General Filters GeneralAire 5500 User manual

1 Form No. 5500-32 Rev C
Code: +0700092EN REV 3.2 04APR2022
ENG
GeneralAire® 5500 Steam Humidier
Installation & User Manual
Before installing or handling the humidier, please carefully read and follow the instructions and safety
standards described within this manual and on the labels attached to the Model 5500 Steam Humidier.
Test water conductivity before installing the Model 5500 Steam Humidier.
Avant d’installer ou de manipuler l’humidicateur, veuillez lire attentivement et respecter les instructions et les
normes de sécurité décrites dans ce manuel et sur les étiquettes apposées sur l’humidicateur à vapeur modèle
5500. Testez la conductivité de l’eau avant d’installer l’humidicateur à vapeur modèle 5500.
Installation Kit and Mounting Straps are included.
Le kit d’installation et les sangles de xation sont inclus.
User manual
Mode d’emploi
Manuel d’installation et d’utilisation
LISEZ ET ENREGISTREZ
CES INSTRUCTIONS
READ AND SAVE
THESE INSTRUCTIONS

2
You must be a qualied
contractor to install this product.
Before You Start
1. Test water conductivity by using AP-2
(GFI #7066) conductivity meter or similar.
2. Check for the following items inside the box:
• Duct Steam Humidier
• Installation Manual
• Installation Kit
• Steam manifold
• 6’Steam hose
• 10’drain hose
• Water tube supply kit (10’ tubing)
• Water ll connector
• GFX4 Digital Automatic Humidistat
• Ball valve
• Hose clamps
• Fasteners
• Mounting straps
IMPORTANT: Remove the following items prior to
installation:
• Remove internal packaging support
located above the cylinder.
• Close the metal cylinder clamp
on top of the cylinder.
• Remove the plastic tie around the cylinder body.
Remove shipping
insert and plastic
before installation.
WARNING: You must select the desired power supply voltage in two places:
1. INTERNAL SWITCH: THE FACTORY DEFAULT SETTING IS 230 VAC; however, the humidier can also be powered at
a nominal voltage of 115 VAC 50/60 Hertz. Ensure the 5500’s internal power selection switch matches the power
supplied to the 5500 (also described in this manual).
230
115
2. CONTROL PANEL - ON INITIAL STARTUP: THE FACTORY DEFAULT SETTING IS SETTING #3 (230V/11A),
if no selection is made. To change this setting, press the ‘RESET/SEL’ button and then adjust the value on
the display to one of the four options shown below. Press the ‘DRAIN/ENT’button to conrm.
Option Voltage Current Output Output Output
1115 V 11 A 10.1 gpd 1.5 kg/h 3.5 lbs/hr
2115 V 14.5 A 13.9 gpd 2.2 kg/h 4.9 lbs/hr
3230 V 11 A 20.9 gpd 3.3 kg/h 7.3 lbs/hr Default setting if no selection is made
4230 V 14.5 A 28.5 gpd 4.5 kg/h 9.9 lbs/hr
NOTE: If the incorrect setting is selected or the setting needs to be changed in the future, please contact Technical
Support for further instruction or follow instruction in Section 4.4.
Before You Start

3 Form No. 5500-32 Rev C
Code: +0700092EN REV 3.2 04APR2022
ENG
WARNINGS
BEFORE INSTALLING OR HANDLING THE REMOTE
BLOWER, PLEASE CAREFULLY READ AND FOLLOW
THE INSTRUCTIONS AND SAFETY STANDARDS
DESCRIBED IN THIS MANUAL AND ON THE
LABELS ATTACHED TO THE REMOTE BLOWER.
THIS PRODUCT MUST BE INSTALLED BY A QUALIFIED
HVAC, PLUMBING, OR ELECTRICAL CONTRACTOR.
ALL WARRANTIES ARE VOID IF INSTALLED BY A NON-
TECHNICIAN.
IMPORTANT:
• Install the humidier out of the reach of children.
• The humidier must be installed in accordance with
all local and national standards.
• All service and/or maintenance operations must be
performed by qualied personnel who are aware
of the necessary precautions and are capable of
performing the operations correctly.
• The conditions of the environment and the power
supply voltage must comply with the specied
values listed on the data label in the humidier.
• All other uses and modications made to the
humidierthatarenotauthorizedbythemanufacturer
are considered incorrect, and the manufacturer
assumes no liability for the consequences of any such
unauthorized use.
CAUTION: ALWAYS DISCONNECT THE MAIN
POWER TO THE HUMIDIFIER BEFORE OPENING OR
SERVICING THE HUMIDIFIER OR REMOTE BLOWER!
IMPORTANT: BEFORE beginning installation:
• Check for shipping damage to cartons. Mark the
shipping waybill accordingly.
• Open cartons and check for any hidden damage.
Mark the shipping waybill accordingly.
• Check packing slip to ensure all items have been
received. Notify General Filters of any shortages
or damaged parts. You must notify General Filters
within 5 working days of any shortages.
PLEASE NOTE: This product is to be installed only in a
residential setting. The conditions of the environment and
the power supply voltage must comply with the specied
values listed on the data label in the humidier. The humidier must
be installed in accordance with all local and national standards. All
other uses and modications made to the humidier that are not
authorized by the manufacturer are considered incorrect, the
manufacturer assumes no liability for the consequences of any such
unauthorized use and will void warranty.
CAUTION: DISCONNECTTHE MAIN POWER BEFORE OPENING
OR SERVICING THE HUMIDIFIER!
CAUTION: ELECTRIC SHOCK HAZARD! The humidier has
components under power inside!
CAUTION: SCALDING HAZARD! The humidier has hot parts
(100°C / 212°F).
WARNING: Install out of reach of children. Your humidier
requires water to operate. Do NOT mount it above materials or
machinery that could be damaged if a leak occurs. General Filters
assumes no responsibility for consequential or inconsequential
damage as a result of any leaks.
PLEASE NOTE: The humidier contains powered electrical
devices and hot surfaces. All service and/or maintenance
operations must be performed by qualied personnel who are
aware of the necessary precautions and are capable of performing
the operations correctly. Disconnect the humidier from the main
power supply before accessing any internal parts.
Disposal of the parts of the humidier: the humidier is made up
of metallic and plastic parts. All parts must be disposed of according
to the local standards on waste disposal.

4
Contents
1. HOW IT WORKS 1
1.1 Operating Stages ...............................................................................................................1
1.2 Cylinder Life............................................................................................................................2
1.3 Calculating Humidity Load............................................................................................3
2. MODEL INFORMATION 4
3. INSTALLATION 5
3.1 Positioning...............................................................................................................................5
3.2 Mounting / Dimensions and Weight......................................................................5
3.3 Fastening to the Wall.........................................................................................................6
3.4 Characteristics of the Supply Water.........................................................................7
3.5 Water Connections ............................................................................................................8
3.6 Steam Distribution & Installation...............................................................................8
3.7 Steam Manifold ................................................................................................................ 10
3.8 Steam Hoses........................................................................................................................ 11
3.9 Room Steam Kit................................................................................................................. 11
3.10 Power Supply Voltage Selection............................................................................. 12
3.11 Power Wiring....................................................................................................................... 12
3.12 Control Wiring.................................................................................................................... 13
3.13 Connect the GFX4 Humidistat for ON/OFF Operation ............................ 14
3.14 Modulating Operation ................................................................................................. 14
3.15 Pressure, Safety, and High Limit Switches (Field Supplied) ................... 14
3.16 Furnace Blower Operation / Air Conditioner Relay Interlock .............. 15
3.17 Wiring Connections........................................................................................................ 16
3.18 Wiring Diagram of Controller....................................................................................17
4. START UP 18
4.1 Start-Up Checklist ............................................................................................................ 18
4.2 Starting the Humidier ................................................................................................ 18
4.3 Controller Display............................................................................................................. 19
4.4 Initial Conguration........................................................................................................ 20
4.5 New Steam System or Replacement Steam Cylinder ............................... 20
5. OPERATING THE HUMIDIFIER 22
5.1 Displaying Information................................................................................................. 22
5.2 Selecting Signal Type..................................................................................................... 22
5.3 Changing the Maximum Production................................................................... 23
5.4 GFX4 Humidistat ............................................................................................................. 23
5.5 Alarms ..................................................................................................................................... 25

5 Form No. 5500-32 Rev C
Code: +0700092EN REV 3.2 04APR2022
ENG
6. TROUBLESHOOTING 26
7. MAINTENANCE 27
7.1 Periodic Checks ................................................................................................................. 27
7.2 Cylinder Maintenance................................................................................................... 27
7.3 Maintenance of Other Plumbing Components ...........................................28
7.4 Replacement Parts........................................................................................................... 28
8. TECHNICAL SPECIFICATIONS 30
9. LIMITED WARRANTY 34

6

1 Form No. 5500-32 Rev C
Code: +0700092EN REV 3.2 04APR2022
ENG
1. HOW IT WORKS
The 5500 Steam Humidier is an electrode humidier. Unlike
heating elements, electrode steam humidiers produce
steam for humidication by passing electric current through
the water between metal electrodes inside the plastic steam
generator cylinder. Steam output is directly proportional to the
conductivity of the water, the power supply (115V or 230V),
and the amount of electrode immersed in the water.
IMPORTANT: Test the water prior to installation with a
conductivity tester (use GFI #7706 or CGF #GF-AP-2 or
similar) to ensure water conductivity falls between 125 to
1250 S/cm.
1.1 OPERATING STAGES
On a call for humidity, the 5500 Steam Humidier (See Fig. 1.a.)
controller will:
• Open the water ll valve ❶ and allow water to enter the
cylinder. A ow restrictor prevents the unit from lling too
quickly or with too much pressure.
• The water ows up the ll tube ❷and into the ll cup
❸, which creates a 1” air gap to prevent backow of
contaminated water into the feed lines, through the second
ll tube❹and into the bottom of the steam cylinder ❺.
Any backow or overow of water travels through the
overow hose ⓫to the drain.
HL
EVP DT
WATER
OUTLET WATER
INLET
DRAIN
CUP
DP
FILL
CUP
1
2
3
4
5
6
7
STEAM
BOILER UNIT
8
9
10
11
Fig. 1.a
• As the water lls the cylinder, it will reach the electrodes
❻ and electrical current will begin to ow. As the water
continues to ll the cylinder, the current will increase. This is
monitored by an amperage transformer connected to one
of the power wires located on the electronic controller.
• When the desired current is reached, the ll valve will close,
and the water will then begin to warm and produce steam.
• If the water reaches the cylinder full probe ❽or if current
rises too much, the drain pump ❿will be activated to drain
away some water and reduce the current ow to acceptable
levels.
NOTE: Any time the drain pump is activated, the
tempering valve ❾will be opened for tempering the
hot drained water down to less than 140°F / 60°C in
accordance to local and national standards.
Periodically, the unit will activate the drain pump ❿ and
drain water to reduce mineral concentration. Every 120 hours
the unit automatically drains to remove mineral sediment on
the bottom of the cylinder. A strainer in the cylinder helps to
prevent mineral debris from jamming the drain pump.
If the 5500 Steam Humidier remains powered but idle (i.e.
without producing steam) for more than 72 hours (3 days), the
cylinder will automatically be emptied of water and will not
rell until the unit is restarted. If there is no water in the cylinder,
there will be no current ow and no steam production.
The electrodes do not burn out but they will eventually
become completely coated with mineral and the cylinder
will then need to be replaced. Cleaning cylinders may cause
electrode damage, therefore voiding its warranty.
See Section 7: Maintenance for more information.
See Fig. 1.b. for basic components.

2
A
B
C
D
E
Fig. 1.b
NO. DESCRIPTION
A User Interface / Display
B Steam Generator Cylinder
C ON / OFF Switch
DFill and Tempering Valves
E Drain Pump
Tab. 1.a
1.2 CYLINDER LIFE
Basics of the Steam Cylinder
The steam cylinder is the engine of the humidier. As the
water is evaporated inside the cylinder, minerals are left
behind. Much of these minerals are removed through the
cylinder drain, however, some are deposited on the walls of
the cylinder and the cylinder electrodes. When a lower section
of the electrodes develops a thick coating, the water level is
raised to expose clean electrode surface. Eventually minerals
cover the electrodes’entire length with a thick coating and little
electrical current can pass between them, resulting in poor
steam output. The humidier can sense the low amperage
and will display the E8 Cylinder Expired error code. There are
several factors that inuence cylinder life. It is recommended
to replace the steam cylinder every year, before or after every
heating season.
Water
Water characteristics (mineral percentage and types) inuence
cylinder life and can vary greatly from place to place. Most
water conditions result in aky scale that eventually lls the
bottom of the cylinder until it can no longer function. Water
with high silica content can result in a thin glass-like coating
on the electrodes that is highly insulating resulting in shorter
cylinder life. Use only cold water since the supply water is
used to temper the hot drain water. Water quality aects the
operation of this unit, so the 5500 Steam Humidier should be
supplied with water that is untreated, drinkable, not softened,
and not demineralized. The water converted into steam
is automatically replaced through an electric ll valve.
Water Filtration
Typically with municipal/city water, additional ltration of the
incoming water supply is not necessary, but may be required
with well or lake water. If mineral content is known to reduce
cylinder life excessively or if cylinder life proves insucient,
then water ltration can be added. In most cases the addition
of a two-element water lter can improve cylinder life.The lter
should contain an activated carbon element and a particulate
lter element rated for about 5 microns or less (micron is a size
measurement) with a ow rate of at least 2 GPM. The activated
carbon will absorb much of the mineral content while the
particulate lter will catch any granular material or sediment. It
is important to remember that an increase in cylinder life will
be accompanied by the need to replace lter elements with
each cylinder change.
Humidity Load and Cylinder Life
Humidity load demands aect cylinder life. Normal installations
where humidity capacity is properly sized require only
intermittent periods where full humidier capacity is required.
This allows the water level in the cylinder to be increased only
as electrode segments become insulated thus extending
cylinder life. Two-stage ltration is recommended, if excessive
sediment and/or water discoloration occurs, especially with
well or lake water.

3 Form No. 5500-32 Rev C
Code: +0700092EN REV 3.2 04APR2022
ENG
Installations that require constant operation at full capacity
will reduce cylinder life. The water level in the cylinder is, on
average, much higher and the electrodes become completely
insulated more quickly.The importance of providing adequate
humidier capacity should not be underestimated.
Maximum Production
Another factor aecting cylinder life is the maximum
production setting. A higher production rate will result in a
shorter cylinder life (See Fig. 1.c.).
Structures Under Construction
In high-end construction projects, humidication is often
required while the structure is being nished. Humidication
is necessary to protect and stabilize wood oors, trim and
decoration. Humidication load, however, in an unnished
structure may be ve to eight times higher than when nished.
5500 Steam humidiers may be operated while construction
is underway, but reduced cylinder life is to be expected. Good
practice dictates that the steam cylinder also be replaced
once the project is completed.
20%100% Output
Cylinder
life
Fig. 1.c
1.3 CALCULATING HUMIDITY LOAD
Steps to Estimate Humidity Load
Humidity Load Calculation (GPD)
Total Square Footage
x Average Ceiling Height
x Factor from Table 1.b.
x 1.05 for each Fireplace
x 2.88
_________________________
Gallons per Day
Pounds of Moisture / Hour / Cubic Foot*
Temp 0F/0C 35% 40% 45% 50%
68°F/20°C 0.00015 0.00018 0.00021 0.00024
70°F/21°C 0.00017 0.00020 0.00023 0.00026
72°F/22°C 0.00019 0.00022 0.00025 0.00028
* Based on .5 air charges per hour
Tab. 1.b
Example:
• 2,500 SF house with 1,000 SF basement (3,500 SF total
square footage)
• 9 ft. ceilings
• 70°F and 40% RH
• 2 replaces
Humidity Load = 3,500 x 9 x .00020 x 1.05 x 1.05 X 2.88 = 20
gpd
For more accurate results based on U.S. geographic region, see
the GeneralAire® online humidity calculator at https://www.
generallters.com/support/humidity-calculator.html.

4
2. MODEL INFORMATION
Model 5500
Fig. 2.a
Installation Kit (Included)
Fig. 2.b
RMB15/RMB35 Room Steam Kits
(Optional and sold separately)
Fig. 2.c
GFI # CGF# DESCRIPTION PARTS INCLUDED
5580 GF-5500 Model 5500 steam unit features:
• 115V – 230V dual voltage
• 125 – 1250 µS/cm water conductivity
using AP-2 (GFI #7066)
• Duct steam injection
• Drain pump output - 10 to 28.5 gpd
(3.5 to 9.9 lbs./hr)
Includes humidier and duct steam mounting
kit components: 6 ft. steam hose, 8 inch steam
manifold, GFX4 humidistat, 10 ft. drain hose,
ball valve, water ll connector, water supply
tubing kit, mounting straps, hardware kit.
Tab. 2.c
Optional Room Steam Kits (Purchased Separately)
GFI # CGF# DESCRIPTION PARTS INCLUDED
7665 RMB15R RMB15 – Room Steam Kit 115V.
For use with 115V setting on steam unit.
115V room blower assembly
and grille package
7660 RMB35R RMB35 – Room Steam Kit 230V.
For use with 230V setting on steam unit.
230V room blower assembly and grille package
Tab. 2.d