Aprilaire 800 Steam Humidifier Manual

READ AND SAVE THESE INSTRUCTIONS

SAFETY CAUTIONS

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 until 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 bodily 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.

INTRODUCTION

Your humidifier will require periodic maintenance to assure continued consistent performance.
Now, please take a few minutes and read this booklet. This will familiarize you with the benefits you will receive from the equipment you just purchased and help you understand the routine maintenance that will be required.
Be sure to register your humidifier warranty online at: www.aprilaire.com/warranty.

Genuine Aprilaire Replacement Model 80 Steam Canisters are available from your installing contractor or from most other heating and air conditioning contractors in your area. Use the dealer locator on our web site (www.aprilaire.com) or look in the Yellow Pages under Humidifying Apparatus or Heating & Air Conditioning Contractors.

PRINCIPLES OF OPERATION

The Aprilaire^® Model 800 Canister Steam Humidifier delivers humidity in the form of steam to the conditioned space via the HVAC system duct or optional Aprilaire Model 850 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.
Steam is delivered into the airstream through a dispersion tube mounted in the HVAC system ductwork. Openings in the dispersion tube are fitted with "tubelets" which extend into the center of the tube. 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.

FIGURE 1 – Fill and Drain System and Canister

SEQUENCE OF OPERATION

When the Automatic Digital Humidifier Control (ADHC) detects humidity below the set point, and provided the humidifier is turned on and the HVAC system blower is operating, the internal controller in the humidifier energizes the electrodes and measures the current flowing through the water between them. The controller adjusts water level in the canister via a fill valve and a drain valve to maintain a constant current. The operating water level in the canister depends on the mineral content of the water which determines conductivity.
The ADHC has the ability to turn on the HVAC system blower if the homeowner or installer chooses to utilize that feature. See ADHC installation manual.

OPERATING MODES

When the humidifier is powered and turned on, the "On/Off" light is illuminated green.
Any time the fill valve is activated, the "Fill" 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 normal operation. During this time, the "Steam" light illuminates green. If the humidifier cannot produce steam at the rated level after trying for 48 hours, the "Steam" light illuminates yellow. The humidifier continues to attempt to produce steam at the rated level for another 48 hours in this mode. If the humidifier cannot produce steam at the rated level in a total of 96 hours, the "Service" light will flash red.
The conductivity of naturally soft water, hard water, and softened water changes as the water heats up, but the controller adjusts the water level to maintain a nominal current between the electrodes. Over the life of the canister, minerals that build up on the electrodes will reduce their effective surface area and affect the resistance between them. The operating water level will increase with use until it reaches the high water level probe. At that point, the "Service" light will flash red indicating that the canister needs to be replaced.
When the humidifier is operating, the "Steam" light on the front illuminates green. If the internal controller attempts to make steam but the water does not contain enough minerals to be conductive, the water level in the tank will reach the high level point and the "Steam" light will illuminate yellow.
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

If the humidifier does not receive a call to operate in 72 hours, the controller drains the canister. The humidifier will resume normal operation when a call for humidity is made.

DISPLAY PANEL

TABLE 1 – Display Panel

Icon	Function
	Main switch. Press to turn humidifier on and off.
	Resets timer for start-up water conditioning.
Light	Solid green when humidifier is turned on.
	Flashes green for one minute once power is restored if humidifier was operating when power was shut off.
	Fill valve indicator.
Light	Solid green during normal operation when canister water is being replenished.
	Flashes green (along with Drain light) indicating fill and drain valves are pulsing to dislodge mineral deposits.
	Solid red if canister needs water but water is not detected. See Troubleshooting Guide.
	Indicates call for humidity.
Light	Solid green during call for humidity.
	Solid yellow if humidifier cannot reach nominal output within first 48 hours of operation due to insufficient water conductivity. Humidifier will continue to cycle valves in an attempt to reach capacity for an additional 48 hours. Approximately 1/10 teaspoon of table salt can be added to fill cup to increase conductivity of water.
	Drain valve indicator.
Light	Solid green to indicate start of drain cycle. Drain cycle occurs: To maintain nominal steam output during normal operation. During end of season shut down. (End of season shut down occurs after 72 hours of inactivity.) If humidifier has operated for 168 hours without a drain cycle. When humidifier is turned off.
	Flashes green (along with fill light) indicating drain and fill valves are pulsing to dislodge mineral deposits.
	Flashes green when humidifier is turned off indicating canister is draining. When flashing stops, main power disconnect can be turned off and front panel can be opened.
	Indicates canister needs to be replaced or humidifier requires other type of service.
Light	Flashes red when canister can no longer supply demand and needs to be replaced because electrodes have been corroded or coated with mineral deposits. Humidifier may continue to generate steam but at a reduced capacity.
	Flashes red if humidifier with new canister cannot generate steam due to insufficient water conductivity after 96 hours of drain/fill activity. Approximately 1/10 teaspoon of table salt can be added to fill cup to increase conductivity of water.
	Solid red if controller detects over-current between electrodes. Causes may include electrodes coated with mineral deposits, blocked drain, or defect in drain valve circuit. See Troubleshooting Guide.

OPERATING INSTRUCTIONS – DIGITAL HUMIDIFIER CONTROL

The Digital Humidifier Control offers two modes of operation, Automatic or Manual. An explanation of both modes follows. (See Figure 2 for Automatic Mode. See Figure 3 for Manual Mode.)

When in the Automatic Mode, this system offers the following benefits:

• You will receive the optimum amount of humidity so that your home and its furnishings are protected from the damaging effects of excess condensation or low humidity during the heating season. The Control automatically adjusts your home's humidity based on the outdoor temperature, increasing the time maximum comfort is maintained.
• Simple operation with few adjustments. In the Automatic Mode, the Control eliminates the need to manually adjust the control when outdoor temperature changes. It also eliminates the need to turn the dial setting to "OFF" during the summer season.

DIGITAL HUMIDIFIER CONTROL INDICATOR LIGHTS

Call Dealer for Service: The red light indicates that the humidifier is not operating normally and that service is required.
Humidifier On: The green light indicates that the humidifier is operating normally.

BLOWER ACTIVATION

Set the Blower Activation Switch to "ON" to allow the Humidifier Control to activate the furnace fan for additional humidification. Refer to TABLE 4 – Operation Guide. This may be required if the humidifier is mounted on a heat pump or a furnace with short run cycles.
When the Blower Activation switch is "ON", the Humidifier Control will turn on the HVAC blower when humidity is required. In the "OFF" position, the humidifier will only operate if humidity is required and the HVAC system is operating.
When the Blower Activation switch is "ON", the Humidifier Control may periodically turn the HVAC blower on to sample the humidity of the air.

AUTOMATIC MODE

FIGURE 2 – Automatic Mode

Your Aprilaire Humidifier Control is installed in the cold air return duct. During the first heating season, your Humidifier Control needs to be set initially to match your home's condition. Please follow these steps when adjusting your control (refer to Figure 2).

1. Turn the dial setting knob to "5", which is within the normal range. During the next 24-48 hours it may be necessary to adjust the dial for more or less humidity, depending on your personal comfort and home's requirements. Refer to TABLE 4 – Operation Guide.
2. During the coldest portion of the first heating season, minor adjustments may be necessary. This is dependent upon your home's construction. Refer to TABLE 4 – Operation Guide.

The humidity in your home will now be accurately controlled to meet your needs and should not need further adjustment during future heating seasons. Make note of the dial setting in the event you temporarily move the knob to "OFF" when performing annual maintenance of your Aprilaire humidifier.

MANUAL MODE

FIGURE 3 – Manual Mode

When installed in the Manual Mode (see Figure 3 – internal switch in "MAN" position and "M" in the display), it is important to anticipate a drop in outdoor temperature and reduce the setting accordingly to avoid excessive condensation. For example, with an outdoor temperature of 20°F the correct setting will be 35%. If the temperature is expected to fall to 0°F that evening, then merely reduce the setting to 25% several hours prior to the temperature change.
See Table 2 for the recommended settings. These settings, which are based on years of research, represent a compromise between humidity levels that would be most desirable for comfort and humidity levels that are suitable for protection of your home and to avoid condensation on your windows. For example, a wintertime indoor humidity of 50% may be considered ideal for comfort, but unfortunately, it probably would result in condensation, which can cause damage to your home. Observing the recommended humidity levels on your Humidifier Control is an important safeguard. Condensation of water on the inside surface of windows in the form of fogging or frost is usually an indication of too much humidity. This same condensation can occur in other areas in your home, possibly resulting in damage.

TABLE 2 – Outdoor Temperature/Indoor Relative Humidity

TEST/RESET
The Test/Reset feature allows the humidifier operation to be checked even if there is no call for humidity. See "Check the Humidifier Operation".

ADDITIONAL INFORMATION – AUTOMATIC MODE
Your humidifier is a precision system that will accurately maintain the humidity in your home. For every 2°F change in outdoor temperature, the Digital Humidifier Control will automatically adjust the indoor humidity by 1%.
The Digital Humidifier Control will accurately control the humidity in your home to a maximum of 45%.
The humidity Values in Table 3 are targets based on outdoor temperature and the Digital Humidifier Control setting. The actual humidity may vary due to conditions in the home (cooking, showering, etc.).

TABLE 3 – % Relative Humidity Guide

TABLE 4 – Operation Guide

CHECK THE HUMIDIFIER OPERATION

DIGITAL HUMIDIFIER CONTROL

Set the knob to "Test/Reset", make sure that the water saddle valve is open and that the humidifier is on. The HVAC fan must be running for the humidifier to function. The humidifier will only operate for 1 minute in test mode. Reduce the Humidifier Control setting to the recommended inside humidity, depending on the outside temperature. DO NOT LEAVE IN TEST MODE AS HUMIDIFIER WILL NOT OPERATE.

ADDITIONAL INFORMATION

Be sure to keep fireplace dampers closed when not in use. They provide an excellent escape route for heat, as well as humidity.
On occasion, indoor moisture producing activities such as clothes drying, cooking, showers, etc., may raise the humidity level higher than it should be, even though the Aprilaire humidifier is not operating. Telltale indications are condensation or frost on cold surfaces such as windows, doors, walls, etc. If such condensation persists for several hours, your home should be ventilated to dissipate the potentially damaging excess moisture.

EFFECT OF WATER CHARACTERISTICS

Your humidifier is designed to operate using softened or unsoftened, cold tap water. Do not use hot water.

MAINTENANCE

Turn humidifier off and allow humidifier to drain. Disconnect power before servicing.
Inspect Humidifier at approximately 500 hour intervals or several times during the humidification season.

• 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 drain.

TO REPLACE THE CANISTER

Replace the canister annually and when prompted by the "Service" light. Use Only Genuine Aprilaire Model 80 Canister.

1. Press On/Off switch to turn humidifier off.
2. Allow humidifier to drain. When the green "drain" LED stops flashing, disconnect main electrical power to humidifier.
3. Remove front panel.
4. Pull three wires off posts on top of canister. (Two large electrode conductors and one water level probe conductor.)
5. Loosen hose clamp at top of canister.
6. Slide hose off top of canister.
7. Slide canister up and out of drain assembly. Discard canister.
8. Remove o-ring from drain assembly using small screw driver.
9. Inspect drain assembly and remove any debris. See drain valve cleaning procedure.
10. Insert new o-ring into slot 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.
11. Make sure strainer is inserted into bottom of new canister.
12. Insert canister into drain assembly. Position canister with label facing outward.
13. Slip steam hose over top of canister and tighten hose clamp.
14. Reattach three wires to posts on top of canister. (Larger electrode conductors are interchangeable.)
15. Replace front panel.
16. Inspect drain line to make sure it is not blocked and has constant downward slope. Clean or replace if necessary.
17. 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 drain.
18. Restore electrical power to humidifier.
19. Turn humidifier on and verify green On/Off light is illuminated.
20. See Start-up procedure.

TO SERVICE FILL VALVE

If water flow from fill valve is restricted, disconnect inlet fitting and remove in-line strainer using small screw from inlet port. Clean or replace strainer.

LIMITED WARRANTY

Your Research Products Corporation Aprilaire^® humidifier unit is expressly warranted for five (5) years from date of installation to be free from defects in materials or workmanship except, however, for the disposable steam canister which will have to be replaced from time to time depending upon the amount of use.
Research Products Corporation's exclusive obligation under this warranty shall be to supply, without charge, a replacement for any part of the humidifier which is found to be defective within such five (5) year period and which is returned not later than thirty (30) days after said five (5) year period by you to either your original supplier or to Research Products Corporation, Madison, Wisconsin 53701, together with the model number and installation date of the humidifier.
THIS WARRANTY SHALL NOT OBLIGATE RESEARCH PRODUCTS CORPORATION FOR ANY LABOR COSTS AND SHALL NOT APPLY TO DEFECTS IN WORKMANSHIP OR MATERIALS FURNISHED BY YOUR INSTALLER AS CONTRASTED TO DEFECTS IN THE HUMIDIFIER ITSELF.
IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE AFORESAID FIVE YEAR PERIOD. RESEARCH PRODUCTS CORPORATION'S LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES, OTHER THAN DAMAGES FOR PERSONAL INJURIES, RESULTING FROM ANY BREACH OF THE AFORESAID IMPLIED WARRANTIES OR THE ABOVE LIMITED WARRANTY IS EXPRESSLY EXCLUDED. THIS LIMITED WARRANTY IS VOID IF DEFECT(S) RESULT FROM FAILURE TO HAVE THIS UNIT INSTALLED BY A QUALIFIED HEATING AND AIR CONDITIONING CONTRACTOR. IF THE LIMITED WARRANTY IS VOID DUE TO FAILURE TO USE A QUALIFIED CONTRACTOR, ALL DISCLAIMERS OF IMPLIED WARRANTIES SHALL BE EFFECTIVE UPON INSTALLATION.
Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above exclusion or limitations may not apply to you.
This warranty gives you specific legal rights and you may also have other rights which vary from state to state.

WARRANTY REGISTRATION

Visit us on-line at www.aprilaire.com to register your Aprilaire product.
If you do not have on-line access, please mail a postcard with your name, address, phone number, model number of product purchased and date of installation to:
Research Products Corporation, P.O. BOX 1467, Madison, WI 53701

RESEARCH PRODUCTS CORPORATION
PO BOX 1467 • MADISON, WI 53701-1467

©2010 Research Products Corporation

Videos

Aprilaire 800 Maintenance - How To Change the Steam Canister Video

Documents / Resources

References

• Warranty Registration for AprilAire Products
• AprilAire is Healthy Air

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