Aprilaire 800, 865, 801, 866 Install Instructions

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Page 1

Steam Humidifier

Series 800 Steam Humidifier

Installation & Maintenance Instructions

TABLE OF CONTENTS

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

Materials List ...........................................3

Principles & Sequence of Operation.......................4

Specifications & Dimensions .............................5

Installation Instructions ..................................8

Choosing a Location .....................................8

- Dispersion Tube Location ..............................8

- Fan Pack Location ...................................10

- Elevation ..........................................11

- Distance from Humidifier to Dispersion Tube/Fan Pack.....12

- Humidifier Location..................................13

Prepare Humidifier for Mounting ..........................14

Install Steam Dispersion Tube/Fan Pack ....................14

Mount Humidifier ......................................14

Install Steam Hose .....................................14

Supply Water..........................................14

Drain Line.............................................15

Electrical Power Wiring & Shut-off Switch ..................15

Automatic Digital Control and Accessory Wiring .............20

Manual Digital Humidistat and Fan Pack Wiring..............21

Automatic Digital Modulating Control Wiring................22

Start-up Procedure .....................................24

Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Shut Down Procedure...................................26

Display Panel ..........................................26

Maintenance...........................................27

Troubleshooting Guide ..................................28

Replacement Parts......................................31

READ AND SAVE THESE INSTRUCTIONS

Page 2

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.

Page 3

MATERIALS LIST

MODELS 800 & 865 MODELS 801 & 866

MATERIALS FURNISHED WITH MODEL 800

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

ADDITIONAL MATERIALS FURNISHED WITH MODEL 865

Fan Pack (instead of dispersion tube) Model 65 Digital humidistat (instead of Model 62 ADHC) 4 housing mounting screws 2 tap connectors 2 wire ties 2 grille mounting screws Neoprene condensation tubing – 3/8” I.D. (10 feet) Model 4028 Drain Tee and Trap Assembly

NOT FURNISHED

MATERIALS FURNISHED WITH MODEL 801

Humidifier Dispersion tube Steam hose (6 feet) 7/8” I.D. drain tubing (10 feet) Hose clamps Saddle Valve Mounting Screws

ADDITIONAL MATERIALS FURNISHED WITH MODEL 866

Fan Pack (instead of dispersion tube) 4 housing mounting screws 2 tap connectors 2 wire ties 2 grille mounting screws Neoprene condensation tubing - 3/8” I.D. (10 feet) Model 4028 Drain Tee and Trap Assembly

NOT FURNISHED

Model 63 Automatic Digital Modulating Control

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

Wiring

1/4” O.D. supply water tubing

Boards for mounting (if required)

Page 4

PRINCIPLES & SEQUENCE OF OPERATION

ube

Drain

Inlet Fill V

The Aprilaire® Steam Humidifier delivers humidity in the form of steam to the conditioned space via the HVAC system duct or 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.

To control the Steam Humidifier as part of the HVAC system, the Model 62 Automatic Digital Humidifier Control (ADHC) is installed to detect the RH level in the duct. When the ADHC detects RH below the set point, and the humidifier and HVAC system blower are operating, the humidifier energizes the electrodes to provide steam. Steam is delivered into the duct work via the steam hose and through the dispersion tube. The dispersion tube is fitted with opening called “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.

FIGURE 1 – Fill and Drain System and Canister

Steam Hose

alve

Overflow

Fill

Supply

Water

Steam Outlet

High Water Level Sensor

Electrodes

Canister

Drain Valve

Drain Cup

Tubelets

Dispersion T in Duct

90-1522

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

FIGURE 2 – Humidifier Output for ADMC Signal

(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

100%

PROPORTIONAL BAND

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.

HUMIDIFIER OUTPUT (%)

2% PROPORTIONAL BAND SETTING

20%

5% PROPORTIONAL BAND SETTING (DEFAULT)

10% PROPORTIONAL BAND SETTING

HUMIDIFIER OFF

-2% -5% -10% RH DIFFERENCE FROM SETPOINT (%)

90-2008

Page 5

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 15). Configure the unit appropriately for the application (see Table 1 for capacity specifications).

TABLE 1 – Humidifier Capacities and Recommended Home Sizes

Amperage Voltage

120V 11.5 2,500 sq ft 1,500 sq ft 1,000 sq ft

Maximum steam

capacity (gal/day)

Maximum recommended home size in ft

Tight Average Loose

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 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 lb.

Page 6

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

BACK VIEW

Mounting

Holes

3-3/8

7-7/8

6-5/8

9-1/8

1-7/8

Water Fill Line Connection

Drain

BOTTOM VIEW

Electrical Knockouts

3 sq

2 sq

1-3/4

8-1/4

1 dia

SPECIFICATIONS & DIMENSIONS (CONTINUED)

Fan Inlet

Manifold

FIGURE 3 – Humidifier Dimensions (inches)

Steam Dispersion Tube

3 sq

90-1518

2 sq

1-3/4

1 dia

8-1/4

90-1518

Fan Pack

17-1/16

7-13/16

90-1554

Fan Outlet Steam Dispersion

3/8

4-3/4

6-7/

6-1/16 7-1/16

Page 7

SPECIFICATIONS & DIMENSIONS (CONTINUED)

WATER QUALITY

Minerals that are naturally found in water cause the water to be electrically conductive. Water conductivity is measured in micro Siemens per centimeter (uS/cm). Mineral content, also described as “water hardness” is usually measured in grains per gallon. Because of the variety of minerals that are found in water, there is no direct correlation between water hardness and conductivity, but generally the higher the mineral content, the higher the conductivity.

The Steam Humidifier is designed to operate on water with conductivity between 125 and 1,250 uS/cm. This correlates loosely with water with hardness between 3 and 36 grains/gallon. Water that is considered “hard” and also softened water work well in the Steam Humidifier. The humidifier will make steam when plumbed to low-conductivity water but it takes longer to reach nominal capacity.

With low conductivity water, it may take the Steam Humidifier one week or more of operation to reach rated capacity, especially if it is wired to operate on 120 volts. When operating on 208/240 volts, the Steam Humidifier usually will reach nominal capacity within a few hours, even with lower conductivity water.

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 (uS/cm)

of water connected to

humidifier

0-125 0-3 Naturally Soft

125-300 3-9 Naturally Soft Long start up time.

300-500 9-15 Slightly Hard 500-640 15-20 Moderately Hard 640-840 20-25 Hard

840-1250 25-36 Very Hard

above 1250 36 Extremely Hard

Estimated grains/gallon

(prior to any water

softening)

Hardness (prior to any

water softening)

Canister behavior Solution

Humidifier does not

function.

Optimal performance

range.

Shortened canister life

due to mineral build up.

Canister performance

degrades quickly.

Installation not recommended.

Power with 208/240VAC,

use constant fan to decrease

time to reach full capacity.

Use either hard or softened

water.

Use softened water.

Installation not recommended.

Page 8

INSTALLATION INSTRUCTIONS

Do not mount humidifier in a location where operating ambient temperatures exceed 104°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 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 8. 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.

Page 9

INSTALLATION INSTRUCTIONS (CONTINUED)

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.

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

Humidifier

Output (gal/day)

Up to 16.0

20.5 – 25.0

25.0 – 35.0

*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

Airflow Velocity*

300 fpm 13” 19” 23” 30”

600 fpm 6” 10” 12” 18” 1200 fpm 3” 5” 6” 13” 1800 fpm 2” 3” 4” 10”

300 fpm 15” 23” 28” 45”

600 fpm 6” 12” 13” 26” 1200 fpm 5” 6” 7” 19” 1800 fpm 3” 4” 5” 16”

300 fpm 24” 31” 36” 60”

600 fpm 17” 22” 26” 48” 1200 fpm 12” 15” 18” 25” 1800 fpm 10” 13” 15” 20”

70°F & 30% RH

Setpoint

70°F & 45% RH

Setpoint

65°F & 45% RH

Setpoint

45°F & 45% RH

Setpoint

Page 10

INSTALLATION INSTRUCTIONS (CONTINUED)

for Steam Hose

FAN PACK LOCATION

The Fan Pack must be located near the Steam Humidifier to minimize the length of the steam hose. If the Fan Pack is mounted directly above the humidifier, 16” is required for the steam hose to make the bend. See Figure 4. NOTE: The loop in the condensate hose is required to prevent steam from escaping into the drain.

Condensation running through the steam hose back into the canister may cause a gurgling noise. Install Tee & Trap #4028 (included with Model 865) as shown in Figure 10 to divert condensation to drain to eliminate the gurgling noise.

Humidity behaves like a gas and under ideal conditions will expand to fill the space. However, air movement due to drafts or as a result of temperature stratification may cause uneven distribution of humidity within the conditioned space. To ensure even RH distribution, install system in a central location. If a central location is not available, it may be necessary to install two systems. Two systems will provide more even RH distribution than one.

To prevent condensation on surfaces and furnishings, install the fan pack so the steam being discharged has enough room to be absorbed into the air before encountering surfaces.

The following guidelines are for a 120V installation in which the unit discharges into a space with 70°F air temperature and 40% RH.

FIGURE 4 – Side View

IMPORTANT:

Loop drain hose below Fan Pack to provide trap.

30" Recommended

for Service Access

NOTE: See Figure 10 for drain tee & trap installation recommendations.

Drain

16" Minimum

90-1551

• Allow 4 feet of unobstructed space directly in front of the grille.

• Allow 2 feet on either side of the grille.

• Allow 1-1/2 feet above the grille.

See Figure 5. If the Steam Humidifier operates on 240V, allow an additional foot of

space between the grille and any obstruction or surface. If the room temperature is less that 70°F, allow an additional 6” to

each distance for every two degree drop in temperature. If the RH set point is higher than 45%, allow an additional foot of

space between the grille and any obstruction or surface. Warmer room air temperature and RH below 35% will reduce the

amount of unobstructed space required to absorb discharged steam, but the distances provided are recommended minimums.

FIGURE 5 – Minimum Clearances

1-1/2 feet minimum to ceiling

2 feet

minimum to

side wall

4 feet

minimum to

objects in

front of grille

Maximize

90-1552

Page 11

INSTALLATION INSTRUCTIONS (CONTINUED)

Wall Studs on Center

Wall Stud

Tube

Terminals

Dispersion tube

Steam hose or pipe.

Insulate pipe with 1” fiberglass

Mount Fan Pack Housing

The Fan Pack installs between the studs of a standard 16” on-center wall. Drywall on both sides of the wall must be removed for piping and wiring the Fan Pack. To ensure proper operation, the Fan Pack must be mounted level. Use the four 1-1/2” mounting screws provided to attach the housing to the wall studs. See Figure 6.

Grille Installation

Use the two 5/8” screws to attach the Fan Pack grille to the fan housing and drywall. See Figure 6. If painting the grille is desired, see a painting professional for acceptable paint products for high temperature (212°F), high humidity environments.

FIGURE 6 – Wall Opening and Mounting

Wall Cut-out

7-1/4"

Fan Pack Hose Connections

Connect the steam hose to the Fan Pack and use hose clamp to secure. See Figure 7. If more than 6 feet is required, use insulated hard pipe as shown in Figure 11. See Specifications & Dimensions (page 5) for the affect on capacity. Ensure the trap is filled with water before making steam connections.

Connect 3/8” ID condensate tubing to the Fan Pack and use wiretie to secure See Figure 7. To create a trap, make a 6” loop in the condensate hose. See Figure 4. NOTE: The 6” loop must be located below the Fan Pack connection. Do not kink the condensate hose. Use wire ties to secure the loop. The loop is required to prevent steam from escaping into the drain.

ELEVATION

The preferred location for the dispersion tube/fan pack 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/fan pack 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 8.

14-1/4"

16"

FIGURE 7 – Fan Pack Hose Connections

Condensate

Steam

Electrical

FIGURE 8 – Dispersion Tube Mounted Above Humidifier

to reduce steam loss.

90° long sweep

or two 45° elbows

Pitch*

Duct

* Pitch steam hose down

from dispersion tube to humidifier:

2"/ft (15%) minimum

when using steam hose.

1/4"/ft when using

hard pipe.

90-1550

90-1560

90-1521

Page 12

INSTALLATION INSTRUCTIONS (CONTINUED)

Drip tee installation for piping over obstruction, or if dispersion tube is lower than humidifier

Reducing Coupling

To Steam Dispersion

Hose Clamp

ube

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 9. When using a fan pack, install Part #4028 close to the humidifier outlet to help prevent noise from gurgling as shown in

Figure 10.

FIGURE 9 – Dispersion Tube Mounted Below Humidifier

90° long

sweep or two

45° elbows

Pitch

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.

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” fiberglass 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 11.

FIGURE 11

Tube or

3/4" x 1"

1" Copper Pipe

1-1/2" Hose Clamp

Steam Hose

Fan Pack

Steam Hose

1-1/2" Hose Clamp

90-1520

FIGURE 10

Steam Hose 1" I.D. (Downward Slope from Humidifier to Tee)

Insulate hard pipe to

reduce steam loss

To Dispersion

Tube/Fan Pack

1" air gap

Open drain required,

see note 1.

Hose Clamp

Steam Humidifier

6" min

8" min

Obstruction

Drip tee

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.

Steam Hose, 1" I.D. (Downward Slope to Tee)

Tee Assembly

Steam Hose 1" I.D.

Hose Clamp

Flared End

Trap Note: Prime with water before using humidifier

Hose Clamp

Part #4028

To Steam Dispersion T or Fan Pack

#4028 KIT CONTENTS:

Hose Clamps (5) Trap (1) Tee Assembly (1)

Humidifier

Drain Hose 7/8" I.D.

90-1527 90-1844

Page 13

INSTALLATION INSTRUCTIONS (CONTINUED)

TABLE 4 – Steam Humidifier Capacity in Gallons/Day

Steam

Hose or

Insulated

Pipe

Length

11.5 Amps 16.0 Amps 11.5 Amps 16.0 Amps 11.5 Amps 16.0 Amps

Steam

Hose

< 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 ambient temperature exceeds 104°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 12 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.

120 Volts 208 Volts 240 Volts

Insulated

Pipe

Steam

Hose

Insulated

Pipe

Steam

Hose

Insulated

Pipe

Steam

Hose

Insulated

Pipe

Steam

Hose

Insulated

FIGURE 12 – Clearances

FRONT VIEW

16" for

90-1519

Electrical Access

16"

for Drain

Pipe

Steam

Hose

16" for Steam

Hose

30" for Service Access

SIDE VIEW

Insulated

Pipe

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

Page 14

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/FAN PACK

Make sure steam dispersion tube/Fan Pack is mounted higher than the humidifier so that condensation that forms in the steam hose runs back into the canister. If the dispersion tube/Fan Pack 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 9.

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 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. 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.

Page 15

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

13). 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 14, 15, 16.

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 14

• 208 VAC – Figure 15

• 120 VAC – Figure 16

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

Page 16

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 13 – Control Circuit Board with Dip Switches

LED D8

Factory setting for

11.5 AMP nominal operation.

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

90-1959

Page 17

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 14 – 240 VAC Wiring Diagram

BLK

POWER

MAIN POWER BREAKER

(NOT PROVIDED)

GND

L2 / N

DOOR SWITCH

ORANGE

TERMINAL

BLOCK

TRANSFORMER POWER

JUMPER WIRE

BLK/WHT

J10

J16

YEL

WATER LEVEL

PROBE

ELECTRODE

STEAM CANISTER

RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS.

ELECTRODE

HUMIDITY CONTROL

DRY

CONTACT

DISPLAY PA NEL

(PROVIDED)

FAN PACK

(OPTIONAL)

RIBBON CABLE

HUMIDISTAT

FAN PACK

J5 J6

J13 120

VAC

SLOW BLOW FUSE

(5X20mm 5A)

CON1

BLK

YEL

J11 208

VAC

ORG RED BLK

WHT

J14 240

VAC

TRANSFORMER

BLUE YEL

HIGH VOLTAGE WIRING

CONTROL CIRCUIT WIRING

HIGH VOLTAGE FIELD WIRING

LOW VOLTAGE FIELD WIRING

90-1903

DRAIN VALV E

FILL

VALV E

Page 18

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 15 – 208 VAC Wiring Diagram

BLK

POWER

MAIN POWER BREAKER

L2 / N

DOOR SWITCH

HUMIDITY CONTROL

(PROVIDED)

DRY

CONTACT

(OPTIONAL)

(NOT PROVIDED)

GND

ORANGE

FAN PACK

TERMINAL

BLOCK

TRANSFORMER POWER

HUMIDISTAT

JUMPER WIRE

J10

BLK/WHT

J13 120 VAC

J16

YEL

208 VAC

J11

J14

240

VAC

WATER LEVEL

PROBE

ELECTRODE

STEAM CANISTER

RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS. MOVE THE JUMPER WIRE TO TERMINAL J11 TO OPERATE AT 208VAC.

ELECTRODE

DISPLAY PA NEL

RIBBON CABLE

FAN PACK

SLOW BLOW FUSE

(5X20mm 5A)

J5 J6

BLK

CON1

YEL

WHT

ORG RED BLK

TRANSFORMER

BLUE YEL

HIGH VOLTAGE WIRING

CONTROL CIRCUIT WIRING

HIGH VOLTAGE FIELD WIRING

LOW VOLTAGE FIELD WIRING

90-1904

DRAIN VALV E

FILL

VALV E

Page 19

INSTALLATION INSTRUCTIONS (CONTINUED)

FIGURE 16 – 120 VAC Wiring Diagram

BLK

POWER

MAIN POWER BREAKER

L2 / N

DOOR SWITCH

HUMIDITY CONTROL

DRY

CONTACT

(NOT PROVIDED)

GND

(PROVIDED)

FAN PACK

(OPTIONAL)

ORANGE

TERMINAL

BLOCK

TRANSFORMER POWER

HUMIDISTAT

JUMPER WIRE

BLK/WHT

J10

J13 120

VAC

J16

YEL

J11 208

VAC

J14 240

VAC

WATER LEVEL

PROBE

ELECTRODE

STEAM CANISTER

RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS. MOVE THE JUMPER WIRE TO TERMINAL J13 TO OPERATE AT 120VAC.

ELECTRODE

DISPLAY PA NEL

RIBBON CABLE

FAN PACK

SLOW BLOW FUSE

(5X20mm 5A)

J5 J6

BLK

CON1

YEL

ORG RED BLK WHT

TRANSFORMER

BLUE YEL

HIGH VOLTAGE WIRING

CONTROL CIRCUIT WIRING

HIGH VOLTAGE FIELD WIRING

LOW VOLTAGE FIELD WIRING

90-1905

DRAIN

VALV E

FILL

VALV E

Page 20

INSTALLATION INSTRUCTIONS (CONTINUED)

AUTOMATIC DIGITAL CONTROL AND 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 17.

FIGURE 17 – Steam Humidifier Accessory Wiring

MODEL 62 DIGITAL HUMIDIFIER CONTROL

24V TERMINALS

24 VAC from HVAC

HGf RCAB ODT GWH

Equipment “R” & “C” Communication with

Fan Signal to HVAC Equipment

Aprilaire 8570 Thermostat

Outdoor Temperature Sensor

Heat Signal from HVAC Equipment

NO NC

Fan Signal from Thermostat

OPTIONAL:

FAN PACK HUMIDISTAT

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.

OPTIONAL:

HIGH HUMIDITY LIMIT SWITCH #4594 Switch breaks C to NC connection when measured RH is above setpoint RH.

90-1544

Page 21

INSTALLATION INSTRUCTIONS (CONTINUED)

ap Connectors

Aprilaire Steam Humidifier

MANUAL DIGITAL HUMIDISTAT AND FAN PACK WIRING (MODEL 865)

Mount the Digital Manual Humidistat in the area to be humidified according to installation instructions included with control. Install the

humidistat in the same room or area as the Fan Pack discharge, but at least ten feet away. Wire the Digital Manual Humidistat to the Steam Humidifier using standard 24 volt thermostat wire. See Figure 18.

Disconnect all power to Steam Humidifier before wiring the Fan Pack terminals to the FAN PACK terminals on the Steam Humidifier. Use standard 24 volt thermostat wire. See Figure 18.

FIGURE 18 – Wiring Diagram for Manual Humidistat and Fan Pack

Model 65 Digital Control

SET

OFFON

Steam Humidifier Fan Pack

24VAC

R H H

24VAC

WIRE – 18 Awg acceptable for 24 VAC application.

YELLOW

FAN PA CK HUMIDISTAT

BLUE

Circuit Board

Transformer

90-1662

Page 22

INSTALLATION INSTRUCTIONS (CONTINUED)

AUTOMATIC DIGITAL MODULATING CONTROL WIRING (MODEL 801 OR 866)

The Automatic Digital Humidifier Control (ADMC) that ships with Model 63 and Model 5558 must be mounted on an interior wall in the living space. Follow instructions provided with the control.

If the ADMC cannot be mounted in the living space, the duct humidity sensor can be used as the primary humidity sensor and the ADMC can be installed in a convenient location. Install the duct humidity sensor in the supply 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. Configure the ADMC to use the duct sensor as primary humidity sensor. See Program Mode Step #17 in the ADMC installation manual.

If protection from over-humidification is desired, install the duct humidity sensor in the supply duct at least 4 feet downstream of the dispersion tube. Configure the ADMC to use the duct sensor as a high humidity limit sensor. See Program Mode Step #17 in the ADMC installation manual. The ADMC must be installed in the living space. See Determine Location For Control section of the ADMC installation manual.

If airflow verification is desired, install optional airflow proving switch Part #4592 in duct and wire in series with the ADMC humidistat circuit. See Figure 19.

FIGURE 19 – ADMC with Model 801

REMOVE

THERMOSTAT FURNACE

BLU (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 atmosphere.

MODULATING

STEAM HUMIDIFIER

DIP SWITCH POSITION

1 2 3 4

YLW (C)

ORG (NO)

BLOWER

ACTIVATION

RELAY

4851

WHT / BLU

ODT

801

HUMIDISTAT

TERMINAL

GND

WHT / YLW

FAN PACK

ADMC

(OPTIONAL)

DUCT SENSOR

NOTE: PLACE ADMC JUMPER J2 IN THE LEFT POSITION (POWERED).

OPTIONAL:

HIGH HUMIDITY LIMIT SWITCH #4594 Switch breaks C to NC connection when measured RH is above setpoint RH.

90-1992

Page 23

INSTALLATION INSTRUCTIONS (CONTINUED)

When the Modulating Steam Humidifier is installed with the Fan Pack, wire the ADMC as shown in Figure 20.

The Aprilaire Automatic Digital Modulating Control is the recommended humidity controller for the Model 801 and Model 866 Modulating Steam Humidifier. However, the Modulating Steam Humidifier can accept a number of different control signals. If using a third party control, configure the Modulating Steam Humidifier internal controller for the third party control signal. See Figure 21 for configuration options.

FIGURE 20 – ADMC with Model 866

STEAM HUMIDIFIER

DIP SWITCH POSITION

ADMC

%RH

36.

STEAM HUMIDIFIER FAN PACK

1 2 3 4

MODULATING

12 13 14

24VAC

1 2

ODT

+24V IN GND

FAN PACK

APRILAIRE MODULATING

STEAM HUMIDIFIER

FIGURE 21 – Third Party Control Signals

CONTROL DIP SWITCH SETTINGS

DIP2 DIP3 HUMIDISTAT SIGNAL TYPE

OFF OFF ON / OFF

ON OFF 0-20 VDC

OFF ON 0-10 VDC or 0-20 mA

ON ON 2-10 VDC or 4-20 mA

WIRE – 18 AWG ACCEPTABLE FOR 24 VAC APPLICATION.

ON / OFF

HUMIDISTAT

MODULATING STEAM HUMIDIFIER HUMIDISTAT TERMINAL

+24V

GND

RECOMMEND USING BLOWER ACTIVATION RELAY PART # 4851

0-10 VDC, 0-20 VDC OR 2-10 VDC

MODULATING STEAM HUMIDIFIER HUMIDISTAT TERMINAL

+24V

GND

0-20 MA OR 4-10 MA

MODULATING STEAM HUMIDIFIER HUMIDISTAT TERMINAL

+24V

GND

90-1995

90-1993

Page 24

START-UP PROCEDURE

1. Once the supply water, drain, steam hose, electrical power and control wiring connections are complete, make sure canister is fully seated into drain valve and three wire connectors on top of canister are secure. (High water probe wire and two interchangeable electrode wires.)

2. Attach side panel and front door.

3. Open saddle valve allowing water to flow to humidifier. Check for leaks.

4. Turn Automatic Digital Control knob to OFF.

5. Close main power switch energizing humidifier.

6. Press On/Off button on humidifier. The On/Off light will illuminate green.

7. Make sure the HVAC blower is operating and adjust the ADHC dial up to initiate a call for humidity. If installed with a Fan Pack, turn On the Model 65 Digital Manual Humidistat. Adjust the humidity set point with the up and down arrows.

Note: The ADHC can be placed into TEST mode to force a call for humidity but this only lasts for one minute. The Steam light will illuminate green indicating a call for humidity and the Fill light will illuminate green indicating the fill valve is open

allowing the canister to fill. You should also hear the water flowing. If water flows down drain while humidifier is filling, check for

kinks or obstructions in the fill hose or fill cup and make sure the O-ring in the drain valve is properly seated in the groove and not damaged or deformed.

8. Once the Fill light turns off, to verify that the humidifier will drain properly, press the On/Off button to turn humidifier off. You may hear the fill valve open allowing cold water to flow into the canister to cool the water in the canister. The Drain light will flash green for 15 seconds then turn green for four minutes while the canister drains. Once the Drain light turns off, the drain cycle is complete.

9. Set ADHC to proper level.

10. Press On/Off button to turn humidifier on.

11. If installed with a Fan Pack, ensure the Fan Pack fan operates.

12. Ensure the steam outlet of the Fan pack is not blocked.

CAUTION

The front of the Fan Pack will be hot. Steam may not always be visible.

Do not touch the front of the Fan Pack or place hand in front of the steam discharge manifold.

Page 25

OPERATING MODES

When the humidifier is powered and turned on, the “On/Off” light is illuminated green. During fill cycles, the “Fill” light illuminates green. When the humidifier is turned on, any time the Humidifier Control sends a call for humidity, the Steam light illuminates green. Any time the drain valve is activated, the “Drain” light illuminates green. During initial start up with a new canister, the humidifier may run through a series of fill/drain cycles until the conductivity of the water is in

a range that allows the humidifier to generate steam at the rated capacity. If the conductivity of the water is low, it may take a week or more for the humidifier to generate steam at the rated capacity. The rated capacity is achieved when the humidifier is detecting a nominal current of either 11.5 or 16.0 amps between the electrodes. If the humidifier has not reached capacity after 168 hours of operation, the Steam light will illuminate yellow on a call for humidity. The humidifier will continue to operate with a yellow Steam light, and may satisfy the humidity requirements. Once rated capacity is reached, the Steam light will illuminate green.

The internal controller adjusts water level in the canister to maintain the nominal current between the electrodes. As minerals build up on the electrodes, their effectiveness decreases, so the controller will increase the water level to submerge more of the electrode surface. When the water has reached the high level probe in the canister and the internal controller no longer detects nominal current, the Service light will flash red indicating that the canister needs to be replaced.

If the humidifier attempts to drain the canister and cannot, the drain and fill valves will pulse on & off for four seconds to dislodge minerals which may be blocking the drain valve ports. The Drain and Fill lights will flash on & off when this occurs.

Any time power is disconnected or humidifier is turned off, the internal timer for start-up and drain cycles is reset. If the humidifier has operated 168 hours without a drain cycle, the drain valve will open and drain the canister. Normal operation will continue. If the humidifier is operating and a power failure occurs, once power is restored, the “On/Off” light will flash green for one minute, then the

humidifier will turn on.

END OF SEASON/PERIOD OF INACTIVITY SHUT-DOWN

The humidifier does not need to be turned off at the end of the humidification season. If 72 hours elapses without receiving a call for humidity, the canister will automatically drain. The Drain light will remain lit for 24 hours. This may also occur during periods of inactivity during the humidification season. The humidifier will resume normal operation when a call for humidity is made.

Page 26

SHUT DOWN PROCEDURE

To turn humidifier off, push ON/OFF button once. Humidifier will begin its four-minute drain cycle. Fill valve will open to temper drain water. The Drain light will flash green for 15 seconds then turn green for four minutes while the canister drains. Once the Drain light turns off, the drain cycle is complete and the humidifier is off.

DISPLAY PANEL

Green lights indicate normal operation. Yellow Steam light indicates humidifier is operating at less than rated capacity. Flashing red Service light indicates canister is near the end of its life and should be replaced if the humidity in the space cannot be maintained. Solid red lights indicate humidifier has shut down and requires service. Disconnecting power to humidifier resets internal timers.

TABLE 5 – Display Panel

Indicator Light Function

Off

Solid green

Flashing Green

Off

Solid Green

Flashing Green

Solid Red

Off

Solid Green

Solid Yellow

Off

Solid Green

Humidifier is turned off or power is disconnected.

Humidifier is turned on.

Humidifier is preparing to turn on. Occurs if power to humidifier was turned off when humidifier was on. Humidifier turns on after light flashes for one minute.

Fill valve not energized.

Fill valve is energized, filling or replenishing canister with water. (During drain cycle when fill valve is open allowing cold water into canister to temper drain water, the fill light does not illuminate.)

Fill and Drain Valves are pulsing to dislodge mineral deposits from drain. Flashes 10 times in 4 seconds. Occurs if high water probe detects water during drain cycle.

Humidifier cannot fill canister. Humidifier stops operating. Occurs after fill valve has been energized for 40 minutes and high water probe does not detect water.

Humidifier is not producing steam

Humidifier is turned on and receiving a call for humidity from the control.

Humidifier is producing steam but at less than the rated capacity. Occurs if humidifier has operated for 168 hours and has not reached nominal current.

Drain valve not energized.

Drain valve is energized, allowing water to drain from canister.

Flashing Green

Flashing Red

Solid Red

Humidifier is preparing to drain. Flashes for 15 seconds indicating fill valve is open allowing cold water into canister.

Canister has reached end of life. Humidifier continues to operate but at reduced capacity. Occurs after humidifier has operated for 168 hours plus another 24 hours at less than 75% of the maximum operating current level between electrodes.

Humidifier is not operating and requires service.

Page 27

MAINTENANCE

NOTICE

• Allow humidier to drain and disconnect power before servicing.

• Service should be performed by a qualied HVAC technician.

Inspect humidifier when servicing.

• Check for loose electrode connections on the canister. Replace electrode wires if connection is loose.

• Check system operation and inspect all plumbing connections and piping for signs of cracks or leaks.

• Inspect drain line to make sure it is not blocked and has constant downward slope. Clean or replace if necessary.

• Inspect steam hose to make sure it has no low spots and has constant upward slope from humidifier to dispersion tube in duct. If dispersion

tube is mounted below humidifier, inspect drip tee and drain.

TO REPLACE THE CANISTER

1. Turn humidifier off.

2. Unit will go through drain cycle – 4 mins – and turn off when complete.

3. Disconnect main electrical power to humidifier at the circuit breaker.

4. Allow the unit to cool.

5. Remove front door.

6. Remove electrode wires, high water probe wire, steam hose and canister.

7. Remove O-ring from groove in drain assembly using a small screw driver.

8. Insect drain assembly and remove any debris – see TO CLEAN THE DRAIN VALVE.

9. Insert new O-ring into groove in drain assembly. (O-ring is provided with Model 80 canister.) Dampen O-ring with water before inserting canister. Do not use oil, grease, or any lubricant besides water.

10. Make sure strainer is inserted into bottom of new canister.

11. Insert canister into drain assembly. Position canister with label facing outward.

12. Reconnect steam hose and wires ensuring wires are fully seated.

13. Replace front door.

14. Restore electrical power to humidifier.

15. Turn humidifier On and verify green On/Off light is illuminated.

16. See Start-up procedure.

17. Check for leaks.

TO CLEAN THE DRAIN VALVE

1. Turn humidifier off.

2. Unit will go through drain cycle – 4 mins – and turn off when complete.

3. Disconnect main electrical power to humidifier at the circuit breaker.

4. Allow the unit to cool.

5. Remove front door.

6. Remove electrode wires, high water probe wire, steam hose and canister.

7. With your finger swirl the fluid/precipitate mixture in the bottom of the drain valve reservoir.

8. Using a sponge or paper towels soak up the water in the reservoir, if necessary use a wet/dry vacuum to remove residue.

9. Clean the inside of the drain port (where coil projects out) by gently swabbing with a bent cotton swab or other soft implement.

10. Rinse the drain valve reservoir with clean water and vacuum as necessary.

11. Replace canister, reconnect steam hose and wires ensuring wires are fully seated.

12. Replace front door.

13. Restore electrical power to humidifier.

14. Turn humidifier On and verify green On/Off light is illuminated.

15. See Start-up procedure.

16. Check for leaks.

TO SERVICE THE FILL VALVE

If water flow from the valve is restricted, disconnect the inlet fitting and remove in line strainer from the inlet port using a small screw. Clean or replace strainer (Part #4004).

Page 28

TROUBLESHOOTING GUIDE

CAUTION

Contact with electrical circuits can cause property damage, personal injury or death. Service and Troubleshooting must be performed by qualiﬁed electrician.

The following troubleshooting guide is intended to help diagnose and resolve general operational problems with the Steam Humidifier and optional Fan Pack. If a problem persists, call Aprilaire Tech Support toll-free at 1-800-334-6011. Please be prepared to describe the exact nature of the problem. For general operational problems, check to make sure humidifier is installed correctly.

TABLE 6 – Humidifier Troubleshooting Guide

Problem Possible Cause Action

General operating problems. Humidifier will not turn on or turn off.

Steam Light does not turn on.

Water is leaking from humidifier.

Water constantly runs down drain.

Humidifier is filling and water is flowing down drain but drain light is not on.

Field-wired terminal connections.

Internal connections. Check electrode and high water probe connections on the top of the canister.

No power to humidifier. Check main power supply and switch.

Humidifier not turned on. Make sure front cover is attached to engage safety interlock switch. Press On/Off button.

No power to 24 volt control circuit.

Call for humidity not being received.

Loose plumbing connections.

Hoses are blocked. Check internal hoses and eliminate kinks or blockage. Drain hose is blocked. Make sure drain hose has constant downward slope and is not blocked. Debris in drain valve

preventing it from closing. O-ring in drain valve is not

properly seated in groove. Water is flowing from fill

cup overflow port. High static pressure in duct

is causing back pressure in canister.

High static pressure in steam line is causing back pressure in canister.

Verify L1, N/L2 and ground connections are properly wired and appropriate voltage is present. Check HUMIDISTAT and (if used) FAN PACK terminal connections are tight and properly wired. HUMIDISTAT terminals must be connected to an on/off device. Check wiring connections and settings on Accessory items such as high limit switch and airflow

proving switch.

Make sure ribbon cable from membrane switch is securely plugged into control circuit board. Make sure black/white wire is attached to terminal that matches input voltage.

Ensure breaker is sized appropriately for the amperage draw. Check for proper voltage across L1 and N/L2 terminals.

Make sure ribbon cable from membrane switch is not damaged and is securely plugged into the control circuit board.

Check fuse on PCB (replace with 5 amp slow burn fuse if necessary). With humidifier energized, check that LED light D8 is energized on the circuit board. If the LED is lit,

replace the membrane switch, if not, replace the circuit board. Check humidistat wiring and setting. (Do not leave ADHC in TEST mode.) Check wiring and settings of high RH limit switch and airflow proving switch. Check water supply connection at fill valve inlet. Tighten as needed. Check internal hose clamp connections. Reposition clamps and tighten as needed. Check steam hose connection on top of canister. Tighten clamp as needed.

Remove canister and clean debris from drain valve.

Remove canister and check O-ring for damage. Replace O-ring as necessary. Ensure O-ring is properly seated in its groove.

Check internal hoses and eliminate kinks or blockage.

Make sure dispersion tube is not discharging into duct with greater than 2.0 in.wg static pressure.

Make sure dispersion tube tubelets are pointed up.

Install a tee and drain trap in any low points in the steam line. See Figure 9.

Page 29

TROUBLESHOOTING GUIDE (CONTINUED)

TABLE 6 – Troubleshooting Guide (continued)

Problem Possible Cause Action

Humidifier makes gurgling sound.

Fill valve makes banging sound.

Humidifier will not fill. Saddle valve not open or pipe not pierced. Make sure saddle valve is properly installed and the valve is open.

Humidifier will not drain. Debris in drain valve blocking outlet port. Remove canister and clean debris from drain valve. Water in duct. Dispersion tube installed incorrectly. Install dispersion tube with tublets facing straight up.

Service light flashing red before end of humidification season.

Yellow steam light. Humidifier operating below rated capacity. (Normal

Humidifier is not satisfying demand.

Excess humidity. Control setting is too high. Adjust control to lower setting.

Solid red fill light. Fill valve has been filling for 40 minutes. Make sure high water pin wire is securely installed.

Solid red service light. Unit senses current 120% above nominal and

Excess condensation in steam hose.

Water hammer from line pressure. Make sure water supply line does not contact ductwork.

Hoses are blocked. Check internal hoses and eliminate kinks or blockage.

Impurities in steam hose or pipe causing foaming. Rinse canister, fill hose and fill cup with clean water. Insufficient absorption distance. Canister full of mineral deposits. Remove canister and rinse with clean water.

Humidifier runs in short cycles (does not reach capacity).

operation for systems plumbed to low conductivity water and systems that operate for short cycles.)

Control setting is too low. Adjust control to higher setting. Control mounted in wrong location. See Installation Instructions with control for correct mounting location. Short run times. Use blower activation feature on ADHC or run constant HVAC fan. Humidifier capacity limited by input power (120V). Operate humidifier on 208/240 volts.

Control mounted in wrong location. See Installation Instructions with control for correct mounting location.

Low spot in steam hose collecting water. Support steam hose along its length ensuring 2” per foot slope from the

High static pressure in the duct is causing back pressure in the duct.

cannot lower amperage after three drain cycles.

Install Tee and Trap Model 4028 as shown in Figure 10. Make sure steam hose has constant downward slope to humidifier or to

tees and traps in low spots of hose. If hard pipe is used for dispersion system, make sure it is insulated.

Install shock arrestor. Install section of 1/4" braided fill line. Conform to local codes. If water supply pressure is greater than 120 psi, install pressure reducer.

Determine absorption distance per Table 3.

Plumb humidifier to filtered water. Plumb humidifier to softened water. Use blower activation feature on ADHC or run constant HVAC fan.

Allowing the humidifier to run for longer cycles to concentrate minerals and increase water conductivity.

Plumb humidifier to softened water. Use blower activation feature on ADHC or run constant HVAC fan. Operate humidifier on 208/240 volts. To determine operating current, attach clamp-on ammeter to one of the

electrode wires on top of canister. Dissolve one teaspoon of salt into one cup of hot water. Add to the fill cup

in 1/4 cup increments until unit operates properly. Yellow steam light will clear after first fill valve cycle at nominal amperage operation. Do not over salt. System will drain and refill with clean water due to over current fault.

Increase capacity to 16.0 amps. Make sure breaker is appropriately sized.

dispersion tube to the humidifier. Make sure dispersion tube is not discharging into a duct with greater than

2.0 in.wg. static pressure. Make sure dispersion tube tubelets are pointed up. Rinse canister to remove mineral deposits or install a new canister.

Page 30

TROUBLESHOOTING GUIDE (CONTINUED)

TABLE 7 – Fan Pack Troubleshooting Guide

Problem Possible cause Action

Water dripping from Fan Pack. Tubing connection. Check all connections.

Fan not operating. See “Fan does not operate”. Steam outlets blocked. Clean steam dispersion manifold outlet. Foaming in canister or steam hose. Rinse components with clean water.

Fan does not operate. Wiring. Check wiring.

Steam Humidifier power. Check that Steam Humidifier is powered and on. No humidity call. Adjust humidistat setting. Check location of humidistat. Circuit board output. Confirm 24 VAC output from Steam Humidifier FAN PACK terminals during a call

Motor failure. Replace fan motor.

Noise. Fan noise. Check for obstructions or damage to fan.

Gurgling. Add a drip tee and trap (PN 4028) to the steam line as close to the Steam

for humidity.

Humidifier as possible to divert condensation to drain. See Figure 10.

Page 31

REPLACEMENT PARTS

Parts are shown for Model 800/865 humidifiers manufactured after November 2014. For parts for steam humidifiers manufactured prior to November 2014,

refer to Aprilaire Humidifier Replacement Parts & Price List.

Refer to the following page for part descriptions.

90-1961

Page 32

REPLACEMENT PARTS (CONTINUED)

Item No. Part No. Description

1 4004 Fill Valve In-line Strainer 2 4975 Membrane Switch

3 5306

4 4978 Electrode Wire (1) 5 4983 Drain Valve 6 5309 Fill Valve 7 4985 Drain Cup Assembly 8 4986 Front Panel & Screw

9 4987 Electrical Access Panel & Screws 10 4988 Safety Interlock Switch 11 4989 Fill Cup and Hoses 12 4990 Fill Cup Cap 13 4991 Steam Dispersion Tube & Screws 14 80 Steam Canister and O-Ring 15 62 Automatic Digital Control for Model 800 16 65 Digital Manual Humidistat

Universal Transformer, Model 865, 866 (75 VA)

Item No. Part No. Description

17 5530 Control Board, Model 800, 865

18 5529

19 4997 Condensate Tubing with Wire Ties 20 4998 Fan Pack Grille 21 4999 Fan Pack Fan 22 5554 Modulating Control Board, Model 801, 866

23 63

4001 Saddle Valve 4028 Drain Trap & Tee 4592 Airflow Proving Switch 4594 High Humidity Limit Switch

4851

4856 Condensate Pump (Rated for 160°F) 4973 Steam Hose (6 ft.) & Clamps 4974 Drain Hose (10 ft.) & Clamps

Universal Transformer, Model 800, 801 (40 VA)

Automatic Digital Modulating Control (ADMC) for Model 801/866

Blower Activation Relay (Optional for use with manual humidistats)