Aprilaire 1150 Installation, Operation And Maintenance Manual
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Aprilaire 1150 Installation, Operation And Maintenance Manual

Steam humidifier installation, operation, and maintenance manual
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Humidifier
Steam Humidifier
Models 1150, 1160, and 1180
Installation, Operation, and Maintenance Manual
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Summary of Contents for Aprilaire 1150

  • Page 1 Humidifier Steam Humidifier Models 1150, 1160, and 1180 Installation, Operation, and Maintenance Manual READ AND SAVE THESE INSTRUCTIONS...

  • Page 2: Table Of Contents

    TAblE Of CONTENTS PRODUCT OVERVIEw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 OPERATION Materials Provided and Not Provided .

  • Page 3: Product Overview

    PRODUCT OVERVIEw Aprilaire Steam Humidifiers create steam by boiling water inside a steam chamber . This is accomplished by the transfer of energy from electric heating elements to the water inside the chamber . A three-level water probe is used to determine when to turn on and off a water fill valve in order to bring water into the chamber .

  • Page 4: Electrical Specifications, Capacities And Weights

    38 .5 Note: Models 1150,1160 and 1180 operate at 50/60 Hz . * 208V may also be used but the steam capacity will be approximately 25% lower than the values above . It is recommended that the same size circuit break-...

  • Page 5: Dimensions

    2 – Dimensions (pertains to Models 1150, 1160 and 1180) Power wire knockout TOP VIEw 11 .89” (302 mm) 5 .50” 6 .50” 1 .00” (25 mm) (140 mm) (165 mm) 3 .09” Control wire knockout (78 mm) Steam outlet 24 .06”...
  • Page 6 16 .00" (406 .4mm) 0 .75" (19 .0mm) Keyhole for 3/8" diameter fasteners (2) 90-914 fIgURE 4 – Distribution Tube Dimensions MODEl 1150 MODEl 1160 14" Tube length 20" Tube length 1 .50 (TYP) 1 .50 (TYP) 3/8" Flat washer 3/8"...

  • Page 7: Overview Of Humidifier Operation

    (e .g ., water level probe inside the steam chamber) to provide: • R elative humidity (RH) control • C hamber water cooling before draining – Model 1150: With an on-off demand signal, the controller To ensure that water is at or below 140°F (60°C) before maintains RH within 5% to 7% of set point .

  • Page 8: Sequence Of Operations

    Note: Sequence is for normal operation, starting with an empty Steam Chamber . Model 1150 Humidifier is connected to: 240 VAC, single phase input power; Model 57 on/off Automatic Steam Humidifier Control (ASHC); Airflow Proving Switch and High Humidity Limit Switch . Water supply is turned on, steam distribution and drain connections are made .
  • Page 9 SEQUENCE Of OPERATIONS Note: Sequence is for normal operation, starting with an empty Steam Chamber . Model 1160 humidifier is connected to: 240 VAC, single phase input power; Model 57 modulating Automatic Steam Humidifier Control (ASHC); Airflow Proving Switch and High Humidity Limit Switch . Water supply is turned on, steam distribution and drain connections are made .
  • Page 10 TAblE 3 – Sequence of operation for Model 1160 and 1180 (continued) Operation Expected Results • The humidifier will go into a forced cool-down period, which lasts about 6 hours for Model 1160 and 7 hours for Model 1180 . During that time, all the LEDs will blink in sequence . • After the forced cool down period, the Fill LED will turn on – the Fill valve will open, water will flow into chamber until it reaches the upper probe. If demand for humidity prevents the chamber from cooling, • Drain LED will turn on and the drain valve will open allowing water to flow from the a forced Autodrain sequence is initiated .
  • Page 11 TAblE 4 – Display Panel light Indications Indicator light(s) Status Description The humidifier is in a forced cool-down period prior to a required automatic drain sequence . Blinking sequentially Normal operation . Power is on . Normal operation . On/Off (switch) Slow blinking (1/sec .) The electronic water level probe needs cleaning .

  • Page 12: Installation

    INSTAllATION fIgURE 7 – Model 1150 wiring Diagram APRIlAIRE STEAM HUMIDIfIER MODEl 1150 SINGLE HEATER WIRING DIAGRAM ON/OFF CONFIGURATION AA-LW420-1...
  • Page 13 8 – Model 1160 wiring Diagram APRIlAIRE STEAM HUMIDIfIER MODEl 1160 DUAL HEATER WIRING DIAGRAM MODULATING CONFIGURATION AA-LW420-2...
  • Page 14 9 – Model 1180 wiring Diagram APRIlAIRE STEAM HUMIDIfIER MODEl 1180 THREE HEATER WIRING DIAGRAM MODULATING CONFIGURATION AA-LW420-3...

  • Page 15: Setting Slide Switches

    Changing these settings will affect humidifier operation. Change on-off positions only per the instructions in this manual or as instructed by Aprilaire technical support staff. On the internal controller inside the humidifier, there are two banks of slide switches . Most are set at the factory according to the model type .
  • Page 16 Do not change . Do not change . Do not change . Do not change . Note: Positions 5-8 and 10–16 are for factory use only . TAblE 6 – Slide Switch Settings by Model Position Model 1150 1160 1180...

  • Page 17: Choosing A Location For Humidifier Components

    CHOOSINg A lOCATION fOR HUMIDIfIER COMPONENTS Before proceeding with the installation, you must first determine where the steam distribution tube will be installed as well as the humidifier itself . Steam Distribution Tube and Controls location Since this dictates the rest of the installation, first determine where the steam distribution tube will be mounted in the ductwork of the HVAC system .
  • Page 18 DISTRIbUTION TUbE AND CONTROl DEVICES lOCATION OPTIONS fIgURE 12 – Recommended Installation locations, Split System Application CHOOSINg A DISTRIbUTION TUbE lOCATION When installing a steam humidifier on a split system, there are three locations that can be used to mount the steam distribution tube: the supply plenum (Location A), the return duct (Location B), or a supply branch (Location C) .
  • Page 19 fIgURE 13 – Placing a Distribution Assembly in a Rooftop Air Handler Application CHOOSINg A DISTRIbUTION TUbE lOCATION When installing a steam humidifier on a packaged rooftop unit application, there are two locations that can be used to mount the steam distribution tube: supply plenum/duct (Location A) or the return plenum/duct (Location B) . Note: Wherever distribution tube is installed, there must be a minimum of 4 .5”...
  • Page 20 1 .5 duct diameters downstream of blower . Leave L (Low) side open to atmosphere . High Humidity limit Switch Aprilaire Model 1150/1160/1180 Switch will be closed Steam Humidifier below high limit set point DRAIN wATER OUT SUPPly wATER IN ¼"...

  • Page 21: Humidifier Control

    1 .5 duct diameters downstream of blower . Leave L (Low) side open to atmosphere . High Humidity Aprilaire Model 1150/1160/1180 limit Switch Steam Humidifier Switch will be closed below high limit set point DRAIN wATER OUT SUPPly wATER IN ¾"...

  • Page 22: Distribution Tube Installation

    . 1 . Cut or drill a 1 5/8” diameter opening in the duct for 1150/1160; 2 1/8” for 1180 . 2 . Drill a 3/8” hole in the opposite surface of the duct so that the distribution tube has a 2”/ft . (15%) pitch, sloping back towards the humidifier .
  • Page 23 fIgURE 16 – Distribution Tube Installation Duct Distribution tube Steam hose; do not exceed 10’ (3 m) in length . Use copper tube if additional length is 4 .5” minimum from required . Mounting nut tube to duct ceiling Hose pitch: 2”/ft (15%) 3/8”...

  • Page 24: Mounting The Humidifier

    . Refer to figure 27 on page 32 for details . If the 10’ hose is not long enough to reach from the humidifier to the distribution tube, use 1-1/2” copper tubing (Model 1150/1160), or 2” copper tubing (Model 1180) .

  • Page 25: Field Wiring

    Adding alternate conduit connections should not be necessary; however, when making holes and knockouts in the humidifier cabinet, protect all internal components from debris and vacuum out cabinet when finished . Failure to comply with this warning can damage sensitive electronic components and void the Aprilaire warranty . below are field wiring connections: • C onnect to line power.
  • Page 26 The 1150/1160 humidifier is designed for 240 VAC, single phase, fIgURE 18 – line Power wiring Requirements 50/60 Hz input power . The Model 1150 requires a 25 amp (minimum) breaker while the Model 1160 requires a 45 amp (minimum) breaker .

  • Page 27: Wiring Diagrams, Input

    21 . IMPORTANT: For Model 1150 on/off control, verify that the shunt on the JP2 jumper is placed over the 2 & 3 position . For Model 1160/1180 modulating control, verify that the shunt on the JP2 jumper is placed over the 1 & 2 position .
  • Page 28 fIgURE 22 – Model 1160/1180: Input wiring for Optional 0-10 VDC Signal by Others IMPORTANT: LW420 controller board slide switch SIgNAl by S1 positions 1 and 2 are OFF OTHERS 0-10 VDC HIgH HUMIDITy lIMIT SwITCH 2-wire shielded cable with ground 2-wire shielded AIRflOw PROVINg cable with ground...

  • Page 29: Airflow Proving Switch Installation

    AIRflOw PROVINg SwITCH INSTAllATION INSTRUCTIONS Description: fIgURE 24 The airflow proving switch is a safety device that will prevent Terminal Diaphragm Enclosure the humidifier from producing steam when there is no airflow present in the HVAC system . The switch is a pressure differential measuring device that determines if there is airflow present Mounting Bracket...
  • Page 30 The final connection size is 1” (DN25) hose or ¾” (DN20) copper for the chamber drain . Do not reduce this connection size . (See figures 25 and 26 for proper drain piping configurations .) A 12” (305 mm) piece of 1” (DN25) hose is provided to function as the flexible connection from the drain valve to the field installed drain plumbing .
  • Page 31 fIgURE 26 – field Piping Overview Showing Hard Pipe Drain Connections Steam hose (maximum run 10’ [3 m]) Water supply line Shock arrester recommended to reduce water hammer ¼” (DN8) compression fitting on fill valve Install plumb Union by installer connection to water supply line;...
  • Page 32 DISTRIbUTION DRIP TEE INSTAllATION If the humidifier cannot be mounted below the steam distribution tube, such that there is a minimum 2”/ft (15%) pitch along the entire hose length, a drip tee as shown below must be installed . Failure to follow the recommendations on this page, when the humidifier is mounted higher than the distribution tube, can result in excessive back pressures on the humidifier .

  • Page 33: Operation

    OPERATION HUMIDIfIER START-UP PROCEDURE wARNINg Line voltage may cause serious injury or death from electrical shock . Do not remove the power/ heater terminal cover until electrical power is disconnected . Only qualified electrical personnel should perform start-up procedure . After the system is properly installed and connected to both electrical and water supplies, it can be started .
  • Page 34 • S et up a fan call at the thermostat. If the humidifier is configured to bring on Probe housing the equipment fan with a humidity demand, skip to next step . OM-4052 Initiate Humidity Demand • F or the default Model 1150, 1160 and 1180 controls, whether in Automatic or Manual Mode, rotate control knob of the Automatic Steam Humidifier Control clockwise to the ‘Test’ position. – V erify that the steam indicator light illuminates and energizes the heaters. In the ‘Test’ position, the humidity demand will last for 1 minute only . wARNINg In the event the humidifier chamber does not contain water and the heaters are energized, turn main power off .

  • Page 35: Maintenance

    Model 1180 chambers weigh 60 pounds (27 kg) when full of water; Model 1160 chambers weigh 40 pounds (18 kg) when full of water; Model 1150 chambers weigh 30 pounds (14 kg) when full of water . Take the necessary precautions to support the additional weight when removing the chamber fasteners.
  • Page 36 D . If the steam chamber is cool to the touch, skip to Step 1E . If the chamber is hot, the water must be cooled down before draining and handling of the chamber . This can be accomplished by allowing sufficient time for the chamber to become cool enough to handle .
  • Page 37 8 . Verify electrical connections: • V erify that all power terminal screws and lugs are tight from power block to heaters. • V erify that all electrical plugs located under the shroud are completely plugged in (transformer, contactor, drain valve, and fill valve) . • Check continuity of control relay (smaller top relay) on Model 1150. Replace if shorted. 9 . Move the drain valve lever back to the auto position . 10 . Turn on the water supply . fIgURE 32 – Steam Chamber with Closed fastener 11 .

  • Page 38: Off-Season Shut Down Procedure

    Off-SEASON SHUT DOwN PROCEDURE Perform steam chamber cleaning and humidifier maintenance at the end of the humidification season . • I f softened water is used, the steam chamber may not need cleaning until after several humidification seasons. • I MPORTANT: The steam chamber should be removed after the first season of use to observe the amount of collected minerals in the chamber. • I f there is more than ½” (13 mm) of minerals in the steam chamber after one season of use, clean the chamber annually. • I f it is determined that cleaning is necessary every two or three seasons, then the only off-season shut-down procedure required is to turn the demand for humidity down to the minimum setting . • T he steam chamber will go into an end-of-season drain after 72 hours without a demand for humidity.

  • Page 39: Troubleshooting

    TROUblESHOOTINg Problem Possible Cause Action All indicator lights are The humidifier is in a forced • T his is normal operation. DO NOT RESET POwER. The humidifier will automatically resume blinking sequentially cool-down period prior to making steam once it has cooled down, drained, and refilled . a required automatic drain sequence .
  • Page 40 Problem Possible Cause Action The On/Off light on Mineral buildup or • R emove probe assembly and clean probe rods; reset power to clear warning. the display panel is oxidation on probe rods blinking slowly (one Deterioration of probe rod • R eplace probe rod assembly. blink per second) assembly The On/Off light on Probe is wired incorrectly • V erify wiring; see wiring diagram.
  • Page 41 Problem Possible Cause Action Heater burnout Improper wiring • V erify proper voltage applied to heater. • V erify proper electrical connections. Water level is too low . • R eplace probe assembly. Mineral buildup on heaters • I f heaters are on continuously and therefore not expanding and contracting with on-off cycles to shed mineral buildup, the humidifier may be undersized . Replace with a larger unit or add an additional humidifier .
  • Page 42 Problem Possible Cause Action Humidity below No humidity demand signal • L ow or no signal from humidistat. Check for proper wiring. desired level from humidistat • N o demand signal by others. • I f using Automatic Steam Humidifier Control in the Automatic Mode and the temperature outside is greater than 60°F, the unit will not operate . If humidity is desired in those conditions, run the Control in Manual Mode .

  • Page 43: Replacement Parts

    REPlACEMENT PARTS Note: See page 45 for a listing of replacement part numbers . fIgURE 33 – Display Panel fIgURE 35 – Internal Controller board Ribbon Connection Input for display Internal controller board detail panel ribbon cable; Display panel see figures 33 and 34 Connector tab ribbon cable position...
  • Page 44 36 – Humidifier Replacement Parts Note: Contact your Aprilaire distributor for availability of parts not listed above . OM-4040...
  • Page 45 4588 4568 made prior to serial number 1138928) Hose, 2” ID X 10’ wire reinforced, 1180 4632 Fuse, 25 amp (for Model 1150 made prior to serial 4569 number 1138928) Dispersion tube, 1-1/2” dia 10” active (1150) 4589 Contactor, 60 AMP (1160/1180) 4570 Dispersion tube, 1-1/2”...

  • Page 46: Distance Calculation

    APPENDIx – AbSORPTION DISTANCE CAlCUlATION Step 1: Enter the Design Conditions Percentage of Outdoor Air Indoor Air Temperature Indoor Setpoint Indoor RH (for the leaving air) leaving Step 2: Find the ‘Moisture Content Factor’ for the leaving air (M leaving In Table 9, find the intersection of T and RH .
  • Page 47 1 .25 1 .87 2 .47 3 .12 3 .74 4 .37 4 .95 5 .53 6 .25 6 .84 7 .43 fIgURE 37 – Aprilaire Steam Humidifiers – Absorption Distance Chart AbSORPTION DISTANCE IN INCHES Entering (%) DUCT HEIgHT...

  • Page 48: Warranty

    Please… Take a few minutes to visit us on-line at www.aprilairecontractor.com to register your Aprilaire product . If you do not have on-line access, please mail a postcard with your name, address, phone number, product purchased and date of purchase to: Research Products Corporation P .O .

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