Air King AK5000 Operating instructions

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Furnace Humidifier
7
REQUIRED SEPARATELY PURCHASED PARTS FOR DRAINAGE
INSTALLATION:
installations, the humidistat is installed near the heating
thermostat for easy adjustment and wiring.)
• 5/8” OD 1/2” ID DRAIN HOSE, LENGTH AS PER YOUR
INSTALLATION.
3. Because the humidistat will be located further away from the
humidifier you will have to purchase approximately 15 to 20
feet of 20 ga low voltage wire.
• HOSE CLAMP FOR 5/8” OD HOSE.
1. Measure the required length of drain tube from the bottom of
the humidifier to an appropriate floor drain.
2. Prepare the drain fitting at the rear of the water pan before
installing the water pan onto the furnace.
3. Referring to figure 26, first drill a small hole (1/8” dia) centered
from the bottom of the drain fitting up through the pan.
Figure 26
4. Then using a 3/8” drill bit
carefully enlarge the hole to allow
for free flow of water.
5. Once the drain fitting has been
drill and the water pan installed
onto the furnace you may install
the drain tube (5/8” OD, 1/2” ID)
not supplied.
6. First install a 5/8” hose clamp
(not supplied) over the end of the
drain tube, then push the drain
tube up over the drain fitting and
secure in place with the hose
clamp. (Fig. 27)
DRAIN FITTING
HOSE CLAMP
DRAIN HOSE
7. Feed the other end of the drain
tube to a floor drain, secure to the
floor drain using a tie strap or
cable tie (not supplied).
Figure 27
4. Drill a small hole in the wall and then fish the low voltage wire
out thru the hole. Leave approximately 6 inches of low voltage
wire leads outside the hole for humidistat connection.
5. Remove the cover plate
from the humidistat and
you will see four holes
at the corners of the
base plate mount the
humidistat on the wall
using the (4) 1” long
screws provided. Make
sure it is level and the
low voltage wire is
coming out thru the 3/8”
hole on the base plate.
(Fig. 28)
4 SCREWS PROVIDED
FOR MOUNTING TO
THE WALL
BASE
PLATE
90˚ WIRE TERMINALS
FOR LOW VOLTAGE
WIRE CONNECTIONS
3/8” HOLE
COVER
PLATE
KNOB
CONTROL
LABEL
Figure 28
6. Strip the low voltage wires and make connections to the
humidistat using the two 90˚ wire terminals provided. Replace
the cover plate.
7. Install the knob onto the humidistat control shaft.
PLENUM/DUCT MOUNTING
1. As shipped, the humidistat is ready for wall mounting. You
must first convert the humidistat from wall mounting to
plenum/duct mounting. The control mechanism must be in
the air stream in order to sense and control the humidity.
2. Remove the cover plate and discard it.
STEP #5: ELECTRICAL INSTALLATION
This unit is supplied with a 24 volt plug in transformer. The
transformer must be plugged into a constant (one that will not be
shut off) 120 volt outlet. The transformer is supplied with 10 feet
of low voltage wire which must feed the humidistat and the
humidifier’s drum motor. Select an outlet within the 10 feet.
HUMIDISTAT
The humidifier is supplied with an exclusive universal humidistat
which can be either wall mounted as furnished or, with a few
minor changes, be mounted on the return (cold) air plenum/duct.
Either wall mounting or plenum/duct mounting works equally
well for humidity sensing and control. Wall mounting provides
easy access to adjust the humidistat setting since it is located in
the living area. Plenum/Duct mounting provides a simple
installation (you should not have to purchase extra low voltage
wire or fish the wires through the wall).
WALL MOUNTING
1. Your humidistat is furnished in the “wall mounting” mode, no
changes to the humidistat are necessary, because the circuit is
low voltage (24 V), no switch box is required.
2. Select a location about five (5) feet above the floor on an inside
wall where normal air circulation exists. (In most residential
PRE-CUT
3. Remove the control
PLENUM
Figure 29
HOLE
mechanism from the
base plate by removing
the two holding screws
at the back, and then,
turning the control
mechanism
180˚
CONTROL
MECHANISM
upside down to allow
SHAFT
the shaft to protrude
out through the 1/2”
BASE PLATE
hole on the base plate
HOLDING SCREWS
(NOTE: base plate
CONTROL LABEL
KNOB
remains in the same
position and only the control mechanism is turned (Fig. 29).
4. Replace the two screws to hold the control mechanism to the
base plate.
5. Attach the two 90˚ electrical terminals to the humidistat.
6. Use adhesive tape (not provided) to affix the humidistat
opening template to the pre-selected location and then drill
the 4 mounting holes and a 3/8” hole in the area mark
humidistat cutout.
7. Using the 3/8” hole as a starting point make the cutout cutting
on the outside of the line.
8. Skip to low voltage wiring section.
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Furnace Humidifier
STEP # 7: COMPLETING THE INSTALLATION.
LOW VOLTAGE WIRING
The 24 volt plug in transformer has 10 feet of low voltage wire
attached. Your 120 Volt outlet should be located close enough to
connect the end of the low voltage wire to the drum motor and have
the duct mounted humidistat located in between. DO NOT PLUG
THE TRANSFORMER IN UNTIL INSTALLATION IS COMPLETE.
1. The humidifier motor lead wire has two push-on terminals
which will mate with the 2 terminals at the end of the low
voltage wire on the transformer. Connect these wires together.
2. In the area where the humidistat is to be mounted position the
low voltage wire harness and carefully separate the 2 wires
apart. (Fig. 30)
3. Cut one of the conductors and strip the insulation from both
ends. (Fig. 31)
CUT ONE OF THE
Figure 30
CONDUCTORS AND
STRIP THE ENDS
Figure 31
LOW
VOLTAGE
WIRE SET
LOW
VOLTAGE
WIRE SET
CUT THE MIDDLE AND
SEPARATE APPROX. 3”
4. Connect the stripped ends to the 90˚ terminals on the
plenum/duct mount humidistat or to the low voltage wire from
the humidistat wall mounted in the living area (depending on
which humidistat installation you chose).
5. Complete the installation of the Duct mounted humidistat.
6. Mount the humidistat onto the return duct by using the four 1”
long sheet metal screws provided (Note the small rectangular
notch at the bottom provided for the access of the low voltage
wire to the humidistat wiring terminals.)
7. Remove the paper backing from the control label and apply
the label onto the face of the base plate.
8. Install the knob onto the humidistat control shaft.
STEP #6: ADJUSTING THE WATER LEVEL
TURNING THE WATER ON
1. Turn on the water supply at both the main water supply and
the self-piercing saddle valve. Check to see if water leaks at
any joints. If there is a leakage, tighten the compression nut to
correct the problem.
2. Water should flow gently into the water pan. If it flows too slow
or too fast, adjust the self-piercing saddle valve.
KNOB
(ROTATE TO ADJUST
THE WATER LEVEL)
ADJUSTING THE WATER LEVEL
1. The water level is adjusted by
altering the height of the float.
2. Rotate the knob of the valve seat
(Fig. 32).
CHECK THE ELECTRICAL WIRING
1. Plug the transformer in and turn up the humidistat to that it is
calling for humidity, 50% +.
2. The drum should start rotating – either direction is fine.
3. Adjust the humidistat down to the off position and the
humidifier will shut off.
INSTALLING THE BYPASS TUBE
4. Retrieve the flexible bypass tube and
two spring clamps
Figure 33
SPRING CLAMP
5. Install the bypass tube on the bypass
collar and damper first.
FLEX TUBE
6. Slide one of the 6” spring clamps
supplied over one end of the bypass
tube. (Fig. 33)
7. Slide this same end of the bypass
tube over the flange of the collar and
secure inplace with the spring clamp.
(Fig. 34)
8. Slide the other 6” spring clamp over
the other end of the bypass tube.
Figure 34
COLLAR FLANGE
SPRING CLAMP
FLEX TUBE
9. Slide this end of the bypass tube onto
the humidifier’s bypass side panel and
secure in place with the spring clamp.
INSTALLING THE FRONT COVER
MOUNTING
PEG
10. Retrieve the humidifier’s front cover.
11. At the top rear of the front there are
2 mounting pegs (Fig. 35). These pegs
will fit into round slots at the top/rear
of both side panels (Fig. 36).
12. With the front cover in the fully
open position (not attached to the
humidifier), tilt the cover at approx
a 30˚ angle and insert one of the
front cover pegs into the round slot
(Fig. 37).
FRONT
COVER
MOUNTING
PEG
Figure 35
ROUND SLOT FOR
FRONT COVER
13. To finish installing the front cover
slightly deflect the top/rear of the
opposite side panel and insert the
other peg into the round slot (Fig. 38).
Figure 36
14. With the front cover installed grasp the bottom and pull down
until fully closed, it will snap closed at the bottom (Fig. 39).
Installation is now complete. Move to humidifier operation section.
Figure 32
INSTALL COVER FULLY
OPEN AT 90˚ ANGLE
3. Adjust the float in such away so that it closes the automatic
valve when the selected water level has been reached.
4. The maximum water level in the pan should not exceed 1/2”
from the top of the water pan.
SNAP
CLOSED
Figure 37
Figure 38
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SNAP
CLOSED
Figure 39
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HUMIDIFIER OPERATION
9
RECOMMENDED MANUAL HUMIDISTAT SETTINGS
OUT SIDE AIR TEMPERATURE MAXIMUM RELATIVE HUMIDITY SETTING
ROTATING DRUM HUMIDIFIER
-20°F /-30°C
15%
Because this rotating drum humidifier utilizes a water
pan/reservoir the unit is 100% efficient, all the water used is
delivered to the air. For this reason the unit does not have to be
interlocked with the furnace cycles, the drum can rotate
whether the furnace is heating or not, no water will be wasted
and the humidistat will control the amount of moisture
delivered to the air.
-10°F /-25°C
20%
0°F / -20°C
25%
+10°F/ -10°C
30%
+20°F/ -5°C
35%
CONTROLLING THE HUMIDITY LEVEL
The mechanical humidistat supplied with this unit is to control
the amount of moisture added to the air in your home – It will
sense the relative humidity level in the air and work as an
ON/OFF switch to control the humidifier, regardless of whether
the furnace is running.
At the beginning of the heating season it may take sometime to
build up the relative humidity level in your home to the desired
level – For the first few weeks turn the humidistat up high to
ensure the humidifier will run. After you feel that you have
achieved the desired relative humidity level turn the humidistat
down until it cycles the humidifier OFF. The humidifier will then
work to maintain the relative humidity at that level.
ACHIEVING AND MAINTAINING A HUMIDITY LEVEL
Outside conditions are the primary factor affecting the humidity
level in your home. The colder it gets outside the less moisture
the outside air will have, your home brings in the outside air
and the humidifier will work to add moisture to it. As outside
conditions change the humidity level in your home will change
as well. Other factors which will affect humidity levels in the
home include, how many air-changes your ventilation system
delivers, the amount of people occupying the home, air leaks,
the use of showers, exhaust fans, HRV’s, and the use of
fireplaces or wood stoves.
SAFELY OPERATING A FURNACE HUMIDIFIER
Proper control of the relative humidity level in the home is key to
ensuring good Indoor Air Quality (IAQ) for your home as well as
protecting against moisture damage.
Although a relative humidity environment of 45 to 50% may be
desirable, setting your humidistat at that point when outside air
temperatures are below 30˚F (-1˚C) can cause condensation on
windows and walls. Continued condensation for extended
periods of time may result in structural damage. Use the chart
below as a guide for maximum relative humidity settings at the
different outdoor air temperatures.
30%F/ 0˚C
40%
ABOVE
45% MAXIMUM
If condensation continues to form on windows at these settings
reduce the humidistat setting by successive 5% increments. After
each reduction in setting allow 6 hours for equilibrium to be
reached before readjustment.
If condensation persists with progressively lower settings made
during a 3 day period turn off the water supply at the saddle
valve, turn the humidistat to OFF and consult your heating
contractor.
When your house is unoccupied for longer than 3 days during
the winter always set the humidistat down to 15% so that severe
weather during your absence will not result in condensation
which may cause damage to your home.
SUMMER SHUT DOWN
During the summer season the humidity level in the air is quite
high. Therefore it is advisable to shut off the humidifier system.
Complete the following steps at the end of the winter season.
1. Close the water supply at the saddle valve.
2. Turn the humidistat knob to the OFF position.
3. Empty and clean the water pan.
4. Close the bypass air damper.
CARE AND MAINTENANCE
Because drum humidifiers utilize a water pan/reservoir they are
susceptible to water deposits and mineral build up, for this reason
we strongly recommend that the yearly maintenance include
• Replacing the evaporator pad
• Cleaning/replacing the float & valve assembly
• Cleaning/replacing the water pan
If you complete all the above tasks at once the amount of time
involved will be greatly reduced and your humidifier will
continue to work at peak efficiency.
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CLEANING OR REPLACING THE EVAPORATOR PAD
(Figures 40 a, b, c)
To clean or replace the
evaporator pad follow the steps
below.
NOTE: Do not rotate the drum
assembly by hand this may
cause damage to the gears in
the drum motor.
1. Unplug the transformer (turn
power off to the humidifier).
Figure 40
a)
DEFLECT
LEFTHAND
FLANGE OUT
b)
DEFLECT
RIGHTHAND
FLANGE OUT
DRUM EVAPORATOR PAD ASSEMBLY
OPEN
END
FIRST
2. Turn off the water supply at
the saddle valve.
3. Open the humidifier front
Cover (Fig. 40a). The cover is
snap closed on the left hand
side, to release slightly
deflect the front cover flange
at the bottom left and lift up.
In the fully open position the
cover will stay open.
valve jet shield, disconnect the
water supply from the valve’s
threaded inlet by using an
adjustable wrench to loosen
and remove by hand (Fig. 41b).
TILT
ASSEMBLY
OUT
c)
SPOKES
DRUM
SHAFT
DISK
FLANGE
PULL OUT
STOP LUGS
BUSHING
4. Gently remove the drum/evaporator pad assembly at the
bearing end (open end) first. Take care not to lose the bearing
which the drum shaft rides in. Once the bearing side is
removed you will be able to tilt the drum/evaporator pad
assembly out from the motor coupling. (Fig. 40b)
5. Loosen the white mounting
nut using an adjustable
wrench and remove by hand.
You can now remove the float
and replace with a new one.
Figure 41
a)
DEFLECT
LEFTHAND
FLANGE OUT
DEFLECT RIGHTHAND
FLANGE OUT
b)
6. Re-attach the components in
reverse order as above.
7. Turn the water back on and
check for and repair any leaks.
8. Plug the transformer back in.
c)
9. To replace or clean selected
components of the float valve
assembly (Fig. 41c), Place your
thumb and forefinger around
the neck of the float.
VALVE JET
SHIELD
PIVET PIN
KNOB
VALVE SEAT
SPIGOT
FLOAT
SQUEEZE
HERE (NECK)
10. Squeeze firmly. This will disengage the two pivot pins from the
holes at the sides of the valve jet shield and release the float.
11. The valve seat and knob can then be pulled off the spigot.
12. When replacing the valve seat be sure that it is pushed down
as far as it will go onto the float.
5. Hold the drum assembly in a horizontal position and pull the
bushing out with your fingers (Fig. 40c).
13. Clean components or replace with new parts and reassembly
the float.
6. Slide the evaporator pad off the drum cage.
14. The float valve assembly can be cleaned by using a solution
of 50/50 water and vinegar.
7. To replace the pad keep the bushing in the extended position
and slide the evaporator pad over the spokes until it is against
the disc flange.
15. Close the front cover.
8. Push the bushing back along the shaft to the stop lugs. The
evaporator pad is now locked into position.
9. Replace the drum/evaporator pad assembly completing step 4
in reverse motor coupling end first.
16. Turn on the water supply and plug the transformer back in.
CLEANING OR REPLACING
THE WATER PAN
Figure 42
a)
(Figures 42 a, b, c)
10. Close the front cover.
11. Turn on the water supply and plug the transformer back in.
To clean or replace the water pan
follow the steps below.
1. Unplug the transformer (turn
power off to the humidifier).
CLEANING OR REPLACING THE FLOAT VALVE
ASSEMBLY/COMPONENTS
DEFLECT
LEFTHAND
FLANGE OUT
b)
2. Turn off the water supply at
the saddle valve.
(Figures 41 a, b, c)
To clean or replace the float valve assembly/components follow
the steps below.
1. Unplug the transformer (turn power off to the humidifier).
2. Turn off the water supply at the saddle valve.
3. Open the humidifier front Cover (Fig. 41a). The cover is snap
closed on the left hand side, to release slightly deflect the front
cover flange at the bottom left and lift up. In the fully open
position the cover will stay open.
4. If you wish to replace the entire float valve assembly included
3. Open the humidifier front
Cover (Fig. 42a). The cover is
snap closed on the left hand
side, to release slightly deflect
the front cover flange at the
bottom left and lift up. In the
fully open position the cover
will stay open.
4. To remove the float from the
jet shield place your thumb
and forefinger around the
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DEFLECT RIGHTHAND
FLANGE OUT
THUMB AND FOREFINGER
SQUEEZE HERE
c)
DEFLECT
SLIGHTLY
SIDE PANEL
SLOT
WATER PAN HOOK
DEFLECT
SLIGHTLY
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neck of the float squeeze firmly and this will disengage the 2
pivot pins from the holes at the sides of the valve jet shield.
(Fig. 42b)
NOTES
5. Remove the drum and evaporator pad assembly bearing end
first (see instructions above).
6. Remove the two screws which secure the water pan to the side
panels, the screws are located at the front, on the underside of
the water pan’s side flanges. There is also a set of hooks on
either side of the front of the pan which fit into slots on both
side panels, to release the water pan deflect each side slightly
in the area where the pan attaches and lift up. (Fig. 42c)
7. Once removed from the slots the pan will slide out.
8. Clean in a 50/50 mixture of water and vinegar.
9. Replace all components in reverse order
10. Close the front cover.
11. Turn on the water supply and plug the transformer back in.
WARRANTY
The manufacturer guarantees the for the period of one year from
the date of purchase, the product will be free of defects in
workmanship and/or material. As well the manufacturer offers a
life time warranty on the flow through humidifier body. During
the warranty period, we will replace or repair any defective part
at no charge if the product is returned prepaid to our factory.
This warranty does not cover any labor or shipping costs, or the
cost of replacement components as part of routine maintenance
(such as Flow Through Humidifier Evaporator Pads, Inlet water
Filters, or Orifice Fittings). Any damage or failure caused by
abuse, misuse, abnormal usage, faulty installation, or improper
maintenance will not be covered by this warranty.
In order to make a claim on this warranty you must be the
original consumer of the product and you must contact the
manufacturer 1-800-465-7300 between 8 AM and 3:30 PM EST
Monday to Friday at the first sign of a defect. You will be required
to present to the manufacturer the original bill of sale showing
date of purchase, place of purchase, and model purchased.
Failure to meet these requirements will void your warranty.
The manufacturer will not be held responsible for any bodily
injuries or damages to personal property or real estate whether
caused directly or indirectly by the product. Some states and
provinces do not allow the exclusion or limitation of incidental or
consequential damages and some states or provinces do not
allow limitations on how long an implied warranty lasts, so these
exclusions or limitations may not apply to you. This warranty
gives you specific legal rights and you may have other rights
which vary from state to state and province to province.
SAVE THIS DOCUMENT AND ATTACH YOUR RECEIPT.
Date of Purchase
Date Of Installation
Place of Purchase
Brand and Model#
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Furnace Humidifier
29
1
28
27
2
26
27
6
7
3
8
5
4
9
10
15
14
17
19
14
25
13
23
16
18
24
11
12
22
21
20
MODEL 1000
ITEM NUMBER
DESCRIPTION
QTY/UNIT
1
cover (specify brand)
1/per
PART NUMBER
011483000
2
humidistat (specify brand)
1/per
01A000000
3
120/24VAC transformer
1/per
010916001
1/per
01A172235
motor side panel
1/per
011481000
tesa foam
8 inches/unit
20221
bypass side panel
1/per
011482000
4
motor
5
6
7
8
tesa foam
6 3/4 inches/unit
20221
9
water level knob
1/per
01A017083
10
water level knob seat
1/per
01A017084
11
float
1/per
01A900903
01A900906
12
jet shield
1/per
13
nylon hex nut
1/per
060011142
14
brass insert
1/per
01A930041
15
rubber ferrule
1/per
01A010816
16
nylon compression nut
1/per
0600110801
17
1/4" plastic water tubing
10 feet/unit
01A930040
18
nylon compression nut
1/per
060010801
19
nylon ferrule
1/per
010926001
20
needle valve assembly
1/per
0PB132055
21
water pan
1/per
011484000
22
drum shaft
1/per
01A900911
23
drum cage
1/per
01A900914
24
bearing
1/per
011509000
25
evaporator water pad
1/per
01A017256
26
by-pass tube
3 feet/unit
010917000
27
6" spring wire clamp
2/per
010938000
28
collar
1/per
01A172107
29
air damper
1/per
01A170930
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MODEL AK5000 AK5500 & AK7000 SUPPLEMENTAL INSTRUCTION SHEET
WARNING: THIS UNIT IS INTENDED TO BE INSTALLED BY AN LICENCED HVAC PROFESSIONAL – FOR THIS
UNIT TO OPERATE PROPERLY THE SUPPLIED 24 VOLT TRANSFORMER MUST BE INTERLOCKED WITH THE
FURNACE HEATING CYCLE – THE 24 VOLT TRANSFORMER SHOULD BE ENERGIZED ONLY WHEN THE FURNACE
IS IN HEATING CYCLE. THIS UNIT WILL NOT OPERATE PROPERLY AND YOU RISK DAMAGE UNLESS YOU
PROPERLY INSTALL THE TRANSFORMER. DO NOT ATTEMPT TO COMPLETE THIS INSTALLATION
UNLESS YOU ARE A LICENCED HVAC PROFESSIONAL.
TRANSFORMER - MODEL AK5000, AK5500, AK7000
•
•
•
•
Hazardous Voltage Can Cause Personal Injury Or Equipment Damage.
Disconnect Power Supply Before Installing or Servicing.
On Multispeed Blower Applications, Do Not Wire The High Voltage Side Of The Transformer To The Same Power
Source That Services The Furnace Blower Or The Transformer May Burn Out Prematurely.
Do Not Attempt to Install the transformer unless you are an HVAC professional.
The transformer supplied with the unit is different then indicated in the supplied Installation/operating instructions. You have
been supplied with a Class 2 120Volt/24 VAC hard wire transformer. It is designed to be connected to the furnace through
the furnace accessory terminals, the furnace heating relay, or interlocked with the furnace blower. Install the transformer on
the outside of a grounded metal junction box using only a 7/8” knockout hole. Secure the transformer in place using the
locking nut on the transformer mounting sleeve.
HUMIDISENSE HUMIDIFIER CYCLING CONTROL - MODEL AK5000, AK5500, AK7000
In the supplied installation/operating instructions reference is made to the electronic “Humidisense” humidifier cycling control,
and indicating LED’s. Because models AK5000, AK5500, & AK7000 are contractor installed units, with the transformer
interlocked with the furnace’s heating cycles the electronic controls and accompanying LED’s are not required or installed on
the units. Your furnace humidifier will automatically cycle ON & OFF when your furnace cycles, no adjustments are required.
ELECTRONIC HUMIDISTAT CONTROL MANUAL AND AUTOMATIC OPERATION - MODEL AK7000
In the supplied Model 7000 installation/operating instructions & maintenance/warranty booklets reference is made to the
electronic humidistat control with manual and automatic operation. This control is not supplied with the contractor model
AK7000, in its place your unit has been provided with a standard mechanical humidistat design for either duct mount or wall
mount installation. Refer to the provided humidistat installation sheet for installation instructions.
ELECTRICAL WIRING – MODEL AK5000, AK5500, & AK7000
Once the wiring is complete you should have all the components wired in series (a continuous loop) as shown in figure 1
below. To make the connection to the humidifier’s solenoid valve use ¼” insulated male terminals or cut the ¼” female
terminals present on the solenoid valves wire then strip the wire ends – connect to the low voltage wire using approved
electrical wire nuts.
06/07
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PN 6785034