Air King AK5000, AK5500, AK7000 Troubleshooting Guide

FLOW-THROUGH

FURNACE
HUMIDIFIER

Installation

Warranty

Maintenance

Troubleshooting Guide

2

Installation

READ COMPLETE INSTALLATION

INSTRUCTIONS AND TEMPLATE

BEFORE STARTING

Attention Installer:

• Installation work and electrical wiring must be done
by qualified person(s) in accordance with all
applicable codes and standards, including fire­related construction.

• 120V may cause serious injury from electrical shock.
Disconnect electrical power to furnace before
starting installation.

• Wear safety glasses, work gloves.

• When drilling or cutting into ducting be extremely
careful not to damage air conditioner coils or other
furnace parts.

• This unit must be installed on ducts at least 10” wide.

• Do not install this unit where extreme temperature
exist (below 45°F-above 145°F).

INSTALLATION TIP. Before starting, fully plan
out the installation. Check for the locations of
humidifier, bypass collar and damper, the
length and type of ducting required, the water
supply, the water drain, the electrical wiring.
This will ensure your installation goes as easily
and quickly as possible.

1. The humidifier body mounted level on the return air
duct (to help even water distribution across
evaporation pad).

2. The humidifier body and bypass duct are installed at
eye level, easily accessible for installation and
routine maintenance.

3. Distance between centers of humidifier body (on
return cold air duct) and bypass inlet (on the warm
air supply duct ) are no more than 30” (to allow for
best air flow).

4. The bypass damper is fully opened.

5. The bypass inlet opening should be at least 6” above
any restrictions (e.g. the air conditioning coils)
inside the duct.

6. The humidifier and bypass collar are at the same level.

7. Take the most direct route to join humidifier and
bypass collar.

INSTALLATION

STEP #1: RIGHT HAND DUCTING
OR LEFT HAND DUCTING

Depending on your furnace or for convenience of your
installation it may be necessary to convert the
humidifier for left hand ducting or right handing
ducting. Follow the steps below to switch the side
which bypass duct will attached to the unit.

1. Remove the humidifier front cover secured in place
with 10-24 plastic thumb screw at the bottom of the
cover .Tilt the about 1/2” away from the body and lift
the cover up to free the hooks at the top of the body.

2. Remove all lose components packaged inside. With
a firm pull, disconnect the water tube from the water
nozzle and remove the evaporator pad assembly by
sliding it toward the top of the humidifier, and then
lifting it out.

3. Remove the two #6 screws which hold the
humidifier side in place , lift the humidifier side out
of the right hand position, turn the part and place it
on other side of the body.

4. Use two #6 crews removed to secure the humidifier
side in the left hand side.

STEP #2 MOUNTING THE HUMIDIFIER ON THE DUCT

1. Use adhesive tape to affix the template onto the duct
in the selected location. Use the level line to template
and level to ensure the humidifier will be level.

2. Drill the 3 marked 1/8” cabinet mounting holes.

3. Drill 2 marked 7/32” cabinet position holes.

4. Cut out the area marked on the template for the
humidifier plenum.

IDEAL INSTALLATION

SUPPLY DUCT

WARM AIR

RETURN DUCT

COLD AIR

10" wide duct minimum

Bypass collar and
unit level

Bypass tube pulled
tight and cut to length

Water flowing to drain

Damper fully open

No more

than 30"

Figure 1

5. Mount the humidifier cabinet on the duct. The two
positioning tabs on the back of the cabinet should
align with the 7/32” holes drilled earlier. Use four
supplied screws to secure the cabinet to the duct.

6. Use level to make sure the cabinet is installed correctly.

7. Firmly insert the water supply tube back into the
water nozzle on the top of the distribution tray.

STEP #3: MOUNTING THE BYPASS COLLAR AND DAMPER

1. Use adhesive tape to affix the bypass template onto
the duct in the selected area.

2. Drill three marked 1/8” holes.

3. Cut out the area to form a circular opening on the duct.

4. Mount the by pass collar and damper using three
supplied screws. Air damper should be installed in the
open position. The top screw secures the damper.

STEP #4: WATER SUPPLY AND DRAINAGE CONNECTION

1. Sand both ends of the water supply tube . Failure to
do so may result in leaks.

2. Prepare the end of the 1/4” tubing for water
connection to the humidifier( all required hardware
is supplied in the valve kit)

3. Make the tube connection to the humidifier. Hand
tighten the nut first taking care not to strip the threads
on the valve, use an adjustable wrench to tighten down
a couple more turns. Do not over tighten.

4. Select the most convenient location for connecting
self piercing needle valve on a cold water pipe.
Connect the needle valve.

5. Once the valve is connected to the pipe, hand
tighten the nut first taking care not to strip threads,
use adjustable wrench to tighten down a couple
more turns. Do not over tighten.

6. Once the valve is mounted and the water tube is
connected you have to pierce the water pipe. Turn the
valve closed all the way and then open so that water
can flow to the humidifier. Check all fittings for leaks
and tighten or repair if necessary. Water will not be
running through the solenoid valve until electrical
connections are made and your furnace is switched on.

7. You must run a drain tube for this unit.

STEP #5: MOUNTING THE HUMIDISTAT
AND ELECTRICAL CONNECTIONS

Humidistat is packaged for wall mounting. For duct
mounting , follow the steps given below

Humidistat should be located upstream (about 6”)
from the humidifier on the return air duct. The unit
comes with a humidistat mounting template. This
template is for duct mounting the humidistat only.

1. Drill four 2.5 mm diameter holes on the template
used for mounting humidistat.

2. Cut out the Humidistat cutout area on duct.

3. Separate the low voltage wire at a suitable point,
cut one wire and strip the ends to connect
Humidistat terminals.

4. Installed the 25VAC transformer on furnace
according to furnace manufacturers’ instructions.

5. Using the two 90° terminals provided in the
Humidistat kit and the low voltage wire, connect one
terminal of the humidistat to one terminal on 25VAC
transformer. Connect other humidistat terminal to
one black lead of the solenoid switch through the
3/8” diameter hole on the back plate.

6. Connect the other terminal of the 25VAC
transformer to remaining black lead of the solenoid
switch. Make sure to cover the exposed wire joints
using wire nuts.

7. Mount the Humidistat using the four screws
provided in the humidistat kit

8. Remove paper backing from Humidistat label and
stick it on the face. Fix the knob on stem.

STEP # 6: TESTING THE UNIT

1. After completing water supply, drain and electrical
connection, secure the bypass duct. If flexible duct is
unavoidable, make sure it is pulled as tight as
possible.

2. Turn on the water. Turn on the furnace power
supply. When the furnace activate, electrical power
is supplied to the humidifier and humidistat.

3. Adjust the setting on Humidistat according to values
given in the label attached to Humidistat.

3

Installation

WARRANTY

The manufacturer guarantees the for the period of one year from the
date of purchase, the product will be free of defects in workmanship
and/or material. As well the manufacturer offers a life time warranty on
the flow through humidifier body. During the warranty period, we will
replace or repair any defective part at no charge if the product is
returned prepaid to our factory.

This warranty does not cover any labor or shipping costs, or the cost of
replacement components as part of routine maintenance (such as Flow
Through Humidifier Evaporator Pads, Inlet water Filters, or Orifice
Fittings). Any damage or failure caused by abuse, misuse, abnormal
usage, faulty installation, or improper maintenance will not be covered
by this warranty.

In order to make a claim on this warranty you must be the original
consumer of the product and you must contact the manufacturer 1-800­465-7300 between 8 AM and 3:30 PM EST Monday to Friday at the first
sign of a defect. You will be required to present to the manufacturer the
original bill of sale showing date of purchase, place of purchase, and
model purchased. Failure to meet these requirements will void your
warranty.

The manufacturer will not be held responsible for any bodily injuries or
damages to personal property or real estate whether caused directly or
indirectly by the product. Some states and provinces do not allow the
exclusion or limitation of incidental or consequential damages and some
states or provinces do not allow limitations on how long an implied
warranty lasts, so these exclusions or limitations may not apply to you.
This warranty gives you specific legal rights and you may have other
rights which vary from state to state and province to province.

SAVE THIS DOCUMENT AND ATTACH YOUR RECEIPT.

Date of Purchase Date Of Installation

Place of Purchase Brand and Model#

See attached table regards specific component warranty periods.

MAINTENANCE

REPLACING/REMOVING THE EVAPORATOR PAD. (REFER TO FIGURES
1 A, B, C)

In order to ensure maximum performance you should replace the
evaporator pad at least once a year, Depending on the condition of your
water you may want to consider more frequent replacement.

1. Turn off the power to the humidifier, Turn off the water supply to the
humidifier, Turn off your furnace.

2. Remove the humidifiers front cover it is secured in place with a thumb
screw.

3. Remove the flexible water supply tube from the water nozzle at the

top of the distribution tray, it is press fit in place.

4. Remove the distribution tray two hooks at the top of the unit secure it in
place. Lift up on the hooks and carefully slide the tray out. As the tray
comes out the evaporator pad may come with it.

5. If the pad does not come out with the distribution tray you may
remove it now. The evaporator pad is held in place by the
distribution tray.

6. Now that the pad is out you may inspect, and or replace with a new
one. It is important that the black spot on the evaporator pad be at
the top.

7. Position the new pad in place bottom first. On the inside of the
humidifier, at the bottom is a trough used to collect draining water.
In the front of the trough are 2 tabs on either side, the evaporator pad
sits behind the 2 tabs.

8. With the pad position correctly at the bottom the distribution tray can
be reinstalled. Make sure that the water nozzle inlet (at the top of the
distribution tray) is facing out. Tilt the pad away from the top of the
unit and position the distribution tray on top of the pad. Guide the
distribution tray into the side channels at the same time deflecting the
2 hooks which secure the distribution tray in place.

9. Carefully push the distribution tray all the way back until the 2 hooks
engage the front edge of the distribution tray.

10. Reinstall the flexible water supply tube into the water nozzle at the
top of the distribution tray, it is press fit.

11. Replace the humidifier’s front cover and secure with thumb screw.

12. Turn on the power to the humidifier, Turn on the water supply to the
humidifier, Turn on your furnace.

REPLACING/REMOVING THE INLET WATER FILTER
(REFER TO FIGURES 2 A, B, C)

The purpose of the inlet water filter is to protect the humidifier’s orifice
fitting (which meters water usage) and the solenoid valve, it stops solids
from plugging those components. This filter should be checked if you
notice that the amount of water being supplied to the humidifier has
reduced. If you live in an area with hard water (high mineral content)
you may want to consider replacing this filter yearly. This filter is
available through our Parts and Service line 1-800-465-7300.

1. Turn off the power to the humidifier, Turn off the water supply to the

humidifier, Turn off your furnace.

2. Remove the bypass tube from the side of the humidifier, 6” spring

clamp secures it in place.

3. Using a wrench remove the water supply tube from the solenoid

valve.

4. The inlet filter is located inside the solenoid valves inlet. Using a

4

Warranty • Maintenance

Figure 1.

ABC

pointy object (ie nail) carefully remove the inlet filter.

5. The inlet filter should be fairly clean and free of debris.

6. Replace or clean the inlet filter if required. If it is punctured in anyway
replace immediately. Remember the filter protects the orifice fitting and
solenoid.

7. Position the cleaned or new filter in the solenoid valve inlet. Push the
inlet filter in place.

8. Carefully reconnect the water supply tube. Hand tighten the nut first
taking care not to strip the threads on the valve, use an adjustable
wrench to tighten down a couple more turns - DO NOT OVER
TIGHTEN, you may strip the threads on the solenoid valve. If leaks
occur you can tighten later to fix them.

9. Reconnect the bypass tube onto the humidifier side and secure in
place with the 6” spring clamp.

10. Turn on the power to the humidifier, Turn on the water supply to the
humidifier, Turn on your furnace.

11. Run the humidifier and check for and repair any leaks.

REPLACING A SOLENOID VALVE (REFER TO FIG 3 A,B,C)

At some point it may become necessary to replace the solenoid valve.
Follow the steps below to complete the repair. It is recommended that
when you replace a solenoid valve you replace the water inlet filter &
the orifice fitting at the same time.

1. Turn off the power to the humidifier, Turn off the water supply to the
humidifier, Turn off your furnace.

2. Remove the bypass tube from the side of the humidifier, 6” spring
clamp secures it in place.

3. Using a wrench remove the water supply tube from the solenoid
valve.

4. On the outlet side of the solenoid valve is the flexible water supply
tube use a wrench to remove this tube from the solenoid valve.

5. Remove the solenoid valve wires from the electrical terminals on the
side.

6. Remove the solenoid valve from the humidifier, 2 screws hold the
valve in place. Depending on the solenoid valve used there may be
a rubber washer installed on each screw. Do not lose these washers
as they are used to reduce valve vibration.

7. Install and secure the new valve in place using the 2 screws remove
earlier, be sure to use the rubber washers

8. Install a new water inlet filter in the solenoid valve’s inlet, it is push fit
in place. (refer to inlet water filter replacement regards installation)

9. The orifice fitting used to meter the water flow to the distribution tray

is located in the inlet of the flexible water supply tube remove in step

4. Remove and discard old fitting and replace with a new one. (refer
to the orifice fitting replacement regards installation)

10. Connect the solenoid valve wires to the 2 electrical terminals marked
24 Volt OUT.

11. Carefully reconnect the water supply tube and the flexible water
supply tube to the solenoid valves inlet and outlet. Hand tighten the
nuts first taking care not to strip the threads on the valve, use an
adjustable wrench to tighten down a couple more turns - DO NOT
OVER TIGHTEN, you may strip the threads on the solenoid valve. If
leaks occur you can tighten later to fix them.

12. Replace the bypass tube on the humidifier’s side and secure with
spring clamp.

13. Turn on the power to the humidifier, Turn on the water supply to the
humidifier, Turn on your furnace.

14. Run the humidifier and check for and repair any leaks.

REPLACING AN ORIFICE FITTING (REFER TO FIG 4 A,B,C)

The orifice fitting is located in the flexible water supply tube feeding
water from the solenoid valve to the distribution tray. The fitting is
installed at the solenoid valve end. This fitting is used to meter the
amount of water supplied to the humidifier. Over time and depending
on the condition of your water it may become plugged and replacement
will be necessary. We recommend that when you replace the orifice
fitting you replace the water inlet filter at the same time. Follow the
steps below to complete the repair.

1. Turn off the power to the humidifier, Turn off the water supply to the
humidifier, Turn off your furnace.

2. Remove the bypass tube from the side of the humidifier, 6” spring
clamp secures it in place.

3. Using a wrench remove the water supply tube from the solenoid
valve.

4. On the outlet side of the solenoid valve is the flexible water supply
tube use a wrench to remove this tube from the solenoid valve.

5. Install a new water inlet filter in the solenoid valve’s inlet, it is push fit
in place. (refer to inlet water filter replacement regards installation)

6. The orifice fitting is located in the inlet of the flexible water supply
tube. You should be able to remove this fitting by hand you may use
a needle nose pliers if required.

7. Install a new orifice fitting it is push fit in place.

8. Carefully reconnect the water supply tube and the flexible water
supply tube to the solenoid valves inlet and outlet. Hand tighten the
nuts first taking care not to strip the threads on the valve, use an
adjustable wrench to tighten down a couple more turns - DO NOT
OVER TIGHTEN, you may strip the threads on the solenoid valve. If

5

Maintenance

Figure 2.

ABC

Figure 3.

ABC