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1. I'm trying to understand why a whole house humidifier is placed on the cold air return where water is injected into the air flow and then it has to pass through a five inch filter before entering combustion area and hot air piping. Would the filter not stop the condensation from going past it?
With humidity that hight, and the warm temperatures, that natural condition is more likely to produce mold than your 70 degree house in the winter. Plus, you will find just increasing your humidity to like 35%-40% with your whole house humidifier makes it very comfortable. AT that level, mold is unlikely an issue.
Bypass style evaporative humidifiers can usually be installed on either the warm (supply) side or the return side; either side provides essentially the same results. Some prefer installing on the return side as, if it fails in a bad way, water is not dripping into the furnace / electronics leading to freezing kids / costly repairs.
Typically the humidifier is installed on the return ducting of the air handler, and a bypass duct is connected to allow humidity to be added to the air. A humidistat is also installed on the return air ducting, which allows the humidifier to activate based on the humidity in the air coming from the house.
0. That's plenty of space to install a humidifier, provided it's air intake scoop is designed to operate or can be installed horizontally. Freezing of the supply line or its drain is a concern; steam humidifiers are recommended for unconditioned spaces. Drain it inside, install a catch pan and a shut-off switch, like you have for your AC coil.
Look at the spec sheet or manual for your model. Look for labels on the control board, probably where the transformer lines come in. Look for labels on the transformer itself. Use a multimeter to measure between C and R terminals. Update: Since you mentioned you have a 9GMXT furnace, it has a 24VAC dedicated humidifier terminal.
It's a closed system, so unless you're sucking in external air to run the humidifier, there shouldn't be any net gain/loss of temperature (at least nothing that you'd notice.) @DA01 Despite it being a closed system evaporation does change the temperature. but it does not change the total amount of heat energy. Google latent heat of vaporization.
Yes, humidifiers that use a foam pad to expose the water to evaporation, usually need to be cleaned and/or replaced every so many years. Usually dissolved minerals build up in the pad and reservoir. In the spring, shut it off, and soak and clean with vinegar to remove as much buildup as you can. If it gets too bad, buy a replacement for next ...
5. The quick answer is that the humidifier/vaporizer causes the orange flame. This happened to us a couple of weeks ago. The gas company said they would send over a technician. He called us first to confirm our orange flame. He asked if we recently turned on a humidifier/vaporizer.
Humidifiers work by evaporating water into the air to increase the moisture level. Your setup would be using room temperature air, and the evaporation effect is going to be greatly diminished compared to using heated air. You may have better luck with a whole-house steam humidifier, but they're also much more expensive.