Aprilaire 800 series Installation & Maintenance Instructions Manual
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Aprilaire 800 series Installation & Maintenance Instructions Manual

Steam humidifier
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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
- Humidifier Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Prepare Humidifier for Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install Steam Dispersion Tube/Fan Pack . . . . . . . . . . . . . . . . . . . . 14
Mount Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Series 800 Steam Humidifier
ReaD anD SaVe THeSe InSTRUCTIonS
Install Steam Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Supply Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Power Wiring & Shut-off Switch . . . . . . . . . . . . . . . . . . 15
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
Steam Humidifier

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Summary of Contents for Aprilaire 800 series

  • Page 1: Table Of Contents

    Steam Humidifier Series 800 Steam Humidifier Installation & Maintenance Instructions Table of ConTenTS Safety Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Install Steam Hose .

  • Page 2: Safety Cautions

    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.

  • Page 3: Materials List

    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”...

  • Page 4: Principles & Sequence Of Operation

    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 Fan Pack . The humidifier generates steam...

  • Page 5: Specifications & Dimensions

    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 &...
  • Page 6 SPeCIfICaTIonS & DIMenSIonS (ConTInUeD) Steam Dispersion Tube fIGURe 3 – Humidifier Dimensions (inches) 8-7/8 1-3/4 8-7/8 Fill Cup 1-3/4 Fill Cup 7-7/8 7-7/8 3 sq 3 sq 3-3/8 3-3/8 1-5/8 1 dia 1-5/8 1 dia 3-3/8 3-3/8 4-1/4 4-1/4 5-3/4 8-1/4 8-1/4 5-3/4...
  • 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 .

  • Page 8: Installation Instructions

    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 .
  • 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.

  • Page 10: Fan Pack Location

    InSTallaTIon InSTRUCTIonS (ConTInUeD) fan PaCk loCaTIon fIGURe 4 – Side View 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 IMPORTANT: the bend .

  • Page 11: Elevation

    InSTallaTIon InSTRUCTIonS (ConTInUeD) Mount fan Pack Housing fIGURe 6 – wall opening and Mounting 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 Wall Stud and wiring the Fan Pack .

  • Page 12: Distance From Humidifier To Dispersion Tube/Fan Pack

    InSTallaTIon InSTRUCTIonS (ConTInUeD) If the dispersion tube must be mounted below the humidifier or fIGURe 9 – Dispersion Tube Mounted below Humidifier 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 Drip tee installation for figure 9 .

  • Page 13: Humidifier Location

    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...

  • Page 14: Prepare Humidifier For Mounting

    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 .

  • Page 15: Drain Line

    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 .
  • Page 16 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. 90-1959...
  • Page 17 InSTallaTIon InSTRUCTIonS (ConTInUeD) fIGURe 14 – 240 VaC wiring Diagram POWER TERMINAL MAIN POWER BREAKER BLOCK (NOT PROVIDED) WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE TRANSFORMER POWER JUMPER WIRE BLK/WHT STEAM CANISTER DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY ORANGE WIRED FOR 240 VOLTS.
  • Page 18 InSTallaTIon InSTRUCTIonS (ConTInUeD) fIGURe 15 – 208 VaC wiring Diagram POWER TERMINAL MAIN POWER BREAKER BLOCK (NOT PROVIDED) WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE TRANSFORMER POWER JUMPER WIRE STEAM CANISTER BLK/WHT DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY WIRED FOR 240 VOLTS.
  • Page 19 InSTallaTIon InSTRUCTIonS (ConTInUeD) fIGURe 16 – 120 VaC wiring Diagram POWER TERMINAL MAIN POWER BREAKER BLOCK (NOT PROVIDED) WATER LEVEL PROBE L2 / N ELECTRODE ELECTRODE TRANSFORMER POWER JUMPER WIRE BLK/WHT STEAM CANISTER DOOR SWITCH RESIDENTIAL STEAM HUMIDIFIER IS SHIPPED FROM THE FACTORY ORANGE WIRED FOR 240 VOLTS.

  • Page 20: Automatic Digital Control And Accessory Wiring

    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 .

  • Page 21: Manual Digital Humidistat And Fan Pack Wiring

    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 Aprilaire Steam Humidifier Model 65 Digital Control 24VAC...

  • Page 22: Automatic Digital Modulating Control Wiring

    InSTallaTIon InSTRUCTIonS (ConTInUeD) aUToMaTIC DIGITal MoDUlaTInG ConTRol wIRInG (MoDel 801 oR 866) The Automatic Digital Humidifier Control fIGURe 19 – aDMC with Model 801 (ADMC) that ships with Model 63 and Model 5558 must be mounted on an interior wall in the living space .
  • Page 23 20 – aDMC with Model 866 installed with the Fan Pack, wire the ADMC as shown in figure 20 . ADMC The Aprilaire Automatic Digital Modulating Control is the recommended humidity controller for the Model 801 and Model 866 +24V Modulating Steam Humidifier .

  • Page 24: Start-Up Procedure

    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 .

  • Page 25: Operating Modes

    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”...

  • Page 26: Shut Down Procedure

    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 .

  • Page 27: Maintenance

    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. •...

  • Page 28: Troubleshooting Guide

    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 .
  • Page 29 TRoUbleSHooTInG GUIDe (ConTInUeD) Table 6 – Troubleshooting Guide (continued) Problem Possible Cause action Install Tee and Trap Model 4028 as shown in figure 10 . Humidifier makes gurgling Excess condensation in steam hose . sound . Make sure steam hose has constant downward slope to humidifier or to tees and traps in low spots of hose .
  • 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 .

  • 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 .
  • Page 32 RePlaCeMenT PaRTS (ConTInUeD) Item no. Part no. Description Item no. Part no. Description 4004 Fill Valve In-line Strainer 5530 Control Board, Model 800, 865 4975 Membrane Switch Universal Transformer, Model 800, 801 5529 (40 VA) Universal Transformer, Model 865, 866 5306 (75 VA) 4997...

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