Aprilaire 800 User Manual

Model 800 Residential Steam Humidifier

Installation & Maintenance Instructions

TABLE OF CONTENTS

Safety Cautions..........................................2

Materials List ...........................................2

Principles of Operation...................................3

Specifications & Dimensions .............................3

Installation Instructions ..................................5

Choosing a Location .....................................5

- Dispersion Tube......................................5

- Humidifier ..........................................7

- Automatic Digital Humidifier Control.....................7

Prepare Humidifier for Mounting ...........................8

Mount Humidifier .......................................8

Steam Dispersion System .................................8

Supply Water...........................................8

Drain Line..............................................9

Automatic Digital Control and Control Wiring .................9

Electrical Power Wiring & Shut-off Switch ...................9

Start-up Procedure .....................................11

Sequence of Operations .................................11

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Display Panel ..........................................12

Maintenance...........................................13

Troubleshooting Guide ..................................14

Replacement Parts......................................16

READ AND SAVE THESE INSTRUCTIONS

SAFETY CAUTIONS

CAUTION

ATTENTION INSTALLER

Read this manual before installing. This product must be installed by qualiﬁed HVAC and electrical contractors and in compliance with local, state, federal, and governing codes. Improper installation can cause property damage, severe personal injury, or death as a result of electric shock, burns, or ﬁre.

Read all cautions and instructions.

Read this manual before performing service or maintenance procedures on any part of the system. Failure to follow all cautions and instructions could produce the hazardous situations described, resulting in property damage, personal injury, or death.

Failure to follow the instructions in this manual can cause moisture to accumulate, which can cause damage to structure and furnishings.

HOT SURFACES AND HOT WATER

This steam humidiﬁcation system has extremely hot surfaces. Water in steam canister, steam pipes, and dispersion tube can be as hot as 212°F (100°C). Discharged steam is not visible. Contact with hot surfaces, discharged hot water, or air into which steam has been discharged can cause severe personal injury. To avoid severe burns, follow procedures in this manual when performing service or maintenance procedures on any part of the system.

DISCONNECT ELECTRICAL POWER

Disconnect electrical power before installing supply wiring or performing service or maintenance procedures on any part of the humidiﬁcation system. Failure to disconnect electrical power could result in ﬁre, electrical shock, and other hazardous conditions. These hazardous conditions could cause property damage, personal injury, or death.

Contact with energized circuits can cause property damage, severe personal injury, or death as a result of electrical shock or ﬁre. Do not remove access panels until electrical power is disconnected.

Follow the shutdown procedure in this manual before performing service or maintenance procedures on any part of the system.

ELECTRICAL SHOCK HAZARD

If the humidiﬁer starts up responding to a call for humidity during maintenance, severe bodily injury or death from electrical shock could occur. Follow the procedures in this manual before performing service or maintenance procedures on this humidiﬁer.

EXCESSIVE SUPPLY WATER PRESSURE

Supply water pressure greater than 120 psi may cause the humidiﬁer to overﬂow.

SHARP EDGES

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

EXCESS HUMIDITY

Do not set humidity higher than recommended. Condensation may cause damage.

MATERIALS LIST

MATERIALS FURNISHED NOT FURNISHED

Humidifier Automatic Digital Humidifier Control Dispersion tube Steam hose (6 feet)

7/8” I.D. drain tubing (10 feet) Hose clamps Saddle valve Mounting screws

Main power disconnect switch Wiring 1/4” O.D. supply water tubing Boards for mounting (if required)

PRINCIPLES OF OPERATION

Steam Outlet

Drain

Supply

Water

Drain Cup

Drain Valve

Canister

Electrodes

High Water Level Sensor

Flow Control Orifice

Inlet Fill Valve

Overflow

Fill

Fill Cup

The Aprilaire

Model 800 Canister Steam Humidifier delivers humidity in the form of steam to the conditioned space via the HVAC system duct or optional Aprilaire Model 850 Fan Pack. The humidifier generates steam by energizing two electrodes that extend into a canister of water. Current flowing between the electrodes causes the water to boil, creating steam. Water is introduced to the humidifier through a fill valve to a fill cup located in the top of the cabinet. The fill cup serves as an overflow reservoir and provides an air gap between the humidifier and water source. The steam canister is filled from the bottom. The canister is seated in a drain cup assembly which includes a drain valve. The drain and fill valves work together to maintain water level in the canister to deliver the rated steam capacity based on the electrical conductivity of the water and to temper drain water. See Figure 1 for representation of fill and drain system and canister.

Steam is delivered into the airstream through a dispersion tube mounted in the HVAC system ductwork. Openings in the dispersion tube are fitted with “tubelets” which extend into the center of the tube. The design of the dispersion tube and tubelets distribute steam over a wide area in the duct and direct any condensed moisture back into the steam hose.

FIGURE 1 – Fill and Drain System and Canister

SPECIFICATIONS & DIMENSIONS

TABLE 1 – Specifications

Voltage kW

Maximum

steam capacity

gal/day amps lbs

Nominal Current draw

(amps)

120V 1.4 11.5 11.5 23

208V 2.4 20.5 11.5 23

240V 2.8 23.3 11.5 23

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Humidifier unit

operating weight

10 1/8"

20 7/8"

FRONT VIEW

3 3/8"

7 7/8"

8 7/8"

3 3/8"

1 5/8"

4 1/4"

5 3/4"

Dispersion Outlet

Electrical Knockouts

Fill Cup

TOP VIEW

7 1/8"

SIDE VIEW

12"

BACK VIEW

Mounting

Holes

3 3/8"

8 3/8"

3 3/8"

Water Fill Line Connection

Drain

BOTTOM VIEW

3" sq

2" sq

8 1/4"

1" dia

STEAM DISPERSION TUBE

3" Mounting Plate to first opening

1 3/4"

SPECIFICATIONS & DIMENSIONS (CONTINUED)

FIGURE 2 – Humidifier & Dispersion Tube Dimensions

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INSTALLATION INSTRUCTIONS

CHOOSING A LOCATION

DISPERSION TUBE

When choosing a location for the dispersion tube three things must be considered: Location in duct, elevation with respect to the humidifier, and distance from humidifier to dispersion tube.

Duct Location

The preferred location for the dispersion tube is in a supply duct because higher temperature air will more readily absorb the moisture. Whether installed in a supply or return, the dispersion tube must be in a straight section of duct to avoid turbulent air and must be far enough upstream of any obstruction or bends in the duct to allow the steam to be fully absorbed to prevent condensation. The exact distance from obstructions in the duct depends on air temperature, RH set point, and airflow velocity in the duct. Table 2 provides absorption distance for typical conditions. The higher the RH setting, the longer the absorption distance. Warmer air shortens the absorption distance. If absorption distance is a concern, install dispersion tube in supply duct and configure humidifier and control to operate only during HVAC system heat call. Call Aprilaire Tech Support at 1-800-334-6011 for additional information on absorption.

The dispersion tube must be mounted on a vertical surface with the tube angled up. If the dispersion tube is mounted on insulated ductwork, make sure insulation is not more than 2” thick at tube location to prevent insulation

from blocking first steam outlet.

TABLE 2 – Absorption Distance (Minimum distance from dispersion tube downstream to any obstruction or bend in duct)

Input

Power

120 V 11.5 gal/day

208 V 20.5 gal/day

240 V 23.3 gal/day

Humidifier

Output

Airflow Velocity

300 fpm 7" 11" 13"

600 fpm 3" 6" 7"

1200 fpm 2" 3" 3"

1800 fpm < 2" 2" 2"

300 fpm 13" 19" 23"

600 fpm 6" 10" 12"

1200 fpm 3" 5" 6"

1800 fpm 2" 3" 4"

300 fpm 15" 23" 28"

600 fpm 6" 12" 13"

1200 fpm 5" 6" 7"

1800 fpm 3" 4" 5"

70°F & 30% RH

Setpoint

70°F & 45% RH

Setpoint

65°F & 45% RH

Setpoint

Pitch

Obstruction

90° long sweep

or two 45° elbows

6" min

8" min

Insulate hard pipe to

reduce steam loss

Dispersion

Tube

1" air gap

Open drain

required,

see note 1.

Drip tee installation for piping over obstruction,

or if dispersion tube is lower than humidifier.

NOTES:

1. Refer to governing codes for drain pipe size and materials.

2. Support steam hose so there are no sags or low spots.

Drip tee

Drain trap

90° long sweep

or two 45° elbows

Steam hose or pipe.

Insulate pipe with

1” fiberglass to

reduce steam loss.

Pitch*

Duct

Dispersion tube

*Pitch steam hose down from dispersion tube to humidifier:

2"/ft (15%) minimum when using steam hose. 1/4"/ft when using hard pipe.

INSTALLATION INSTRUCTIONS (CONTINUED)

Elevation

The preferred location for the dispersion tube is higher than the humidifier so that the steam hose has a constant downward slope of at least 2” per foot from the dispersion tube to the humidifier. If hard pipe is used, the slope can be 1/4” per foot. With the constant downward slope, any condensation that forms in the steam hose will drain back into the steam canister. See Figure 3. If the dispersion tube must be mounted below the humidifier or if the steam hose needs to run up and over an obstruction, a drip tee with drain trap must be installed as shown in Figure 4.

FIGURE 3 – Dispersion Tube Mounted Above Humidifier

Distance from Humidifier to Dispersion Tube

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FIGURE 4 – Dispersion Tube Mounted Below Humidifier

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The capacity of the humidifier is reduced by the length of the steam hose or pipe due to condensation. The maximum recommended length of steam hose is 6 feet. Use hard pipe insulated with 1” fiberglass for lengths greater than 6 feet. Table 3 provides humidifier capacity with various lengths of steam hose and pipe. If 6-foot steam hose does not reach from humidifier to dispersion tube, splice in 1” copper pipe using ¾” x 1” reducing couplings as shown in Figure 5.

TABLE 3 – Steam Humidifier Capacity in Gallons/Day

Steam Hose

120 Volts 208 Volts 240 Volts

or Insulated Pipe Length

< 2 ft. 11.5 11.5 20.5 20.5 23.3 23.3

2 ft. 11 11 20 20 23 23 4 ft. 10 11 19 20 22 23

Steam Hose Insulated Pipe Steam Hose Insulated Pipe Steam Hose Insulated Pipe

6 ft. 9 11 18 20 21 22

8 ft. 10 19 22 10 ft. 10 19 22 12 ft. 10 19 22 14 ft. 9 18 21 16 ft. 9 18 21 18 ft. 9 18 21 20 ft. 9 18 20

16" for Steam

Hose

30" for Service Access

16" for Electrical Access

16"

for Drain

FRONT VIEW

SIDE VIEW

INSTALLATION INSTRUCTIONS (CONTINUED)

Steam Hose

Dispersion Tube

Steam Hose

1-1/2" Hose Clamp

1" Copper Pipe

3/4" x 1" Reducing Coupling

Humidifier

FIGURE 5

90-1527

HUMIDIFIER

Do not mount humidifier in a location where ambient temperature exceeds 120ºF or where freezing temperatures may occur.

Mount humidifier in a location that allows access for servicing, and clearance to remove front panel for replacing the canister and side panel for access to the electrical components during installation. See Figure 6 for minimum clearances around humidifier.

The humidifier should be mounted as close to the dispersion tube as possible. Table 3 shows how capacity is reduced as the distance between the humidifier and dispersion tube increases. If the humidifier is mounted on the duct directly below the dispersion tube, allow space for a bend in the steam hose.

The humidifier can be mounted to a wood surface, or to sheet metal ductwork if it is structurally stable. Do not mount humidifier to fiber duct board.

The humidifier must be mounted to a vertical surface and must be mounted level in the upright position.

Do not mount humidifier near sources of electromagnetic emissions such as power distribution transformers.

ADHC (AUTOMATIC DIGITAL HUMIDIFIER CONTROL) MODEL 62

The ADHC must be mounted in the return air duct at least 6” upstream of any fresh air intake ducts or sources of moisture (steam dispersion tube if it is in the return.) Follow instructions provided with the control.

If the application requires a wall-mounted control in the conditioned space, use Aprilaire Part #4993, which includes a wall-mountable manual humidistat, a relay to activate the HVAC blower, and wiring instructions.

FIGURE 6 – Clearances

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INSTALLATION INSTRUCTIONS (CONTINUED)

PREPARE HUMIDIFIER FOR MOUNTING

Unpack carton. Open front panel by removing screw and lifting panel up and away from humidifier. Disconnect three wires from top of canister by pulling straight up. The two large wires are the electrode conductors. The smaller wire is connected to the high water level sensor. Remove canister by twisting and pulling it up and out of drain assembly. Remove two screws on right side of humidifier and lift side panel off housing to expose electrical compartment.

INSTALL STEAM DISPERSION TUBE

Note: If humidifier will deliver steam via the Model 850 Fan Pack instead of the dispersion tube, follow instructions included with Fan Pack.

Make sure steam dispersion tube is mounted higher than the humidifier so that condensate that forms in the tube runs back into the canister. If the dispersion tube cannot be mounted higher than the humidifier or if the steam hose must extend up from the humidifier then down to the dispersion tube due to an obstruction, a drip tee and drain trap system must be installed as shown in Figure 4.

Drill a 1-1/4” diameter hole in a vertical surface of the duct at the location chosen for the dispersion tube. Position the tube so it is angled up. Secure with four sheet metal screws provided.

MOUNT HUMIDIFIER

Secure humidifier to wood surface using screws provided, or to sheet metal duct. If mounting to stud frame wall, install two spanner boards to studs and fasten humidifier to spanner boards. Make sure humidifier is mounted plumb.

Verify that the o-ring is in place in the slot in the drain assembly. Dampen the o-ring with water, then reinsert canister. (Do not use oil, grease or any lubricant besides water.) Rotate the canister so the caution label is visible. Reattach the electrode conductors (interchangeable) and the high water level sensor wire.

INSTALL STEAM HOSE

Six feet of steam hose is provided with the humidifier. If the steam hose must be cut, use a hacksaw. If additional length is required, use 1” O.D. metal or copper pipe. Do not use PVC pipe for steam line. Insulate pipe with 1” thick fiberglass to reduce steam loss. See Table 3 for humidifier capacity at various lengths of steam hose and pipe.

Use the steam hose provided. Other hoses may have impurities which can cause foaming in the canister. Foaming can cause water level inaccuracies and reduced steam production. When using pipe, remove all traces of residual materials used to connect the pipe to prevent foaming.

Attach steam hose to dispersion tube and then to top of canister using hose clamps provided. Make sure steam hose has a constant slope of at least 2” per foot between the dispersion tube and the humidifier. Any and every low spot in the steam hose or pipe must have a drip tee and drain trap. Fill drain trap with water before making final connections.

SUPPLY WATER

Plumb the humidifier to cold tap water. Do not use hot water because unheated supply water is used to cool water drained from the humidifier. To operate properly, water conductivity must be within the range of 125 to 1,250 uS/cm (micro Siemens per centimeter), which is

roughly equivalent in hardness to 3 to 36 grains per gallon. Do not use demineralized water. The humidifier will produce steam immediately as long as the mineral content of the water is within the specified range. For proper operation, supply water pressure must be between 25 psi and 120 psi.

Supply water piping must be free of oils, lubricants, solder flux and other contaminants, which can cause foaming in the canister that can lead to water sputtering from the dispersion tube into the duct.

Install the saddle valve according to the instructions printed on the bag. Run ¼” copper tubing from the saddle valve to the humidifier. Extend the tubing up through the port in the bottom of the humidifier and connect it to the fill valve. Double wrench to prevent leaking and damage to valve.

INSTALLATION INSTRUCTIONS (CONTINUED)

DRAIN LINE

Attach the 7/8” I.D. drain tubing provided to the drain assembly at the bottom of the humidifier. Secure with the hose clamp provided. Do not over tighten.

Make sure the drain line has a constant downward slope from the humidifier to the drain and is not kinked or blocked.

AUTOMATIC DIGITAL CONTROL AND CONTROL WIRING

The control circuit operates on 24VAC. The ADHC (Automatic Digital Humidifier Control) Model 62 must be mounted in the return air duct at least 6” upstream of any fresh air intake

ducts or sources of moisture (steam dispersion tube if it is in the return.) Follow instructions provided with the control. Connect “H” terminals on ADHC to “HUMIDISTAT” terminals on humidifier circuit board.

If protection from over-humidification is desired, install optional high humidity limit switch #4594 at least 4 feet downstream of the dispersion tube. If airflow verification is desired, install optional airflow proving switch #4592 in duct. The high humidity limit switch and the airflow proving switch are wired in series with the ADHC (humidistat) circuit.

ELECTRICAL POWER WIRING & SHUT-OFF SWITCH

CAUTION

Only qualiﬁed electrical personnel should perform ﬁeld wiring procedures. Improper wiring or contact with energized circuits can cause property damage or severe personal injury.

All wiring must be installed in accordance with all governing electrical codes and with the wiring diagram provided inside the front panel. Power wiring must be rated for 105°C (220°F). Do not loop power wiring. Do not use aluminum wire. A safety grounding system that meets all governing electrical codes is required. The ground connection must be made with solid metal to metal

connections. Ground wire must be the same size as the power wiring. Humidifier draws 11.5 amps ±10%. Use12.7 amps when sizing circuit. The Model 800 Steam Humidifier can operate with 120, 208 or 240 VAC. If using 208V or 240V, remove jumper between N and L2

terminals on power terminal block.

When wiring to 208 or 240 V, run two conductors plus neutral plus ground.

WIRING INSTRUCTIONS

Install disconnect switch (not provided) between line power source and humidifier. Knock-outs for power wiring and low voltage control circuit wiring are located on the top of the humidifier. Connect power and ground wiring as shown in wiring diagram, Figure 7. Do not run high voltage power lines over internal circuit boards.

(PROVIDED)

(NOT PROVIDED)

MAIN POWER SWITCH

J10-1

AUTOMATIC DIGITAL

J1-1

J1-2

ELECTRODE

WATER LEVEL

ELECTRODE

24V AC

COM

ORG

YEL/WHT

RED

BLK

YEL

BRN

BLU

WHT

COM

24V AC

COM

24V AC

COM

24V AC

DRAIN VALV E

FILL VA LVE

POWER RELAY COIL

J6-2

J6-1

120V AC

SAFETY SWITCH

BLU

+24V DC

J13-2

J13-1

J11-2

J11-1

J12-2

J12-1

STEAM CYLINDER

J3-2

J3-1

J1-2

TERMINAL BLOCK

BLK

WHT

24V AC

YELLYEL/WHT

CONTROL PCB CURRENT SENSING PCB

J1-1

TRANSFORMER 75VA

HUMIDITY CONTROL

HIGH LEVEL PROBE

STATIC

CONTROL CIRCUIT WIRING

HIGH VOLTAGE WIRING

FIELD WIRING

(OPTIONAL)

FAN PA CK

+24V AC

COM

HUMIDISTATFAN

BLK

YEL

FOR 120V INSTALLATION, CONNECT POWER TO L1 AND N WITH N-L2 JUMPER IN PLACE (PROVIDED).

FOR 208 OR 240 VOLT INSTALLATIONS, REMOVE N-L2 JUMPER

AND CONNECT POWER TO L1, N, AND L2

YEL

POWER RELAY CONTACTS

PROBE

DISCHARGE

GROUND

JUMPER

J10-2

DISPLAY PA NEL

RIBBON CABLE

GROUND

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 7 – Wiring Diagram

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Aprilaire 800 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual