CONDAIR HUMIDITY LTD.
Liability Notice
Condair does not accept any liability for installations of humidity equipment installed by unqualified personnel
or the use of parts/components/equipment that are not authorized or approved by Condair.
Copyright Notice
Copyright 2014, CONDAIR AG / CONDAIR HUMIDITY LTD. All rights reserved.

Contents
How the Humidifier Works.............................. 1
SE Humidifier Models ..................................... 3
SE Humidifier Features................................... 6
SE Humidifier Components ............................ 7
Description of Components............................ 8
SE Outdoor Components ................................ 9
SE Humidifier Specifications & Dimensions10
Humidifier Specification Checklist...............14
Humidifier Load.............................................15
Humidifier Controls .......................................18
Installation Location .....................................18
Steam Distribution Method ..........................19
SE Series Options and Accessories .............19
Sample Specification....................................24
Location .........................................................29
Indoor Location .............................................30
Plumbing........................................................35
Boiler Steam & Boiler Condensate Return..38
Electrical ........................................................40
Steam Distribution ........................................41
Steam Lines & Condensate Returns ...........42
SETC Controls................................................46
Condair Controls ...........................................47
Control Location............................................49
Control wiring ................................................50
Staged Modulation (SETC Only) ...................51
Condair e-Links (Optional SETC Only) ..........52
Variable Definition ........................................53

1 | SE Engineering Manual
The SETC Steam Exchange Humidifier
The SETC/ is an atmospheric steam generator designed for air humidification via steam
distributor, blower pack, or steam manifold. The SETC uses pressurized steam from a boiler fed
into a heat exchanger submerged in potable, RO, or DI water to generate heat and steam.
The main applications of SE series humidifiers is humidification of buildings which have a high
pressure boiler which can also be used for heating or other industrial processes. SE humidifiers
take the steam produced by the boiler, which contains anti-scaling chemicals, and utilizes it to
produce clean and pure atmospheric steam for humidification.
How the Humidifier Works
Figure 1: Humidifier Schematic
Steam Generation
After initial start-up and tank filling the humidifier will sit in standby mode, awaiting a call for
humidity.
When a call is received, the humidifier will send a signal to the actuator. The actuator will
open as required and the flow of boiler steam will begin.

SE Engineering Manual | 2
Energy from the boiler steam is transferred to the fresh water tank through a heat exchanger
inside of the unit. This causes the water to boil. Full boil from a cold tank can take up to 15
minutes. On SETC models, the Keepwarm feature can be activated to reduce boil time.
Once the humidifier has reached full boil, the humidifier will modulate the actuator,
controlling the flow of steam into the unit. This will allow the unit to reduce its output level
as the humidity levels in the conditioned environment are satisfied.
During the boiling process minerals are left behind from the water. The unit will occasionally
activate the drain pump to flush out some of the minerals in the water and reduce the
concentration in the tank. The fill valve will also be activated periodically to replace water
that is boiled off during normal operation.
When the demand to the unit stops, the unit will close the control valve and steam
production will stop. The unit will enter standby mode and await a call for humidity. If
Keepwarm is activated (SETC only), the control valve will be opened periodically to heat the
tank.
Drains
As steam is produced minerals are left behind in the SE’s tank. The SE performs periodic
drains to reduce the amount of minerals that will precipitate as scale.
In general more frequent drains result in less maintenance. The amount of water drained to
control mineral concentration in the tank can be configured in the SETC’s software.
To cool drain water the SE activates the fill valve whenever the drain pump is activated.
Cool fill water flows down from the fill box and blends with hot tank water in the lower mixing
box before being drawn into the drain pump. The drain cooling feature can be deactivated
via software.
Steam Distribution
Steam generated by the humidifier may be introduced into the conditioned environment in
several different ways. The most common method for introducing steam into the conditioned
environment is to mount a steam distributor tube in a supply air duct as shown in Figure 1:
Humidifier Schematic. For larger ducts or larger loads it is also common to use a steam
manifold with a single steam line connection and multiple tubes for distributing the steam. For
introducing steam directly into a room, remote mounted blower packs are used. (see Steam
Distribution on page 41)
Steam Line
The steam line connects the atmospheric steam outlet of the humidifier to the atmospheric
steam distributor. The SETC is an atmospheric steam generator so it is very important no
restrictions are present in the steam line and that the steam line is sized to carry the full output
capacity of the humidifier. Length of these lines must be minimized to reduce the efficiency loss
of the humidification system.
Whenever steam is distributed, condensate is formed in the distribution system. Insulating
steam lines is one important way to reduce the amount of condensate formed. Steam lines
must be sloped so that condensate does not collect in the lines and create a restriction to
steam flow.

3 | SE Engineering Manual
Condensate Return
The condensate must be collected and removed from the distribution system so that it does not
build up and leak into the duct (or room if blower pack is used). Condensate must be collected
and fed to drain. (see Figure 24: Condensate Traps on page 43)
SE Humidifier Models
Indoor Models
The SETC with its Total Controller and state-of-the-art features and options is the most
advanced steam exchange humidifier available. The SETC is available in capacities ranging from
50 lb/hr (23 kg/hr) to 1050 lb/hr (475 kg/hr). SETC humidifiers are packaged in five different
cabinets depending upon capacity. See Figure 7: SE Indoor Dimensions on page 11 for
dimensional information.
Figure 2: SE Series Indoor Models

SE Engineering Manual | 4
SETC Outdoor Models
The SETC Series Outdoor Models are designed to be rooftop mounted on a roof curb (by others).
When properly installed the outdoor enclosure will provide protection from rain, wind, and snow
in areas with ambient temperature –40 to 104 °F (-40 to 40 °C) and relative humidity 0 - 100%
(non condensing). All outdoor models include a ventilation package to prevent overheating in
warm months, and a freeze protection package to prevent freezing in cold months.
The SETC Outdoor is available in capacities ranging from 100 lb/hr (45 kg/hr) to 1050 lb/hr
(475 kg/hr). The SETC Outdoor humidifiers are packaged in four different cabinets depending
upon capacity. See Figure 8: SETC Outdoor Dimensions on page 12 for dimensional information.
Figure 3: SE Series Outdoor Models
SETC Outdoor 100-175
SETC Outdoor 250-375
SETC Outdoor 525-750
SETC Outdoor 1050

5 | SE Engineering Manual
The SETC
The SETC model’s Total Controller provides a graphic LCD screen and keypad, accepts
additional control signals, optional building management system connectivity (BACnet,
Lonworks, Johnson N2, and Modbus), and optional Internet monitoring via Condair Online. See
Table 1: SETC Features for a listing of the two control systems features.
Figure 4: SETC User Interfaces
The SETC LCD screen and keypad - Allows easy configuration of all features of the SETC
humidifier such as blowdown rate, full tank blowdown, control signals, 3 day drain, and others.
The LCD screen also provides status information indicating current status and configuration, a
graph of recent operation, service and fault messages, and troubleshooting information. One of
the key features of the SETC controller is tracking operation and providing information about
service requirements to make it easy to service and maintain the SETC.

SE Engineering Manual | 6
SE Humidifier Features
The SETC humidifier includes many advanced features that sets it apart from other humidifiers.
The following list outlines some of the SE series key features.
Table 1: SETC Features
General
SETC
SETC Outdoor
High efficiency stainless steel heat exchangers
X
X
Internal steam trap on each heat exchanger
X
X
Control Valve, actuator, and wye strainer included
X
X
Modulating output for excellent humidity control
X
X
Range of capacities to match load requirements
X
X
50 to 10,500 lb/hr (23 –4770 kg/hr) output with staged
modulation.
X
X
Standard 230 VAC power requirement
X
X
C-UL-US
X
X
30 month warranty
X
X
Clean and atmospheric steam
X
X
Installation / Maintenance
Heat exchanger with flat sides for easy cleaning.
X
X
Wide range of water management options
X
X
Floor or optional stand mounting
X
(Curb Mount)
Choice of steam distribution (BP, Distributor, SAM-e)
X
X
Electronics
Graphic Display Screen with Keypad input
X
X
LED status indicators
X
X
Remote status via dry points
X
X
Proportional and Integral Control
X
X
Internal control from humidity sensor inputs
X
X
Manual Capacity Adjustment
X
X
On/Off operation
X
X
Compatible with all standard Industrial controls
X
X
Single and dual channel control
X
X
BMS integration via Links 2 / Links XPS / e-Links to Lonworks,
BACnet, Johnson
Option
Option
Modbus Protocol included as standard
X
X
Other
Weatherproof Enclosure
X
Curb mount
X
Freeze protection valve and keep warm
X
Electrical cabinet heater and exhaust fan
X
Selectable 3 day drain after no period with no demand
X
X
Potable, deionized, and reverse osmosis water
X
X

7 | SE Engineering Manual
SE Humidifier Components
Figure 5: SETC Humidifier Components

SE Engineering Manual | 8
Description of Components
Table 2: Humidifier Components
Component
Function of Component
Actuator
Opens and closes the control valve in proportion to demand for steam.
Auxiliary Drain Outlet
Drains water from tank in case of pump failure.
Base
Provides an integrated floor support for the humidifier.
Clean Out Port(s)
Provides access to clean scale from the tank and heat exchanger.
Condensate Drain
Drains condensate formed from boiler steam in the heat exchanger(s)
Control Terminal
Strip
Terminal strip for connecting external controls, blower pack, and actuator to humidifier.
Control Valve
Controls the amount of steam allowed into the heat exchanger which in turn controls the
output of the humidifier.
Display and Keypad
User interface for configuring the humidifier.
Drain Outlet
Drain port used for draining water from the humidifier tank.
Drain Pump
Drains water from humidifier.
Driver Board
Provides input and output connections to humidifier components.
Fill Box
Provides an air gap for backflow prevention.
Fill Valve
Controls flow of water into humidifier.
Float Chamber
Measures water level in the humidifier tank.
Gasket
Seals heat exchanger face plate and clean out port cover to tank.
Heat Exchanger(s)
Exchanges energy from boiler steam to the tank water to produce steam for humidification.
The faceplate mounts the heat exchanger to the tank.
High Voltage
Terminal Block
Primary power connection from remote disconnect to humidifier.
Manual Drain Switch
Manually activates pump to drain water from the tank.
Mixing Box
Blends hot tank water with cool fill water to provide drain water cooling.
On/Off Switch
Turns power On/Off to humidifier controller. Note: Turn off humidifier disconnect to shut
off primary power to the humidifier.
P Trap
Prevents steam from flowing out the drain outlet.
Remote Relay Board
Provides a terminal strip to dry contacts which open/close to indicate the humidifier is on,
humidifying, needs service, or is in a fault condition.
Steam Inlet
Connection for boiler steam, it is connected to the heat exchangers.
Steam Outlet
Connect to atmospheric steam line with steam hose.
Steam Trap
Drains condensate from the heat exchanger without letting boiler steam escape to drain.
Tank
Holds the water used to generate clean steam for humidification.
Total Controller
Controls all functions of the humidifier’s operation and provides user interface for
configuration of the humidifier.
Transformer
Steps primary 230 volts down to 24 volts for the controller and internal components such
as the fill valve and drain valve.
Vacuum Break
Prevents a siphon from occurring when the drain pump is stopped.
Wye Strainer
Protects CV valve and other system components from dirt and rust in the piping system.

9 | SE Engineering Manual
SE Outdoor Components
Figure 6: SETC Outdoor Components
Table 3: SETC Outdoor Components
Component
Function of Component
Cabinet Drain
Drain outlet for integrated cabinet drain pan (outdoor unit only). Drain to rooftop.
Cabinet Thermostat
Sensor that activates the heaters if the cabinet temperature is too cold for the
electronics (will not prevent the tank and water components from freezing).
Exhaust Fan
Cooling fan which is activated if the electrical cabinet gets too hot.
Heater
Electrical cabinet heater used to keep electronics warm enough for operation and
cold weather start up only.
Lifting Hooks
Hooks provided for lifting the humidifier.
Mounting Panel
A panel provided on the outside of the humidifier for mounting a dedicated external
disconnect.
Outdoor Cabinet
An enclosure that provides protection from precipitation and allows the SETC to be
installed outdoors.
Outdoor Mounting Base
An integrated support for the humidifier which includes a drain pan (outdoor unit
only), a pipe chase, and a means for curb mounting the humidifier.
Pipe Chase
An opening in the outdoor cabinet’s drain pan which is used for routing electrical
power, controls, boiler steam, boiler condensate, fill water, and drain water through
the base of the humidifier.
Steam Outlet
Outlet for steam produced by the humidifier. Connect to steam line with steam hose.
Mounting Panel
(External Disconnect)
Exhaust Fan
Cabinet Thermostat
Lifting Hook (4)
Heater
Cabinet Drain
(Drain Pan)
Outdoor Cabinet
Steam Outlet
Outdoor Mounting Base
(With integral drain
pan)
Pipe Chase
(not visible)

SE Engineering Manual | 10
SE Humidifier Specifications and Dimensions
Table 4: SETC Specifications
Model
Control
Valve
kV (CV)
Control
Valve,
Steam
Inlet,
Wye
Port
(BSP)
Cond-
ensate
Port
(BSP)
Net/Full
Weight
lb (kg)
Required fill
line flow
gal (l) /min
Required
Drain
capacity
gal (l) /min
Electrical
50
2.51 (2.9)
1/2
3/4
125/180
(57/82)
2.6 (10)
5.2 (20)
Voltage
230
Phase
1
Amps
0.65 A
Power
0.15 KW
Max
Disconnect
10 A
100
4.76 (5.5)
3/4
3/4
267/423
(121/192)
175
8.65 (10)
1
3/4
250
10.38 (12)
1
3/4
355/599
(161/272)
375
17.3 (20)
1 1/4
3/4
525
24.22 (28)
1 1/2
1
529/992
(240/450)
750
34.6 (40)
2
1
4.5 (17)
8 (29)
1050
56.22 (65)
2 1/2
1 1/4
703/1384
(318/628)
Table 5: SETC Capacities and Water Consumption
Model
*Supply Steam
Pressure
Psig (Bar)
*Max Output
lb/hr (kg/hr)
Approximate
Boiler Steam
Consumption
lb/hr (kg/hr)
**Water
Consumption
gal (l) /hr
**Drain Volume
gal (l) /hr
50
5 (0.35)
13
(6)
15
(7)
2.3
(9)
0.8
(3)
10 (0.69)
32
(14)
36
(16)
5.7
(21)
1.9
(7)
15 (1.034)
50
(23)
58
(26)
9.0
(34)
3.0
(11)
100
5 (0.35)
26
(12)
30
(14)
4.7
(18)
1.6
(6)
10 (0.69)
63
(29)
72
(33)
11.3
(43)
3.8
(14)
15 (1.034)
100
(45)
115
(52)
18.0
(68)
6.0
(23)
175
5 (0.35)
46
(21)
52
(24)
8.2
(31)
2.7
(10)
10 (0.69)
110
(50)
127
(58)
19.8
(75)
6.6
(25)
15 (1.034)
175
(80)
201
(91)
31.5
(119)
10.5
(40)
250
5 (0.35)
65
(30)
75
(34)
11.7
(44)
3.9
(15)
10 (0.69)
158
(72)
181
(82)
28.3
(107)
9.4
(36)
15 (1.034)
250
(114)
288
(131)
44.9
(170)
15.0
(57)
375
5 (0.35)
98
(44)
112
(51)
17.5
(66)
5.8
(22)
10 (0.69)
236
(107)
272
(123)
42.5
(161)
14.2
(54)
15 (1.034)
375
(170)
431
(196)
67.4
(255)
22.5
(85)
525
5 (0.35)
137
(62)
157
(71)
24.5
(93)
8.2
(31)
10 (0.69)
331
(150)
380
(173)
59.5
(225)
19.8
(75)
15 (1.034)
525
(239)
604
(274)
94.4
(357)
31.5
(119)
750
5 (0.35)
195
(89)
224
(102)
35.1
(133)
11.7
(44)
10 (0.69)
473
(215)
543
(247)
84.9
(321)
28.3
(107)
15 (1.034)
750
(341)
863
(392)
134.8
(510)
44.9
(170)
1050
5 (0.35)
273
(124)
314
(143)
49.1
(186)
16.4
(62)
10 (0.69)
662
(301)
761
(346)
118.9
(450)
39.6
(150)
15 (1.034)
1050
(477)
1208
(549)
188.7
(714)
62.9
(238)
* Supply steam pressure must be present at the control valve to achieve rated output
** At maximum output , 25% blow down, and with drain water cooling activated.

11 | SE Engineering Manual
Figure 7: SE Indoor Dimensions

SE Engineering Manual | 12
Table 6: SETC Outdoor Specifications
Model
Net/Full
Weight
lb (kg)
Amps
,
A
Power
.
KW
Max.
Disconnect
A
Voltage
and
Phase
100
267/423
(121/192)
2.7
0.65
10
Voltage
230
Phase
1
Hertz
50
175
2.7
0.65
10
250
355/599
(161/272)
2.7
0.65
10
375
2.7
0.65
10
525
529/992
(240/450)
4.8
1.15
10
750
4.8
1.15
10
1050
703/1384
(318/628)
6.9
1.65
10
Note: See Table 4: SETC Specifications and Table 5: SETC Capacities and Water Consumption on page 10 of SE
Series Installation manual for remaining specifications
Figure 8: SETC Outdoor Dimensions
¾”
BSPP

13 | SE Engineering Manual
Specifying the SE Humidifier
14 Humidifier Specification Checklist
15 Humidifier Load
15 Humidification Load
15 Supply Line Losses
16 Distributor Losses
17 Supply Steam Pressure
18 Humidifier Controls
18 Installation Location
19 Steam Distribution Method
19 SE Series Options and Accessories
24 Sample Specification

SE Engineering Manual | 14
Humidifier Specification Checklist
The following checklist can be used to specify the SE Series Humidifier. A description of each
selection is provided later on in this section.
Humidifier Tag: _______________ Zone _______________
Humidifier Model ____________________________ Part No _______________
Humidifier Load ______________kg/hr =
Humidification Load _______ + Supply Line Losses_______+ Distribution Losses_______
Supply Steam Pressure __________ BAR Capacity at Supply Pressure __________________
Humidity Control
Demand Transducer On/Off Signal Type _______
By Others By Condair, Part No_______________
High Limit
Demand (SETC Only) Transducer On/Off Signal Type _______
By Others By Condair, Part No _______________
Location
Indoor Stand Ceiling kit Part No _______________
Outdoor
Steam Distribution
Duct Width _____________ Height __________________
SAM-e
Header Length __________ Tube spacing __________ Part No _______________
Distribution Tube Length ______________ Qty ________ Part No _______________
Steam Inlet type __________________ Part No _______________
Tube Insulation, Qty ________________ Part No _______________
Header Insulation, Part No _______________
Mounting Frame, Part No _______________
Distributor, Length ______________ Qty ____________ Part No _______________
Blower Pack, Qty ____________ Part No _______________
Additional Options (See Table 8: Options and Accessories)
_________________________________________________________________________________
_________________________________________________________________________________

15 | SE Engineering Manual
Humidifier Load
The SE Series humidifiers are available with capacities ranging from 50 to 1050 lb/hr (23 to
477 kg/hr). In addition to the available models, up to 10 humidifiers can be combined together
to operate from one control signal for capacities of over 10,500 lb/hr (4,770 Kg/hr). The
humidifier(s) selected must have a capacity equal to or greater than the load.
The humidifier load is made up of three components;
1Humidification Load - Water that must be added to the air to achieve the desired humidity
level.
2Supply Line Losses –Water that condenses in the steam lines between the humidifier and
the location where the steam is being introduced into the air.
3Distributor Losses –Water that condenses in the steam distributor itself.
Figure 9: Humidifier Load
Humidification Load
The easiest way to calculate the humidification load for any application is to use Condair’s
Humidifier Engineering and Load-sizing Program. Many engineering handbooks, such as the
ASHRAE Handbook, also provide information on selecting a humidity setpoint, the effects of
relative humidity, and methods for manually calculating the humidification load.
Supply Line Losses
Table 11: Maximum Recommended Length of Steam Line on page 44 provides maximum
recommended lengths for various steam line sizes as well as possible losses due to
condensation in steam lines. Table 12: Equivalent Length of Some Common Fittings on page
44 gives equivalent lengths of some common fittings used in making steam lines. The
information in the tables along with information about the layout and length of the steam line
should be used to estimate the supply line losses.
2) Supply
line losses 3) Distributor
losses
1) Humidification
load
Humidifier
Distributor
Steam supply
line
1) Humidification load
+ 2) Supply line losses
+ 3) Distributor losses
= Humidifier Load

SE Engineering Manual | 16
Example 1: Supply Line Losses - SE 250 with 30 ft (9.15 m) x 3 in. (76 mm) steam line with one
90º elbow.
1Obtain possible losses for 3 in line from Table 11.
A = 0.24 kg/hr/mor 0.16 lb/hr/ft
2Calculate the equivalent length of steam line using 3 in. 90º Elbow in Table 12.
B = 9.15m + 1.53m = 10.68m or 30 ft + 5 ft = 35 ft.
3Multiply the equivalent length by the possible losses to get supply line losses.
C = B x A
= 10.68 x 0.25 = 2.67 kg/hr
or
= 35 x 0.16 = 5.6 lb/hr
Distributor Losses
Convection heat transfer between a steam distributor in a duct and the air in the duct is the
primary mechanism responsible for distributor losses. The amount of losses is proportional to
the length of distributor and the temperature of the air in the duct. Distributor loss estimation
depends on the type and configuration of the distributor being used. Consult the
documentation for the distributor for more information.

17 | SE Engineering Manual
Supply Steam Pressure
One of the unique features of the steam exchange humidifier is that its maximum output is
affected by the steam supply pressure. Models are designated by the capacities at maximum
supply pressure of 15 psi (1.034 Bar). An SETC 1050 will produce 1050 lb/hr (477 Kg/hr) of
steam when supplied with 15 psi (1.034 Bar) steam. If the available steam supply pressure is
lower than 15 psi (1.034 Bar) measured at the control valve, then the output will be reduced as
shown in Figure 10. Table 5: SETC Capacities and Water Consumption on page 10 also
provides steam output at 0.69 and 0.35 BAR (10 and 5 psi) supply pressures.
Figure 10: Output as a Function of Supply Steam Pressure
To select the model(s) of SE humidifier that is required to fulfill a given humidifier load
requirement, the output must be de-rated if the supply steam pressure is lower than 15 psi
(1.034 Bar).
Example 2: SE 250 Output –What is the maximum capacity of an SE 250 supplied with 12 psi
(0.83 bar) steam pressure?
Note:.
The pressurized steam supply line must be designed to provide rated pressure at the
control valve when there is 100 % demand (control valve completely open). Pressure
losses in the steam supply line will reduce SE output.