Aprilaire 800, 800LC Installation Manual

Series 800 Steam Humidifier

Installation & Maintenance Instructions

TABLE OF CONTENTS

Safety Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 2	Supply Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 12
Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.3. . . .	. . Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 13
Principles & Sequence of Operation . . . . . . . . . . . . . . . . . . . . . .	. 4	Electrical Power Wiring & Shut-off Switch . . . . .	. . . . . . . . . . . . 13.
Specifications & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .	.5.	Automatic Digital Control & Accessory Wiring . .	. . . . . . . . . . . . .18
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8	Thermostat in a Zoned HVAC System . . . . . .	. . . . . . . . . .19. . . . . .
Choosing a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 8. . . . .	. Manual. . Digital Humidistat & Fan Pack Wiring . .	. . . . . . . . . . 20. . .
- Dispersion Tube Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.8	Automatic Digital Modulating Control Wiring . . .	. . . . . . . . . . . . . 21
- Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.9. . .	Start-up Procedure . . . . . . . . . . . . . . . . . .	. . . . . . . . . .23. . . . . . .
- Distance from Humidifier to Dispersion Tube/Fan Pack . . . . .	10	Operating Modes .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..	.. .. .. .. .. .. .. .. .. .. .. .. 24
- Humidifier Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	11	Shut Down Procedure . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 25
Prepare Humidifier for Mounting . . . . . . . . . . . . . . . . . . . . . . .	12. . .	Display Panel . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . 25. . . . . .
Install Steam Dispersion Tube/Fan Pack . . . . . . . . . . . . . . . . . . . .	12	Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 26
Mount Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12. . . . .	Troubleshooting. . . . Guide . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . 27. . .
Install Steam Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	12. . . . .	Replacement. . . Parts. . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . 29

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AprilairePartners.com

P.O. Box 1467

Madison, WI 53701-1467 800.334.6011 F: 608.257.4357 Printed in USA

©2018 Aprilaire – Division of Research Products Corporation

10010605 B2206277J 2.18

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 unless 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 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 to structure and furnishings.

2

MATERIALS LIST

MODEL 800 / 800LC

MATERIALS FURNISHED

Humidifier

Model 62 Automatic Digital Humidifier Control Dispersion tube

Steam hose (6 feet)

7/8” I..D.. drain tubing (10 feet) Hose clamps

Saddle valve Mounting screws

NOT FURNISHED

Main power disconnect switch Wiring

1/4” O..D.. supply water tubing Boards for mounting (if required)

MODEL 801

MATERIALS FURNISHED

Humidifier Dispersion tube Steam hose (6 feet)

7/8” I..D.. drain tubing (10 feet) Hose clamps

Saddle Valve Mounting Screws

NOT FURNISHED

Model 63 Automatic Digital Modulating Control Main power disconnect switch

Wiring

1/4” O..D.. supply water tubing Boards for mounting (if required)

3

PRINCIPLES & SEQUENCE OF OPERATION
The Aprilaire® Steam Humidifier delivers humidity in the
form of steam to the conditioned space via the HVAC	FIGURE 1 – Fill and Drain System and Canister
system duct or the Fan Pack.. The humidifier generates
steam by energizing two electrodes that extend into a			Tubelets
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			Dispersion Tube
cup located in the top of the cabinet.. The fill cup serves		Steam Hose	in Duct
as an overflow reservoir and provides an air gap between	Overflow	Steam
the humidifier and water source.. The steam canister is		Outlet
filled from the bottom.. The canister is seated in a drain		High Water Level Sensor
cup assembly which includes a drain valve.. The drain and		Electrodes
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		Canister
system and canister..

To control the Steam Humidifier as part of the HVAC	Inlet		Fill	Drain Valve
	Fill Valve
system, the Model 62 Automatic Digital Humidifier Control
(ADHC) is installed to detect the RH level in the duct..				Drain Cup
When the ADHC detects RH below the set point, and the		Supply
humidifier and HVAC system blower are operating, the
		Water		Drain
humidifier energizes the electrodes to provide steam..
Steam is delivered into the duct work via the steam hose				90-1522
and through the dispersion tube.. The dispersion tube is

fitted with “Tubelets™..” 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.. The blower activation function on the ADHC allows the control to turn on the HVAC system blower to maintain the proper RH level even when the furnace or air handler is in stand-by mode.. See ADHC installation manual..

Humidity can be distributed directly into the living space via the Fan Pack.. When the Model 65 Manual Digital Humidistat detects RH below the set point, the humidifier energizes the electrodes to provide steam via the steam manifold at the bottom of the Fan Pack.. Steam is dispersed by the fan located behind the grille above the steam manifold.. The fan will operate for two minutes after the call for humidity ends, to disperse any residual steam..

To provide precise control to the Modulating Steam Humidifier, the Automatic Digital Modulating Control (ADMC) should be installed in the living space.. The ADMC will vary the Modulating Steam Humidifier output based on the difference between set point and actual RH.. The ADMC sends a proportional signal to the Modulating Steam Humidifier providing precise control of living space humidity.. See Figure 2 for Steam Humidifier output vs RH demand.. The ADMC can be used in place of the ADHC and Manual Digital Humidistat to provide On/Off control to the Steam Humidifier not equipped with the modulating feature.. See the ADMC installation and operating manual for details..

FIGURE 2 – Humidifier Output for ADMC Signal
									PROPORTIONAL BAND
	100%				SETTING				T)
(%)								(DEF	AUL
OUTPUT				BAND			SETTING
			PROPORTIONAL			BAND
HUMIDIFIER									SETTING
								BAND
		2%		PROPORTIONALPROPORTIONAL
			5%
	20%				10%
									HUMIDIFIER OFF
					-2%				-5%	-10%
							RH DIFFERENCE FROM SETPOINT (%)
										90-2008

4

SPECIFICATIONS & DIMENSIONS

This humidifier is able to produce steam at various capacities depending on the voltage and current applied.. The unit can be wired to use an input voltage of 120, 208 or 240 Volts and input amperage can be set to 11..5 or 16..0 amps by changing a dip switch on the control circuit board (see the Electrical Power Wiring & Shut Off Switch section on page 13).. Configure the unit appropriately for the application (see Table 1 for capacity specifications)..

TABLE 1 – Humidifier Capacities and Recommended Home Sizes

		Maximum steam	Maximum recommended home size in ft2*
Amperage	Voltage	capacity (gal/day)	Tight	Average	Loose
	120V	11..5	2,500 sq ft	1,500 sq ft	1,000 sq ft
11..5	208V	20..5	4,500 sq ft	2,500 sq ft	1,500 sq ft
	240V	23..3
	120V	16..0	3,500 sq ft	2,000 sq ft	1,500 sq ft
16..0	208V	30..0	6,000 sq ft	4,000 sq ft	2,500 sq ft
	240V	34..6

*Assumes 8 ft ceiling height, adjust as necessary for higher ceilings.. For homes with multiple furnaces/air handlers a humidifier should be installed on each..

Model 800 Series Shipping Weight: 28 lbs Model 865 Shipping Weight: 39 lbs Humidifier Operating Weight: 23 lbs**

**As minerals precipitate, unit weight can increase to approximately 30 lbs..

5

SPECIFICATIONS & DIMENSIONS (CONTINUED)

FIGURE 3 – Humidifier Dimensions (inches)				Steam Dispersion Tube
8-7/8	Fill Cup				1-3/4
7-7/8					1-3/4
				3 sq
3-3/8				3 sq
3-3/8	1-5/8				1 dia
		4-1/4			1 dia
			5-3/4		8-1/4
					8-1/4
				2 sq
				2 sq
	Electrical Knockouts			90-1518
TOP VIEW	Dispersion Outlet
10-1/8				7-1/8	4
					1
				Mounting	12
				Holes
	20-7/8
					4
FRONT VIEW				SIDE VIEW	BACK VIEW
Drain
	Water
	Fill Line
	Connection
3-3/8	1-7/8	2
3-3/8
6-5/8	Electrical
7-7/8	Knockouts
9-1/8
BOTTOM VIEW
90-1518
6

SPECIFICATIONS & DIMENSIONS (CONTINUED)

WATER QUALITY

Minerals that are naturally found in water contribute to water’s electrical conductivity; water conductivity is measured in microsiemens per centimeter (uS/cm).. Mineral content, also described as “water hardness” is usually measured in grains per gallon.. Variation is found among water samples but generally the higher the mineral content, the higher the conductivity..

The Steam Humidifier is designed to operate on water with conductivity between 100 and 1,250 uS/cm.. This correlates loosely with water hardness between 3 and 36 grains/gallon.. Water that is considered “hard” and softened water work well in the Steam Humidifier.. The humidifier makes steam when plumbed to low-conductivity water but it takes longer to reach nominal current..

Two canisters are available for use with the Steam Humidifier.. The Model 80 canister is used in most installations and is optimized for “hard” and softened water.. The Model 80 typically works best when the Steam Humidifier is installed at 208 or 240 VAC.. If the Steam Humidifier has a yellow Steam light in the first two weeks of running with a new canister, the Steam Humidifier is taking a long time to reach its nominal current; changing to the Model 80LC canister will prevent this from happening in the future..

The Model 80LC canister is optimized for use in areas where the water conductivity is less than 300 uS/cm or when the Steam Humidifier is installed at 120VAC.. The Model 80LC should not be used with softened water.. If the Steam Humidifier is draining too frequently, the water conductivity is too high; changing to the Model 80 canister will reduce the drain frequency..

As water in the canister boils and turns into steam, minerals are left behind.. Minerals remaining in solution increase the conductivity of the water.. Minerals also deposit onto the submerged portions of the electrodes rendering those areas ineffective.. As this occurs, the level of water in the canister rises to expose uncoated electrode surface..

There are benefits and trade-offs to consider when the application allows a choice between hard and softened water:

Hard water: The benefit of hard water is less frequent draining and filling than with soft water, which results in better energy and water efficiency and more consistent steam output.. However, canister replacement could be more frequent with hard water, because mineral deposits coat the electrodes.. The harder the water, the more frequent the need for a new canister..

Softened water: The benefit of softened water is longer canister life (depending on water chemistry) than with hard water, because softened water does not coat the electrodes nearly as much as hard water.. However, softened water ions stay in solution to much higher concentrations than hard water ions.. This requires more frequent draining and filling, which results in lower energy efficiency, higher water consumption and less consistent steam output..

TABLE 2 – Water Quality Guidelines

Conductivity	Grains/Gal	Hardness	Recommended Canister by Voltage
(uS/cm)			120VAC		208VAC		240VAC
75-100	0-3	Naturally Soft	Installation Not		80LC		80LC
			Recommended
100-300	3-9	Naturally Soft	80LC		80LC		80LC
300-500	9-15	Slightly Hard	80LC		80		80
500-650	15-20	Moderately Hard	80LC		80		80
650-850	20-25	Hard	80LC		80		80
850-1250	25-36	Very Hard	80LC		80		80
above 1250	above 36	Extremely Hard		Installation Not Recommended
		Softened	80		80		80

7

INSTALLATION INSTRUCTIONS

CAUTION

Each humidifier requires its own steam hose and dispersion tube. Do not connect steam hoses from more than one humidifier together. Back-pressure from one humidifier can lower the water level in the canister in the other humidifier and cause operational problems.

Do not install the dispersion tube in a duct with greater than 2 in. wg static pressure. High duct pressure can cause backpressure in the canister which can result in unstable unit operation.

Do not mount humidifier in a location where operating ambient temperatures exceed 140°F or where freezing temperatures may occur.

CHOOSING A LOCATION

DISPERSION TUBE LOCATION

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 and Absorption Distance

Absorption distance, the unobstructed straight line distance needed for steam to be fully absorbed, is dependent on air velocity, air temperature and relative humidity in the duct.. Determine absorption distance based on the lowest duct temperature, lowest air velocity and highest humidity that the system will see. The dispersion tube must be located in a straight section of duct far enough upstream of any obstructions or bends in the duct.. Use Table 3 to determine the appropriate absorption distance..

Operation during AC calls is not recommended because of the potential for condensation in the ductwork.. Configure controls to lock out the humidifier during AC calls and use the blower activation feature on the ADHC to allow the humidifier to run with the blower only.. Call Aprilaire Tech Support at 1-800-334-6011 for additional information on steam absorption..

The dispersion tube must be mounted with the plate on a vertical surface with the tube angled up as shown in Figure 4.. The steam tubelets must face up regardless of the airflow direction in the duct.. The plate is labeled “UP”to indicate proper orientation.. On horizontal duct runs install the dispersion tube low in the duct, on vertical runs center the tube on the duct..

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..

Note: If dispersion tubes for two humidifiers are installed in one duct, double the dispersion distances.. If three dispersion tubes are installed, triple the dispersion distance.. Position dispersion tubes so one does not discharge directly onto another..

8

INSTALLATION INSTRUCTIONS (CONTINUED)

TABLE 3 – Absorption Distance (Minimum distance from dispersion tube downstream to any obstruction or bend in duct)

	Humidifier	Airflow Velocity*	70°F & 30% RH	70°F & 45% RH	65°F & 45% RH	45°F & 45% RH
	Output (gal/day)		Setpoint	Setpoint	Setpoint	Setpoint
		300 fpm	13”	19”	23”	30”
	Up to 16..0	600 fpm	6”	10”	12”	18”
		1200 fpm	3”	5”	6”	13”
		1800 fpm	2”	3”	4”	10”
		300 fpm	15”	23”	28”	45”
	20..5 – 25..0	600 fpm	6”	12”	13”	26”
		1200 fpm	5”	6”	7”	19”
		1800 fpm	3”	4”	5”	16”
		300 fpm	24”	31”	36”	60”
	25..0 – 35..0	600 fpm	17”	22”	26”	48”
		1200 fpm	12”	15”	18”	25”
		1800 fpm	10”	13”	15”	20”

*Velocity in feet per minute = Duct airflow volume in cubic feet per minute / duct area in square feet.. Example: 1,200 cfm through 16” x 12” duct = 1,200/(12 x 16/144 sq.. in../sq ft..) = 1,200/1..333 = 900 fpm

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 4..

FIGURE 4 – Dispersion Tube Mounted Above Humidifier

	Steam hose or pipe.	5”minimum	Duct
	Insulate pipe with 1” fiberglass
	to reduce steam loss.	Pitch*
	90° long sweep
	or two 45° elbows		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.

90-1521

9

INSTALLATION INSTRUCTIONS (CONTINUED)

NOTICE

CONTROL CONDENSATE FLOW AND COLLECTION.

Failure to follow steam hose recommendations in this manual can result in reduced or erratic performance, increased noise and condensate in the duct.

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, Part #4028, must be installed as shown in Figure 5.. When using the Fan Pack, install Part #4028 close to the humidifier outlet to help prevent noise from gurgling as shown in Figure 6..

DISTANCE FROM HUMIDIFIER TO

DISPERSION TUBE/FAN PACK

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” thick insulation rated for 212°F or higher for lengths greater than 6 feet.. Table 4 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 3/4” x 1” reducing couplings as shown in Figure 7..

FIGURE 7	To Steam
	Dispersion
	Tube or
3/4" x 1"	Fan Pack
Reducing Coupling	Steam Hose
	1-1/2" Hose Clamp
	1" Copper Pipe
	1-1/2" Hose Clamp
	Steam Hose

Humidifier

90-1527

FIGURE 5 – Dispersion Tube Mounted Below Humidifier

Drip tee installation for	90° long
piping over obstruction,		Pitch
or if dispersion tube is	sweep or two
	45° elbows
lower than humidifier.

Insulate hard pipe to reduce steam loss

To Dispersion

Tube/Fan Pack

6" min

8" min

1" air gap

Open drain required,

see note 1.

90-1520

Obstruction

Drip tee

Part #4028

Drain trap

NOTES:

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

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

FIGURE 6

Hose Clamp

To Steam

Hose Clamp Dispersion Tube

or Fan Pack

Steam Hose
1" I.D.	Steam Hose, 1" I.D.
(Downward
Slope from	(Downward Slope to Tee)
Humidifier
to Tee)	Tee
	Assembly
	Steam	#4028 KIT
	Humidifier	CONTENTS:
	Steam	Hose Clamps (5)
	Hose	Trap (1)
	1" I.D.	Tee Assembly (1)

Hose

Clamp

Flared

End

Trap

Note: Prime with water before using humidifier

Hose Clamp

Drain Hose

7/8" I.D.

90-1844

10

INSTALLATION INSTRUCTIONS (CONTINUED)

TABLE 4 – Steam Humidifier Capacity in Gallons/Day

	Steam		120 Volts				208 Volts				240 Volts
	Hose or
		11.5 Amps		16.0 Amps		11.5 Amps		16.0 Amps		11.5 Amps		16.0 Amps
	Insulated
	Pipe	Steam	Insulated	Steam	Insulated	Steam	Insulated	Steam	Insulated	Steam	Insulated	Steam	Insulated
	Length	Hose	Pipe	Hose	Pipe	Hose	Pipe	Hose	Pipe	Hose	Pipe	Hose	Pipe
	< 2 ft..	11..5	11..5	16..0	16..0	20..5	20..5	30..0	30..0	23..3	23..3	34..6	34..6
	2 ft..	11	11	15..5	15..5	20	20	29	29..5	23	23	34	34
	4 ft..	10	11	14..5	15..5	19	20	28	29..5	22	23	33	34
	6 ft..	9	11	13..5	15	18	20	27	29	21	22	32	33
	8 ft..		10		14		19		28		22		33
	10 ft..		10		14		19		28		22		33
	12 ft..		10		14		19		28		22		33
	14 ft..		9		13		18		27		21		32
	16 ft..		9		13		18		27		21		32
	18 ft..		9		13		18		27		21		32
	20 ft..		9		13		18		27		20		31

HUMIDIFIER LOCATION

Do not mount humidifier in a location where operating ambient temperature exceeds 140°F or where freezing temperatures may occur. Extreme temperatures may cause the humidifier to leak which can damage furnishings or structure..

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 8 for minimum clearances around humidifier..

The humidifier should be mounted as close to the dispersion tube as possible.. Table 4 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.. Allow a minimum of 2” of steam hose to extend straight out of the humidifier before beginning any bends; this will help ensure a tight connection with the top of the canister..

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.. Sound isolation may be desired when mounting to sheet metal ductwork..

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

FIGURE 8 – Clearances
		16" for
		Steam
		Hose
	FRONT VIEW
	16" for	30" for
4"	Electrical	Service
	Access	Access
	16"	SIDE VIEW
	for Drain
90-1519

11

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 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

Make sure steam dispersion tube is mounted higher than the humidifier so that condensation that forms in the steam hose 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 (Part #4028) must be installed as shown in Figure 5..

Drill a 1-1/4” diameter hole in a vertical surface of the duct at the location chosen for the dispersion tube.. Position the dispersion tube so it is angled up, regardless of airflow direction.. UP is stamped on the mounting bracket to aid in proper installation.. Secure with four sheet metal screws provided..

MOUNT HUMIDIFIER

Secure humidifier to a sturdy wall using screws provided, or to sheet metal duct.. Humidifier initially weighs 23 lbs with a full canister, but will increase in weight over time due to the precipitation of minerals inside the canister.. Make sure mounting system will support weight.. If mounting to stud frame wall, install two spanner boards to studs and fasten humidifier to spanner boards.. Make sure humidifier is mounted plumb..

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 insulation rated for 212°F or higher to reduce steam loss.. See Table 4 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, reduced steam production and water sputtering into the duct.. When using pipe, remove all traces of residual materials used to connect the pipe to prevent foaming..

Verify that the O-ring is in place in the groove in the drain assembly.. Dampen the O-ring with water (DO NOT use oil, grease,or any lubricant besides water), then reinsert the canister with the caution label positioned toward the front of the unit..

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.. Support the steam hose in multiple locations over its span to prevent sagging..

Attach and fully seat the electrode conductors (interchangeable) and the high water level sensor wire to the top of the canister..

SUPPLY WATER

Plumb the humidifier to cold, hard or softened water.. Do not use hot water because unheated supply water is used to cool water draining from the humidifier. Do not use demineralized or reverse osmosis water.. For proper operation, supply water pressure must be between 25 psi and 120 psi.. Hard or softened water may be used provided it has conductivity between 125 microS/cm and 1250 microS/cm.. See Table 2..

Supply water piping must be free of oils, lubricants, solder flux and other contaminants, which can cause foaming.. Follow local plumbing codes. An external backflow preventer may be needed..

Install the saddle valve according to the instructions printed on the bag.. Run 1/4” copper tubing from the saddle valve to the humidifier.. Connect it to the fill valve.. Double wrench to prevent leaking and damage to valve.. Addition of a stainless steel braided water line can help reduce valve noise..

Note: Adding an inline particulate filter can increase canister life in areas with high levels of suspended solids.. DO NOT use filters that release scale inhibitors, filters of this type can significantly decrease canister life..

12

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..

If floor drain is not available, use condensate pump (Part #4856) to route water to a suitable drain.. Provide at least 16 inches for of drain line between the Steam Humidifier and the condensate pump..

Note: The humidifier uses cold water to temper drain water to less than 140°F..

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.. 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..

With factory settings, the Steam Humidifier draws 11..5 amps +/- 10%.. Use a minimum 20 amp dedicated circuit when installing to operate at 11..5 amps.. The Steam Humidifier can be set to draw 16..0 amps +/- 10% by repositioning dip switch #1 on the control circuit board (see Figure 9).. When set to 16 amps, use a minimum 25 amp dedicated circuit.. For both applications, size wire according to local codes..

The Steam Humidifier is shipped from the factory wired for 240 VAC operation, but it can operate on 120, 208 or 240 VAC.. If using 120V or 208V, move the black/white jumper wire to the proper tab on the control circuit board. See Figures 10, 11, 12..

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 provided..

Connect power and ground wiring as shown in appropriate wiring diagram..

•240 VAC – Figure 10

•208 VAC – Figure 11

•120 VAC – Figure 12

Do not run high voltage power lines over internal circuit boards..

13

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 9 – Control Circuit Board with Dip Switches

Factory setting for 11.5 AMP nominal operation.

LED D8

Slide Dip Switch #1 to “ON” position for 16.0 AMP nominal operation.

90-1959

14

INSTALLATION INSTRUCTIONS (CONTINUED)
FIGURE 10 – 240 VAC Wiring Diagram
		BLK
			BLK
				YEL
	POWER
MAIN POWER BREAKER	TERMINAL			J16
(NOT PROVIDED)	BLOCK	J8	J10
GND						WATER LEVEL
						PROBE
L2 / N						ELECTRODE	ELECTRODE
L1
	TRANSFORMER POWER
	JUMPER WIRE
		BLK/WHT				STEAM CANISTER
	P7
DOOR SWITCH
						STEAM HUMIDIFIER IS SHIPPED FROM
ORANGE						THE FACTORY WIRED FOR 240 VOLTS.
HUMIDITY CONTROL
(PROVIDED)	HUMIDISTAT
DRY	1		J11		J13	J14
CONTACT	2
			120		208	240
FAN PACK			VAC		VAC	VAC
(OPTIONAL)
						P3
	FAN PACK					ORG
						RED
						BLK
						WHT
DISPLAY PANEL	J2
	10
RIBBON CABLE						TRANSFORMER
	1					P4
						BLUE
						YEL
		SLOW BLOW FUSE
		(5X20mm 5A)
						HIGH VOLTAGE WIRING
	J5	J6	CON1			CONTROL CIRCUIT WIRING
						HIGH VOLTAGE FIELD WIRING
						LOW VOLTAGE FIELD WIRING
		BLK	YEL
	DRAIN		FILL
	VALVE		VALVE
90-1903

15

INSTALLATION INSTRUCTIONS (CONTINUED)
FIGURE 11 – 208 VAC Wiring Diagram
		BLK
			BLK
				YEL
	POWER
MAIN POWER BREAKER	TERMINAL			J16
(NOT PROVIDED)	BLOCK	J8	J10
GND						WATER LEVEL
						PROBE
L2 / N						ELECTRODE	ELECTRODE
L1
	TRANSFORMER POWER
		JUMPER WIRE				STEAM CANISTER
		BLK/WHT
	P7
DOOR SWITCH						STEAM HUMIDIFIER IS SHIPPED FROM
						THE FACTORY WIRED FOR 240 VOLTS.
ORANGE						MOVE THE JUMPER WIRE TO TERMINAL
						J13 TO OPERATE AT 208VAC.
HUMIDITY CONTROL
(PROVIDED)	HUMIDISTAT
DRY	1		J11		J13	J14
CONTACT	2
			120		208	240
FAN PACK			VAC		VAC	VAC
(OPTIONAL)
						P3
	FAN PACK					ORG
						RED
						BLK
						WHT
DISPLAY PANEL	J2
	10
RIBBON CABLE						TRANSFORMER
	1					P4
						BLUE
						YEL
		SLOW BLOW FUSE
		(5X20mm 5A)
						HIGH VOLTAGE WIRING
	J5	J6	CON1			CONTROL CIRCUIT WIRING
						HIGH VOLTAGE FIELD WIRING
						LOW VOLTAGE FIELD WIRING
		BLK	YEL
	DRAIN		FILL
	VALVE		VALVE
90-1904

16

INSTALLATION INSTRUCTIONS (CONTINUED)
FIGURE 12 – 120 VAC Wiring Diagram
		BLK
			BLK
				YEL
	POWER
MAIN POWER BREAKER	TERMINAL			J16
(NOT PROVIDED)	BLOCK	J8	J10
GND						WATER LEVEL
						PROBE
L2 / N						ELECTRODE	ELECTRODE
L1
	TRANSFORMER POWER
	JUMPER WIRE
		BLK/WHT				STEAM CANISTER
	P7
DOOR SWITCH
						STEAM HUMIDIFIER IS SHIPPED FROM
ORANGE						THE FACTORY WIRED FOR 240 VOLTS.
						MOVE THE JUMPER WIRE TO TERMINAL
						J11 TO OPERATE AT 120VAC.
HUMIDITY CONTROL
(PROVIDED)	HUMIDISTAT
DRY	1		J11		J13	J14
CONTACT	2
			120		208	240
FAN PACK			VAC		VAC	VAC
(OPTIONAL)
						P3
	FAN PACK					ORG
						RED
						BLK
						WHT
DISPLAY PANEL	J2
	10
RIBBON CABLE						TRANSFORMER
	1					P4
						BLUE
						YEL
		SLOW BLOW FUSE
		(5X20mm 5A)
						HIGH VOLTAGE WIRING
	J5	J6	CON1			CONTROL CIRCUIT WIRING
						HIGH VOLTAGE FIELD WIRING
						LOW VOLTAGE FIELD WIRING
		BLK	YEL
	DRAIN		FILL
	VALVE		VALVE
90-1905

17

INSTALLATION INSTRUCTIONS (CONTINUED)

AUTOMATIC DIGITAL CONTROL & ACCESSORY WIRING (MODEL 800)

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 and at least 12” upstream of the steam dispersion tube if it is mounted in the return.. Follow instructions provided with the control.. Connect “H” terminals on ADHC to “HUMIDISTAT” terminals on humidifier circuit board.. The “H” terminals on the Model 62 provide a dry contact switch to energize the humidifier..

If the application requires a wall-mounted humidistat in the conditioned space, use Manual Humidistat Part #4655, Digital Manual Humidistat Part #65, Automatic Digital Modulating Humidistat Part #63 or any Aprilaire thermostat with integrated humidifier control functionality.. Use Blower Activation Relay Part #4851 with Aprilaire Manual and Digital Manual Humidistats in order to allow the humidifier to turn on the HVAC system blower when humidity is required..

If protection from over-humidification is desired, install optional high humidity limit switch Part #4594 at least 4 feet downstream of the dispersion tube.. If airflow verification is desired, install optional airflow proving switch Part #4592 in duct.. The high humidity limit switch and the airflow proving switch are wired in series with the ADHC (humidistat) circuit.. See Figure 13..

FIGURE 13 – Steam Humidifier Accessory Wiring

FAN PACK HUMIDISTAT

MODEL 62 DIGITAL HUMIDIFIER CONTROL

24V TERMINALS

24 VAC from HVAC	R C A B ODT W G H H Gf
Equipment “R” & “C”
Communication with
Aprilaire 8570 Thermostat

Outdoor Temperature Sensor

Heat Signal from HVAC Equipment

Fan Signal from Thermostat or

Zone Panel Equipment Terminals

Fan Signal to HVAC Equipment

C

NO

NC

OPTIONAL:

AIR FLOW PROVING SWITCH #4592 Connect 1/4" plastic tubing from H (High) side

of proving switch to the airflow sensing probe located 1.5 duct diameters downstream of blower. Leave L (Low) side open to amosphere.

C NO NC

OPTIONAL:

HIGH HUMIDITY LIMIT SWITCH #4594 Switch breaks C to NO connection when measured RH is above setpoint RH.

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