GeneralAire 5500 Instruction Manual

Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
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.
Installation Kit and Mounting Straps are included.

You must be a qualied
contractor to install this product.
Before You Start
1. Test water conductivity.
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 powe-
red 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
1 115 V 11 A 10.1 gpd 1.5 kg/h 3.5 lbs/hr
2 115 V 14.5 A 13.9 gpd 2.2 kg/h 4.9 lbs/hr
3 230 V 11 A 20.9 gpd 3.3 kg/h 7.3 lbs/hr Default setting if no selection is
made
4 230 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 Techni-
cal Support for further instruction.
Before You Start

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er that are not authorized by the
manufacturer 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
SERVICINGTHE 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: DISCONNECT THE 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.

Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
Contents
1. HOW IT WORKS 11
1.1 Operating Stages ............................................................................................................ 11
1.2 Cylinder Life......................................................................................................................... 13
1.3 Calculating Humidity Load.........................................................................................14
2. MODEL INFORMATION 15
3. INSTALLATION 16
3.1 Positioning............................................................................................................................ 16
3.2 Mounting / Dimensions and Weight................................................................... 16
3.3 Fastening to the Wall...................................................................................................... 17
3.4 Characteristics of the Supply Water...................................................................... 18
3.5 Water Connections ......................................................................................................... 19
3.6 Steam Distribution & Installation............................................................................ 20
3.7 Steam Manifold (12”& 17.5”Options Available) ........................................... 22
3.8 Steam Hoses........................................................................................................................ 23
3.9 Room Steam Kit................................................................................................................. 23
3.10 Power Supply Voltage Selection............................................................................. 24
3.11 Power Wiring....................................................................................................................... 24
3.12 Control Wiring.................................................................................................................... 25
3.13 Connect the GFX4 Humidistat for ON/OFF Operation ............................ 26
3.14 Modulating Operation ................................................................................................. 26
3.15 Pressure, Safety, and High Limit Switches (Field Supplied) ................... 27
3.16 Furnace Blower Operation / Air Conditioner Relay Interlock .............. 27
3.17 Wiring Connections........................................................................................................28
3.18 Wiring Diagram of Controller.................................................................................... 29
4. START UP 30
4.1 Start-Up Checklist............................................................................................................ 30
4.2 Starting the Humidier ................................................................................................ 30
4.3 Controller Display............................................................................................................. 31
4.4 Initial Conguration........................................................................................................ 32
4.5 New Steam System or Replacement Steam Cylinder............................... 33

Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
5. OPERATING THE HUMIDIFIER 34
5.1 Displaying Information................................................................................................. 34
5.2 Selecting Signal Type..................................................................................................... 34
5.3 Changing the Maximum Production................................................................... 35
5.4 GFX4 Humidistat............................................................................................................... 35
5.5 Alarms ..................................................................................................................................... 37
6. TROUBLESHOOTING 38
7. MAINTENANCE 39
7.1 Periodic Checks................................................................................................................. 39
7.2 Cylinder Maintenance................................................................................................... 39
7.3 Maintenance of Other Plumbing Components ........................................... 41
7.4 Replacement Parts...........................................................................................................42
8. TECHNICAL SPECIFICATIONS 43
9. LIMITED WARRANTY 47

Page | 11 Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
1. HOW IT WORKS
The 5500 Steam Humidier is an electrode humi-
dier. Unlike heating elements, electrode steam
humidiers produce steam for humidication by
passing electric current through the water betwe-
en metal electrodes inside the plastic steam gene-
rator cylinder. Steam output is directly proportio-
nal to the conductivity of the water, the power
supply (115V or 230V), and the amount of electro-
de immersed in the water.
IMPORTANT: Test the water prior to installation
with a conductivity tester (use GFI #5539 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 Figure 1.a.) controller will:
• Open the water ll valve ❶and 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 ❻and 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.

Page | 12
Periodically, the unit will activate the drain pump
❿and drain water to reduce mineral concentra-
tion. 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 even-
tually 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 Figure 1.b. for basic components.
A
B
C
D
E
Fig. 1.b
NO. DESCRIPTION
A User Interface / Display
B Steam Generator Cylinder
C ON / OFF Switch
D Fill and Tempering Valves
E Drain Pump
Tab. 1.a

Page | 13 Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
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 depo-
sited 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 mine-
rals cover the electrodes’ entire length with a thick
coating and little electrical current can pass betwe-
en them, resulting in poor steam output. The humi-
dier can sense the low amperage and will display
the E8 Cylinder Expired error code. There are seve-
ral factors that inuence cylinder life.
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 shor-
ter 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, additional ltration of the incoming water
supply is not necessary. 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 particu-
late 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 impor-
tant 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 cylin-
der life.
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 humi-
dier capacity should not be underestimated.

Page | 14
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.gene-
rallters.com/support/humidity-calculator.html.
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 Figure 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 stabi-
lize wood oors, trim and decoration. Humidica-
tion 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

Page | 15 Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
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
• 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.a
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.b

Page | 16
3. INSTALLATION
3.1 POSITIONING
The 5500 Steam Humidier has been designed for
wall mounting and since it is an electrode steam
humidier, should be placed close to the point
where the steam will be ducted to minimize the
steam hose length (and the amount of condensate).
IMPORTANT: Certain minimum clearances
must be maintained around the unit for safety
and maintenance. (See Figure 3.a. and Table 3.a)
IMPORTANT: DO NOT introduce steam into
duct that has interior insulation.
E
A
B
C
D
F
Fig. 3.a
Item Description Inches mm
A Side 6 150
B Top 6 150
C Side 6 150
D Bottom 6 150
E Front 24 600
F Angularity 0.20 max
Tab. 3.a
3.2 MOUNTING / DIMENSIONS AND
WEIGHT
Removing the Front Cover
The front cover is fastened by two tabs at the top
and one screw located at the bottom center of the
unit. Use a Phillips head screwdriver to remove the
screw (Figure 3.b.), then swing and lift cover away
from the back part of the unit. Return it in reverse
order. Be careful not to over-tighten the screw.
See Table 3b for dimensions and weights.
A
B
C
Fig. 3.b
Item Description Inches mm
A Width 13.0 345
B Depth 8.25 206
C Height 21.0 533
Pounds Kilos
Empty weight 16 7.3
Weight with water 24 10.9
Shipping weight 26 11.8
Tab. 3.b

Page | 17 Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
3.3 FASTENING TO THE WALL
The 5500 Steam Humidier can be installed on a nished wall or exposed studs per the following options:
• Option 1: Attach directly to a wall using the supplied screws and anchors. Use the two inner holes of the
supplied mounting strap as a template for the humidier mounting holes (marked by “A” in Figure 3.c).
Once marked, the two top screws can be installed rst and then the steam unit can be hung on the screws
using the keyhole slots.
• Option 2: Attach to studs using the supplied mounting straps (Figure 3.c.). The mounting straps can be
used to span an open stud cavity or secured to studs through a nished wall. Secure the mounting straps
to the studs using the two outer holes. Then secure the steam humidier to the mounting straps using
the two inner holes, which will align to the mounting holes in the steam unit.
18.48”
[469.5 mm]
2.13”
[54 mm]
2.52“
[64 mm]
TOP
AA
5.51”
[140 mm]
11.02”
[280 mm]
AA
4.09”
[103.9 mm] 3.15” [80 mm] 1.46”
[837 mm]
1.67”
[42.5 mm]
1.38”
[35 mm]
BOTTOM
16”(406.4 mm)
11.02”(280 mm)
3.49”
[88.6 mm]
1“
[25.4 mm]
MOUNTING STRAP
(2 PER UNIT)
2.13”(54 mm)
Fig. 3.c

Page | 18
3.4 CHARACTERISTICS OF THE SUPPLY WATER
The humidier must be supplied with water with the following characteristics:
• Incoming Pressure: Between 20psi and 90psi or 0.1 and 0.8 MPa (1 - 6 bar)
• Maximum intermittent pressure: 110psi (8 bar). Maximum intermittent pressure includes water hammer
or other supply water pressure spikes. High-water pressure can be addressed with water hammer arrestors
or pressure regulators.
• Temperature: Between 33°F and 70°F or 1°C and 21°C
• Flow-rate: Minimum of 0.45 L/min or 0.12gpm
• Hardness: No greater than 40°fH (equal to 400 ppm of CaCO3)
• Conductivity: From 125 to 1250 S/cm
• Absence of organic compounds
• The characteristics of the water of supply must fall within the following limits (Table 3.c.)
NORMAL WATER LOW SALT
CONTENT WATER
UNITS MIN MAX MIN MAX
Hydrogen ions (pH) 7 8.5
Specic conductivity (R,20°C) S/cm 125 500
Total dissolved solids (c R) mg/l (*) (*) (*) (*)
Dry residue at 180°C mg/l (*) (*) (*) (*)
Total hardness mg/l CaCO 0 200 50 160
Temporary hardness mg/l CaCO = 150 = 200
Iron + Manganese mg/l Fe + Mn = 0.2 = 0.2
Chlorides ppm Cl = 20 = 30
Chlorides mg/Si2O = 20 = 20
Chlorine residue mg/l Cl- = 0.2 = 0.2
Calcium sulphate mg/l CaS4O = 60 = 100
Tab. 3.c
* Values are dependent on the specic conductivity: cR~=0.65*σR, 20°C; R180~=0.9*σR, 20°C.
NOTE: There is no relationship between the hardness and conductivity of water.
IMPORTANT: The following water types are not acceptable:
• Softened water (will lead to foam, electrode corrosion and greatly shortened cylinder life)
• Water containing disinfectants or corrosion inhibiters (potential irritants)
• Industrial water, boiler water or water from cooling circuits
• Any potentially chemically or bacteriologically-contaminated water
• Heated water

Page | 19 Form No. 5500-32 Rev B
Code: +0700092EN REV 2.0 22042021
3.5 WATER CONNECTIONS
Before proceeding, make sure that
the humidier is disconnected
from the main power supply.
Connection to the main water supply
Connect the ll valve and the water supply line
using a soft ¼” poly hose capable of absorbing
water hammering in order to avoid damage to
the ll valve. Route the water line through the
bottom of the unit. As soft poly tubing is used in
the installation, install tubing support to prevent
tubing collapse and leaks. The tting threads onto
the ll valve inlet located on the bottom of the
humidier using a 3/4” G connection (supplied).
NOTE: A strainer is built into the ll valve tting
underneath the unit that requires periodic clea-
ning. Be sure to allow clearance for access (See
Figure 3.d.).
Water Drain and Drain Hose
The 5500 Steam Humidier requires a connection to
a drain. A 10’ length of ¾” ID drain hose is included
with unit. Attach the drain hose to the water drain
tting and secure with the hose clamp provided.
The hose must have a constant downward slope
(cannot be kinked, blocked, or create a trap) and can
be routed directly to a oor drain, condensate pump,
or drain standpipe. Trim the drain hose as needed
and ensure that that drain hose is located such that
it cannot be blocked or pinched after installation.
See Technical Specications for drain ow rate.
Condensate Pump
When using a condensate pump, ensure pump is
capable of storing about 1.1 gallons in 15 seconds
with a pump output of 3 gpm or more.
Water drain tting Fill valve and lter
Fig. 3.d

Page | 20
3.6 STEAM DISTRIBUTION &
INSTALLATION
The maximum allowed duct static pressure is 2 in.
WC.
IMPORTANT: Allow 5 feet (1-1/2 M) of straight
return duct downstream of the distributor pipe
or nozzle for absorption of the steam. Always
allow 3 feet (0.9M) of straight supply duct upstre-
am of the distributor pipe or nozzle for evapora-
tion of the steam. Turbulent air ow may require
longer lengths.
8” Steam Manifold (included)
The model 5500 Steam Humidier comes standard
with an 8”steam manifold. An optional steam nozz-
le and steam manifolds are available separately for
other installations.
The 8” steam manifold should be installed on a
vertical surface and must be angled up (see Figure
3.e.). The steam distribution holes must always be
facing up; the holes should never be installed facing
downward. A condensate hose is not required. To
install the 8” steam manifold, drill a 1” diameter hole
in the vertical surface of the duct as shown in Figu-
re 3.g. Apply silicone sealant to the mounting plate
of the tube. Attach the manifold to the duct using
(4) #10 sheet metal screws (supplied). Connect the
steam hose with the hose clamps provided.
.25” Dia.
(4) Holes
8.301.76
.90” Dia.
UP
2” Sq.
3” Sq.
Fig. 3.e
Side Installation Horizontal Duct
Height >8”
1/3 Height
Fig. 3.f
Side Installation Vertical Duct
==
8” Min
Fig. 3.g
Important: DO NOT introduce
steam into a duct that has interior
insulation.