Condair DL II Adiabatic Air Humidification System
Planning Manual
Introduction
This planning manual details the Condair DL Adiabatic Hybrid Humidifier and its various versions. It provides an overview of the system, available options, and essential notes on design and installation requirements, including ductwork, positioning, and water quality.
For any questions after reviewing this documentation, please contact your Condair representative for assistance.
System Overview
The Condair DL adiabatic air humidification system leverages the principles of atomization and evaporation to achieve efficient humidification. It atomizes water using low-pressure stainless steel nozzles, optimally distributed across the unit's cross-section for high evaporation efficiency and uniform humidity distribution.
A post-evaporation unit, featuring premium ceramic media, is located at the end of the humidification distance. This unit captures humidifying water, maximizes evaporation, and prevents water accumulation in downstream components, ensuring breathable, aerosol-free, and hygienically humidified air.
System Versions
The Condair DL system is available in two base models tailored for different AHU/duct sizes:
- Type A: Includes a booster pump to ensure a required water pressure of 7 bar at 100% demand.
- Type B: Does not include a booster pump. This type is suitable when the reverse osmosis system can consistently provide 3-7 bar water pressure. The system configuration depends on the specified water pressure during ordering.
Both models support various functional extensions via options. Key specifications include:
| Parameter | Type A (with booster pump) | Type B (without booster pump) |
|---|---|---|
| AHU/duct inside width | 450 ... 8400 mm | 450 ... 8400 mm |
| AHU/duct inside height | 450 ... 4000 mm | 450 ... 4000 mm |
| Humidification capacity | 5 ... 1000 l/hr | 5 ... 1000 l/hr |
Condair DL System Components
The Condair DL System comprises four main components:
- Control unit (1)
- Central unit (2)
- Nozzle System (3)
- Post Evaporative Unit with Ceramic Media (4)
Key associated items include a humidity sensor/controller, electrical isolator, air cleaning valve (option), pressure gauge, external water filter, shut-off valve, compressed air supply, RO water supply, drain valve, test valve, water supply flushing valve (option), and spray circuit lines.
Note: Items marked with an asterisk (*) are to be provided by others.
Overview Humidification Unit
The humidification unit consists of:
- Support frame (1)
- Nozzle unit (2)
- Spray nozzles (3)
- Lateral sealing plates (3)
- Upper sealing plates (4)
- Support frame post-evaporation unit (5)
- Ceramic plates (6)
- Rubber sealing duct floor (7)
- Wall feed throughs spray circuits (8)
Functional Description
Refer to the Condair DL operation manual for detailed functional descriptions.
Condair DL Unit Properties and Clearances
Dimensions
The system requires specific dimensions within the AHU/duct:
- AHU/duct internal width: 450 ... 8400 mm
- AHU/duct internal height: 450 ... 4000 mm
- Installation length "L": 600 ... 900 mm (larger lengths available as special order)
A minimum installation section of 500 mm is required for the nozzle unit and post-evaporation unit.
System Weights
Approximate weights for system components:
| Component | DL Type A | DL Type B |
|---|---|---|
| Central Unit | approx. 54 kg | approx. 35 kg |
| Control Unit | approx. 15 kg | approx. 15 kg |
| Post-evaporation Unit (wet) | approx. 55 kg/m² humidifier area | approx. 55 kg/m² humidifier area |
| Post-evaporation Unit (dry) | approx. 40 kg/m² humidifier area | approx. 40 kg/m² humidifier area |
Electrical Requirements
Mains Voltage:
- DL Type A: 200-240 VAC / 50-60 Hz
- DL Type B: 115-240 VAC / 50-60 Hz
The mains supply must be connected to terminals "XE1" via a supplied snap ferrite "SF". Both phase "L1" and neutral conductor "N", along with protective earth wires "PE", must pass through the ferrite twice. High leakage current requires a second protective earth conductor, connected directly to potential equalization, with wire cross-section compliant with local regulations. If a single earth conductor is used, its cross-section must be 10 mm².
Mandatory Installation: A fuse F3 (10 A slow acting), an electrical isolator "Q" (all-pole disconnecting device with min. 3 mm contact clearance), and a residual current circuit breaker (30 mA trigger current) must be installed in the mains supply line.
Power Consumption:
- Control Unit (including solenoid valves): 55-65 VA (varies with valve count and display mode).
- Booster Pump: approx. 12 VA per 10 kg/hr spray capacity.
Refer to the Condair DL II installation manual for more details.
Water Supply Requirements
| Requirement | Range |
|---|---|
| Water Type | Fully demineralized (RO or DI) |
| Conductivity | 0.5 ... 15.0 µS/cm |
| Inlet Pressure | 3 ... 7 bar |
| Inlet Temperature | Max. 20 °C |
| Additives | None (unless approved by Condair) |
| Germ Count | Max. 100 cfu/ml at inlet |
Required Clearances
Specific minimum clearances are required around the humidification unit for installation and maintenance:
- Before nozzle grid: 500 mm
- After post-evaporation unit: 100 mm
- Between nozzle grid and inspection door: 40 mm
- From the right side of the inspection door to the end post evaporation unit: 400 mm
These clearances are illustrated in figures showing side and top views, emphasizing the need for an inspection door and proper drainage slope (min. 2° to center drain).
Available Options
Various options enhance the Condair DL system's functionality:
- Silicone Free: Produced with silicone-free components.
- Leak monitoring: Detects water accumulation with sensors in and below the central unit, closing the inlet valve upon detection.
- Sterile filter: Automatic self-monitoring filter upstream of the booster pump for enhanced hygiene. Requires periodic replacement.
- Air cleaning: Additional fittings for drying and flushing the system with compressed air, suitable for shutdowns or flushing needs.
- External pipe flush: Allows flushing of the water supply line from the RO unit to the drain, bypassing the DL unit.
- External water filter 5 µm: Prefilter installed at the water inlet to the central unit. Requires periodic replacement.
- Gateway board: Enables LonWorks or BACnet IP/BACnet MS/TP communication, offering flexibility in network integration.
- Mounting rack: Provides a rack for mounting the central and control units.
- Disinfection for service: Adds a T-connector and check valves to introduce disinfectant. Not recommended for loads >180 kg/hr due to pressure loss.
- Water temperature monitoring: Monitors inlet water temperature to trigger flushing, preventing freezing or reducing bacterial growth risk.
- External valve block with auxiliary outlet valve: Houses the valve block separately from the central unit, useful when the central unit is distant or a constant downslope cannot be maintained.
- Clamping sheet bottom rubber sealing post evaporator: Spring steel clamping sheets for better stabilization of the rubber seal at the bottom of the post-evaporator.
Note: Specific options may have availability restrictions based on the DL Type (A or B) and other selected options.
Design Requirements
Key parameters required for sizing and selecting the Condair DL system include:
| # | Required Parameter | Purpose |
|---|---|---|
| 1 | Air volume | Calculates air velocity (droplet separator needed if > 2.5 m/s) and humidification capacity. |
| 2 | Outside air portion (%) | Calculates humidification capacity and mixed air temperature/humidity. |
| 3 | Air temperature before humidifier | Calculates humidification capacity. |
| 4 | Air humidity before humidifier | Calculates humidification capacity. |
| 5 | Humidity setpoint after humidifier | Calculates humidification capacity. |
| 6 | Right/left side nozzle grid connections | Determines wall feed-through locations and nozzle grid production. |
| 7 | Duct internal dimensions (tolerance: ±25 mm) | Sizes the humidification unit (nozzle grid, post-evaporation unit). Height must include pan height. |
| 8 | Thickness of AHU wall | Determines wall feed-through length (75 mm or 125 mm). |
| 9 | Distance between humidification system and central unit | Determines water hose length (max. 10 m, same floor recommended). |
| 10 | Humidifier section length | Requires 600-900 mm of AHU section for feasibility (nozzle grid to post-evaporation unit). |
| 11 | Drain pan depth | Determines rubber seal height at the bottom of the drain pan. |
| 12 | Internal dimensions "H" and "W" of the AHU/duct | Precise determination of humidifier unit dimensions. "H" is measured from ceiling to top edge of drain pan frame. |
Installation Requirements
AHU/Duct Requirements
The installation requires specific AHU/duct features:
- Installation Section: A dedicated section for the nozzle unit and post-evaporation unit must be clear of obstructions.
- Waterproofing: The AHU/duct must be light, waterproof, and made of non-corrosive material. Components contacting RO water must be stainless steel or plastic.
- Inspection Window/Door: A waterproof inspection door with a coverable window and safety lock is mandatory. An inspection door before the nozzle grid or between the nozzle grid and post-evaporation unit is required. An additional door after the post-evaporation unit is recommended. Minimum door width is 400 mm; height should be 750 mm or 25 mm higher than the nozzle grid height if the AHU height is less than 762 mm.
- Drain Pan: A waterproof stainless steel drain pan with a minimum 2° slope to the drain is essential. Drains before and after the post-evaporation unit are required, individually piped via a siphon to the wastewater system with an open outlet for hygiene.
- Load Bearing: AHU load-bearing capacity must be sufficient. Larger units with mounting legs require reinforcement traverses. The post-evaporator unit weighs approximately 55 kg/m² when wet.
- Air Flow: Uniform airflow across the full cross-section of the post-evaporation unit is crucial to prevent drops from bypassing ceramic plates. Upstream/downstream AHU equipment (silencers, cross beams, directional changes, bends, cross-sectional changes, air coolers, heating coils, air filters) can impair function and may require rectifiers or perforated plates (approx. 60% open).
- Air Filter: An air filter rated ISO ePM1 60% or better is required at the air inlet.
- Heating: Due to adiabatic cooling, a preheating coil is necessary to meet temperature and humidity setpoints. If a heater is present, it must be at least 500 mm from the humidification unit.
- Insulation: Duct insulation is recommended when ambient temperatures may be low.
- AHU/Duct Light: Waterproof lighting made of non-corrosive material should be installed in the section between the nozzle unit and post-evaporation unit.
- AHU/Duct Support: The AHU/duct should be elevated on supports to allow spray circuit lines to maintain a constant downslope to the central unit connections.
Requirements for Positioning of the Central and Control Units
Proper placement of the central and control units is critical:
- Floor Drain: The central unit must be installed in rooms with a floor drain. Sensitive materials should be kept clear of the unit. If no floor drain is available, a leak monitoring device is mandatory.
- Ambient Conditions: The installation room must maintain ambient temperatures between 5-40 °C and humidity up to 80% RH (non-condensing).
- Location: All DL equipment must be installed in a conditioned indoor space. Outdoor installation is prohibited due to the risk of bacterial growth from summer heat. Avoid locations prone to freezing. Heat treatment of water lines is not permitted for hygiene reasons.
- Spray Circuit Lines: The length of spray circuit lines between the central unit and duct wall feed-throughs should be minimized (max. 10 m) and maintain a constant downslope.
- Accessibility: Units must be freely accessible for maintenance, adhering to minimum clearances (refer to Fig. 4).
- Protection: Central and control units have IP21 protection and must be shielded from dripping water and dust.
- Proximity: Units should ideally be installed adjacent to the duct/AHU where wall feed-throughs are located.
Common positioning mistakes are detailed in Section 6.6.
Appendix Summaries
The appendices provide detailed guidance and examples:
- Appendix A: Correct AHU/Duct Layout illustrates proper installation with required clearances, drain pan slope, and support structures.
- Appendix B: Layout Faults identifies common errors such as obstacles in the installation section, missing lights, improper duct support, missing drain pans, lack of traps on drains, and missing inspection windows.
- Appendix C: Images of Layout Faults visually depicts non-permissible constrictions and incorrect installations in vertical AHU/ducts.
- Appendix D: Wrong Nozzle Grid Connection Side explains the consequences of incorrect nozzle grid connections, leading to sagging spray lines and standing water, and advises ordering correct pre-assembled grids.
- Appendix E: Images of Proper Installations shows examples of correct mounting rack positioning relative to the nozzle grid and wall feed-throughs, emphasizing the need for constant downslope in spray circuit lines.
- Appendix F: Common Positioning Mistakes details issues like sagging spray lines under doors, central unit connections being above wall feed-throughs, incorrect hose routing, and upward routing of spray lines, offering remedies and suggesting the optional external valve block if correct routing is impossible.
- Appendix G: Checklist Commissioning provides a comprehensive checklist covering general installation, electrical checks, control functions, options testing, and data recording for system commissioning.
- Appendix H: Operating Ranges lists the technical specifications and operating parameters for both Type A and Type B systems, including humidification capacity, pressures, electrical requirements, control accuracy, sound levels, air velocity limits, water quality, and ambient conditions.
Humidification, Dehumidification and Evaporative Cooling | Condair Group
