Aprilaire 1150 Humidifier User Manual
Contents
1. CUT ALONG DASHED LINE PP RESEARCH PRODUCTS corporation 1015 E Washington Ave e Madison WI 53703 Phone 888 782 8638 Fax 608 257 4357 www aprilairecontractor com 61000134 06 06 B2203636B 2006 Research Products Corporation2. Make sure the Outdoor Temperature Sensor is located at least 3 feet away from all exhaust vents Automatic Mode Only SYMPTOM Humidifier operates constantly Humidifier or Automatic Steam Humidifier Control chatters or clicks ON and OFF rapidly Red Diagnostic Light is on TROUBLESHOOTING PROCEDURE e f the humidity level in the building is less than the knob setting or is within the proportional control band Model 1160 and 1180 only the Automatic Steam Humidifier Control will operate the humidifier until the humidity level is higher than the knob setting e In the Test mode verify unit will operate for approximately one minute e Check the resistance of the sensor by removing the wires of the Outdoor Temperature Sensor and measuring the resistance across the wires with an ohmmeter Confirm reading to outdoor temperature in Table 4 For Manual Operation verify that resistance across the leads of Resistor Case is between 44 000 and 48 000 ohms e Make sure the Outdoor Temperature Sensor is mounted completely outside the building on the North East or West side of the building and out of direct sunlight Automatic Mode Only e Rotate the Automatic Steam Humidifier Control knob counterclockwise to the Off position and observe whether the humidifier turns off Steam indicator light on the humidifier should go off If the humidifier still operates in the Off position check summary wiring
3. FIGURE 3 Modulating Setting for Model 1160 or 1180 STEP 2 DETERMINE LOCATION FOR CONTROL AND MOUNT ON DUCT The Control must be mounted in the return duct of the HVAC system See Figure 4 for a split system installation and Figure 5 for a rooftop unit installation The Control must be at least 1 foot upstream of the steam dispersion tube and any fresh air intake ductwork Use the template in the back of this manual to mark the duct opening After cutting the hole in the duct mount the Control tightly to the duct using 4 sheet metal screws not provided FIGURE 4 Split System Installation RETURN AIR DROP SUPPLY AIR PLENUM HIGH LIMIT HUMIDITY AUTOMATIC SWITCH STEAM HUMIDIFIER CONTROL POSSIBLE DISPERSION TUBE SUPPLY LOCATIONS AIR DUCT AIR FLOW PROVING SWITCH FIGURE 5 Rooftop Unit Installation Cooling Coil Economizer i Heating Coil Filters control device ra Outside O Air ANN A A Motorized Air Dampers Dispersion Tube B Dispersion Tube A AUTOMATIC Air Flow STEAM Proving Switch HUMIDIFIER f CONTROL Boi Duct High Limit Humidity Control A AV from Dispersion Point A Return Duct Supply Duct STEP 3 DETERMINE LOCATION FOR OUTDOOR TEMPERATURE SENSOR The location of the Outdoor
4. humidity higher than recommended Condensation regardless of the humidifier model being controlled The automatic mode damage may result incorporates the supplied Outdoor Temperature Sensor to automatically adjust the control set point based on the outdoor temperature The manual mode does not require an outdoor temperature measurement and is used for specific set point control with the control set point manually adjusted by the user The Automatic Steam Humidifier Control will accurately control the humidity in the conditioned space within the range of 15 55 RH Do not set humidity up to rec ended levels if there is condensation on the inside of windows Condensation damage may result Do not mount Automatic Steam Humidifier Control on supply plenum or duct High supply temperatures will cause the control to malfunction 4 When installing Automatic Steam Humidifier Control on downflow CONTROL TYPE furnaces ensure blower continues to run after a heat call is satisfied to eliminate high temperatures from damaging the ON OFF CONTROL FOR MODEL 1150 Automatic Steam Humidifier Control The Automatic Steam Humidifier Control sends a 10 VDC signal to the 5 Do not configure Automatic Steam Humidifier Control for humidifier when the measured return air relative humidity is 3 or more Modulating Control jumper JP2 set to 1 amp 2 when connected to a below the set point This energizes the humidifier at 100 output
5. to the field wiring terminal block of the Steam Humidifier according to Figure 9 Use 3 wire shielded cable with ground for the wiring from the Control to the Humidifier Note the terminal designations below AUTOMATIC STEAM HUMIDIFIER CONTROL I l Serial Communications for optional devices 24V 24 VDC input power c Common H Command Signal to Steam Humidifier H Command Signal to ground not used ODT Outdoor Temperature Sensor STEAM HUMIDIFIER 30 24 VDC output power c Humidifier Common 1 Command Signal from Control FIGURE 9 Wiring Diagram TO OUTDOOR TEMPERATURE SERIAL COMMUNICATION TO APRILAIRE MODEL 8570 THERMOSTAT OPTIONAL SENSOR tt tt a __ AUTOMATIC STEAM HUMIDIFIER CONTROL H Copr 3 WIRE SHIELDED CABLE W GROUND HUMIDIFIER PANEL SHIELD GND LUG STEAM HUMIDIFIER FIELD WIRING TERMINAL BLOCK OPERATION SYSTEM CHECKOUT COMMAND COMMON SIGNAL 1 For system test be sure that all Steam Humidifier plumbing distribution and electrical connections are set up in accordance with the instructions in the Steam Humidifier Installation Operation and Maintenance Manual nd all precautions therein are followed v 2 Turn on the water supply to the humidifier Make sure the drain valve is closed 3 Turn on power to the humidifier 4 Set up a fan call at the thermostat If the humidifier is configured to bring on the equipment fan when a deman
6. 10 is not lit If the Red Diagnostic Light is lit re check the wiring If the Red Turn the dial to a setting of 4 At this setting when the Outdoor l Diagnostic Light does not go off refer to the troubleshooting section of Temperature is 20 F the indoor relative humidity set point of the Automatic this manual Note that the Red Diagnostic Light will turn on momentarily Steam Humidifier Control will be 35 RH During the next 24 48 hours it when first powered up may be necessary to adjust the dial for more or less humidity depending on the occupants comfort and the requirements of the conditioned space Refer to the Operation Guide Table 1 FIGURE 10 During the coldest portion of the first heating season minor adjustments may be necessary This is dependent upon the unique features and construction of Red Diagnostic the conditioned space Refer to the Operation Guide Table 1 oy 2 Light 9098099999 L TABLE 1 Operation Guide Condition Solution Condensation on windows Reduce the setting on the control dial by 1 increment J l 24V C H H ODT Lack of humidity Increase the setting on the control dial by 1 increment CAUTION The relative humidity in the conditioned space will now be accurately A high relative humidity setting on the Control may cause controlled and should need no further adjustment during future heating excessive condensati
7. Automatic Steam Humidifier Control e Do not mount Automatic Steam Humidifier Control downstream of the bypass outlet CONTROL TEMPLATE False humidity conditions will cause humidifier to operate incorrectly 1 CUT TEMPLATE ALONG DASHED LINE 2 PLACE THIS TEMPLATE ON THE RETURN PLENUM UPSTREAM OF BEFORE THE DISPERSION TUBE 3 TRACE THE OUTSIDE EDGES OF THIS TEMPLATE 4 REMOVE TEMPLATE AND ACCURATELY CUT THE PLENUM OPENING 5 USING 4 SHEET METAL SCREWS INSTALL AUTOMATIC STEAM HUMIDIFIER CONTROL IN PLENUM OPENING LIMITED WARRANTY Your Research Products Corporation Aprilaire Automatic Steam Humidifier Control 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 Automatic Steam Humidifier Control 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 Automatic Steam Humidifier Control THIS WARRANTY SHALL NOT OBLIGATE RESEARCH PRODUCTS CORPORATION FOR ANY LABOR COSTS AND SHALL NOT APPLY TO DEFECTS IN WORKMANSHIP OR MATERIALS FURNISHED BY YOUR INSTALLER AS CONTRASTED TO DEFECTS DISCOVERED IN THE AUTOMATIC STEAM HUMIDIFIER CO
8. NTROL 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 To register your Aprilaire product or for more information visit www aprilairecontractor com 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 PO BOX 1828 Madison WI 53701 Thank you Your Warranty Registration information will not be sold or shared outside of this company
9. OT LEAVE IN TEST MODE AS HUMIDIFIER WILL NOT OPERATE e Make sure water supply valve is open e f humidifier still does not operate refer to the Aprilaire Steam Humidifier Installation Operation and Maintenance Manual Humidifier operates only e f outdoor temperature is greater than 60 F or less than 30 F the Automatic Steam TABLE 4 in Test mode Humidifier Control will only operate in the Test mode Automatic Mode Only 5 aia Outdoor Resistance e f the humidity level in the building is higher than the knob setting or the proportional Temperature kQ control band Model 1160 and 1180 only the Automatic Steam Humidifier Control will not 30 F 230 6 operate the Humidifier 20 F 163 8 e Check the resistance of the sensor by removing the leads of the Outdoor Temperature Sensor from the terminals and measuring the resistance across the wires with an ohmmeter Confirm reading to outdoor temperature in Table 4 For Manual Operation remove leads and verify that resistance across the leads of Manual Mode Resistor Case is between 44 000 and 48 000 ohms Make sure the Outdoor Temperature Sensor is mounted completely outside the building on the North East or West side of the building and out of direct sunlight Automatic Mode Only If Outdoor Temperature Sensor is mounted in fresh air intake duct make sure the probe is no more than 36 inches from the outside wall Automatic Mode Only
10. Temperature Sensor must meet these three requirements 1 Must be mounted on North East or West side of building out of direct sunlight 2 Must be at least 3 feet from all exhaust vents 3 Must be above expected snow line See Figure 6 Incorrect humidity levels will result if these requirements are not met Attach the sensor bracket to the building with a 8 galvanized screw FIGURE 6 Outdoor Temperature Sensor Location North East Outdoor or West side Temperature of building Sensor 1 Sensor Outdoor Above expected Bracket snow line i Temperature Sensor leads STEP 4 LOCATE ACCESS HOLE FOR WIRING TO OUTSIDE SENSOR Look for or provide an opening in the building envelope for running wire to the Sensor A convenient way to get wire to the Sensor is to make use of unused wires running to the A C condensing unit if applicable Other ways are to use existing holes for telephone lines A C lines water meter etc Read all equipment instructions beforehand for possible conflicts and warnings Do not run outdoor temperature sensor wiring alongside wires carrying high voltage 120VAC or higher STEP 5 ALTERNATE LOCATION FOR OUTDOOR TEMPERATURE SENSOR The Sensor can also be mounted in the center of either e PVC fresh air intake pipe for the split system furnace OR e Fresh air intake duct Mount the sensor with a 8 galvanized screw In both cases the Sensor must be no more than 3 feet from the outside w
11. The Model 1150 Steam Humidifier Failure of humidifier may result Steam Humidifier is either on at 100 capacity or it is off MODULATING CONTROL FOR MODEL 1160 amp 1180 The Automatic Steam Humidifier Control sends a signal to the humidifier between 0 and 10 VDC based on a the difference between measured relative humidity and set point relative humidity and b where this difference or error falls within an adjustable proportional control band The output of the Control and therefore the Steam Humidifier is a proportion of maximum output based on a and b above See Figure 1 for graphical representation of the output FIGURE 1 Modulating Control Output 1 __ PROPORTIONAL CONTROL BAND l Note The Proportional Control Band can be adjusted to 6 9 12 or 15 RH The factory setting of 12 is depicted at left 6 0 6 MEASURED RH SETPOINT RH As an example using the 12 proportional band factory setting when the measured RH is 6 above the set point the output will be 0 VDC when the measured RH is 6 below set point the output will be 10 VDC when the measured RH is 3 below set point the output will be approximately 7 5 VDC The humidifier uses this varying signal to time proportion the operation of the heating elements in the tank 10 VDC output corresponds with 100 humidifier capacity 5 VDC with 50 capacity etc Modulating control will result in a more precise
12. all See Figure 7 If it is not feasible to use the Outdoor Temperature Sensor in any of the ways described the Automatic Steam Humidifier Control can be set for Manual Operation See Figure 8 on the next page for details FIGURE 7 Alternate Location for Outdoor Temperature Sensor E FRESH AIR INTAKE HERRE ENESAS 3 CENTER LINE 0UTSIDE WALL STEP 6 ROUTE THE WIRE TO CHOSEN SENSOR LOCATION Run wire to the outdoor temperature sensor Sensor is not affected by lead length up to 300 feet Use standard thermostat wire Do not run outdoor temperature sensor alongside wires carrying high voltage 120 VAC or higher STEP 7 ATTACH SENSOR WIRE TO AUTOMATIC STEAM HUMIDIFIER CONTROL Strip wires 1 4 inch and insert the wires from the Sensor into the terminals labeled ODT on the Automatic Steam Humidifier Control INSTALLING THE AUTOMATIC STEAM HUMIDIFIER CONTROL FOR MANUAL OPERATION 1 Insert the Manual Mode Resistor Case into the terminals labeled ODT on the Automatic Steam Humidifier Control 2 Snap the Manual Mode Resistor Case into the slot provided so that Resistor Case sticks out from the bottom edge of the base 3 Remove the control knob and apply the Manual Mode label to the cover aligning the sticker and knob holes Re install the knob FIGURE 8 Manual Mode MANUAL MODE STEP 8 WIRE THE CONTROL TO THE HUMIDIFIER Wire the Control
13. control of relative humidity OUTDOOR TEMPERATURE COMPENSATION AUTOMATIC MODE The automatic mode is the preferred method when the application requires that the Control automatically adjust the RH set point based on the outdoor temperature This is recommended for all comfort based applications such as office buildings schools day cares etc It is also recommended for any application where the primary concern is to avoid the potential for condensation that can form on areas within the building such as windows and within walls When installed in this mode the Control utilizes an Outdoor Temperature Sensor that will track the actual outdoor temperature The Control then automatically adjusts the desired indoor RH MANUAL MODE SPECIFIC SET POINT CONTROL The manual mode is the preferred method when the application requires that a specific set point be maintained regardless of the outdoor temperature This is recommended for all process based applications such as print shops book stores test facilities etc When installed in this mode the Outdoor Temperature Sensor is replaced with a manual resistor case that prevents the Control from adjusting the space RH set point based on the outdoor temperature and controls to the specific set point selected on the Control Note If the building is not designed to handle the amount of RH the humidifier is supplying the building occupants may need to adjust the RH setting on the C
14. d for humidity is recognized skip to the next step 5 Initiate a humidity demand from the Control by rotating the control knob of the Automatic Steam Humidifier Control clockwise to the Test position 6 If all is set up properly the Steam indicator light on the humidifier will illuminate and the heaters will be energized In the Test position the AUTOMATIC MODE OPERATION NOTES humidity demand will last for one minute The Automatic Steam Humidifier Control is installed in the return duct During the first heating season the 8 Setting the Control Automatic Steam Humidifier e f using Automatic Mode and the conditioned space is occupied Control needs to be adjusted set the Control to knob setting 4 to match the requirements and construction of the conditioned space Please follow these steps when adjusting the e f the conditioned space is unoccupied set the Control to Off Control refer to Figure 12 7 If the Steam indicator light does not illuminate when the Control is turned to the Test position refer to the troubleshooting section of this manual FIGURE 12 e For Manual Mode and the conditioned space is occupied set to 35 or to a level that matches the application s needs For information on the initial adjustment period refer to the operation 1 notes in the next section AUTOMATIC MODE 9 Make sure the Red Diagnostic Light on the Control see Figure
15. diagram for correct Automatic Steam Humidifier Control installation e f humidifier still does not shut off refer to the troubleshooting section in the Aprilaire Steam Humidifier Installation Operation and Maintenance Manual e Check voltage at Automatic Steam Humidifier Control 24V and C terminals Voltage should be 22 VDC minimum 26 VDC maximum e Make sure Outdoor Temperature Sensor wiring is not run alongside wires carrying high voltage 120 VAC or higher Automatic Only e Check that the wiring is correct See Figure 9 e Measure the resistance of the Outdoor Temperature Sensor by removing the leads from the terminal and measuring the resistance across the wires with an ohmmeter Confirm the reading with the temperature in Table 4 For Manual Operation verify that the resistance across the leads of the Manual Mode Resistor Case is between 44 000 and 48 000 ohms CUT ALONG DASHED LINE WARNING Sharp edges on the opening may cause cuts Use care when cutting the plenum opening and installing the Automatic Steam Humidifier Control CAUTION e Do not mount Automatic Steam Humidifier Control on supply plenum or duct The unit will not withstand supply temperatures and will malfunction e When installing Automatic Steam Humidifier Control on counterflow furnaces ensure blower AUTOMATIC STEAM continues to run after a heat call is satisfied to eliminate high temperatures from damaging the HUMIDIFIER i
16. nd FIGURE 11 setting may need to be widened To change use a small flat head screwdriver to rotate P q he potentiometer in the Automatic Steam 6 is D E b o N k Humidifier Control board See Figure 11 90 901 The recommended settings on the humidistat are based on years of research MANUAL MODE OPERATION NOTES for an average building See ASHRAE Handbook HVAC Systems and Equipment Ch 20 Humidifiers Note these settings may not be appropriate The Automatic Steam Humidifier Control is installed in the return duct for every application These settings represent a compromise between RH levels When installed in the Manual Mode the Control provides specific set point that would be most desirable for comfort reasons and humidity levels that are control If the building is not designed to handle the amount of RH the suitable for protection of the conditioned space and to avoid condensation on humidifier is supplying the RH setting on the Control may need to be windows and within walls For example a wintertime indoor RH of 50 may adjusted to a lower value be considered ideal for comfort but unfortunately it probably would result in during extreme days to damage to the conditioned space Observance of the recommended RH levels prevent condensation on FIGURE 13 on the humidistat therefore is an important safeguard Condensation of interior surfaces For e
17. on on windows and within walls Set the seasons Make note of the dial setting in the event the knob is temporarily relative humidity in accordance with the instructions in this manual moved when performing annual maintenance of the Aprilaire Steam Do not set the relative humidity higher than recommended Humidifier Table 2 below shows the way the Automatic Steam Humidifier Control automatically adjusts the relative humidity based on the outdoor OPERATION NOTES FOR MODULATING CONTROL temperature For example when the knob is set to 4 and the outdoor FOR MODEL 1160 amp 1180 temperature is 20 F the conditioned space will be controlled to 35 RH As explained in the Principles of Operation section of this manual when TABLE 2 Relative Humidity Guide configured for modulating control the Automatic Steam Humidifier Control Outdoor Temperature F sends a 0 10V signal to the humidifier to vary the capacity of the Steam 0 10 20 30 40 Humidifier depending on where the measured return air relative humidity 10 WG 20 alls relative to the set point as well as the proportional control band This will result in a more precise control of relative humidity 22 The proportional control band can be set to 6 9 12 or 15 RH The 28 actory setting is 12 Note that the proportional control band is centered 35 on the RH set point Refer back to Figure 1 he humidifier is cycling on and off too requently the proportional control ba
18. ontrol to a lower value during extreme days to prevent condensation on interior surfaces The RH setting should be adjusted upward when the outdoor temperature goes up INSTALLATION CAUTION Improper jumper settings may damage humidifier The shunt on the JP2 header pin must be set in accordance with the instructions in this manual STEP 1 VERIFY CONTROL TYPE When shipped with a Steam Humidifier the Automatic Steam Humidifier Control is preset at the factory to match the humidifier model Model 1150 Steam Humidifier is configured for on off control while the Model 1160 1180 Steam Humidifier is configured for modulating control When shipped as a replacement Model 57 the Control is preset for use with a Model 1150 i e on off control If using the Model 57 with a Model 1160 or 1180 the control type setting must be changed for modulating control See below Remove the door to the Automatic Steam Humidifier Control and look at the area on the circuit board above the terminal block The three pin header labeled JP2 should be set in the following manner For the Model 1150 the Control must be set to the on off configuration The shunt must be placed on the 2 amp 3 pins See Figure 2 FIGURE 2 On Off Setting for Model 1150 For the Model 1160 or 1180 the Control must be set to the modulating configuration The shunt must be placed on the 1 amp 2 pins See Figure 3
19. r EVA e Automatic Steam Humidifier Control Safety Installation and Operation Manual READ COMPLETE INSTALLATION INSTRUCTIONS BEFORE STARTING WARNING This product must be installed by a qualified heating and air conditioning contractor Failure to do so could result in serious injury from electrical shock or damage to product and voids product warranty due to possible product misapplication THESE INSTALLATION INSTRUCTIONS ARE FOR THE AUTOMATIC STEAM HUMIDIFIER CONTROL ONLY For Aprilaire Humidifier installation follow Aprilaire Humidifier Installation Instructions WARNING PRINCIPLES OF OPERATION 1 240 volts may cause serious injury from electrical shock Disconnect electrical power to the Steam Humidifier before starting installation The Aprilaire Automatic Steam Humidifier Control is designed to be installed in the return duct of the HVAC system The control strategy of the Automatic Steam Humidifier Control is matched to the humidifier being controlled when used with a Model 1150 Aprilaire Steam Humidifier the Control supplies an on off signal to the humidifier When used with a Model 1160 or 1180 Aprilaire Steam Humidifier the Control supplies a 2 Sharp edges may cause serious injury from cuts Use care when cutting plenum openings and handling ductwork CAUTION modulating signal to the humidifier In terms of outdoor temperature compensation the Control can be set up in automatic or manual mode Do not set
20. xample water on inside windows in the form of fogging or frost is an indication of too with an outdoor temperature much relative humidity This same condensation can occur in other areas of of 20 F the correct setting will the conditioned space with the possibility of damage resulting be 35 relative humidity If the temperature is expected to fall to 0 then reduce the setting to 25 several hours prior to the temperature change It is important to adjust the RH setting upward when the outdoor temperature MANUAL MODE goes back up again TABLE 3 Outdoor Indoor Relative Humidity Outside Temperature Recommended RH 40 F 45 30 F 40 20 F 35 10 F 30 OF 25 10 F 20 20 F 15 TROUBLESHOOTING GUIDE Applies to both Automatic and Manual Operation unless indicated otherwise SYMPTOM TROUBLESHOOTING PROCEDURE Humidifier does not e Make sure equipment blower is operating and thermostat is calling for heat operate in Test mode e Make sure the Outdoor Temperature Sensor is connected to the ODT terminals of the control For Manual Operation make sure Manual Mode Resistor Case is in place of the Sensor e Check main wiring diagram for correct Automatic Steam Humidifier Control installation e Check voltage at Automatic Steam Humidifier Control 24V and C terminals Voltage should be 22 VDC minimum 26 VDC maximum e In Test mode humidifier will operate for 1 minute only DO N
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