Bryant 901KAX Installation, Start-up And Service Instructions Manual

Installation, Start-up
and Service Instruction

ELECTRONIC AIR CLEANER

NOTE: Read the entire instruction manual before starting the
installation.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause personal injury or property damage.
Consult a qualified installer, service agency, or your distributor or
branch for information or assistance. The qualified installer or
agency must use factory authorized kits or accessories when
modifying this product. Refer to the individual instructions pack­aged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses and work gloves.
Read these instructions thoroughly and follow all warning or
cautions attached to the unit. Consult local building codes and
National Electric Code (NEC) for special requirements.

Recognize safety information. This is the safety-alert symbol
When you see this symbol on unit or in instructions and manuals,
be alert to potential for personal injury.

Understand the signal word DANGER, WARNING, or CAU­TION. These words are used with the safety-alert symbol. DAN­GER identifies the most serious hazards which willresultinsevere
personal injury or death. WARNING signifies a hazard which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions that will result in enhanced installation, reliability, or
operation.

INTRODUCTION

Model 9011KAX Electronic Air Cleaner (EAC) is available in 3
sizes: 012 (300 to 1400 CFM), 016 (500 to 1800 CFM), and 020
(700 to 2000 CFM). (See Fig. 1.)

These plate-type air cleaners are designed for use with residential
and light commercial forced-air heating and/or cooling systems.
They may be installed in the vertical or horizontal section of a
typical return-air duct system. (See Fig. 2.)

These air cleaners are easily field-converted from right- to left­hand units. Cabinets are designed to support up to 400 pounds
when used in under-the-furnace applications.

A. Cabinet

The cabinet includes an electrical junction box and power safety
interlock, and houses the air cleaner components. These compo­nents are:

1. Mechanical pre-filters—Expanded aluminum mesh first­stage filter that removes lint and large dust particles.

2. Cell assemblies—Cells consisting of combined ionizer
wires and collector plates.

Ionizer part of cell has tungsten wires that receive positive
charge and are mounted between grounded aluminum
channels supported by glazed ceramic insulators.

Collector part of cell consists of alternately charged collec­tor plates.

901KAX

Cancels: II 901K-12-3 II 901K-12-4

10-01-94

.

A91465

Fig. 1—Model 31KAX

The EAC components are listed below and shown in Fig. 3.

1. Power door assembly.

2. Two pre-filters.

3. Cabinet containing 2 air-cleaning cell assemblies.

4. A parts bag including electrical bushing, plug buttons, wire
chase, and airflow label.

B. Power Door Assembly

The power door assembly consists of:

1. Unit operation light, ON-OFF switch, and door attachment
knob—all installed on door cover.

2. Door base plate contains a solid-state power pack that
converts 120vac to high voltage DC (a 240v Conversion
Kit, KEAVC0101240 is available). All wiring is mounted
internally. A line-voltage disconnect (male plug) and high­voltage buss bar are mounted on the base plate externally.
Four screws must be removed toexposethepower pack and
wiring.

The supply circuit to the power pack, which is wired across the
furnace blower motor, is controlled by an ON-OFF power switch.
With the power switch ON (assuming power door is in place and
blower motor is operating), 120vac ± 10 percent single-phase, 60
Hz power is applied to the power pack (240v conversion kit
transformer converts 240v to 120vac). Output of the power pack
assembly is approximately 7300vdc.

These Installation Instructions consist of the following:

Section I—Locating Unit
Section II—Installation
Section III-Electrical Connections
Section IV-Startup and Adjustments
Section V—Routine Maintenance and Service

—1—

7

⁄8-IN. ELECTRICAL

ENTRANCE FOR DUCT

APPLICATION

8 1⁄2″

REAR MOUNTING FLANGE

A

1

⁄16″

2

16 7⁄8″

1″

C

B

ELECTRICAL ENTRANCE (5⁄8-IN. DIA)

FOR FURNACE APPLICATIONS

3″

21″

OPERATION
LIGHT

LOGO

REMOVABLE
POWER DOOR

KNOB

ON/OFF

SWITCH

A91466

MODEL A B C

901KAX012 24-3/4 21-3/4 19-1/2
901KAX016 27-1/4 24-1/4 22
901KAX020 31-1/2 28-1/2 26-1/4

Fig. 2—Dimensional Drawing

TABLE 1—COMPONENT INFORMATION

MODEL 901KAX012 901KAX016 901KAX020
Air Volume Range 300-1400 500-1800 700-2000
Electrical Data

(Input to power door)
Electrical Data

(Output To Collector Cell)
Approx Ship. Wt. 120v 50 54 57

Note: Using the EAC on air duct systems designed for airflows lower than 300 CFM for 012-size units, 500 CFM for 016-size units, or 700 CFM for 020-size units, is
not recommended.

120v, single phase, 60 Hz 120v, single phase, 60 Hz 120v, single phase, 60 Hz

120v—1.0 milliamps @ 7300vdc

TABLE 2—PRESSURE DROP AT VARIOUS AIRFLOWS

901KAX012 901KAX016 901KAX020

CFM Pressure Drop (In. wc) CFM Pressure Drop (In. wc) CFM Pressure Drop (In. wc)

300 0.005 500 0.010 700 0.010
400 0.010 600 0.025 800 0.013
600 0.020 800 0.020 1000 0.018

800 0.030 1000 0.028 1200 0.023
1000 0.050 1200 0.035 1400 0.030
1100 0.060 1400 0.045 1600 0.038
1200 0.065 1600 0.065 1800 0.045
1300 0.075 1700 0.070 1900 0.048
1400 0.085 1800 0.080 2000 0.050

See Service Guide, and Troubleshooting Flow Chart for supple­mentary information.

I. LOCATING UNIT

Fig. 4 shows the air cleaner in the return-air duct of various furnace
installations, with or without air conditioning. Other methods of
installing the unit are permissible if the design criteria outlined in
this section is observed.

A. A. Planning an Installation

When planning an installation, consider the following:

1. Air cleaner is approved only for indoor installation. If
outdoor installation is used, unit must be housed in weather­proof enclosure.

2. Air cleaner may be placed in horizontal position on its right
or left side or in vertical position on its bottom or back. It
must be installed on inlet air side of heating and/or cooling
unit. Be sure that airflow through air cleaner is in same

direction as "airflow arrows" on cells.

—2—

POWER DOOR

ASSEMBLY

PRE-FILTERS CELL ASSEMBLY

Fig. 3—View of Major Components

CAUTION: Cabinets will support a maximum weight of

400 lbs when installed beneath a vertical furnace or
air-handling unit. When setting furnace on cabinet, do not
drop it into place. Position furnace correctly on cabinet to
prevent a corner from slipping down and damaging
cabinet.

3. Allow minimum 16-in. clearance in front of unit for
cleaning and maintenance.

4. Air outlets and returns must not be blocked with furniture,
drapes, or other objects.

5. Air cleaner should be installed where all air circulated by
system will pass through it.

CAUTION: Never use air cleaner to collect grease or
other flammable contaminants.

B. Humidifiers

An evaporative, supply-duct-mounted humidifier may be installed
without affecting the EAC. A bypass-type evaporative humidifier
should be installed so that the moist air does not contact the air
cleaner. When an atomizing-type humidifier is used, it should
always be installed in the supply-air system.

CAUTION: If an atomizing-type humidifier is installed
upstream from the air cleaner, the efficiency of the
electronic cells will be decreased by high humidity, salts,
and minerals. Service problems will result.

If bypass-type humidifier is installed upstream from the EAC, the
following precautions should be taken.

1. Humidifier must be installed as far from EAC as possible.

2. A standard, disposable furnace filter must be installed
between humidifier and EAC to trap water droplets and
mineral salts.

3. Electronic cells of air cleaner must be washed frequently to
prevent mineral deposit buildup.

C. Outdoor Air

When outdoor air is added to the return-air duct, sufficient heat
must be added to maintain the return-air temperature of 40°F
minimum or minimum specified by air handling equipment manu­facturer. Temperatures lower than 40°F can cause ionizer wire
failure under certain conditions.

A91467

NOTE: The maximum operating temperature of the EAC is
125°F.

II. INSTALLATION
NOTE: See Fig. 4 for suggested installation positions.

CAUTION: Turn off all power to furnace or fan coil

before beginning installation.

Proceed as follows to install EAC:

1. Remove and discard existing furnace mechanical filters.
They are not required when using an EAC. Thoroughly
clean blower compartment of furnace.

2. Move ON-OFF switch to OFF and remove power door by
rotating knob (approximately 10 turns counterclockwise)
until door is free. Grasp power door by knob and remove it
from cleaner cabinet by pulling it towards you. This motion
disengages power supply connector.

3. Slide out pre-filters and air cleaner cells.

4. For size 016 EAC furnace side application, cut open return
knockout at the side of the furnace cabinet. For size 012 and
020, cut opening as shown in Fig. 5—Opening Detail.

5. In order to prevent air leakage, use foam tape provided to
attach air cleaner to side of furnace or system blower.

NOTE: The unit is shipped for furnace right side application. For
left side application, rotate rear mounting flange 180° by removing
4 screws in the back of the air cleaner. Be sure all 4 screws are in
place after the rotation. Relocate the junction box on the furnace to
the right side, if required.

6. Hook back flange into the opening. Use air cleaner cabinet
front support flange adjacent to the unit as template and drill
2 holes on furnace casing. (See Fig. 6.)

7. Secure the unit by screwing 2 provided screws into drilled
holes. (See Fig. 6.)

8. Prepare return-air duct for installation to unit. Return air
must use full cabinet opening. Duct should run straight into
unit.

CAUTION: Do not baffle any portion of the entering-air
side of the air cleaner.

NOTE: Baffles may be necessary in upflow applications.
(See Fig. 7.)

—3—

DOWNFLOW APPLICATION

RETURN AIR
PLENUM

FAN-COIL
UNIT

SUPPLY AIR
PLENUM

ELECTRONIC

AIR CLEANER

A91468

SUPPLY AIR
PLENUM

COOLING
COIL

UPFLOW
FURNACE

ELECTRONIC
AIR CLEANER

RETURN AIR
PLATFORM

GAS SUPPLY

UPFLOW APPLICATION

A91470

VENT

RETURN

AIR PLENUM

ELECTRONIC

AIR CLEANER

HORIZONTAL
FURNACE

SERVICE

PLATFORM

SUPPLY

AIR PLENUM

HORIZONTAL FURNACE APPLICATION

A91469

UPFLOW
FURNACE

3 TO 1
TRANSITION
DUCT WORK

ALTERNATE
AIR CLEANER
POSITION

AIRFLOW

ELECTRONIC
AIR CLEANER

COOLING
COIL

FURNACE SIDE APPLICATION

—4—

CAUTION: If flanged sheet metal ducts are metal­screwed to the unit casing, do not use screws longer than
1/2 in.

CAUTION: Airflow across air cleaner must be uniform
for best results. Install turning vanes if air cleaner is
installed close to an elbow. Depending on size of furnace,
it may or may not be necessary to reduce ductwork on
leaving-air side of air cleaner. For any application,
maintain a 3-to-1 duct reduction ratio (3 in. of duct length
for every 1-in. of reduction in size).

A86134

Fig. 4—Typical Applications

9. Check airflow and component configuration. (See Fig. 8.)

10. Seal all joints on downstream side of air cleaner to prevent
infiltration of contaminated air.

III. ELECTRICAL CONNECTIONS

All wiring must comply with applicable local and national codes.
To determine best power wiring routing refer to Section A for
Internal Electrical Connections and Section B for External Elec­trical Connections.

NOTE: For general information a line to line wiring diagram is
provided. (See Fig. 9.)

FURNACE

KNOCKOUTS

1

⁄8 IN.

18 5⁄8″
17 1⁄4″

1

16

⁄4″

1

⁄4″

3

3

⁄4″

2

7

⁄16″

2

0

3

⁄4″

1

0

4 1⁄4″ 5 3⁄4″

5

DIA HOLE

REAR OF

25″

FURNACE

1

28

⁄2″

1

⁄8 IN.

DIA HOLE

1

⁄16″

18 5⁄8″
17 1⁄4″

1

16

⁄4″

3 1⁄4″

3

⁄4″

2

7

⁄16″

2

0

3

⁄4″

1

KNOCKOUTS

0

4 1⁄4″ 5 3⁄4″

1

5

⁄16″

FURNACE

1

⁄8 IN.

DIA HOLE

016012

1

⁄8 IN.

DIA HOLE

27 1⁄2″

28 1⁄2″

17

16 1⁄4″

REAR OF
FURNACE

7

2

⁄16″

1 3⁄4″

18 5⁄8″

1

15

10

3

2

FURNACE

KNOCKOUTS

1

⁄8 IN.

DIA HOLE

⁄4″

5

⁄8″

1

⁄2″

⁄4″

0

0

13

⁄16″

1 5⁄16″

3

⁄4 IN.

DIA HOLE

1

⁄8 IN.

DIA HOLE

020

27

1

⁄2″

28 1⁄2″

REAR OF
FURNACE

A91471

Fig. 5—Opening Detail

CAUTION: Be sure all incoming power is off before

beginning any procedures.

A. Internal Electrical Connections

Proceed as follows to make internal electrical connections.

1. With power door removed, remove junction box cover
adjacent to female plug on casing upper channel. (See Fig.

10.)

PLUG

BUSHINGS

SCREWS

FURNACE
OPENING

SCREWS

SCREWS

FLANGE

Fig. 6—Electronic Air Cleaner Installation

A89117

2. Install protective bushing from inside the air cleaner into the
upper hole on the side channel adjacent to the furnace. Be
sure bushing projects into furnace opening protecting wires
from sharp edges on cabinet opening.

3. Install protective bushing through top rail as shown in Fig.

10.

4. Plug unused hole on top of unit with plug provided in parts
bag.

5. Route power wires through bushing channel at top of
cabinet, down side channel, and through bushing in side
channel and into furnace opening. (See Fig. 10.)

6. Replace cover of junction box.

7. Install wire cover (provided in parts bag) under top flange
and secure to side channel with provided screw.

8. Connect power leads as follows:
a. Single Speed Furnaces—EAC is wired in parallel with

fan motor. (See Fig. 11.)

b. Multispeed Direct-Drive Motor—If the EAC is wired

to a multispeed direct-drive motor, it must be isolated by
a relay or sail switch. Use either air cleaner relay P/N
P283-1203 or sail switch P/N 69105D1. (See Fig. 12 or

13.)

c. Furnaces with Printed-Circuit Boards—EAC is wired

to furnace terminals EAC 1 and EAC 2. See Fig. 14 for
wiring connections.

9. Connect ground wire to base unit ground.

FURNACE

BAFFLES

ELECTRONIC

AIR CLEANER

A91472

Fig. 7—Installing Baffles if Needed

—5—