Aprilaire 60, 62 User Manual

Model 60 shown.

Automatic

Digital Humidifier Control

Model 60 &62

Safety and Installation Instructions

RE AD COMP L ETE INS TA L LATIO N IN S TRUC TION S

AN D TE MPLATE BEF ORE START I NG INSTAL L AT ION.

WARNING

ATTENTION INSTALLER: This product must be

installed by a qualified heating and air conditioning
contractor. Failure to do so could result in serious
injury from electrical shock.

WARNING

1. 120/240 volts may cause serious injury from
electrical shock. Disconnect electrical power to the
furnace and humidifier before starting installation.

2. Sharp edges may cause serious injury from cuts.
Use care when cutting plenum openings and
handling ductwork.

CAUTION

1. Do not set humidifier higher than recommended.
Condensation damage may result.

2. Do not set humidity up to recommended levels if
there is condensation on the inside of windows of
any unheated living space. Condensation damage
may result.

3. Do not mount the Humidifier Control on the supply
plenum or duct. The unit cannot withstand the
plenum temperatures and will malfunction.

4. When installing the Humidifier Control on a
counterflow furnace, ensure the blower continues to
run after the heat call is satisfied to eliminate high
temperatures from damaging the Humidifier Control.

5. Do not mount the Humidifier Control downstream of
the bypass outlet. False humidity conditions will
cause the humidifier to operate incorrectly.

6. Avoid installing the Humidifier Control with the
display facing downward to prevent the Humidifier
Control from incorrectly measuring the relative
humidity (RH) in the duct.

TABLE OF CONTENTS

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 4

System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 18

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . .page 20

THESE INSTALLATION INSTRUCTIONS

ARE FOR THE APRILAIRE

HUMIDIFIER CONTROL ONLY!

For Aprilaire

follow Aprilaire Humidifier Installation Instructions.

®

AUTOMATIC DIGITAL

®

humidifier installation,

32

Water Panel

Indicator

Settings

INSTALLATION

B

A

C

STEP 1: Unpack the Humidifier Control Carton

Make sure all components are present (see Figure A):

A. Humidifier Control
B. Outdoor Temperature Sensor
C. Manual Mode Label

Figure A

STEP 2: Disassemble the Humidifier Control

Remove the knob. Remove the cover by pulling at the bottom and
swinging it out and upward.

STEP 3: Check the Change Water Panel Indicator Setting

This setting will control when the indicator light turns on,
reminding you to change your water panel. If your Control came
with a humidifier, the Control is pre-set for the humidifier. If the
installation site has a 3-month or shorter heating season or very
hard water, you may want to adjust the setting (see Figure B).

90-1201B

Figure B

Use the “OFF” setting for Model 800

Series humidifiers.

Use Setting “A”

for Model 400 Series
humidifiers in areas
with very hard water.
The indicator will light
after 150 hours of
humidifier operation.

Use Setting “B”

for Model 400 Series,
and for 500 Series, 600
Series and 700 Series
humidifiers in areas
with very hard water.
The indicator will light
after 300 hours of
humidifier operation.

Use Setting “C” for Model 500 Series,
600 Series and 700 Series humidifiers.
The indicator will light after 600 hours of

90-1202B

humidifier operation.

The Model 62 shipped with the Model 800 Steam Humidifier is
factory set to “OFF”. The Model 62 does not have the “Change
Water Panel” light on the Control. The Canister Change indicator
for the Model 800 is on the humidifier.

54

STEP 4: Determine Location for Humidifier Control

6" MIN.

RETURN

DUCT

HUMIDIFIER

CONTROL

FRESH AIR

INTAKE

COIL

HUMIDIFIER

BYPASS

CONNECTION

and Mount Control

Humidifier Control must be mounted on the Return Duct, at least
6 inches upstream of the following (see Figure C):

• Humidifier

• Humidifier Bypass Ductwork (if applicable)

• Fresh Air Intake Ductwork (if applicable)

Ambient operating temperature of the Humidifier Control is to be
from 20°F to 120°F to prevent damage to the control display.

Figure C

90-1137

DUCT (SHEET METAL) MOUNT:

After location for Control is selected, drill a 3/4 inch hole for the
RH sensor (the RH sensor extends from the back of the
Humidifier Control).

Use 2 sheet metal screws, 3/4 inch long (not provided), to mount
the Humidifier Control. Use the mounting slot to level the Control,
then secure the Control with the second sheet metal screw.

Make sure the Humidifier Control sensor gasket is seated tightly
around the drilled hole. Do not install Control without gasket.

DUCT (FIBER BOARD) MOUNT:

After location for Control is selected, cut a rectangular hole in
the duct board, no smaller than 6-9/16 inches long by 4-3/8
inches wide.

Cut a rectangular piece of sheet metal to fit behind the hole in
duct board for mounting the Humidifier Control.

Drill a 3/4 inch hole for the RH sensor (the RH sensor extends from
the back of the Humidifier Control) into the sheet metal plate.

Use 2 sheet metal screws, 3/4 inch long (not provided), to mount
the Humidifier Control.

Make sure the Humidifier Control sensor gasket is seated tightly
around the drilled hole. Do Not Install Control Without Gasket.

Secure the sheet metal plate, with the Humidifier Control
mounted, inside the duct (see Figure D).

CONTROL REPLACEMENT:

When replacing an existing control, the duct opening left by the
removed control must be covered completely. Locate and install
the new control as instructed previously in Step 4.

76

Figure D – Fiber Board Duct Mount

CONTROL BOARD

COVER

KNOB

BASE PLATE

RETURN DUCT

RETURN

DUCT

SHEET METAL

PLATE

CUT OPENING IN
RETURN DUCT

SHEET METAL PLATE

GASKET

SCREW (x2)

INSIDE OF

RETURN

DUCT

HHGfW GODTBACR

OUTDOOR

TEMPERATURE

SENSOR

24 VAC FROM

HVAC EQUIPMENT

“R” AND “C”

COMMUNICATION

WITH APRILAIRE

8570 THERMOSTAT

HEAT SIGNAL

FROM HVAC
EQUIPMENT

FAN SIGNAL

FROM

THERMOSTAT

SOLENOID

CONTROL

OUTPUT

FAN SIGNAL

TO HVAC

EQUIPMENT

Figure E – Digital Humidifier Control 24V Terminals

90-1203B

90-1397B

98

3 FEET MAX.

CENTER LINE

OUTSIDE WALL

STEP 5: Determine Location for Outdoor
Temperature Sensor

The location of the Outdoor Temperature Sensor must meet
these three requirements:

1. Must be mounted on North, East or West side of house out of
direct sunlight.

2. Must be at least 3 feet from all exhaust vents.

3. Must be above expected snow line (see Figure F).

Incorrect humidity levels will result if these requirements are not
met.

Figure F

OUTDOOR

TEMPERATURE SENSOR

LEADS

NORTH, EAST
OR WEST SIDE
OF HOME

ABOVE EXPECTED

SNOW LINE

OUTDOOR

TEMPERATURE

SENSOR

SENSOR

BRACKET

SENSOR

90-998

STEP 6: Locate Existing Access Hole to Outside

A convenient way to get the Sensor wire outside is to make use
of unused wires running to the A/C condensing unit (if
applicable). Other ways are to use existing holes for Cable TV
lines, telephone lines, A/C lines, etc. Read all equipment
instructions beforehand for possible conflicts and warnings.

STEP 7: Alternate Location for Outdoor
Temperature Sensor

WARNING

If Outdoor Temperature Sensor is mounted in an intake
duct or pipe, do not set Blower Activation switch to “ON”.

The Sensor can also be mounted in the center of either:

• PVC fresh air intake pipe for the HVAC system

OR

• fresh air intake duct. Mount the sensor with a #8 galvanized
screw.

In both cases, the Sensor must be no more than 3 feet
from the outside wall. See Figure G.

If it is not feasible to use the Outdoor Temperature Sensor in any
of the ways described, the Humidifier Control can be installed for
Manual Operation. See “Installing the Humidifier Control for
Manual Operation” and Figure J for details.

Figure G

90-999

1110

STEP 8: Route the Wire from Control to Sensor

Run wire to the outdoor temperature sensor. Sensor is not
affected by lead lengths less than 300 feet.

CAUTION

Do not run outdoor temperature sensor alongside
wires carrying high voltage (120 VAC or higher).

Secure the sensor bracket with a #8 screw.

STEP 9: Attach Sensor Wire to Humidifier Control

Strip wire 1/4 inch, and insert the wires from the Sensor into the
terminals labeled “ODT” on the Humidifier Control. See Figure H
for location of terminals.

Figure H

90-1219B

BLOWER ACTIVATION

Set the Blower Activation Switch to “ON” to allow the Humidifier
Control to activate the furnace fan for additional humidification.
This may be required if the humidifier is mounted on a heat pump
or a furnace with short run cycles.

When the Blower Activation switch is “ON”, the Humidifier
Control will turn on the HVAC blower when humidity is required.
In the “OFF” position, the humidifier will only operate if humidity
is required and the HVAC system is operating.

When the Blower Activation switch is “ON”, the Humidifier
Control may periodically turn the HVAC blower on to sample the
humidity of the air.

Installing the Humidifier Control for
Manual Operation

If it is not feasible to install the Outdoor Temperature
Sensor, the Humidifier Control can be operated in
Manual Mode.

1. Position the Mode Switch in the “MAN” position.
Manual indicator “M” will be displayed.

2. Apply the Manual Mode Label to the cover,
aligning the sticker and knob holes.

Figure J

90-1236B

1312

G

Y

W

C

R

THERMOSTAT

120 VAC

R

C

W

Y

G

FURNACE

OUTDOOR

TEMPERATURE

SENSOR FOR
AUTOMATIC

MODE

NORTH, EAST

OR WEST SIDE

OF HOME

ABOVE EXPECTED

SNOW LINE

CONTINUOUSLYPOWERED

24 VAC TRANSFORMER

PROVIDED WITH HUMIDIFIER

CONNECT

TO HOT WATER

SUPPLY

CONNECT
DRAIN LINE
HERE

OUTPUTSINPUTSPOWER

GW

CRHHODT GfA

ADHC TERMINAL STRIP

B

STEP 10: Model 60 Wiring for Model 400, 500, 600 and

700 Series Humidifiers – See Figure K

WARNING

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

Strip the wires used for all Humidifier Control terminal
connections 1/4 inch.

NOTES:

• The Model 60 must be continuously powered from “R” and
“C” on the furnace to function properly.

• The minimum VA required is 2.0 VA.

• In order for the humidifier to operate, the HVAC blower must
be running and the Model 60 must be calling for humidity.

WIRING DESCRIPTION:

• Wire external 24 VAC transformer into a constant power source
other than the heating, ventilating, air conditioning equipment

120 VAC line at the junction box before it enters the HVAC
equipment. Connect the 24 volt side of the transformer to one
of the “H” terminals on the humidifier control and to one of the
humidifier solenoid valve wires. Connect the other solenoid

(HVAC) blower circuit. The transformer can be powered off the

valve wire to the other “H” terminal.

• Wire “R” and “C” on the Model 60 to “R” and “C” on the
furnace terminal strip.

• Remove the thermostat “G” wire from the furnace terminal
strip and wire it to “G” on the Model 60 control.

• Wire “Gf” on the Model 60 to “G” on the furnace terminal
strip.

• Wire “W” on the Model 60 to “W” on the furnace terminal
strip.

• Replace cover and knob.

Figure K – Model 60 Wiring for Model 400, 500, 600
and 700 Series Humidifiers

90-1510

1514

OUTPUTSINPUTSPOWER

G

W

C

RHHODT GfA

ADHC TERMINAL STRIP

B

MODEL 800

STEAM HUMIDIFIER

OUTDOOR TEMPERATURESENSOR

FOR AUTOMATICMODE

FURNACE

THERMOSTAT

R

C

W

Y

G

G

Y

W

C

R

STEP 11: Model 62 Wiring for Model 800 Series Steam

Humidifier – See Figure L

WARNING

120/240 volts may cause serious injury from electrical
shock. Disconnect electrical power to the furnace
and humidifier before starting installation.

Strip the wires used for all Humidifier Control terminal
connections 1/4 inch.

NOTES:

• The Model 62 must be continuously powered from “R” and
“C” on the furnace to function properly.

• The minimum VA required is 2.0 VA.

• In order for the humidifier to operate, the HVAC blower must
be running and the Model 62 must be calling for humidity.

WIRING DESCRIPTION:

• Wire “H” terminals on the Model 62 to the “Humidifier”
terminals on the Model 800 control board.

• Wire “R” and “C” on the Model 62 to “R” and “C” on the
furnace terminal strip.

• Remove the thermostat “G” wire from the furnace terminal
strip and wire it to “G” on the Model 62 control.

• Wire “Gf” on the Model 62 to “G” on the furnace terminal
strip.

• Wire “W” on the Model 62 to “W” on the furnace terminal
strip.

• Replace cover and knob.

Figure L – Model 62 Wiring for Model 800 Series
Steam Humidifier

90-1511

1716

SYSTEM CHECKOUT

1. Replace the cover by snapping it into the Humidifier Control

base. Also replace the knob onto the Control.

2. Turn Blower Activation switch to OFF

3. Restore power to the HVAC system.

4. Activate the HVAC system or heat pump (Fan or Heat).

5. Once the blower is operating, rotate the knob of the

Humidifier Control Clockwise to the “Test/Reset” position.
When the knob is set in the “Test/Reset” position, the green
“Humidifier On” light will illuminate. After 5 seconds, the
green “Humidifier On” light will blink, indicating a system
reset.

6. If the Humidifier Control and humidifier are set up properly,

you should hear the solenoid valve click into the open
position. On the Model 800 Steam Humidifier, the “Steam”
light will illuminate green. In the “Test/Reset” position, the
humidifier will operate for 1 minute. If the Humidifier Control
is left in the “Test/Reset” position for more than 1 minute,
the “H” terminals will open (closing the solenoid valve), and
the knob and display backlights will flash, indicating that the
Humidifier Control is still in the “Test/Reset” position.

7. If the humidifier does not activate with the Humidifier Control

in the “Test/Reset” position, refer to the troubleshooting
guide.

Blower Activation Test

• Deactivate HVAC system or heat pump.

• Turn knob to OFF.

• Set switch to Blower Activation ON.

• Turn the knob to Test/Reset. The Humidifier On light will
illuminate. After 5 seconds, the green “Humidifier On” light
will blink, indicating a system reset.

• If the Humidifier Control and humidifier are set up properly,
the solenoid valve should click and the HVAC blower
should activate.

• If the humidifier does not activate with the Humidifier
Control in the “Test/Reset” position, refer to the
troubleshooting guide.

• If HVAC blower does not activate with the Humidifier
Control in the "Test/Reset" position, refer to the
troubleshooting guide.

8. Setting the Humidifier Control:

• If the home is occupied, set the Humidifier Control to
“Normal”. (For Manual Mode, set to 35%.)

• If the home is vacant, set the Humidifier Control to “OFF”.

• If in Manual Mode and system is installed during cooling
season, set the Humidifier Control to “OFF”.

9. Instruct the homeowner to refer to the Aprilaire Owner’s
Manual for the initial adjustment period.

10. Make sure the red “Call Dealer for Service” light is not
flashing. If the red “Call Dealer for Service” light is flashing,
refer to the troubleshooting guide.

1918

TROUBLESHOOTING GUIDE

SYMPTOM

Call Dealer For Service Light Flashing (see Figure M).

TROUBLESHOOTING PROCEDURE

Applies to both Automatic and Manual Operation unless
indicated otherwise.

Display Error Code: E1: RH Sensor

Rotate Humidifier Control knob to the “Test/Reset” position.
After 5 seconds, the green “Humidifier On” light will blink,
resetting the error. If E1 returns, replace the Humidifier Control.

Display Error Code: E2: Control Knob

Rotate Humidifier Control knob to the “Test/Reset” position.
After 5 seconds, the green “Humidifier On” light will blink,
resetting the error. If E2 returns, replace the Humidifier Control.

Display Error Code: E3: Outdoor Temperature Sensor

Auto Mode (switch in “AUTO” position)

1. Make sure that the Outdoor Temperature Sensor is properly
connected to the ODT terminals on the Humidifier Control.

2. Measure the resistance of the Outdoor Temperature Sensor
by removing the leads from the Humidifier Control terminals
and measuring the resistance across the wires with an
ohmmeter. Confirm the reading with the temperature in
Table 1 on page 22. Reconnect the ODT Sensor leads. If the
resistance value does not match the temperature value,
replace the Outdoor Temperature Sensor.

TROUBLESHOOTING PROCEDURE (CONTINUED)

3. Rotate Humidifier Control knob to the “Test/Reset” position.
After 5 seconds, the green “Humidifier On” light will blink,
resetting the error. If E3 returns, replace the Humidifier
Control.

Manual Mode (switch in “MAN” position)

1. Make sure the ODT terminals are clear of any wires that
may short the terminals together other than the ODT sensor.

2. Rotate Humidifier Control knob to the “Test/Reset” position.
After 5 seconds, the green “Humidifier On” light will blink,
resetting the error. If E3 returns, replace the Humidifier
Control.

Display Error Code: E4: Communication

This error applies to systems wired to an Aprilaire Model 8570
Thermostat (see Figure Q) using the “A” and “B” terminals.
Rotate the Humidifier Control knob to the “Test/Reset”
position. After 5 seconds, the green “Humidifier On” light will
blink, resetting the error. If E4 returns, check the wiring
between the Digital Humidifier Control and Model 8570 check
the connections at “A”and “B” on the humidifier control and
the Model 8570. Make sure the Model 8570 is wired and
operating properly according to the Model 8570 manual.

2120

TABLE 1

Red “Call Dealer For Service” Light

Yellow “Change Water Panel” Light

Green “Humidifier On” Light

Outdoor Temperature (°F) Resistance (

-30 231.8

-20 163.4

-10 117.3
0 84.8

10 62.2
20 46.1
30 34.4
40 26.1
50 19.9
60 15.3
70 11.9
80 9.3
90 7.3

100 5.8

Figure M

90-1227

kΩ) ±10

SYMPTOM

Humidifier does not operate in “Test/Reset” mode.

TROUBLESHOOTING PROCEDURE

• Check wiring diagrams for correct Humidifier Control
installation

• Make sure that the blower is operating and the HVAC
system is calling for heat.

• Check wiring diagrams for correct Humidifier Control
installation.

• If connected to a Model 400 Series humidifier, make sure
both floats in the bottom of the scale control insert are in
the down position. If necessary, dump out water to lower
the floats.

• Check voltage at the Humidifier Control “R” and “C”
terminals. Voltage should be 22 VAC minimum to 30 VAC
maximum.

• Make sure that the saddle valve is open.

• In “Test/Reset mode, the humidifier will operate for 1
minute only. DO NOT LEAVE THE HUMIDIFIER CONTROL IN
“TEST/RESET” MODE AS THE HUMIDIFIER WILL NOT
OPERATE.

2322

SYMPTOM

Yellow “Change Water Panel” light is blinking (see Figure M).

TROUBLESHOOTING PROCEDURE

Check the condition of the Water Panel and replace it if
mineral deposits are blocking air flow. Follow the instructions
on the Water Panel box. Rotate the knob to the “Test/Reset”
position for at least 5 seconds to reset Water Panel change
timer. Check that the timer setting is correct for the humidifier
model and water conditions (see Figure B). DO NOT LEAVE
THE HUMIDIFIER CONTROL IN “TEST/RESET” MODE AS THE
HUMIDIFIER WILL NOT OPERATE.

SYMPTOM

Humidifier operates only in “Test/Reset” mode.

• If outdoor temperature is greater than 60°F or less than

-30°F, the Humidifier Control will only operate in the
“Test/Reset” mode (for 1 minute).

• If the humidity level in the home is higher than the
Humidifier Control knob setting, the Humidifier Control will
not operate the humidifier.

TROUBLESHOOTING PROCEDURE

• Measure the resistance of the Outdoor Temperature Sensor
by removing the leads from the Humidifier Control terminals
and measuring the resistance across the wires with an
ohmmeter. Confirm the reading with the temperature in
Table 1. Reconnect the ODT Sensor leads. If the resistance
value does not match the temperature value, replace the
Outdoor Temperature Sensor.

• Make sure that the Outdoor Temperature Sensor is mounted
completely outside the house on the North, East or West
side of the house and out of direct sunlight. (Automatic
Mode Only)

• Make sure that the Outdoor Temperature Sensor is located
at least 3 feet away from all exhaust vents. (Automatic
Mode Only)

• If Outdoor Temperature Sensor is mounted in the fresh air
intake duct, make sure that the sensor is no more than 3
feet from the outside wall. (Automatic Mode Only)

2524

SYMPTOM

Humidifier operates constantly.

• If the humidity level in the home is less than the Humidifier
Control knob setting and there is a continuous fan call or
heat call (depending on setup), the Humidifier Control will
operate the humidifier until the humidity level is higher than
the Humidifier Control knob setting.

TROUBLESHOOTING PROCEDURE

• Set Blower Activation switch to OFF.

• In the “Test/Reset” mode, verify that the humidifier turns off
after 1 minute.

• Check the Outdoor Temperature Sensor resistance and
location, as instructed on the previous page.

• Rotate the Humidifier Control knob counterclockwise to the
“Off” position, and observe whether the humidifier turns
off. If the humidifier still operates in the “Off” position,
perform the following:

1. Check the wiring diagram for correct Humidifier Control

Installation.

2. Remove the wires from the “H” terminals on the

Humidifier Control. If the humidifier continues to operate,
replace the solenoid valve.

SYMPTOM

Humidifier or Humidifier Control “chatters” or clicks On and
Off rapidly.

TROUBLESHOOTING PROCEDURE

• Check for steady 22 VAC to 30 VAC across the “R” and “C”
terminals of the Humidifier Control with a voltmeter.

• Check, with a voltmeter, that the HVAC signal across the
“W” and “C” and “G and C” terminals of the Humidifier
Control is a steady 22 VAC to 30 VAC.

• Make sure that the Outdoor Temperature Sensor wiring is
not running alongside other wires carrying high voltage
(120 VAC or higher). (Automatic Mode Only)

SYMPTOM

Humidifier blower does not activate during Blower Activation
Test.

TROUBLESHOOTING PROCEDURE

• Set the Blower Activation Switch to “ON”.

• Check wiring diagrams for correct Humidifier Control
installation.

2726

RESEARCH PRODUCTS CORPORATION

P.O. BOX 1467 • MADISON,WI 53701-1467

Call 800/334-6011 • FAX [phone]

28

10008977 6.10

B2205119A