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Aprilaire 1150 Humidifier User Manual

1. See the Troubleshooting section in this manual for more information On The humidifier is draining Normal operation Drain 1 is Blinn The allowed amount of time for draining has been exceeded Fault in drain operation 9 Humidifier will continue operate See Troubleshooting section On The humidifier is filling Normal operation Fill Blinkin The allowed amount of time for filling has been exceeded Fault in fill operation 9 Humidifier will operate See Troubleshooting section On The humidifier is making steam Normal operation Steam The humidifier has received a demand signal but cannot make steam because Blinking There is not enough water in the chamber or e An enable safety switch is open or Note AUTODRAIN SEQUENCE MINIMIZES OUTPUT INTERRUPTIONS The humidifier drains and flushes automatically at regular intervals to remove minerals from the chamber After the humidifier has run for a preprogrammed amount of time and if there is no demand for humidity the humidifier sits idle until the chamber cools and then it drains If the humidifier has not completed an autodrain sequence due to continual demand signal interruptions after an additional amount of run time the humidifier begins a cool down period and then it drains IMPORTANT The humidifier attempts to complete an autodrain sequence when there is no demand for humidity However if an autodrain sequence is not com
2. 27 MAINTENANCE Inspect and Service the Humidifier 29 Off season Shut Down Procedure 31 TROUBLESHOOTING 32 REPLACEMENT PARTS 36 APPENDIX ABSORPTION DISTANCE CALCULATION 38 WARRANTY Back Cover WARNING 240 volts may cause serious injury or death from electrical shock Disconnect power before installing supply wiring Water temperature in excess of 140 F 60 C may cause serious injury due to burns Allow unit to cool before draining or removing chamber The humidifier chamber distribution assembly and all connected hose or piping may contain or discharge hot steam and or hot water at 212 F 100 C Discharged steam is not visible Contact with hot surfaces discharged hot water or air into which steam has been discharged may cause severe personal injury Water pressure greater than 80 psi 550 kPa may cause the humidifier to overflow Humidifier weighs up to 80 Ibs when operating Improper mounting of humidifier may cause humidifier to fall from wall or ceiling resulting in serious injury Mount humidifier to a structurally stable surface per the instructions in this manual Failure to properly ground unit may result in property damage due to fire or serious injury or death from electrical shock Failure to follow the instruc
3. Fill valve does not close Malfunctioning level control system Check that probe electrical plug is fully engaged Verify that probe is wired per wiring diagram Verify the green and yellow ground wire is connected to the C terminal and the subpanel If the internal control board relay output is shorted to fill valve coil replace board If needed clean probe rods Check water conductivity Water conductivity must be at least 100 uS cm Add salt to increase Fill valve is stuck open Check for control voltage across fill valve coil terminals 33 and C on control terminal strip Check if fill valve is installed backwards If yes repipe Check if there is an obstruction that does not allow valve to seat properly Clean or replace valve as needed Drain valve is open e f automatic drain valve is locked in manual open position reset to automatic Replace valve if there is a broken return spring on the drain valve e Clean or replace drain valve if an obstruction in the valve does not allow complete closure Fill valve cycles on and off frequently several times per minute Malfunctioning level control system f needed clean probes Verify that probe wiring is correct e Check water conductivity Water conductivity must be at least 100 uiS cm Add salt to increase Drain valve not fully closed e f an obstruction does not allow drain valve to fully close clean valve Unit does not
4. NEM Steam outlet Venting LEFT SIDE VIEW 0 611 mm FRONT VIEW mii NN AEG SE D ka EN N UC NET SN 999 254 mm Chamber drain 1 37 35 mm 4 BOTTOM VIEW 24 06 611 mm Chamber fill y 0 83 21 mm 1 lt 3 06 78 mm gt _ 1 19 30 mm FIGURE 3 Mounting Hole Locations BACK VIEW 16 00 406 4mm 0 75 19 0mm KEYHOLE FOR 3 8 DIA FASTENERS 2 FIGURE 4 Distribution Tube Dimensions MODEL 1150 aaa 14 TUBE LE G 1 50 TYP 0 3 8 FLAT WASHER 3 8 16 X 1 2 HEX HEAD BOLT 10 ACTIVE DISTRIBUTION LENGTH is o j MOLDED TUBELET 1 1 2 DIA DISTRIBUTION TUBE WITH 3 16 ORIFICE MODEL 1160 20 TUBE LENGTH 1 50 8 3 8 FLAT WASHER 3 8 16 X 1 2 HEX HEAD BOLT 16 ACTIVE DISTRIBUTION LENGTH e e e e e e e e 4 7 MOLDED TUBELET 1 1 2 DIA DISTRIBUTION TUBE WITH 1 4 ORIFICE 90 912 90 913 OVERVIEW OF HUMIDIFIER OPERATION INTERNAL CONTROLLER The internal control
5. Check fill valve strainer clean or replace if clogged e f the fill light is also blinking refer to the Fill light on the display panel is blinking on and off section below Verify that lever on drain valve actuator is in Auto position Fill light on the display panel is blinking on and off fill fault Unit will not operate When in a fill sequence the internal controller allows 15 minutes for water to reach the maximum upper water level If water is not sensed at the top probe of the probe assembly after filling for 15 minutes the fill light on the display panel will blink on and off There are two causes for this either the chamber did not fill or the chamber filled but water is not being detected Chamber is not full Verify that lever on drain valve actuator is in Auto position Verify that water shut off valve is open Verify that the fill valve electrical plug is fully engaged Verify proper fill valve wiring at terminals 33 and C Verify voltage supplied to fill valve is correct Valve coil should be 24 VAC Check fill valve strainer clean or replace if clogged Check the strainer by disconnecting the fill valve inlet fitting Remove the strainer with a small screwdriver Fill valve may be plumbed backward Note flow direction and correct as needed Verify that water supply pressure is at least 25 psi 175 kPa Verify that fill and drain valve wiring are not
6. Your Warranty Registration information will not be sold or shared outside of this company 61000129 B2203603A RESEARCH PRODUCTS 1015 E Washington Ave e Madison WI 53703 Phone 888 782 8638 e Fax 608 257 4357 www aprilairecontractor com 2004 Research Products Corporation
7. Mounting bolt 3 8 16 x 1 2 d Humidifier Secure and seal Tube pitch 2 ft 1596 face plates OM 4008 FIGURE 13 Distribution tube 4 5 minimum from tube to duct ceiling 3 8 16 Threaded rod Face Plates 7 MOUNTING THE HUMIDIFIER Mounting the humidifier on the wall When mounting on a wood stud wall studs 16 406 mm on center locate studs and position lag bolts in place so that each of the bolts centers on a stud Mark hole locations and predrill 6 mm diameter pilot holes Secure cabinet to wall with lag bolts provided When mounting on a metal stud wall locate the studs 16 406 mm on center and drill a 3 8 10 mm hole through the studs and wall Push a 3 8 10 mm bolt through the wall studs and a backing plate on the backside of the wall and secure with a nut and washer If 16 406 mm on center studs are not available mount spanner boards on the wall spanning two studs If two horizontal boards are used locate one at the top of the cabinet for the lag bolts and the other board located 3 76 mm on center from the bottom of the cabinet For hollow block or poured concrete wall mounting mark holes 16 apart Drill appropriate pilot holes for two 3 8 10 mm toggle bolts or two 3 8 10 mm machine bolt lead anchors Secure cabinet in place When suspending the unit from ceiling or roof structural members Require
8. INC pe THERMOSTAT OPTION G EQUIPMENT d AUTOMATIC STEAM R EQUIPMENT HUMIDIFIER CONTROL ee 46 POWER 24 VDC HEAT CONTACTOR K29 NO 23 403 ORANGE 404 VIOLET 405 COMMON OVERTEMPERATURE THERMOSTAT MANUAL RESET S36 AALW420 2 10 SETTING SLIDE SWITCHES IMPORTANT Slide switch on off positions 1 through 16 are preset at the factory These settings are determined by output capacity water type and demand signal type 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 Others however must be set according to the details of each particular installation See Figure 8 Note the Off slide switch position is to the left while the On slide switch position is to the right For wiring details see page 21 Type of Control Input Model 1150 with an on off control 1 slide switch positions 1 and 2 Off Model 1160 with modulating control S1 slide switch positions 1 and 2 Off Model 1160 with 0 10 VDC signal by others S1 slide switch positions 1 and 2 Off Model 1160 with 4 20 mA signal by others S1 slide switch positions 1 and 2 On Inlet water ty
9. VAC fill valve outpu 24 VAC drain valve outpu Remote alarm or 1 fan blower start Note 14 f vvv vs 99 1 i ON 9 ON ZEEE HE HOOW ECE HG 206 WAA Terminal blocks J1 and J4 are removable for easier wiring OM 2029 FIGURE 32 Humidifier Replacement Parts Note Contact your Aprilaire distributor for availability of parts not listed above Description Steam Chamber 1150 Part Number Description Gasket 2 5 0 0 X 1 9 1 0 Part Number Steam Chamber 1160 4561 29 Water Level Probe ASSY 4580 3 Quick Release Handle 1150 4562 30 Plug 24 vert wire assy probe w o conduit 4581 Quick Release Handle 1160 4563 31 Gasket 1150 Steam Chamber 4582 5 Cover Shroud Aprilaire 1150 amp 1160 4564 Gasket 1160 Steam Chamber 4583 9 Terminal block pressure contact 3 pole 4565 38 Valve assy 1 4 24V compression fill 4584 10 Relay AC safety 1150 4566 44 Valve assy 3 4 sweat drain 4585 11 Relay DC control 1150 4567 60 Drain assy 3 4 electric sweated 4587 12 Fuse holder single pole 30amp 1150 4568 61 Over temperature thermostat non reset
10. a possibility consider installing a shock arrestor Water pressure must be between 25 psi and 80 psi 175 kPa and 550 kPa Drain piping may be of any code approved material copper steel or plastic rated for 140 F 60 C minimum If drainage by gravity is not possible use a reservoir pump rated for 140 F 60 C water 23 The final connection size is 1 DN25 hose or 34 DN20 copper for the chamber drain Do not reduce this connection size See Figures 21 and 22 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 The flexible connection provides a disconnect point so that the chamber can be removed for cleaning See Figure 21 Hard piping can be connected directly to the drain valve but the vertical drop should be minimized prior to a horizontal run Install a union at the beginning of the horizontal run to remove the chamber for cleaning See Figure 22 If the equivalent length of pipe from the humidifier drain to the plumbing system drain is more than 10 3 m increase the pipe size to 14 DN32 See Figures 21 and 22 FIGURE 21 Field Piping Overview Showing Hose Drain Connection Steam hose maximum 10 3 mj Water supply line Shock arrester i recommended to reduce water hammer DN8 compression fitting on fill valve Y connection to water
11. backing up with water Verify drain line pitch Pitch drain pipe toward drain 1 8 ft 196 minimum e Verify drain line size If piping run is over 10 3 increase drain pipe size from 34 DN20 to 14 DN32 Verify that the drain line is not plugged Disconnect drain piping from the humidifier at the hose or union connection Replace or clean drain piping if there is standing water in the piping or if water does not flow freely through the drain piping Problem The On Off light on the display panel is blinking slowly one blink per second The On Off light on the display panel is blinking rapidly 10 blinks per second illogical probe fault Possible Cause Mineral buildup or oxidation on probe rods Deterioration of probe rod assembly Probe is wired incorrectly Action Remove probe assembly and clean probe rods reset power to clear warning Replace probe rod assembly Verify wiring see wiring diagram Verify that probe wires are routed separately from high voltage wires to avoid interference Verify the green and yellow ground wire is connected to the subpanel and to the C terminal Deterioration of probe rod assembly Replace probe rod assembly Chamber water is foaming e Clean chamber No remote fault indication drain fault fill fault illogical probe fault Note This is an optional connection System fan blower doesn t operate Field wiring no
12. drains at intervals based on operating time output capacity and water type At the end of the drain cycle the supply water is brought on to briefly flush the chamber Chamber water cooling before draining To ensure that water is at or below 140 F 60 C before discharging to the plumbing system the humidifier remains idle for a defined period of time before draining Ensuring duct airflow The humidifier will not make steam unless the HVAC system blower is on and the airflow proving switch verifies there is airflow in the duct The display panel shows operating status and troubleshooting information See the display panel detail Figure 5 and the table describing display panel lights Table 2 For more information about blinking indicator lights see the troubleshooting section in this manual FIGURE 5 Display Panel On Off switch Un p amp OFT Steam Fill Drain On Off Indicator light OM 2028 M TABLE 2 Display Panel Light Indications Indicator light s Status Description All Blinking sequentially from The humidifier is in a forced cool down period prior to a required automatic drain sequence right to left Normal operation On Power is on Normal operation On Off switch Slow blinking 1 sec The electronic water level probe needs cleaning Fast blinking 10 sec Probe logic fault See Troubleshooting section
13. of open space in the duct downstream of the distribution tube required for steam to be absorbed into the air If the duct contains obstructions such as dampers or elbows within the absorption distance condensation on those obstructions can occur Factors affecting absorption distance include RH of air upstream of the distribution tube air temperature inside the duct air velocity in the duct and amount of moisture required In most Model 1150 and 1160 applications the clear space required for absorption distance is less than 36 In fact in many applications the absorption distance may be as short as 6 If the duct has obstructions within 36 of the distribution tube actual absorption distance can be calculated In applications with a large difference between the RH upstream and downstream of the distribution tube an absorption distance greater than 36 may be required To calculate actual absorption distance follow the procedure listed in the Appendix Humidifier Location When selecting the location of the humidifier consider the following e Proximity to duct To avoid having to install a drain at the distribution tube in the duct the distribution tube must be mounted at an elevation higher than the humidifier 10 3 m length of vapor hose is provided with the unit The hose can be cut if less than 10 3 m is needed The hose must have a constant downward slope from the distribution tube to the humidifier of at least 2 ft 15 If t
14. require backflow prevention IMPORTANT Minimum water supply pressure is 25 psi 175 kPa Electrical Torque S lug locati Before start up verify that electrical connections have been made per nach das Nm governing codes and the wiring requirements listed in this manual Power block 16 1 8 e Verify that all power terminal screws and lugs are tight from power block to heaters See Table 5 for torque specifications Contactor or Relay 16 1 8 e Verify that the transformer drain valve fill valve and contactor electrical 8 32 nut 20 22 que Heater 8 5 mm plugs located under the humidifier shroud are completely plugged in a em 32 nut m 25 28 e Confirm the internal controller board slide switch S1 and 52 positions 35 mm marked 1 through 16 are in the correct on or off position 6 Und 35 40 Heater 8 gauge wire wire lug 6 mm 25 28 10 14 gauge wire 8 mn 20 22 27 Water Supply e Turn water supply on confirm drain valve is closed Power e Turn the supply power on Verify that the On Off indicator light illuminates along with the Fill indicator light Verify that the fill valve opens and adds water until the humidifier chamber is full at which time the fill valve closes and the Fill indicator light turns off Verify that there are no leaks from the humidifier FIGURE 24 Probe Rod Assembly Create Water Seal e Unplug the probe plu
15. this maintenance occurred at the end of a humidification season turn the demand for humidity down to the minimum setting and the humidifier will go into an end of season drain after 72 hours 14 If this maintenance occurred during the humidification season turn the demand for humidity to the desired set point OFF SEASON SHUT DOWN PROCEDURE Perform steam chamber cleaning and humidifier maintenance at the end of the humidification season f softened water is used the steam chamber may not need cleaning until after several humidification seasons e IMPORTANT The steam chamber should be removed after the first season of use to observe the amount of collected minerals in the chamber e f there is more than 2 13 mm of minerals in the steam chamber after one season of use clean the chamber annually e 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 The steam chamber will go into an end of season drain after 72 hours without a demand for humidity e When humidification is desired turn the demand up to the desired set point and the system will start up 31 TROUBLESHOOTING Problem All indicator lights are blinking seguentially from right to left All indicator lights are off Possible Cause The humidifier is in a forced cool down period prior to a required automatic drai
16. 34 DN20 copper Se supply line water chamber drain and PUA pressure must be between overflow piping 25 psi and 80 psi rated for 140 F 175 kPa and 550 kPa 60 C If piping run water conductivity is over 10 3 m minimum 100 pS cm increase pipe 77 fill valve has integral to 14 DN32 eee strainer 1 25 mm air gap 1 25 mm flexible drain hose and clamps Spill funnel plumb to Open drain required Locate air gap only in floor drain spaces with adequate temperature and air movement to absorb flash steam otherwise condensing on nearby surfaces may occur Refer to governing codes for drain pipe size and maximum discharge water temperature lt Notes e Dashed lines indicate provided by installer The water supply inlet is more than 1 25 mm above the skim overflow port eliminating the possibility of backflow or siphoning from the chamber No additional backflow prevention is required however governing codes prevail OM 4017 24 FIGURE 22 Field Piping Overview Showing Hard Pipe Drain Connections Union by installer 34 DN20 copper chamber drain and overflow piping rated for 140 F 60 C If piping run is over 10 3 m increase pipe to 14 DN32 1 25 mm air gap Spill funnel Steam hose maximum run 10 3 mj plumb to floor drain NN E Bwa wamama mnanaa maaana Open drain reguired Locate air gap only in spaces wit
17. AIR PLENUM 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 Note Wherever distribution tube is installed there must be a minimum of 4 5 between top of tube and the duct ceiling Refer to Figures 12 and 13 on page 17 Location A is the best choice because e The distribution tube is humidifying 100 of the air and e The supply air temperature is typically warmer than the return air temperature allowing for better absorption Location B is the second choice because the distribution tube is humidifying 100 of the air but the cooler temperature of the return air requires more space for absorption Location C should be the last choice because in most cases there is more than one branch off the supply air plenum and less than 10096 of the air would be humidified in such a multi branch system However if there is only one branch the Location C would be considered equal to Location A because the same reasons listed under Location A would apply Choosing control device locations e Install the high humidity limit switch a recommended optional device a minimum of 5 1 5 m downstream of the distribution tube e Install the Automatic Steam Humidifier Control in the return air drop a minimum of 6 upstre
18. Humidifier Steam Humidifier Models 1150 and 1160 Installation Operation and Maintenance Manual READ AND SAVE THESE INSTRUCTIONS TABLE OF CONTENTS PRODUCT OVERVIEW 3 Materials Provided and Not Provided 3 Electrical Specifications Capacities and Weights 4 DIMENSIONS s s T 5 Overview of Humidifier Operation 7 INSTALLATION Wiring Diagrams 9 Setting Slide Switches 11 Choosing a Location for Humidifier Components 13 Distribution Tube Installation 15 Mounting the Humidifier 18 Field s sre RES RI REPRE 19 Airflow Proving Switch Installation 23 Supply Water and Drain 23 ATTENTION INSTALLER This product must be installed by qualified HVAC and electrical contractors Failure to do so voids product warranty due to possible product misapplication This product must be installed in compliance with local state and federal codes CAUTION 1 Do not set humidity higher than recommended Condensation damage may result 2 Failure to follow the instructions in this manual for installation of distribution tube airflow proving switch and high humidity limit switch may cause condensation damage OPERATION Start up Procedure
19. On and provide wiring to control terminals NO 0 and NC See Figure 8 for slide switch positions If you change any on off settings record them in Table 3 for future reference TABLE 3 Factory Slide Switch Settings Slide switch S1 Slide switch S2 Position Factory setting My setting Position Factory setting My setting Do not change 3 Off 11 Of Do not change 4 Off 12 Of Do not change 5 See Table 4 Do not change 13 Of Do not change 6 Off Do not change 14 Of Do not change Do not change 0 Do not change Do not change 0 Do not change Note Positions 5 8 and 10 16 are for factory use only TABLE 4 Slide Switch S1 Settings by Model Position Model 1150 Off On 1160 On Off 12 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 Refer to Figure 10 for split system installations and Figure 11 for rooftop unit installations These figures also indicate where control devices are to be installed Absorption Distance Absorption distance is the amount
20. PTION 1 AUTOMATIC STEAM HUMIDIFIER CONTROL POWER 24 VDC 24 VDC CONTROL RELAY K27 NO 2 24VAC SAFETY RELAY K29 BROWN 403 ORANGE 404 VIOLET 405 6060 NO 2 3 NC 1 4 COMMON OVERTEMPERATURE THERMOSTAT MANUAL RESET S36 AALW420 1 FIGURE 7 Model 1160 Wiring Diagram APRILAIRE STEAM HUMIDIFIER MODEL 1160 DUAL HEATER WIRING DIAGRAM MODULATING CONFIGURATION EARTH GROUND HEATER INPUT LINE POWER EQUIPMENT BLOCK GROUND SINGLE MAXIMUM POWER WIRING PHASE 8KW CONTROL CIRCUIT 240 VOLT WIRING 33 3 AMPS FIELD WIRING OVERTEMPERATURE THERMOSTAT S3 LEGEND RELAY CONTACTOR OVERTEMPERATURE TRANSFORMER THERMOSTAT S4 SWITCH HEATER Q9 INTEGRAL TO T7 OR SOLENOID JUMPER FIXED IMPEDANCE WATER PROBE TRANSFORMER T7 75VA INTERNAL CONTROLLER 1 2 30 NC BOARD SEE NOTE ARE FIELD WIRING CONNECTIONS MADE TO FIELD WIRING TERMINAL COMMON BLOCK IN HUMIDIFIER FILL VALVE N C Y14 DRAIN VALVE N C Y16 AIR FLOW SWITCH S18 ENABLE INPUT HIGH LIMIT HUMIDISTAT COMMAND SIGNAL OPTIONAL S18A JP2 JUMPER 1 amp 2 MODULATING CONFIGURATION EQUIPMENT TO OUTDOOR TEMPERATURE SENSOR TERMINALS G THERMOSTAT gt TO A A MODEL 8570 4
21. Refer to Figure 23 on page 26 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 18 FIELD WIRING Humidifier field wiring All wiring must be in accordance with all governing codes and with the humidifier wiring diagram Wiring diagrams are on pages 9 and 10 in this manual and the wiring diagram for your humidifier model is located inside the removable shroud Power supply wiring must be rated for 221 F 105 C The maximum ambient temperature is 80 F 27 C Field wiring connections and requirements e Conduit knockouts are provided on the top of the cabinet Control wiring knockouts are on the back right power wiring knockouts are on the back left e Control wiring and power wiring must be run in dedicated or separate earthed metal conduit cable trays or trunking e Separate the line voltage wiring from low voltage control circuit wiring when routing electrical wiring inside the humidifier cabinet o not use chassis or safety grounds as current carrying commons Never use a safety ground as a conductor or neutral to return circuit current CAUTION 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 Apri
22. S FURNISHED BY YOUR INSTALLER AS CONTRASTED TO DEFECTS DISCOVERED IN THE STEAM HUMIDIFIER ITSELF IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED IN DURATION TO THE AFORESAID TWO 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 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 Box 1828 Madison WI 53701 Thank you
23. TEAM HUMIDIFIER CONTROL HIGH HUMIDITY Cav 6 H LIMIT SWITCH 3 WIRE SHIELDED p 3 x CABLE W GROUND i WIRE SHIELDED 71 AIRFLOW NEN PROVING SWITCH CABLEW GROUND i 1 i i 1 iol d STEAM HUMIDIFIER Bo FIELD WIRING 24006 COMMON COMMON TERMINAL BLOCK ENABLE COMMON COMMAND SIGNAL 21 22 FIGURE 18 Model 1160 Input Wiring for Optional 0 10 VDC Signal by Others IMPORTANT Internal controller board slide switch S1 positions 1 and 2 are OFF SIGNAL BY OTHERS 0 10 VDC HIGH HUMIDITY LIMIT SWITCH 3 WIRE SHIELDED CABLE W GROUND 2 WIRE SHIELDED AIRFLOW PROVING SWITCH gt CABLE W GROUND STEAM HUMIDIFIER FIELD WIRING TERMINAL BLOCK COMMAND SIGNAL FIGURE 19 Model 1160 Input Wiring for Optional 4 20 mA Signal by Others IMPORTANT Internal controller board slide switch S1 positions 1 and 2 are ON SIGNAL BY OTHERS 4 20 MA HIGH HUMIDITY input resistance 250 ohms LIMIT SWITCH 3 WIRE SHIELDED pd CABLE W GROUND SHIELDED AIRFLOW PROVING SWITCH gt CABLE W GROUND F 4 STEAM HUMIDIFIER FIELD WIRING TERMINAL BLOCK COMMAND SIGNAL AIRFLOW PROVING SWITCH INSTALLATION INSTRUCTIONS Description T FIGURE 20 The airflow proving switch is a safety device that will prevent the humidifier from producing steam when there is n
24. am of the distribution tube e Install the airflow proving switch in the supply air plenum FIGURE 11 Placing a Distribution Assembly in a Rooftop Air Handler Application Cooling Coil Economizer Heating Coil control device ra 9 Outside Air High Humidity Limit Switch from Distribution Point B Motorized Air Dampers Distribution 8 minimum 5 minimum Distribution Tube B Airflow Proving Switch 6 minimum i Automatic Steam M N High Humidity Humidifier Control A Limit Switch from Distribution Point A Return Duct Supply Duct 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 between top of tube and the duct ceiling Refer to Figures 12 and 13 on page 17 Location A is the best choice because e The distribution tube is humidifying 100 of the air e The supply air temperature is typically higher than the return air temperature allowing for better absorption of the steam Note In
25. applications using zone control products the distribution tube must be installed upstream of all zone control dampers to ensure that all zones receive humidified supply air Choosing control device locations e Install the high humidity limit switch a recommended optional device a minimum of 5 1 5 m downstream of the distribution tube e Install the Automatic Steam Humidifier Control in the return air duct a minimum of 6 upstream of the distribution tube e Install the airflow proving switch in the supply air plenum DISTRIBUTION TUBE INSTALLATION After the location for the distribution tube has been identified follow the steps below and refer to Figure 12 to install the distribution tube in the duct 1 Cut or drill a 1 5 8 diameter opening in the duct 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 The distribution tube is to be positioned in the duct such that 1 1 2 3 1 2 of the tube is extending out of the duct for attachment of the steam hose 3 Use a 3 8 16 mounting bolt included to secure the end of the tube to the far side of the duct 4 If the duct is wider than the distribution tube attach a 3 8 16 threaded rod cut to the appropriate length not provided to the end of the tube Secure end of threaded rod with 3 8 16 nut and washer See Figure 13 5 Orient distribution tube so that tubelets steam o
26. d Parts 2 Brackets P N 4593 4 Bolts 1 4 20 3 4 long plated 4 Nylon insert nuts 1 4 20 8 Flat Washers 1 4 20 plated thin washers 8 Washers 1 4 20 plated 4 Threaded Rods 3 8 16 length depends on installation specifics Not provided Procedure 1 Remove the shroud covering of the humidifier 2 Insert the first bolt through the side slot farthest to the rear of the humidifier Follow the Fastener Sequence listed below ensuring the bolt head is on the inside of the humidifier frame 3 Repeat the Fastener Sequence for the humidifiers vertical side slot located toward the front NOTE The metal of the frame will need to be flexed in order to insert the left front bolt 4 Repeat steps 2 amp 3 for the other side 5 Use four lengths of 3 8 inch threaded rod to suspend the humidifier Observe all applicable codes and standards Fastener Sequence Starting from the inside of the humidifier Bolt flat washer through the vertical slots on the side of the humidifier frame 1 4 20 washer 1 4 20 washer Bracket use the small holes the same side as the slots flat washer Nylon insert nut INSTALL STEAM HOSE Attach one end of the steam hose to the distribution tube and the other end to the humidifier Secure with 1 1 2 hose clamps at both ends Ensure that a minimum pitch of 2 ft 1596 is maintained along length of hose If pitch is not possible it will be necessary to install a tee fitting and p trap
27. e electrical supply G Allow the steam chamber to completely drain H Disconnect the drain hose or field installed union from the drain valve connection on the back left corner of the cabinet Disconnect the drain valve electrical plug 29 2 Remove the steam chamber see Figure 25 for drawing item numbers FIGURE 26 Probe Rod Assembly e Hold up on the bottom of the steam chamber Item 6 in drawing and remove the top mounting nuts Items 2 and 3 Hold up on the bottom of the steam chamber while removing the bottom mounting nut Item 4 When the bottom mounting nut is removed the handle Item 5 falls away from the steam chamber Use both hands to support the steam chamber and lower it straight down to clear heaters Use care not to damage gasket which is attached to the top lip of the chamber 3 Clean the steam chamber interior by rinsing with clean water Use a putty knife or similar flat instrument to remove mineral deposits Clean the strainer inside the steam chamber located over the steam chamber drain opening Use a wire brush and verify that all the strainer holes are open Probe housing 4 Open the drain valve with the manual lever on the side of the actuator Item 11 and run water through the drain valve to remove any collected sediment 5 Unscrew the probe assembly and clean the plastic probe housing ensuring that all passageways are clear see Figure 26 Clean the probe rods using steel wool or a simila
28. em drain the P trap is not filled with water Disconnect the probe assembly to allow the fill valve to overfill the chamber to fill the P trap f there is excessive internal steam pressure determine the cause of the high pressure e g high duct static pressure undersized orifices in distribution tube and repair as required If drain valve does not close fully determine the cause and clean repair or replace as needed If fill valve is stuck open repair or replace Replace leaking gasket or vapor hose Unit is undersized replace with a larger unit or add additional humidifier Verify that humidistat is calling for humidity Check for control voltage if limit controls airflow proving switch etc are not allowing unit to operate Check power fuse If open replace fuse with equal fuse Verify contactor and transformer electrical plugs are fully engaged Check if the heater over temperature switch has been tripped Reset or replace if necessary Check water conductivity Water conductivity must be at least 100 uS cm Add salt to increase Check if the non resettable over temperature thermostats have tripped Replace if necessary If heaters are burned out refer to heater burnout problem on page 34 Humidity control input type not the same as the operating mode e Check the internal control board connections and slide switches S1 and S2 positions 1 and 2 See pages 11 12 for more information Excessi
29. et manual switch located above heater on humidifier cover Verify contactor and transformer electrical plugs are fully engaged Non resettable over temperature thermostats in power lines to heaters are open Model 1160 only Replace non resettable thermostats Check all components for over temperature damage Determine cause of dry fire by checking for a frozen contactor or a probe assembly malfunction and remedy before restarting humidifier Reduced or no output even though water level is correct Malfunctioning control system e Check if auxiliary limit controls are not allowing system to operate e g high humidity limit switch airflow proving switch etc Reset replace or calibrate as needed Check if the heater over temperature thermostat has tripped Reset if necessary e Check if the non resettable over temperature thermostats have tripped Replace if necessary Check fuse in power circuit If open replace fuse with equal fuse Heater malfunctioning e Verify that contactor and transformer electrical plugs are fully engaged e Verify that proper voltage is being applied to heaters Check heater amperage e f heater power device is not functioning replace 33 Problem Heater burnout Possible Cause Improper wiring Water level is too low Mineral buildup on heaters Action e Verify proper voltage applied to heater Verify proper electrical c
30. former contactor drain valve and fill valve 9 Move the drain valve lever back to the auto position 10 Turn on the water supply 30 11 Turn on the electrical power FIGURE 28 Steam Chamber 12 Allow the steam chamber to fill with water and initiate a humidity demand with Closed Fastener signal see Figure 28 for drawing item numbers IMPORTANT Verify that the gasket seal is not leaking prior to leaving the humidifier unattended 2 Fu P7 Chamber cover gl If a leak is observed in the left front or side of the gasket loosen backing nut Item 7 in drawing one turn and tighten fastener nut Item 2 down onto the cover flange Continue this one turn at a time until the leak stops 1 19 If a leak is observed in the right front or side of the gasket loosen backing y 4 5 4 nut Item 8 one turn and tighten fastener nut Item 3 down onto the cover flange Continue this one turn at a time until the leak stops If a leak is observed in the rear of the steam chamber loosen backing nut Item 9 two turns and tighten up fastener nut Item 4 onto the handle Continue this two turns at a time until the leak stops Replace gasket if necessary 13 If
31. g from the probe assembly located on the chamber cover see Figure 24 to allow the fill valve to energize and overfill the chamber This ensures that the water seal P trap is filled with water When water is seen coming from the drain line plug the probe plug back into the probe assembly Initiate Fan Call e Set up a fan call at the thermostat If the humidifier is configured to bring on the equipment fan with a humidity demand skip to next step Probe housing Initiate Humidity Demand e For the default Model 1150 and 1160 controls whether in Automatic or Manual Mode rotate control knob of the Automatic Steam Humidifier Control clockwise to the Test position Verify 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 Operation of the heaters without water may cause humidifier malfunction and or fire resulting in property damage personal injury or death NOTE Do not leave the Automatic Steam Humidifier Control in the Test position Refer to the Installation and Operation Manual for the Automatic Steam Humidifier Control for more details 28 MAINTENANCE The best way to determine how often the humidifier needs maintenance is to remove the steam chamber and inspect it after the first year of ope
32. h adequate temperature and air Water supply line Shock arrester recommended to reduce water hammer DN8 compression fitting on fill valve connection to water supply line water pressure must be between 25 psi and 80 psi 175 kPa and 550 kPa water conductivity minimum 100 pS cm fill valve has an integral strainer movement to absorb flash steam otherwise condensing on nearby surfaces may occur Refer to governing codes for drain pipe size and maximum discharge water temperature Notes e Dashed lines indicate provided by installer The water supply inlet is more than 1 25 mm above the skim overflow port eliminating the possibility of backflow or siphoning from the chamber No additional backflow prevention is required however governing codes prevail 25 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 This may lead to distribution tube spitting steam blowing through the P trap before the plumbing system or leaking gasket IMPORTANT Steam hose must be supported to prevent sagging or low spots FIGURE 23 Drip Tee Installation S
33. he distribution tube must be installed at an elevation lower than the humidifier install a drip tee and drain as shown in Figure 23 Required clearances see Figure 9 FIGURE 9 R ded Mini Recommended Minimum e Electrical connections Service and Maintenance Clearances Electrical power supply water supply piping and drain piping must also be considered Electrical power supply connections are made at the upper m im left rear corner of the unit The control wiring is in the upper right rear To distribution tube corner Another consideration when choosing a location for the humidifier Secured to gt ne supporting is to avoid areas close to sources of electromagnetic emissions such as wall Right side 12 power distribution transformers aS reve niin i Supporting e Plumbing connections wall Water supply piping connections are made in the lower right rear corner TRE Drain piping connections are made at the lower left rear corner 12 305 mm Front 36 915 mm Floor 24 610 mm DISTRIBUTION TUBE AND CONTROL DEVICES LOCATION OPTIONS FIGURE 10 Recommended Installation Locations Split System Application AUTOMATIC STEAM HUMIDIFIER CONTROL ALWAYS IN RETURN AIR DROP LOCATED UPSTREAM RETURN AIR DROP OF THE DISTRIBUTION TUBE gt lt DISTRIBUTION TUBE HIGH LIMIT C DISTRIBUTION TUBE A HIGH LIMIT B AIRFLOW NL em PROVING SWITCH ALWAYS IN SUPPLY
34. iling contactor or malfunctioning controls Replace contactor or troubleshoot the control system Fill valve noise A clicking sound as the fill valve opens or closes and a hissing sound during fill are normal A slamming sound as fill valve closes is water hammer and can be minimized by installing a shock arrestor e A loud buzzing sound indicates poor alignment of valve plunger Replace valve 35 REPLACEMENT PARTS Note See page 37 for a listing of replacement part numbers FIGURE 29 Display Panel Ribbon Connection Internal controller board detail Display panel ribbon cable connector Connector tab position Connect to pins 1 through 9 x 0M 2030 FIGURE 30 Display Panel Connector Polarity Connector tab on ribbon cable wa Programming port p factory use only Internal v controller lt N board 0M 2031 36 FIGURE 31 Internal Controller Board Slide switches 1 and 2 positions 1 through 16 LED indicating power is on Four mounting Input for display panel ribbon cable see Figures 29 and 30 Programming port for factory use only holes 5 32 dia Water detect bottom probe inpu Water detect middle probe inpu Water detect top probe inpu Off on enable inpu VDC input demand signa VDC input demand common 24 VDC supply 24 VAC common 24 VAC ho 24 VAC contactor relay outpu 24
35. is equipped to provide RH setpoint compensation based on the actual outdoor temperature When the weather gets colder outside there can be problems with condensation when introducing humidity into the building The control recognizes this and adjusts the setpoint in the building to a lower level The control will still provide humidity to the building but will not attempt to maintain a humidity level higher than is appropriate for the current outdoor temperature For applications that require specific set point control regardless of outdoor temperature the Control can be set up for manual operation In Manual Mode the outdoor temperature sensor is not used and the RH is controlled to the specific setting on the Control MATERIALS PROVIDED MATERIALS NOT PROVIDED 1 Humidifier Model 1150 1 heater 12 Ibs hr Model 1160 2 heater 24 Ibs hr Electrical Supplies quick disconnect box 1 Distribution Tube Model 1150 10 active 14 overall Model 1160 16 active 20 overall Conduit and wire for power to the unit and wiring to control devices 1 10 ft Steam Hose 1 Y2 I D 1 1ft Drain Hose 1 ID Plumbing Supplies supply and drain 2 Hose Clamps for Steam Hose 1 2 1 0 piping LM GSP 2 Hose Clamps for Drain Hose 1 1 0 High Humidity Limit Switch 2 Face Plates for Mounting Distribution Tube 1 set Hanging Brackets 2 3 8 x2 Lag Bolts for Mounting Humidifier for mounting humidifier from ceiling 1 Automatic Steam Humidifie
36. laire warranty Below are field wiring connections Connect to line power Refer to the wiring diagram or the dataplate on the outside of the cabinet for wire sizing amperage e Connect to control signal wiring from the Automatic Steam Humidifier Control or from signal by others Mount the Automatic Steam Humidifier Control in the return air duct as shown in the drawing on pages 14 and 15 See page 21 for wiring details Also refer to the Installation and Operating Manual for the Automatic Steam Humidifier Control Connectto the HVAC system blower To start the HVAC equipment blower when the humidifier receives a humidity demand signal wire the NO O and NC control terminals to the HVAC system as shown on the wiring diagram Connectto a remote fault alarm optional The humidifier may be field programed to send a fault alarm signal to a remote device instead of sending a signal to start the HVAC system blower To enable this function set slide switch S2 position 9 to On and provide wiring to control terminals NO 0 and NC Connect to the duct airflow proving switch wiring The airflow proving switch is a safety device that will prevent the humidifier from producing steam when there is no airflow present in the HVAC system See page 23 for details e Connect to the duct high humidity limit switch wiring a recommended optional device Locate the duct high humidity limit switch the correct distance downstream of the dist
37. ler within the humidifier cabinet responds to external inputs e g humidistat and airflow proving switch and internal inputs e g water level probe inside the steam chamber to provide Relative humidity RH control Model 1150 With an on off demand signal the controller maintains RH within 596 to 796 of set point Model 1160 With a modulating demand signal the humidifier maintains RH within 2 to 4 of set point Modulating demand signal options include a 0 10 VDC humidistat signal humidistat provided or a signal by others 0 10 VDC or 4 20 mA Automatic water level control and safety shut down If there is insufficient water an electronic water level probe sends a signal to the controller to add water or to turn off the heaters Operating time monitoring The controller accumulates humidifier run time to activate end of season draining water cool down and auto draining Automatic preheating During chamber refilling once there is enough water in the chamber the heaters energizes at 10096 until the water approaches boiling temperature to preheat the chamber water so it is warm when the humidifier receives a humidity demand signal DISPLAY PANEL AND INDICATOR LIGHTS Automatic end of season draining If the humidifier doesn t receive a humidity demand signal for 72 hours the chamber automatically drains Periodic drain and flush To reduce mineral buildup in the chamber the humidifier automatically
38. n sequence On Off switch is off Display panel ribbon cable connection Transformer secondary circuit breaker tripped Action This is normal operation DO NOT RESET POWER The humidifier will automatically resume making steam once it has cooled down drained and refilled e Push On Off switch on display panel e Connect display panel ribbon cable Verify ribbon cable is connected correctly See Figures 29 and 30 e Check for wiring shorts reset breaker Power panel breakers are open Check power block for proper voltage present at transformer Verify transformer electrical plug is fully engaged Steam light on the display panel is blinking on and off The enable safety circuit is not satisfied e f no other lights are on or blinking check the airflow proving switch Verify that tube orientation in the duct is correct Verify tube is connected to the switch correctly f connections are correct and switch does not close with airflow replace switch e Check high humidity limit switch if installed Verify connection per the wiring diagram and the diagram on the high humidity limit switch cover Verify that the high humidity limit switch is the correct distance downstream of distribution tube f connections and location are correct replace high humidity limit switch Low water condition e f the fill light is also on Verify that the water shut off valve is open
39. n Automatic Steam Humidifier Control mounted in the return duct that will sense the relative humidity RH in the return air If the return air is below the RH setpoint the control will send the humidifier a signal to begin producing steam Once this happens the airflow proving switch included will check to ensure that the equipment blower is operating If the blower is not operating the humidifier will send the equipment a signal to turn the fan on e The Aprilaire Steam Humidifier Model 1150 12 lb hr unit features an Automatic Steam Humidifier Control with on off control The on off control will send a 10 VDC signal to the humidifier when the measured return air RH is 3 or more below setpoint to turn the unit on at 100 output e The Aprilaire Steam Humidifier Model 1160 24 Ib hr unit features an Automatic Steam Humidifier Control with modulating control This control sends a signal between 0 and 10 VDC that is proportional to the difference between setpoint RH and the measured return air RH The signal for 100 humidifier output is 10 VDC and occurs at a control point that is adjustable The signal for 50 output is 5 VDC and occurs at the setpoint The adjustable RH proportional control band can be set on the board to 6 9 12 default or 15 The humidifier uses this varying signal to time proportion the operation of the heating elements in the chamber The Automatic Steam Humidifier Control features an outdoor temperature sensor and
40. ng X 1 0A 1 00 Mentering Note this step assumes that the outdoor air being brought into the system will contribute an insignificant amount of moisture relative to what s being added by the humidifier For example if Outdoor Air percentage is 20 and the Mleaving factor is 2 4 the calculation would be Mentering 24x 1 ii 20 100 1 92 Step 4 Find the RH for the entering air In Table 7 find the row that corresponds to the temperature Tindoor Then slide across this row and find the value closest to Mentering which was calculated in Step RHEntering Finally slide up this column to determine the RH for the entering air Step 5 Find the Absorption Distance Using the Absorption Chart Figure 33 draw a vertical line up from the intersection of RHEntering along the bottom horizontal axis to the intersection of the diagonal line corresponding to RHLeaving From this point draw a line horizontally to the intersection of the duct height This is the minimum required absorption distance for the given duct height and the above Design Conditions Absorption Distance Note duct height assumes a horizontal flow system For vertical drop systems duct height should be considered as the duct dimension perpendicular to the distribution tube Example The design conditions of 40 outdoor air 72 F indoor air temperature and an indoor RH setpoint of 50 would require an absorption di
41. o airflow present in the HVAC system The switch is a pressure differential measuring device that determines if there is airflow present Mounting based on the pressure differential between the HVAC system and Bracket atmosphere The switch contains a diaphragm calibration spring and a snap acting SPDT switch See Figure 20 for details Terminal um n y Enclosure Operation Inlet H High A u Inlet L Low When the HVAC equipment fan is off the airflow proving switch is open In the event of a demand call from the humidistat in this state the airflow proving switch would prevent the humidifier from starting or producing steam When the airflow proving switch senses that the HVAC equipment fan is on the switch closes This position will allow the humidifier to come on and produce steam Installation Do not mount in this TE manner Diaphragm The airflow proving switch is mounted on any surface free from must be mounted in vibration The airflow proving switch must be installed with the a vertical plane diaphragm in a vertical plane See Figure 20 for acceptable and unacceptable mounting configurations Avoid mounting the switch with the inlet line connections facing up The air sampling probe included must be located a minimum of 1 5 duct diameters downstream from the discharge of the HVAC equipment blower It is connected to the airflow proving switch b
42. oise can produce undesirable effects on electronic control circuits which affects controllability Electrical noise is generated by electrical equipment such as inductive loads electric motors solenoid coils welding machinery or fluorescent light circuits The electrical noise or interference generated from these sources and the effect on controllers is difficult to define but the most common symptoms are erratic control or intermittent operational problems IMPORTANT e For maximum electromagnetic compatibility effectiveness wire all humidity high limit and airflow controls using multicolored shielded plenum rated cable with a ground wire for the shield Connect the ground wire to the C terminal on the field wiring terminal block in the humidifier See Figure 15 Use wire less than 2 50 mm in length for the shielded cable ground wire e Do not ground shield at the device end 20 C terminal Control input wiring The internal controller offers four input control types Which are field adjustable The factory default control type for Model 1150 is the Automatic Steam Humidifier Control on off configuration as shown in Figure 16 The factory default control type for Model 1160 is the Automatic Steam Humidifier Control modulating configuration as shown in Figure 17 IMPORTANT For Model 1150 on off control verify that the shunt on the JP2 jumper is placed over the 2 amp 3 position For Model 1160 modula
43. onnections e Replace probe assembly e 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 Inspect chamber for severe mineral buildup on or around heater If present increase cleaning frequency or use softened supply water Heater corrosion Inspect heater for surface corrosion or pitting This is usually caused by a high chloride level in the supply water Unit does not fill with water No water supply to fill valve Verify that manual water supply valve is open and that pressure exists Check if water supply line strainer is plugged Clean strainer or replace Verify fill valve electrical plug is fully engaged Unit control is not on Press On Off switch on display panel Verify transformer electrical plug is fully engaged Malfunctioning fill valve Unplug probe head Fill valve should open If fill valve does not open Verify fill valve electrical plug is fully engaged Verify proper 24 VAC terminals 33 and C to fill valve If voltage is present and valve does not open replace valve Malfunctioning level control system Check terminals 3 4 5 and C on the internal controller board terminal block for correct wiring Humidifier is in auto drain mode Normal operation Chamber will fill after completing auto drain sequence
44. ool 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 As an alternative if the drain piping is designed to handle intermittent drain water temperatures up to 212 F 100 C the chamber may be cooled down by moving the lever located on the drain valve actuator to the manual open position The fill valve eventually opens allowing water to run into the chamber until it is cool enough to handle IMPORTANT If water is not draining from the chamber after Step 1D the drain valve is likely clogged and the chamber must be cooled by introducing overfill water into the chamber To do this unplug the probe plug from the probe assembly located on the chamber cover to allow the fill valve to energize and overfill the chamber When the chamber is cool enough to handle plug the probe plug back into the probe assembly Take necessary precautions to support the additional water weight when removing the steam chamber fasteners WARNING Opening the drain valve when the steam chamber is hot may discharge water with a temperature up to 212 F 100 C into the plumbing system This may cause damage to the plumbing system Do not touch the chamber or drain piping until the chamber has had sufficient time to cool or serious injury may result E Shut off the water supply F Shut off th
45. pe The controller allows autodrain settings for three water supply types FIGURES Slide Swiichas e Normal water hardness greater than 4 and less than LED 10 grains gallon amp Mounting hole zi V 1 l Hard water hardness greater than or equal to 10 grains gallon Position TYPE OF CONTROL INPUT e Softened water hardness less than or equal to 4 grains gallon WATER TYPE OO GN The humidifier is preprogrammed for use with normal water If your water supply is hard or softened follow the instructions below FACTORY USE ONLY V Llggcr ee zt e For hard water supply greater than or equal to 10 grains gallon MUWE ALAR FAN BLOWER CONTROL of hardness Set switch S1 position 3 to On position 4 remains Off See Figure 8 FACTORY USE ONLY hs ei o x e For softened water supply Set switch S1 position 4 to On position 3 remains Off See Figure 8 Substituting a remote fault alarm for blower starting The humidifier may be field programmed to send a fault alarm signal Internal Controller Board to a remote device instead of sending a signal to start the HVAC Note equipment blower Slide switches are shown in the off position To enable this function set slide switch S2 position 9 to
46. perform autodrain sequence No power to automatic drain valve Verify drain valve electrical plug is fully engaged Check if 24 VAC is present at the internal controller board terminals 32 and C for drain valve Drain fault plugged drain valve or plugged drain pipe Check drain valve piping Defective automatic drain valve f voltage is present at valve and it still does not open replace valve Unit does not perform end of season drain Input signal always has a demand Reduce demand signal at the humidistat Drain valve Verify drain valve electrical plug is fully engaged Verify drain valve is wired correctly to control board Check 24 VAC across valve coil during test cycle terminals 32 and C on control terminal strip 34 Problem Humidity below desired level Possible Cause No humidity demand signal from humidistat Unit is operating but fails to meet required humidity output Heating elements not operating Action Low or no signal from humidistat Check for proper wiring No demand signal by others e 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 If using Automatic Steam Humidifier Control verify that the Control is not in Test Mode e f steam is passing to the plumbing syst
47. pleted within a defined period of time the humidifier ignores the demand signal until completing an autodrain sequence This could cause the relative humidity level in the humidified space to drop until the autodrain sequence completes INSTALLATION FIGURE 6 Model 1150 Wiring Diagram HEATER INPUT EARTH GROUND LINE POWER EQUIPMENT BLOCK GROUND APRILAIRE STEAM HUMIDIFIER MODEL 1150 SINGLE HEATER WIRING DIAGRAM ON OFF CONFIGURATION SINGLE POWER WIRING jen CONTROL CIRCUIT Te WIRING MAXIMUM AKW FIELD WIRING Tt 240 VOLT 16 7 AMPS LEGEND RELAY CONTACTOR TRANSFORMER SWITCH HEATER Q9 INTEGRAL TO T7 OR FIXED IMPEDANCE SOLENOID JUMPER WATER PROBE FUSE mmc rtozdm TRANSFORMER T7 75VA m m m COMMAND SIGNAL EQUIPMENT TERMINALS G THERMOSTAT INTERNAL CONTROLLER BOARD SEE NOTE 1 2 30 ARE FIELD WIRING CONNECTIONS MADE TO FIELD WIRING TERMINAL COMMON BLOCK IN HUMIDIFIER FILL VALVE N C Y14 DRAIN VALVE N C Y16 ENABLE INPUT AIR FLOW SWITCH S18 G EQUIPMENT R EQUIPMENT 5 9 S HIGH LIMIT HUMIDISTAT OPTIONAL 18A JP2 JUMPER 2 amp 3 ON OFF CONFIGURATION TO OUTDOOR TEMPERATURE SENSOR TO A A MODEL 8570 p THERMOSTAT O
48. r Control 1 Airflow Proving Switch 1 Installation Operation and Maintenance Manual FIGURE 1 Product Overview Distribution Tube 1 DN40 flexible steam hose Control wiring knockout Power wiring knockout Electrical controls area Internal controller board Field wiring terminal block Electrical power area Display panel Immersion heaters 1 in Model 1150 2 in Model 116 Fill Valve NS SS ji fitting SS A ONZO comer g Removable steam chamber Cover shroud Ps TABLE 1 Electrical Specifications Current draw 0 OM 4006 1150 54 Shipping weight Operating weight tamps Circuit includes packaging and humidifier only with kamba pacity Single phase fa kw all materials in the box water in chamber minimum Ibs hr kg h 240V lbs kg lbs kg circuit breakers be used with 208V single phase as listed above for 240V 1160 24 10 9 33 3 45 8 70 32 74 34 Note Models 1150 and 1160 operate at 50 60 Hz 208V single phase may also be used but the steam capacity will be approximately 25 lower than the values above It is recommended that the same size FIGURE 2 Dimensions pertains to Models 1150 and 1160 Power wire knockout TOP VIEW 11 88 302 mm 6 50 m 1 00 25 mm n A Y anannnnn 00000000 3 09 78 mm Control wire knockout
49. r mild abrasive material Inspect the composite plastic probe assembly for any signs of cracking roughness or deterioration Replace if necessary with Part Number 4580 6 Install the probe assembly probe plug probe housing and the gasket into the cover see Figure 26 7 Re install the chamber see Figure 27 for drawing item numbers FIGURE 27 Chamber with e Using both hands lift the chamber Item 6 in drawing up around the heaters Open Fastener until the threaded fasteners penetrate the cover flange e Hold the chamber in place with one hand and pull the handle Item 5 toward you and onto the threaded fastener the front bottom of the eoss 1 chamber Make sure gasket is centered on chamber flange e 1 Chamber cover Push the handle up against the backing nut Item 9 and run nut Item 4 up the threaded fastener so it holds the handle in place Tighten nut Items 2 and 3 down on the threaded fasteners extending through the cover flange Tighten nuts Items 2 3 and 4 to complete the process of returning the chamber to its position prior to removal Reconnect the drain hose to the drain valve connection in the back left corner 0 4020 e Reconnect the drain valve electrical plug 8 Verify electrical connections e Verify that all power terminal screws and lugs are tight from power block to heaters e Verify that all electrical plugs located under the shroud are completely plugged in trans
50. ration Potable water carries a variety of minerals and other materials in a mix that varies from location to location This variation in water quality combined with the hours of operation and duty cycle determines the frequency maintenance required TO INSPECT AND SERVICE HUMIDIFIER FIGURE 25 Chamber with Closed Fastener ll ah 1 Access and prepare the steam chamber Item 6 for removal see Figure 25 for drawing item numbers CAUTION If the drain light is blinking on the display panel Item 1 in drawing H7 Chamber cover 2 there is water in the chamber that was unable to drain Model 1160 chambers fre f weigh 40 pounds 18 kg when full of water Model 1150 chambers weigh 30 pounds 13 4 kg when full of water Take the necessary precautions to support the additional weight when removing the chamber fasteners A Loosen the fasteners on the top of the shroud y B Remove the fasteners on the bottom of the shroud C Remove the shroud WARNING WARNING 240 volts may cause serious injury or death from electrical shock Do not remove the power heater terminal cover Item 10 while the electrical power is on D If the steam chamber is c
51. reversed Remove fill valve and check for any foreign material plugging the valve Excessive water hammer can bend a needle valve on the supply line and make it difficult to open If this is happening the valve may need to be replaced Install a water hammer shock arrestor Chamber is full Clean or replace probe e Check water conductivity Water conductivity must be at least 100 uiS cm Add salt to increase Drain light on the display panel is blinking on and off drain fault Unit will continue to operate When in autodrain sequence or end of season drain the internal controller allows 14 minutes for the water level to drop from the top probe to below the lowest probe If the chamber does not drain to this level in the time allotted the drain light on the display panel will blink on and off Verify that drain valve electrical plug is fully engaged Check drain valve wiring at terminals 32 and C Check for voltage present at the valve Input power to the drain valve actuator should be 24 VAC if present clean or replace valve Check if the chamber drain outlet from the humidifier is plugged Clean if needed Water detection probes Clean probes or replace probe rod assembly Fill valve Fill valve may be plumbed backwards Note flow direction on valve body and replumb if necessary e f fill valve is plumbed correctly and leaking water replace fill valve Drain line is
52. ribution tube See Figure 10 on page 14 and Figure 11 on page 15 for more location guidelines IMPORTANT Installation of a duct high humidity limit switch is highly recommended WARNING WARNING electrical shock LINE POWER The humidifier is designed for 240 VAC single phase 50 60 Hz input power The Model 1150 requires a 25 amp minimum breaker while the Model 1160 requires a 45 amp minimum breaker Install a fused quick disconnect box nearby the humidifier for easy access during maintenance of humidifier See Figure 14 208 VAC single phase 50 60 Hz input power may also be used Note that when using 208 VAC the steam capacity of each unit will be reduced by approximately 25 compared to rated capacity at 240 VAC Line power grounding requirements The ground connection must be made with solid metal to metal connections The ground must be a good radio frequency earth Ground wire should be the same size as power wiring CONTROL WIRING Proper control wiring prevents electrical noise 240 volts may cause serious injury or death from electrical shock Shut off power at main breaker before installing supply wiring for humidifier Failure to properly ground unit may result in property damage due to fire or serious injury or death from FIGURE 14 Line Power Wiring Requirements Power supply Fused disconnect FIGURE 15 Shielded Cable Wire Connection to C Terminal Electrical n
53. rifices point up To help verify this on the section of tube that will be sticking outside of the duct mark a spot that is line with the tubelets 6 If the distribution tube is shorter than the duct width causing the steam tubelets to be outside the duct plug the exposed tubelet openings with silicon caulk 7 Attach each of the two halves of the face plate to the duct using sheet metal screws fitting the face plates tightly against the distribution tube 8 Seal any gaps around face plates using silicon caulk CAUTION The hose must have a minimum pitch of 2 ft 1596 from the distribution tube back to the humidifier If not possible due to obstructions or duct configuration a drip tee and drain must be installed See Figure 23 on page 26 Failure to follow these recommendations can result in excessive back pressures on the humidifier This may lead to distribution tube spitting steam blowing through the P trap before the plumbing system or leaking gasket WARNING Distribution tube steam hose tubing or hard pipe may contain steam and surfaces may be hot Discharged steam is not visible Contact with hot surfaces or air into which steam has been discharged may cause severe personal injury FIGURE 12 Distribution Tube Installation Steam hose do not exceed 10 3 m in length 4 5 minimum from Mounting nut tube to duct ceili Hose pitch 2 ft 15 3 8 16 4
54. stance of 20 in a system with a duct height of 18 MLeaving would be 3 68 MEntering would be 2 20 and RHentering would be 30 38 TABLE 7 Moisture Content Factor Relative Humidity RH 25 30 35 40 55 60 0 0 0 0 T 0 r1 0 5 0 2 0 eo 0 a 0 0 0 0 0 FIGURE 33 Aprilaire Steam Humidifiers Absorption Distance Chart ABSORPTION DISTANCE IN INCHES 50 45 40 35 30 25 20 15 10 5 nekek ROO c ec 0 0 0 0 LEAVING RH 10 20 30 40 50 ENTERING RH DUCT HEIGHT 39 WARRANTY Your Research Products Corporation Aprilaire Steam Humidifier Model 1150 or 1160 is expressly warranted for two 2 years from the date of installation to be free from defects Research Products Corporation s exclusive obligation under this warranty shall be to supply without charge a replacement for any part of the Steam Humidifier which is found to be defective within a two 2 year period and which is returned no later than thirty 30 days after the two 2 year period by you or your original supplier to Research Products Corporation Madison WI 53701 together with the model number and installation date of the Steam Humidifier THIS WARRANTY SHALL NOT OBLIGATE RESEARCH PRODUCTS CORPORATION FOR ANY LABOR COSTS AND SHALL NOT APPLY TO DEFECTS IN WORKMANSHIP OR MATERIAL
55. t installed Provide field wiring to a remote fault indicator from NO 0 NC control terminal block Remote fault relay is not switching e Check relay continuity NO O NC control terminal block for contact closure Field supplied remote fault indicator lamp is burned out System fan blower power is off System fan blower is not wired to internal controller board Check if lamp by others is burned out replace if needed Turn power supply on Check wiring diagrams on pages 9 and 10 for wiring to NO O and NC terminals Internal controller board is configured for remote fault indication e Slide switch S2 position 9 must be in off position See page 11 for more information Humidifier does not energize chamber does not heat up Nonexistent supply voltage to humidifier Check main line fuse Check main line safety switch Verify contactor electrical plug is fully engaged Nonexistent control voltage e Check for proper supply voltage per wiring diagram Verify proper wiring of multi tap transformer Verify transformer electrical plug is fully engaged Check for control circuit voltage 24 VAC If voltage is not present at H and C check transformer circuit breaker Reset if needed by pressing On Off switch on display panel Reset manual over temperature switch located above heater on humidifier cover Humidifier over temperature thermostat is open Res
56. table 13 Fuse 20amp 1150 4569 Not shown in drawing 14 Contactor 60 AMP GE 1160 4570 Electrical Wire Harness 4586 18 Terminal 20amp DIN rail mount 4571 Hose 1 1 2 ID X 10 wire reinforced 4588 19 Transformer 120 208 240 480V 24V Sec 4572 Tube weld 1 1 2 dia 10 active distribution 1150 4589 20 Overlay amp switch Internal Controller Board LED AP 4573 Tube weld 1 1 2 dia 16 active distribution 1160 4590 21 Board Internal Controller 4574 Duct plate 3 25 sq w 1 51 hole galv 4591 22 Standoff PC board clip 4575 Airflow switch AFS 112 150 electric 4592 23 Heater 4576 Hanging Bracket 4593 26 Over temperature thermostat resettable 4577 High Humidity Limit Switch 4594 27 Probe housing nylon 4578 Automatic Steam Humidifier Control 57 37 APPENDIX ABSORPTION DISTANCE CALCULATION Step 1 Enter the Design Conditions Percentage of Outdoor Air OA Indoor Air Temperature Tindoor Setpoint Indoor RH for the leaving air RH Leaving Step 2 Find the Moisture Content Factor for the leaving air MLeaving In Table 7 find the intersection of Tindoor and RHLeaving The intersection of those ake ap MLeaving two points is the Moisture Content Factor for the leaving air M Step 3 Find the Moisture Content Factor of the entering air MEntering Use the following equation to calculate the moisture content of the entering air Mentering MLeavi
57. team hose or hard pipe Insulate tubing and hard pipe to Sa steam loss Humidifier Dashed lines indicate provided by installer To distribution tube lt Copper tubing or pipe drip tee 6 150 mm recommended by installer 8 200 mm minimum MEM 1 25 mm Funnel or floor drain air gap Refer to governing codes for drain pipe size and maximum temperature requirements fa T w DN20 26 OPERATION HUMIDIFIER START UP PROCEDURE WARNING 240 volts 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 START UP PROCEDURE Mounting Before filling with water check mounting to verify that the steam chamber is level and securely supported Refer to Maintenance Section page 29 for details on securing the steam chamber Piping Verify that all piping connections are completed as recommended and that water pressure is available Use cold or hot supply water If the water pressure is above 60 psi 415 kPa and or water hammer is excessive install a pressure reducing valve or shock arrester Even though the humidifier has an internal 1 25 mm air gap some governing codes may
58. ting control verify that the shunt on the JP2 jumper is placed over the 1 amp 2 position 4 To change the input control type on Model 1160 to signal by others see Figure 18 for a 0 10 VDC signal and see Figure 19 for a 4 20 mA signal input resistance 250 ohms IMPORTANT Note the internal controller slide switch S1 settings in each control input wiring diagram FIGURE 16 Model 1150 Input Wiring for Automatic Steam Humidifier Control on off configuration IMPORTANT SET JUMPER TO 2 amp 3 POSITION Internal controller board JP2 FOR ON OFF CONFIGURATION slide switch S1 positions SERIAL COMMUNICATION 1 and 2 are OFF TO APRILAIRE MODEL 8570 TO OUTDOO THERMOSTAT OPTIONAL PERATURE SENSOR 4 LL AUTOMATIC GJ steam HUMIDIFIER CONTROL HIGH HUMIDITY LIMIT SWITCH 3 WIRE SHIELDED i CABLE W GROUND Li 1 s WIRE SHIELDED AIRFLOW PROVING SWITCH CABLEW GROUND Lo d STEAM HUMIDIFIER FIELD WIRING 24VDC ENABLE COMMON COMMON COMMON TERMINAL BLOCK COMMAND SIGNAL FIGURE 17 Model 1160 Input Wiring for Automatic Steam Humidifier Control modulating configuration 1238 IMPORTANT WM SJ EE TO 1 amp 2 POSITION Internal controller board FOR MODULATING CONFIGURATION slide switch S1 positions SERIAL COMMUNICATION 1 and 2 are OFF TO APRILAIRE MODEL 8570 TO OUTDOOR THERMOSTAT OPTIONAL TEMPERATURE SENSOR AUTOMATIC S
59. tions in this manual may cause moisture to accumulate which may cause bacteria and mold growth or dripping water into building spaces Dripping water may cause property damage 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 Once the chamber is full and there is a call for humidity from the Automatic Steam Humidifier Control the heating elements will be energized causing the water to boil The boiling water creates steam which due to the moderate pressurization of the chamber that comes from boiling is forced through the vapor hose and steam distribution tube into the duct system As water is boiled off the water level in the steam chamber will drop The water probe will sense when it reaches a low point and will cause the fill valve to open The process of boiling the water in the steam chamber will cause minerals and impurities in the water to drop out Depending on the hardness and quality of the water this can create a substantial build up within the steam chamber The unit will drain the chamber periodically to help clean the steam chamber and reduce the amount of cleaning required during maintenance Aprilaire Steam Humidifiers are controlled by a
60. ve outside air volume Verify proper operation of fans and dampers Humidity above Improperly located Relocate using guidelines described on page 14 set point humidistat Reduced airflow Check fans and dampers Malfunctioning controls Check for incorrect supply voltage Check for incorrect control signal e Check for improper wiring hookup Check if relay contactor shorted Repair or replace as needed Improper slide switch e f the humidifier is receiving a 4 20 mA signal by others the slide switches need to set as shown settings on page 11 or the humidifier will run continuously Hunting humidity Malfunctioning control e f there is a faulty or inaccurate humidity controller replace swings above and below desired set point system Relocate improperly located control components See humidity control placement information on page 13 Noisy operation Thunder type noise is coming from chamber during refill This is normal on larger units and is caused by the cold fill water collapsing steam in the chamber Reduce water pressure minimum of 25 psi 172 if inlet water pressure is too high Contactor noise Verify that contactor and transformer electrical plugs are fully engaged Verify 24 VAC at H on internal control board and at C on terminal strip Contactor normally makes a clunk sound as it pulls in A continuous chattering noise is not normal and is symptomatic of a fa
61. y a 1 4 field supplied plastic tubing The hose is connected to inlet H on the switch housing while inlet L remains open to the atmosphere See Figure 20 Using the Normally Open and Common terminals inside the terminal enclosure wire the airflow proving switch to the field wiring terminal block in the humidifier according to the wiring diagram on page 21 depending on the humidifier model number See Figures 16 19 on page 21 The airflow proving switch is field adjustable from 05 w c to 12 w c To adjust the set point turn the adjusting screw counter clockwise CCW until motion has stopped Next turn the adjusting screw 4 complete turns in a clockwise direction to engage the spring From this point the next 10 turns will be used for calibration The optimum setting is one that will only close the switch when the fan is in operation Each full turn of the adjustment screw represents approximately 1 2 w c To properly calibrate an airflow proving switch a digital manometer or other pressure measuring device should be used to confirm the actual set point SUPPLY WATER AND DRAIN PIPING The humidifier is designed to operate with hot or cold hard or soft water Be sure to set slide switches on the internal controller board to guidelines on page 11 Supply water piping may be of any code approved material copper steel or plastic The fill valve connection size is 4 DN8 compression fitting In cases where water hammer may be

Aprilaire 1150 Humidifier User Manual

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