Steam Humidifier Series 800 Steam Humidifier Installation & Maintenance Instructions Table of Contents Safety Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Materials List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Principles & Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . .
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.
MATERIALS LIST ModelS 800 & 865 ModelS 801 & 866 Materials Furnished WITH MODEL 800 Materials Furnished WITH MODEL 801 Humidifier Humidifier Model 62 Automatic Digital Humidifier Control Dispersion tube Dispersion tube Steam hose (6 feet) Steam hose (6 feet) 7/8” I.D. drain tubing (10 feet) 7/8” I.D.
Principles & Sequence of Operation 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.
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).
Specifications & Dimensions (continued) Steam Dispersion Tube Figure 3 – Humidifier Dimensions (inches) 3-3/8 3-3/8 8-7/8 8-7/8 7-7/8 7-7/8 1-3/4 1-3/4 FillFillCup Cup 3 sq 3 sq 1-5/8 1-5/8 3-3/8 3-3/8 4-1/4 4-1/4 1 dia 1 dia 8-1/4 8-1/4 5-3/4 5-3/4 2 sq 2 sq Electrical ElectricalKnockouts Knockouts TOP TOPVIEW VIEW 90-1518 Dispersion DispersionOutlet Outlet 10-1/8 10-1/8 7-1/8 7-1/8 44 11 Mounting Mounting Holes Holes 20-7/8 20-7/8 1212 44 Drain Drain Water Water FillFillLine Line Co
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.
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.
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.
INSTALLATION INSTRUCTIONS (continued) 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.
INSTALLATION INSTRUCTIONS (continued) 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.
INSTALLATION INSTRUCTIONS (continued) 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.
INSTALLATION INSTRUCTIONS (continued) Table 4 – Steam Humidifier Capacity in Gallons/Day Steam Hose or Insulated Pipe Length < 2 ft. 2 ft. 4 ft. 6 ft. 8 ft. 10 ft. 12 ft. 14 ft. 16 ft. 18 ft. 20 ft. 120 Volts 11.5 Amps 208 Volts 16.0 Amps 11.5 Amps 240 Volts 16.0 Amps 11.5 Amps 16.0 Amps Steam Hose Insulated Pipe Steam Hose Insulated Pipe Steam Hose Insulated Pipe Steam Hose Insulated Pipe Steam Hose Insulated Pipe Steam Hose Insulated Pipe 11.5 11 10 9 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.
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.
INSTALLATION INSTRUCTIONS (continued) Figure 13 – 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.
INSTALLATION INSTRUCTIONS (continued) Figure 14 – 240 VAC Wiring Diagram BLK BLK YEL MAIN POWER BREAKER (NOT PROVIDED) POWER TERMINAL BLOCK J8 GND J16 J10 WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE L1 TRANSFORMER POWER JUMPER WIRE BLK/WHT STEAM CANISTER P7 DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS.
INSTALLATION INSTRUCTIONS (continued) Figure 15 – 208 VAC Wiring Diagram BLK BLK YEL MAIN POWER BREAKER (NOT PROVIDED) POWER TERMINAL BLOCK J8 GND J16 J10 WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE L1 TRANSFORMER POWER JUMPER WIRE BLK/WHT STEAM CANISTER P7 DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS. MOVE THE JUMPER WIRE TO TERMINAL J11 TO OPERATE AT 208VAC.
INSTALLATION INSTRUCTIONS (continued) Figure 16 – 120 VAC Wiring Diagram BLK BLK YEL MAIN POWER BREAKER (NOT PROVIDED) POWER TERMINAL BLOCK J8 GND J16 J10 WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE L1 TRANSFORMER POWER JUMPER WIRE BLK/WHT STEAM CANISTER P7 DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS. MOVE THE JUMPER WIRE TO TERMINAL J13 TO OPERATE AT 120VAC.
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.
INSTALLATION INSTRUCTIONS (continued) 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.
INSTALLATION INSTRUCTIONS (continued) Automatic Digital Modulating Control wiring (Model 801 or 866) 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.
INSTALLATION INSTRUCTIONS (continued) Figure 20 – ADMC with Model 866 ADMC 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. 1 2 36.
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.
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.
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.
Maintenance NOTICE • Allow humidifier to drain and disconnect power before servicing. • Service should be performed by a qualified 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.
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.
TROUBLESHOOTING Guide (continued) TABLE 6 – Troubleshooting Guide (continued) Problem Possible Cause Action Humidifier makes gurgling sound. Excess condensation in steam hose. 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. Fill valve makes banging sound. Water hammer from line pressure.
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. Wiring. Check wiring. Steam Humidifier power. Check that Steam Humidifier is powered and on. No humidity call. Adjust humidistat setting.
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.
REPLACEMENT PARTS (continued) Item No. Part No. Description 32 1 4004 Fill Valve In-line Strainer 2 4975 Membrane Switch 3 5306 4 Item No. Part No.
