Installation & User Manual FORM NO. 5500-32; Rev.
1. Duct Steam Humidifier 2. Installation Manual 3. Installation Kit a. b. c. d. e. f. g. h. i. j.
Before installing or handling the humidifier please carefully read and follow the instructions and safety standards described in this manual and on the labels attached to the 5500 Steam Humidifier. Test water conductivity prior installation to ensure conductivity falls between 125 to 1250 μS/cm.
TABLE OF CONTENTS 1. How The 5500 Steam Humidifier Works 4 1.1 Basic Operation 1.2 Cylinder Life 1.3 Calculating Humidity Load 4 5 5 2. Model Information 6 3. Installation 7 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 4. 4.1 4.2 4.3 4.4 4.5 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.
1. HOW THE 5500 STEAM HUMIDIFIER WORKS 1.1 Basic Operation The 5500 Steam Humidifier is an electrode humidifier. Unlike heating elements, electrode steam humidifiers produce steam for humidification by passing electric current through the water between metal electrodes inside the plastic steam generator cylinder. Steam output is directly proportional to the conductivity of the water, the power supply (115V or 230V), and the amount of electrode immersed in the water.
1.2 Cylinder Life 1.2.1 Basics of the Steam Cylinder The Steam Cylinder is the engine of the humidifier. As the water is evaporated inside the cylinder, minerals are left behind. Much of these minerals are removed through the cylinder drain, however, some are deposited on the walls of the cylinder and the cylinder electrodes. When a lower section of the electrodes develops a thick coating, the water level is raised to expose clean electrode surface.
1.3.1 Steps to Determine Humidity Load (cont.) Example: • 2,500 SF house with 1,000 SF basement (3,500 SF total square footage) • 9 ft ceilings • 70°F and 40% RH • 2 fireplaces • Humidity Load = 3,500 x 9 x .00020 x 1.05 x 1.05 X 2.88 = 20 GPD For more accurate results based on U.S. geographic region, see the GeneralAire on-line humidity calculator at https://www.generalfilters.com/support/humidity-calculator.html. 2.
3. INSTALLATION 3.1 Positioning The 5500 Steam Humidifier has been designed for wall mounting and since it is an electrode steam humidifier, should be placed close to the point where the steam will be ducted to minimize the steam hose length (and the amount of condensate). Certain minimum clearances must be maintained around the unit for safety and maintenance. (See Figure 3.a. and Table 3.a) DO NOT introduce steam into duct that has interior insulation. B Table 3.a. Figure 3.a.
3.2.2 Fastening to the Wall There are several options to install the steam unit to a finished wall or exposed studs. • Option 1: Attach directly to a wall using the supplied screws and anchors. Use the two inner holes of the supplied mounting strap as a template for the mounting holes (marked by “A” in Figure 3.d). Once marked, the two top screws can be installed first and then the steam unit can be hung on the screws using the keyhole slots.
3.3 Plumbing 3.3.1 Water Characteristic Requirements The humidifier must be supplied with water with the following characteristics: • Incoming Pressure: Between 20psi and 90psi or 0.1 and 0.8 MPa (1 - 6 bar) ▪ • • • • • • • Maximum intermittent pressure 110psi (8 bar) Maximum intermittent pressure includes water hammer or other supply water pressure spikes. High-water pressure can be addressed with water hammer arrestors or pressure regulators.
3.3.4 Condensate Pump When using a Condensate Pump, ensure pump is capable of storing about 1.1 gallons in 15 seconds with a pump output of 3 gpm or more. 3.4 Steam Distribution & Installation The maximum allowed duct static pressure is 2 in. WC. IMPORTANT: Allow 5 feet (1-1/2 M) of straight return duct downstream of the distributor pipe or nozzle for absorption of the steam. Always allow 3 feet (0.9M) of straight supply duct upstream of the distributor pipe or nozzle for evaporation of the steam.
Table 3.d. Figure 3.i. Steam Nozzle A B C D E F G H I Inches 1.24” 1.96” 2.20” 2.26” 3.93” 0.31” 0.86” 1.18” 0.47 or 0.87” Millimeters 31.5 mm 50 mm 56 mm 57.5 mm 100 mm 8 mm 22 mm 30 mm 12 or 22 mm Apply silicone sealant to this face Figure 3.j. Steam Nozzle Installation Min 8” Height >8” Airflow 1000 cfm min. Airflow 1000 cfm min. = 24” min Upstream 1/3 Height = = = Airflow 1000 cfm min. 36”min Downstream Bottom Installation Horizontal Duct 3.4.
Installing the Steam Manifolds or Steam Nozzle (Sections 3.4.1 – 3.4.3) 1. Cut a round hole in the side of the duct to match either the nozzle or manifold diameter. 2. Apply silicone sealant to the mounting plate and insert the nozzle or manifold through the hole and secure with sheet metal screws. For 12” and 17.5” manifolds, install end bracket to maintain correct slope. 3. Connect the steam and condensate hoses using the hose clamps supplied. 3.4.
Figure 3.m. for Steam Nozzle, 12” and 17.5” Steam Manifold – Optional Installation Condensate drain for nozzle. Condensate drain for nozzle. : The standard steam unit comes with 6 feet (1.8m) of steam hose. Maximum total length of rubber steam hose is 3.65m (12 feet). The maximum total length of insulated copper tubing may be up to 6.1m (20 feet). The maximum combined allowed length of steam hose and insulated copper tubing is 9.75m (32 feet). In all cases, minimize sharp bends and elbows.
3.5 Power Supply Voltage Selection Select the desired Power Supply Voltage Setting! The factory setting is 230 Vac. The humidifier can be powered at either a nominal voltage of 115 Vac 50/60 Hertz or a nominal voltage of 230 Vac 50/60 Hz. If the main power supply is 115 Vac, the setting must be changed accordingly, following the procedure described below: 1. Make sure the power cable is disconnected from the main power supply and that the power button is in the OFF position. 2.
3.7 Control Wiring 5500 Steam Humidifiers allow for the connection of any simple or automatic humidistat, safety devices such as high-limit humidistat, air flow proving switch, or remote ON/OFF switch. The control wiring terminal blocks are located at the top right of the control module ( (Figure 3.q.). Figure 3.q. The humidifier is operated by the closing of a mechanical humidistat H, or by the closing of a voltage-free remote contact, or alternatively by a combination of both.
3.7.3 Pressure, Safety, and High Limit Switches (Field Supplied) Highly Recommended. Remove the jumper between terminals AB-AB and connect any simple high-limits air flow switch (suggest part HC-201; GFI #7520 or similar); a pressure switch (suggest part 12500; GFI #7021 or similar), and remote contacts in series to terminals AB-AB; otherwise, if no such dry contacts are available, the jumper must remain in place between terminals AB-AB. DO NOT apply any voltage to AB-AB.
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4. START-UP 1. Before starting, check that there are no water leaks and that the electrical components are dry. 2. DO NOT connect power if the humidifier is damaged or even partially wet! When installation is completed, flush the supply pipe for 10 minutes by piping water directly into the drain without sending it into the humidifier. This will eliminate any scale or residue that may cause foam when boiling. 4.
• • • At the end of this initialization operation, a sequence of characters will be shown on the display to indicate the selected output and voltage, according to the following scheme: o CH + size (kg/h) + U + voltage (1 = 115V, 2 = 230V) 1. CH01U1 = 1.6 kg/h 115V 2. CH02U1 = 2.2 kg/h 115V 3. CH03U2 = 3.3 kg/h 230V Default setting is Option 3 if no selection is made 4. CH04U2 = 4.5 kg/h 230V o If no selection is made within 10 seconds, the unit will start using the default setting Option 3.
5.3. Changing the Maximum Production The Maximum Production feature can be adjusted between 20% to 100% of the nominal production, in 5% increments, in order to suit the environmental characteristics. The 5500 Steam Humidifier is factory set at 100%. 1. Switch steam humidifier off. 2. Press both and hold both buttons “RESET/SEL” and “DRAIN/ENTER” and switch steam humidifier back on. When the wrench blinks, release the two buttons. 3. Press “RESET/SEL” until the display shows 01.
5.7 Alarms In the event of an alarm, the red alarm LED will flash, the alarm relay will close, and the alarm code will flash in the display. Multiple alarms will flash in sequence, alternating with the main display. Pressing the “RESET/SEL” button for 2 seconds will reset the alarms, although still active alarms will continue to display. Display Description Action Red Led Alarm Relay -- Remote on-off open Unit disabled Off Off Jumper terminals AB-AB Unit not configured.
6. TROUBLESHOOTING Table 6.a Problem The humidifier does not turn on The humidifier does not start operation The humidifier fills with water without producing steam Excess humidity or moisture in the duct Water leaks on to the floor below Water in the cylinder turns black Heavy arcing occurs within hours of start-up Humidifier continuously fills and drains without producing steam 22 | P a g e Causes 1. No electrical power 2. ON/OFF switch of the humidifier in position 0 (open) 3.
7. MAINTENANCE 7.1 • • • • Periodic Checks After one hour of operation: Check that there are no significant water leaks. Every fifteen days: Check operation for water leaks and the general condition of the cylinder. Check that during operation there is no arcing between the electrodes. Every three months: Check operation for water leaks and, if necessary, replace the cylinder. Check that there are no blackened parts of the cylinder.
7.3 5 Replacement Parts 12 12 6 4 7 15 6 2 10 1 1 2 3 3 11 8 4 5 8 Exploded View of O-Ring Placement14 • Bushing is permanently affixed to drain pump. • O-ring is included with replacement cylinder. 24 | P a g e Item USA GFI Part No. CANADA CGF Part No.
8. TECHNICAL SPECIFICATIONS Capacity / VAC / kW Steam pressure 5.5 lbs/hr (2.5 kg/h): 110 VAC 1-phase 50-60 Hz, 1.86 kW 12 lbs/hr (5.4 kg/h): 230 VAC 1-phase 50-60 Hz, 4.05 kW 3.81 in WC / 950 Pa Dimensions (inches / mm) 21” H x 13.5” W x 8.25” DP (533 x 343 x 210 mm) Weight empty/packaged/installed 16 / 26 / 24 lbs. (7.
9. LIMITED WARRANTY GeneralAire® Model 5500 Steam Humidifiers, if properly registered on www.generalfilters.com/support/warranty-registration, are warranted to the consumer against defects in materials and workmanship for a period of five years from the date of installation, so long as the product has been installed by a qualified contractor and operated in accordance with all appropriate manuals and wiring diagrams in a residential structure.
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