Aprilaire 400 Troubleshooting guide
Contents
1. Model 60 shown Automatic Digital Humidifier Control Model 60 amp 62 Safety and Installation Instructions READ COMPLETE INSTALLATION INSTRUCTIONS AND TEMPLATE BEFORE STARTING INSTALLATION 4 WARNING ATTENTION INSTALLER 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 4 WARNING 1 120 240 volts may cause serious injury from electrical shock Disconnect electrical power to the furnace and humidifier before starting installation 2 Sharp edges may cause serious injury from cuts Use care when cutting plenum openings and handling ductwork 4 CAUTION Do not set humidifier higher than recommended Condensation damage may result Do not set humidity up to recommended levels if there is condensation on the inside of windows of any unheated living space Condensation damage may result Do not mount the Humidifier Control on the supply plenum or duct The unit cannot withstand the plenum temperatures and will malfunction When installing the Humidifier Control a counterflow furnace ensure the blower continues to run after the heat call is satisfied to eliminate high temperatures from damaging the Humidifier Control Do not mount the Humidifier Control downstream of the bypass outlet False humidity conditions will cause the humidifier to operate incorrectly Avoid installi2. f the humidifier does not activate with the Humidifier Control in the Test Reset position refer to the roubleshooting guide e If HVAC blower does not activate with the Humidifier Control in the Test Reset position refer to the roubleshooting guide 8 Setting the Humidifier Control e f the home is occupied set the Humidifier Control to Normal For Manual Mode set to 35 f the home is vacant set the Humidifier Control to OFF f in Manual Mode and system is installed during cooling season set the Humidifier Control to OFF 9 Instruct the homeowner to refer to the Aprilaire Owner s Manual for the initial adjustment period 10 Make sure the red Call Dealer for Service light is not flashing If the red Call Dealer for Service light is flashing refer to the troubleshooting guide TROUBLESHOOTING GUIDE SYMPTOM Call Dealer For Service Light Flashing see Figure TROUBLESHOOTING PROCEDURE Applies to both Automatic and Manual Operation unless indicated otherwise Display Error Code E1 RH Sensor Rotate Humidifier Control knob to the Test Reset position After 5 seconds the green Humidifier On light will blink resetting the error If returns replace the Humidifier Control Display Error Code E2 Control Knob Rotate Humidifier Control knob to the Test Reset position After 5 seconds the green Humi
3. BYPASS CONNECTION Figure 90 1137 DUCT SHEET METAL After location for Control is selected drill a 3 4 inch hole for the RH sensor the RH sensor extends from the back of the Humidifier Control Use 2 sheet metal screws 3 4 inch long not provided to mount the Humidifier Control Use the mounting slot to level the Control then secure the Control with the second sheet metal screw Make sure the Humidifier Control sensor gasket is seated tightly around the drilled hole Do not install Control without gasket DUCT FIBER BOARD MOUNT After location for Control is selected cut a rectangular hole in the duct board no smaller than 6 9 16 inches long by 4 3 8 inches wide Cut a rectangular piece of sheet metal to fit behind the hole in duct board for mounting the Humidifier Control Drill a 3 4 inch hole for the RH sensor the RH sensor extends from the back of the Humidifier Control into the sheet metal plate Use 2 sheet metal screws 3 4 inch long not provided to mount the Humidifier Control Make sure the Humidifier Control sensor gasket is seated tightly around the drilled hole Do Not Install Control Without Gasket Secure the sheet metal plate with the Humidifier Control mounted inside the duct see Figure D CONTROL REPLACEMENT When replacing an existing control the duct opening left by the removed control must be covered completely Locate and install
4. R and erminals Voltage should be 22 VAC minimum to 30 VAC maximum ake sure that the saddle valve is open n Test Reset mode the humidifier will operate for 1 minute only DO NOT LEAVE THE HUMIDIFIER CONTROL IN TEST RESET MODE AS THE HUMIDIFIER WILL NOT OPERATE 23 SYMPTOM Yellow Change Water Panel light is blinking see Figure TROUBLESHOOTING PROCEDURE Check the condition of the Water Panel and replace it if mineral deposits are blocking air flow Follow the instructions on the Water Panel box Rotate the knob to the Test Reset position for at least 5 seconds to reset Water Panel change timer Check that the timer setting is correct for the humidifier model and water conditions see Figure B DO NOT LEAVE THE HUMIDIFIER CONTROL IN TEST RESET MODE AS THE HUMIDIFIER WILL NOT OPERATE SYMPTOM Humidifier operates only in Test Reset mode e f outdoor temperature is greater than 60 F or less than 30 F the Humidifier Control will only operate in the Test Reset mode for 1 minute e f the humidity level in the home is higher than the Humidifier Control knob setting the Humidifier Control will not operate the humidifier TROUBLESHOOTING PROCEDURE 24 Measure the resistance of the Outdoor Temperature Sensor by removing the leads from the Humidifier Control terminals and measuring the resistance across the wires
5. see Figure B 4 Figure B Use the OFF setting for Model 800 Series humidifiers Use Setting A Wate Panel OFF for Model 400 Series Indicator humidifiers areas Settings with very hard water The indicator will light after 150 hours of humidifier operation Use Setting B for Model 400 Series and for 500 Series 600 Series and 700 Series humidifiers in areas with very hard water The indicator will light after 300 hours of humidifier operation Use Setting for Model 500 Series 600 Series and 700 Series humidifiers The indicator will light after 600 hours of humidifier operation 90 1202B The Model 62 shipped with the Model 800 Steam Humidifier is factory set to OFF The Model 62 does not have the Change Water Panel light on the Control The Canister Change indicator for the Model 800 is on the humidifier 4 Determine Location for Humidifier Control and Mount Control Humidifier Control must be mounted on the Return Duct at least 6 inches upstream of the following see Figure C Humidifier e Humidifier Bypass Ductwork if applicable e Fresh Air Intake Ductwork if applicable Ambient operating temperature of the Humidifier Control is to be from 20 F to 120 F to prevent damage to the control display RETURN DUCT K 6 MIN x HUMIDIFIER CONTROL FRESHAIR 6 INTAKE
6. ABOVE EXPECTED LEADS SNOW LINE 90 998 STEP 6 Locate Existing Access Hole to Outside A convenient way to get the Sensor wire outside is to make use of unused wires running to the A C condensing unit if applicable Other ways are to use existing holes for Cable TV lines telephone lines A C lines etc Read all equipment instructions beforehand for possible conflicts and warnings 10 STEP 7 Alternate Location for Outdoor Temperature Sensor 4 WARNING If Outdoor Temperature Sensor is mounted in an intake duct or pipe do not set Blower Activation switch to ON The Sensor can also be mounted in the center of either e PVC fresh air intake pipe for the HVAC system 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 wall See Figure G If it is not feasible to use the Outdoor Temperature Sensor in any of the ways described the Humidifier Control can be installed for Manual Operation See Installing the Humidifier Control for Manual Operation and Figure J for details Figure G 0 w CENTER LINE FEET OUTSIDE WALL 90 999 STEP 8 Route the Wire from Control to Sensor When the Blower Activation switch is ON the Humidifier Control may periodically turn the HVAC blower on to sample the Run wire to the outdoor temperature sensor Sensor
7. Q using the A and B terminals Rotate the Humidifier Control knob to the Test Reset position After 5 seconds the green Humidifier On light will blink resetting the error If E4 returns check the wiring between the Digital Humidifier Control and Model 8570 check the connections at A and on the humidifier control and the Model 8570 Make sure the Model 8570 is wired and operating properly according to the Model 8570 manual 21 TABLE 1 Humidifier does not operate in Test Reset mode TROUBLESHOOTING PROCEDURE Outdoor Temperature F Resistance kQ 10 30 231 8 20 163 4 10 117 3 0 84 8 10 62 2 20 46 1 30 34 4 40 26 1 50 19 9 60 15 3 70 11 9 80 9 3 90 73 100 5 8 Figure M Red Call Dealer For Service Light Yellow Change Water Panel Light Green Humidifier Light 90 1227 22 Check wiring diagrams for correct Humidifier Control installation ake sure that the blower is operating and the HVAC system 15 calling for heat Check wiring diagrams for correct Humidifier Control installation f connected to a Model 400 Series humidifier make sure both floats in the bottom of the scale control insert are in he down position necessary dump out water to lower he floats Check voltage at the Humidifier Control
8. with an ohmmeter Confirm the reading with the temperature in Table 1 Reconnect the ODT Sensor leads If the resistance value does not match the temperature value replace the Outdoor Temperature Sensor Make sure that the Outdoor Temperature Sensor is mounted completely outside the house on the North East or West side of the house and out of direct sunlight Automatic Mode Only Make sure that the Outdoor Temperature Sensor is located at least 3 feet away from all exhaust vents Automatic Mode Only If Outdoor Temperature Sensor is mounted in the fresh air intake duct make sure that the sensor is no more than 3 eet from the outside wall Automatic Mode Only 25 SYMPTOM Humidifier operates constantly e f the humidity level in the home is less than the Humidifier Control knob setting and there is a continuous fan call or heat call depending on setup the Humidifier Control will operate the humidifier until the humidity level is higher than the Humidifier Control knob setting SYMPTOM Humidifier or Humidifier Control chatters or clicks On and Off rapidly TROUBLESHOOTING PROCEDURE TROUBLESHOOTING PROCEDURE Set Blower Activation switch to OFF In the Test Reset mode verify that the humidifier turns off after 1 minute Check the Outdoor Temperature Sensor resistance and location as instructed on the previous page e Rotate the Humidifier Cont
9. C blower must be running and the Model 62 must be calling for humidity WIRING DESCRIPTION e Wire terminals on the Model 62 to the Humidifier terminals on the Model 800 control board e Wire R and on the Model 62 to R and C on the furnace terminal strip e Remove the thermostat G wire from the furnace terminal strip and wire it to G on the Model 62 control e Wire Gf on the Model 62 to G on the furnace terminal strip e Wire W on the Model 62 W on the furnace terminal strip Replace cover and knob Figure L Model 62 Wiring for Model 800 Series Steam Humidifier 1 1 ADHC TERMINAL STRIP POWER INPUTS __ OUTPUTS R cla W GIH H Gf SSS N x 74 J T MODEL 800 STEAM HUMIDIFIER OUTDOOR TEMPERATURE SENSOR FOR AUTOMATIC MODE lt R R clo 6 6 Y y 2 w w THERMOSTAT FURNACE 90 1511 17 SYSTEM CHECK0UT 1 On ES Replace the cover by snapping it into the Humidifier Control base Also replace the knob onto the Control Turn Blower Activation switch to OFF Restore power to the HVAC system Activate the HVAC system or heat pump Fan or Heat Once the blower is operating rotate the k
10. Model 60 G on the furnace terminal strip Wire W on the Model 60 to W on the furnace terminal strip Replace cover and knob Figure K Model 60 Wiring for Model 400 500 600 and 700 Series Humidifiers ADHC TERMINAL STRIP H POWER INPUTS OUTPUTS cla w NORTH EAST WEST SIDE N OUTDOOR 5 TEMPERATURE w SENSOR FOR lt 22 AUTOMATIC 4 4 7 MODE AB0VE EXPECTED SNOW LINE k CONNECT CONNECT DRAIN LINE TOHOTWATER HERE SUPPLY R R 1 120VAC 6 1 y 20 CONTINUDUSLY POWERED w W 24 VAC TRANSFORMER PR0VIDED WITH HUMIDIFIER 90 1510 15 STEP 11 Model 62 Wiring for Model 800 Series Steam Humidifier See Figure L 4 WARNING 120 240 volts may cause serious injury from electrical shock Disconnect electrical power to the furnace and humidifier before starting installation Strip the wires used for all Humidifier Control terminal connections 1 4 inch NOTES e The Model 62 must be continuously powered from R and on the furnace to function properly The minimum VA required is 2 0 VA In order for the humidifier to operate the HVA
11. difier On light will blink resetting the error If E2 returns replace the Humidifier Control Display Error Code E3 Outdoor Temperature Sensor Auto Mode switch in AUTO position 1 Make sure that the Outdoor Temperature Sensor is properly connected to the ODT terminals on the Humidifier Control 2 Measure the resistance of the Outdoor Temperature Sensor by removing the leads from the Humidifier Control terminals and measuring the resistance across the wires with an ohmmeter Confirm the reading with the temperature in Table 1 on page 22 Reconnect the ODT Sensor leads If the resistance value does not match the temperature value replace the Outdoor Temperature Sensor 20 TROUBLESHOOTING PROCEDURE CONTINUED 3 Rotate Humidifier Control knob to the Test Reset position After 5 seconds the green Humidifier On light will blink resetting the error If E3 returns replace the Humidifier Control Manual Mode switch in MAN position 1 Make sure the ODT terminals are clear of any wires that may short the terminals together other than the ODT sensor 2 Rotate Humidifier Control knob to the Test Reset position After 5 seconds the green Humidifier On light will blink resetting the error If E3 returns replace the Humidifier Control Display Error Code E4 Communication This error applies to systems wired to an Aprilaire Model 8570 Thermostat see Figure
12. is not humidity of the air affected by lead lengths less than 300 feet Installing the Humidifier Control for Manual Operation 4 CAUTION Do not run outdoor temperature sensor alongside wires carrying high voltage 120 VAC or higher If it is not feasible to install the Outdoor Temperature Sensor the Humidifier Control can be operated in Secure the sensor bracket with a 8 screw Manual Mode z mon 1 Position the Mode Switch in the MAN position STEP 9 Attach Sensor Wire to Humidifier Control Manual indicator will be displayed Strip wire 1 4 inch and insert the wires from the Sensor into the 2 Apply the Manual Mode Label to the cover terminals labeled ODT on the Humidifier Control See Figure aligning the sticker and knob holes for location of terminals Figure J Figure H Dealer for Service Change Water Panel O Humidifier 90 1219B BLOWER ACTIVATION Set the Blower Activation Switch to ON to allow the Humidifier Control to activate the furnace fan for additional humidification This may be required if the humidifier is mounted on a heat pump or a furnace with short run cycles When the Blower Activation switch is ON the Humidifier Control will turn on the HVAC blower when humidity is required In the OFF position the humidifier will only operate if humidity is re
13. ng the Humidifier Control with the display facing downward to prevent the Humidifier Control from incorrectly measuring the relative humidity RH in the duct TABLE OF CONTENTS Installation Bees 4 page 18 Troubleshooting Guide page 20 THESE INSTALLATION INSTRUCTIONS ARE FOR THE APRILAIRE AUTOMATIC DIGITAL HUMIDIFIER CONTROL ONLY For Aprilaire humidifier installation follow Aprilaire Humidifier Installation Instructions INSTALLATION STEP 1 Unpack the Humidifier Control Carton Make sure all components are present see Figure A A Humidifier Control B Outdoor Temperature Sensor C Manual Mode Label Automatic Humidifier Control A Indoor Humidity m O Call for Service DN Changa Weter Figure 90 12018 2 Disassemble the Humidifier Control Remove the knob Remove the cover by pulling at the bottom and swinging it out and upward STEP 3 Check the Change Water Panel Indicator Setting This setting will control when the indicator light turns on reminding you to change your water panel If your Control came with a humidifier the Control is pre set for the humidifier If the installation site has a 3 month or shorter heating season or very hard water you may want to adjust the setting
14. nob of the Humidif ier Control Clockwise to the Test Reset position When the knob is set in the Test Reset position the green Humidi fier On light will illuminate After 5 seconds the green Humidifier On light will blink indicating a system reset you sho position ight wi humidifi is left i he H f the Humidifier Control and humidifier are set up properly uld hear the solenoid valve click into the open On the Model 800 Steam Humidifier the Steam illuminate green In the Test Reset position the er will operate for 1 minute If the Humidifier Control the Test Reset position for more than 1 minute terminals will open closing the solenoid valve and he knob and display backlights will flash indicating that the Humidifi er Control is still in the Test Reset position f the humidifier does not activate with the Humidifier Control in the T guide lest Reset position refer to the troubleshooting Blower Activation Test e Deactivate HVAC system or heat pump e Turn knob to OFF e Set switch to Blower Activation ON e Turn the knob to Test Reset The Humidifier On light will illuminate After 5 seconds the green Humidifier On light will blink indicating a system reset If the Humidifier Control and humidifier are set up properly the solenoid valve should click and the HVAC blower should activate
15. quired and the HVAC system is operating ee MANUAL MODE 12 10 Model 60 Wiring for Model 400 500 600 and 100 Series Humidifiers See Figure K 4 WARNING 120 volts may cause serious injury from electrical shock Disconnect electrical power to the furnace before starting installation Strip the wires used for all Humidifier Control terminal connections 1 4 inch NOTES e The Model 60 must be continuously powered from R and on the furnace to function properly The minimum VA required is 2 0 VA e In order for the humidifier to operate the HVAC blower must be running and the Model 60 must be calling for humidity WIRING DESCRIPTION Wire external 24 VAC transformer into a constant power source other than the heating ventilating air conditioning equipment HVAC blower circuit The transformer can be powered off the 120 VAC line at the junction box before it enters the HVAC equipment Connect the 24 volt side of the transformer to one of the H terminals on the humidifier control and to one of the humidifier solenoid valve wires Connect the other solenoid valve wire to the other H terminal e Wire R and on the Model 60 to R on the furnace terminal strip e Remove the thermostat G wire from the furnace terminal strip and wire it to G on the Model 60 control e Wire Gf on the
16. rol knob counterclockwise to the Off position and observe whether the humidifier turns off If the humidifier still operates in the Off position perform the following 1 Check the wiring diagram for correct Humidifier Control Installation 2 Remove the wires from the terminals on the Humidifier Control If the humidifier continues to operate replace the solenoid valve Check for steady 22 VAC to 30 VAC across the terminals of the Humidifier Control with a voltmeter e Check with a voltmeter that the HVAC signal across the W and and terminals of the Humidifier Control is a steady 22 VAC to 30 VAC e Make sure that the Outdoor Temperature Sensor wiring is not running alongside other wires carrying high voltage 120 VAC or higher Automatic Mode Only SYMPTOM Humidifier blower does not activate during Blower Activation Test TROUBLESHOOTING PROCEDURE Set the Blower Activation Switch to ON e Check wiring diagrams for correct Humidifier Control installation 26 27 RESEARCH PRODUCTS CORPORATION BOX 1467 MADISON WI 53701 1467 Call 800 334 6011 FAX 608 257 4357 10008977 6 10 2205119 28
17. the new control as instructed previously in Step 4 Figure D Fiber Board Duct Mount CONTROL BOARD COVER GASKET SCREW x2 KNOB N INSIDE OF RETURN DUCT BASE PLATE Ts SHEET METAL PLATE RETURN DUCT RETURN SHEET METAL CUT OPENING IN X crue DUCT 90 1203B Figure E Digital Humidifier Control 24V Terminals 2 212 22 883 28 28 R C A B ODT W G H H Gf OUTDOOR FAN SIGNAL TEMPERATURE TO HVAC SENSOR EQUIPMENT Y Y T Y COMMUNICATION HEAT SIGNAL SOLENOID WITH APRILAIRE FROM HVAC CONTROL 8570 THERMOSTAT EQUIPMENT OUTPUT 24 VAC FROM FAN SIGNAL HVAC EQUIPMENT FROM R AND THERMOSTAT 90 1397B 5 Determine Location for Outdoor Temperature Sensor The location of the Outdoor Temperature Sensor must meet these three requirements 1 Must be mounted on North East or West side of house out of direct sunlight 2 Must be at least 3 feet from all exhaust vents 3 Must be above expected snow line see Figure F Incorrect humidity levels will result if these requirements are not met Figure F NORTH EAST WEST SIDE OUTDOOR OF HOME TEMPERATURE SENSOR SENSOR SENSOR 7 OUTDOOR TEMPERATURE SENSOR
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