condair OptiSorp Series Short Evaporation Steam Instruction Manual

condair OptiSorp Series Short Evaporation Steam Instruction Manual

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This document and the information disclosed herein are proprietary data of Condair Group AG. Neither this document, nor the information contained herein shall be reproduced, used, or disclosed to others without the written authorisation of Condair Group AG, except to the extent required for installation or maintenance of recipient’s equipment.

Liability Notice
Condair Group AG 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 authorised by Condair Group AG.

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Technical modifications reserved

Notes on steam distribution system OptiSorp

OptiSorp – Steam distribution system for very short humidification distance
The OptiSorp is made from stain less steel and high-grade plastic components. It is designed for connection to the Condair steam humidi fiers. The OptiSorp steam distribu tion system is installed directly in the air duct or in an air-handling unit. It comprises horizontal collec tor pipes and several vertical pipes provided with steam nozzles. The OptiSorp separates the condensate from the inlet steam and feeds this uniformly and drip-free to the air flow. In particular the steam ab sorption distance is considerably less compared with conventional steam distribution pipes.

Note: To ensure a safe support of the collector pipes we recommend the use of the specially designed support for the steam distribution system OptiSorp. The entire support is made from stainless steel and available in four different mounting sets for duct heights ranging from 450 to 3200 mm (see table inchapter 3.7). The mounting sets comprise all necessary parts for the correct support of a OptiSorp system.

Positioning of the steam distribution system

The positioning of the steam distri bution system should be deter mined when laying out the air-conditioning system. The following points should be observed to en-sure correct humidification of the air. The conditions must be main tained exactly to ensure that the OptiSorp system satisfies the high demands made of it. A layout based on incorrect data, an unfavorable installation position or wrong instal lation can result in excessive hu midity with separation of conden sate and therefore to damage from water. The air duct must therefore be sealed in the area of the absorp tion distance and provided with a water drainage tray with outlet. The system is preferably fitted immedi ately following the air heater (and before the cooling coils). Other in stallation situations require addi tional care. A viewing port immedi ately following the system is highly recommended for installation and inspection of operation of the instal lation. Installation of the system is always made laterally to the air flow. With vertical air flow the nozzle tubes are fitted at an angle of 20° to 30° to enable the condensate to flow away easily. With exception of determination of the steam absorption distance, the same basic rules apply to the OptiSorp steam distribution system as to the standard steam distributor pipes (see installation and operating instructions of the humidifier).

Determination of steam absorption distance
Determination of the absorption distance “BN ” depends on various factors. For simple determination of the absorption distance “BN ” the table can be used. The nominal values obtained from the table re fer to an air inlet temperature of 10 °C to 30 °C. The length of the steam absorption distance can be calculated more accurately with the Condair software program. The result must be compared with the actual steam absorption distance or with the minimum spacings to be observed.

Notes on installation

Before installation check that the correct OptiSorp system is used and that the system is in accord ance with the type and steam out put on the specification label.
The OptiSorp is suitable for instal lation in air ducts or air-conditioning units. For this purpose the templates supplied are attached to the ventilation duct spaced according to the collectors. The duct plate is cut out round. The connection side of the pre-fitted system is inserted from inside through these holes.
The connector pieces are then fit ted on the pipes from outside and screwed to the duct wall. The collector pipes should be aligned hor izontally and secured at the end on the duct wall. For large systems or in special cas es, where this type of installation is not possible, the collector pipes can be fitted individually from out side. The nozzle tubes are then in serted in the collectors in the air duct and secured with the hose clamps and O-rings. Suitable pliers are required for the installation. All parts are supplied loose for this case if required.
Then install the steam and condensate hoses according to the instructions in the installation and operating instructions of the humidifier. It is advisable to drain the con densate separately and not return it to the humidifier owing to the in creased volume.

Notes on steam distribution system OptiSorp

Notes for the planning engineer

Layout
The choice of the OptiSorp steam distribution system can be made with the Condair software programme or from the layout tables. The system is determined by the number of steam connections of the steam humidifier. This also determines the maximum steam output. The max imum possible collector lengths and collector spacing is selected depending on the duct width and height.

Overview OptiSorp systems

| System 1| System 2| System 3| System 4
---|---|---|---|---

| ****

|

|

Number ofsteam connectors| 1| 2| 3| 4
Max. steam capacity| 45 (30) kg/h| 90 (60) kg/h| 135 (90) kg/h| 180 (120) kg/h
Duct width (B)| 450…2700 mm
Duct height (H)| 450…1650 mm| 450…2200 mm| 800…3200 mm| 800…3200 mm

1. For duct width <600 mm the values in brackets apply. 

Notes for the planning engineer

Dimension diagrams

Systems 1..

System 2…

Power selection diagram OptiSorp Systems

Collector length L| mm| 350| 500| 650| 800| 1000| 1200| 1500| 1800| 2000| 2300| 2500
---|---|---|---|---|---|---|---|---|---|---|---|---
B min.| mm| 450 1)| 600| 750| 900| 1100| 1300| 1600| 1900| 2200| 2500| 2700
System 1| m D max.| kg/h| 30 **1)| 45
---|---|---|---|---
D2| mm| 350| 500| 650| 800| 1000| 1200| 1500
H min.| mm| 450 2)| 600 2)| 800| 950| 1150| 1350| 1650
Total height HT OptiSorp System| mm| 462| 612| 762| 912| 1112| 1312| 1612
****System 2| m D max.| kg/h| 60 ****1)| 90
---|---|---|---|---
D2| mm| 350| 500| 650| 800| 1000| 1200| 1500| 1800| 2000
H min.| mm| 450 2)| 600 2)| 800| 950| 1150| 1350| 1650| 1950| 2200
Total height HT OptiSorp System| mm| 462| 612| 762| 912| 1112| 1312| 1612| 1912| 2112
****System 3| m D max.| kg/h| 90 ****1)| 135
---|---|---|---|---
D2| mm| 325| 400| 500| 600| 750| 900| 1050| 1200| 1350| 1500
H min.| mm| 800| 950| 1150| 1350| 1650| 1950| 2300| 2600| 2900| 3200
Total height HT OptiSorp System| mm| 762| 912| 1112| 1312| 1612| 1912| 2212| 2512| 2812| 3112
****System 4| m D max.| kg/h| 120 1)| 180
---|---|---|---|---
D2| mm| 300| 375| 475| 575| 725| 875| 1050| 1200| 1350| 1500
H min.| mm| 800 2)| 950 2)| 1150 2)| 1350 2)| 1650 2)| 1950 2)| 2300 2)| 2600 2)| 2900 2)| 3200 2)**
Total height HT OptiSorp System| mm| 832| 982| 1182| 1382| 1682| 1982| 2332| 2632| 2932| 3232

1. For “B min.” <600 mm, the steam capacity of the corresponding system is limited to these values!.
2. If the air ducts of these systems are designed with “H min.”, the mounting plates of the steam inlet will protrude on the bottom and on the top in thin-walled air ducts. If this is not desired we recommend to design the air ducts in the total height of the OptiSorp system.

Type key

1. No. OptiSorp system
2. Collector length “L” in [mm]
3. Collector distance “D2” in [mm]
4. Steam capacity “mD ” in [kg/h]

Determination of the humidification distance “BN ”

Entering humidity φ 1 in % r.H.| Leaving humidity φ 2 in % r.H.
---|---
40| 50| 60| 70| 80| 90
5| 0.22 m| 0.28 m| 0.36 m| 0.48 m| 0.66 m| 1.08 m
10| 0.20 m| 0.26 m| 0.34 m| 0.45 m| 0.64 m| 1.04 m
20| 0.16 m| 0.22 m| 0.30 m| 0.41 m| 0.58 m| 0.96 m
30| 0.10 m| 0.17 m| 0.25 m| 0.36 m| 0.52 m| 0.88 m
40| | 0.11 m| 0.20 m| 0.30 m| 0.45 m| 0.79 m
50| | | 0.13 m| 0.24 m| 0.38 m| 0.69 m
60| | | | 0.16 m| 0.30 m| 0.58 m
70| | | | | 0.20 m| 0.45 m
The length of the absorption distance BN in mis for ducts with <600 mm about 50% longer

Planning data OptiSorp steam distribution system (for faxing!)

Layout data required| Installation 1| Installation 2| Installation 3| Installation 4
---|---|---|---|---
1.     Clear height of air duct “B” (without insulation)| mm| | | |
2.     Clear width of air duct “H” (without insulation)| mm| | | |
3.     Wall thickness of air duct “A” (without insulation)| mm| | | |
4.5.| Air volume per hour or| m3/h| | | |
Air speed| m/s| | | |
6.     Air duct static pressure| Pa| | | |
7.     Temperature after humidification| °C| | | |
8.     Abs. humidity before humidification| g/kg| | | |
9.10.| Humidity increase (∆x) or| g/kg| | | |
Rel. humidity after humidification| %| | | |
11. Humidifier capacity| kg/h| | | |
12. Steam humidifier selected| type| | | |
13. Number of steam connections| pcs.| | | |
14. Following air-cond. components| type| | | |
15. Existing humidification distance| m| | | |
OptiSorp System selected| type| | | |
–   Collector length (L)| mm| | | |
–   Collector spacing (D2)| mm| | | |
–   Steam output at 500 Pa (mD)| kg/h| | | |
Order| No.| | | |

Determination of the OptiSorp Systems

Example:
Unit: Condair RS 40 400V 3~, with one steam connector
Duct width B = 1410 mm
Duct height H = 1210 mm
Max. steam capacity = 35 kg/h

1. Determination of the system
   The system to be used is determined by the corresponding table of the respective device:
   – Condair RS
   **| Voltage| | | Condair RS|
   ---|---|---|---|---|---
   23 0V/1~| 5…10| –––| –––| –––| –––
   200V/3~| –––| 16…30| 40…60| –––| –––
   230V/3~| 5…10| 16…30| 40…60| –––| –––
   380V/3~| 5…10| 16…40| 50…80| –––| –––**
   1| 400…415V/3~| 5…10| 16…40| 50…80| 100…120| 140…160
   | 440…600V/3~| 10| 16/20/30/40| 50…80| –––| –––

– Condair EL

| V oltage| Condair EL
---|---|---
200…240V/1~| 5…10| —| —| —| —| —
200V/3~| 5…8| 10…15| 20…30| 35…60| —| —
230V/3~| 5…8| 10…15| 20…30| 35…60| 70…90| 105…120
400…415V/3~| 5…8| 10…15| 20…30| 50…90| 105…135| 152…180
440…600V/3~| 5…8| 10…15| 20…45| 50…90| —| —
Steam distribution system OptiSorp| 1x System 1| 1x System 2| 1x System 3| 1x System 4

– Condair GS****

2. Determination of the collector length “L”: Go in the table with the collector length to the right until value “B min.” is greater than the width “B” of your duct. The collector length to be selected is the value in the field to the left.

3. Determination of the maximum steam capacity of the selected system:
   The determination of the required maximum steam output ” mD max.” for the selected system is based on the steam output of the humidifier. In our example (Condair RS 40 with 40 kg/h steam capacity) the required steam capacity is >30 kg/h but <45 kg/h.

4. Determination of the collector distance “D2”: Go in the table of the corresponding system (selected system in the example: System 1) to the right until the value “H min.” is greater than the height of your duct. The collector distance “D2” to be selected is the value in the field to the left.

Collector length L| mm| 350| 500| 650| 800| 1000| 1200| 1500| 1800| 2000| 2300| 2500
---|---|---|---|---|---|---|---|---|---|---|---|---
B min.| mm| 450 1)| 600| 750| 900| 1100| 130| 0| 1600| 1900| 2200| 2500| 2700
| | |
2
System 1| m D max.| kg/h| 30 **1)| 45
---|---|---|---|---
D2| mm| 350| 500| 650| 800| 1000| 1200| 1500
H min.| mm| 450 2)| 600 2)| 800| 950| 115| 0| 1350| 1650
Total height HT OptiSorp System| mm| 462| 612| 762| 912| 111| 2| 1312| 1612
| | |
4
System 2| m D max.| kg/h| 60 ****1)| 90
---|---|---|---|---
D2| mm| 350| 500| 650| 800| 1000| 1200| 1500| 1800| 2000
H min.| mm| 450 2)| 600 2)| 800| 950| 1150| 1350| 1650| 1950| 2200
Total height HT OptiSorp System| mm| 462| 612| 762| 912| 1112| 1312| 1612| 1912| 2112
System 3| m D max.| kg/h| 90 ****1)| 135
---|---|---|---|---
D2| mm| 325| 400| 500| 600| 750| 900| 1050| 1200| 1350| 1500
H min.| mm| 800| 950| 1150| 1350| 1650| 1950| 2300| 2600| 2900| 3200
Total height HT OptiSorp System| mm| 762| 912| 1112| 1312| 1612| 1912| 2212| 2512| 2812| 3112
System 4| m D max.| kg/h| 120 1)| 180
---|---|---|---|---
D2| mm| 300| 375| 475| 575| 725| 875| 1050| 1200| 1350| 1500
H min.| mm| 800 2)| 950 2)| 1150 2)| 1350 2)| 1650 2)| 1950 2)| 2300 2)| 2600 2)| 2900 2)| 3200 2)**
Total height HT OptiSorp System| mm| 832| 982| 1182| 1382| 1682| 1982| 2332| 2632| 2932| 3232

1. and 2) see table in chapter 2.4.
   The following results in our example: System 1 with a collector distance “D2” of 1000 mm and a collector length “L” of 1200 mm.

Mounting

Safety
The OptiSorp steam distribution system must only be installed by adequately qualified personnel. Observe and comply with all safety instructions in the installation and operating instructions of the steam humidifier.

Delivery
The OptiSorp steam distribution system will be delivered either premounted or as single components. Observe the corresponding mounting instructions.

Mounting positions
The OptiSorp steam distribution system can be installed in horizontal or vertical ducts. When mounting in a vertical duct the nozzle pipes must have a minimum declination of 20° and the end pieces of the collector pipes must be turned, so that the vertical condensate connection directs straight downwards (see figure below).
Note: Before mounting the OptiSorp system check the type designation and steam capacity on the data plate to ensure that the correct OptiSorp system is installed in the right place. In addition to this installation and operating instructions please observe and comply with the instructions regarding the steam installation (positioning, max. length of steam pipe, etc.) in the installation and operating instructions of the steam humidifier.

Mounting overview OptiSorp systems

1. System
   

2. System
   

3. System
   

4. System
   

Mounting the premounted OptiSorp system

1. Remove the protection covers.

2. Measure the distance of the collector pipes and affix the installation template on the duct wall at the designed place with this distance (permissible variation ±3 mm) and cut out the open ings.

3. From inside of duct, insert the collector pipes through the prepared openings.

4.  Slip from the outside flange, O-ring and steam hose connections onto the tube and fix them by the four screws. Pay attention that the condensate drains are below the steam hose connection.

5.  Starting with the lowest collector pipe fix the steam hose connections with the 4 screws at the duct wall.

6. Align the collector pipes with a down-slope of 2° against the steam connector. Then, fasten the pipe ends on the duct using M8 threaded rod or the specially designed support available as accessory (see mounting drawing in chapter 3.7).

7. Connect the steam hose(s) to the steam outlet connector(s) of the humidifier and fasten with the hose clamp(s). Then lead the steam hose(s) to the collector pipe(s) according to the instructions for the hose layout in the installation manual of the corresponding humidifier.
   Note: The Condair GS devices 65 .., 90 …, 130 …, 195 … and 260 … are supplied with connection adapters for the steam hose installation. Please observe the special instructions in the installation manual for the Condair GS when installing these adapters.

8. Connect the steam hose(s) DS80 and the condensate hoses to the collector pipes according to the overview in chapter 3.4. Secure the steam hose(s) to the collector pipe(s) with the hose clamp and guide the condensate hoses downwards into an open discharge funnel.
   Note: For system 1, connect the steam hose to the lower steam connector and close the upper steam connector with the supplied sealing cap and the hose clamp.

Mounting the different parts of the OptiSorp system

1. Remove the protection covers.

2. Affix the installation templates on the duct wall at the designed place with the correct distance of the collector pipes (permissible variation ±3 mm). Cut out the openings.

3. Slip the flange, O-ring and steam hose connections onto the tube and fix them by the four screws. From outside of the duct, insert the premounted collector pipes through the prepared openings.

4. Put one half tube clip with O-ring onto both ends of the nozzle pipes. Slide the nozzle pipes into the holes of the collectors to the limit stop and so that the nozzles are situated one against the others. With a suitable clamp press both halves of the clips together until they will be fixed by a “click”.

5. Starting with the lowest collector pipe fix the steam hose connections with the 4 screws at the duct wall.

6. Align the collector pipes with a down-slope of 2° against the steam connector. Then, fasten the pipe ends on the duct using M8 threaded rod or the specially designed support available as accessory (see mounting drawing in chapter 3.7).

7. Connect the steam hose(s) to the steam outlet connector(s) of the humidifier and fasten with the hose clamp(s). Then lead the steam hose(s) to the collector pipe(s) according to the instructions for the hose layout in the installation manual of the corresponding humidifier.
   Note: The Condair GS devices 65 .., 90 …, 130 …, 195 … and 260 … are supplied with connection adapters for the steam hose installation. Please observe the special instructions in the installation manual for the Condair GS when installing these adapters.

8. Connect the steam hose(s) DS80 and the condensate hoses to the collector pipes according to the overview in chapter 3.4. Secure the steam hose(s) to the collector pipe(s) with the hose clamp and guide the condensate hoses downwards into an open discharge funnel.
   Note: For system 1, connect the steam hose to the lower steam connector and close the upper steam connector with the supplied sealing cap and the hose clamp.

OptiSorp Support (accessory)

Range duct height [mm]| Art./SAP No.| Upper foothold (Pos. 1)Length [mm]| Rail (Pos. 2)Length [mm]| Lower foothold (Pos. 3)Length [mm]| Bracket (Pos. 4 )
---|---|---|---|---|---
450…950| 1117477| 450| 500| none| 4
950…1350| 1117478| 450| 500| 450 mm| 4
1350…2300| 1117479| 450| 1400| 450 mm| 4
2300…3200| 1117480| 450| 2300| 450 mm| 4

Putting into operation and operation

Putting into operation
When connected to several basic units these should be operated in parallel. Otherwise condensate runs into the units switched off and fills these until overflow occurs. Problems can then arise when switching on again.

The following should be ensured when putting into operation:

1. that the system pressure don’t increase over 1500 Pa. The system pressure is componed of the air duct static pressure, the pressure drop over the OptiSorp system (typical 500 Pa) and the back pressure in the steam hose (typical 100 Pa/m)
2. that no water splashes from the steam distribution system and the condensate runs out of the system satisfactorily. Condensating forma tion may be caused by:
   • Steam supply pipe not properly drained
   • Metallic steam pipe inadequately insulated
   • Overstressed steam generator feeds water through steam pipe
   • System condensate drain is block ed
   • Extreme back-pressure in condensate hose
   • Incorrect installation of conden sate hose

Operation

• Carry out visual checks periodically
• Further details according to the installation and operating instructions of the humidifier

Spare parts list

1. Flange connection cpl. DV81 : ø45. 1113746
2. O-ring (3 pcs) : ø59.69 x ø5.34. 1119190
3. End piece with fixation : 1117559
4. Sealing cap ø10 (3 pcs) : 2559239
5. Hose clamp (2 pcs) : DV81 with DS80 2538896. DV81 with Z10 2538898
6. Internal sealing: DV81 2526236
7. Hose clamp with O-ring : 1117893
8. O-ring for hose clamp (5 pcs) : 1118549
9. Sealing cap steam connector ø41 mm with hose clamp : 2567039

Material specifications

304. Hose clamps| Stainless steel 1.4301 (AISI 304)
     Steam nozzles| Stainless steel 1.4305 (AISI 303)
     Flange connection and end piece| Plastic PPS DIC Z-230 (GF 30%) black
     Screws and nuts| Stainless steel, galvanized steel
     O-rings| EPDM
     Sealing cap| EPDM
     Internal sealing (option)| Stainless steel ring 1.4301 (AISI 304) with EPDM seal
     Support (option)| Stainless steel 1.4301 (AISI 304)

Appendix

Drilling template

1. System 1&2
   
   Dimensions in mm

2. System

3. System

CONSULTING, SALES AND SERVICE:

Condair Group AG
Gwattstrasse 17, 8808 Pfäffikon SZ, Switzerland
Phone : +41 55 416 61 11, Fax : +41 55 588 00 07
info@condair.com, www.condairgroup.com

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