Page 1
Installation, Start-Up and Service Instructions
INTRODUCTION
Model 31KAX Plate Electronic Air Cleaner is available in three
sizes: 012 (300 to 1400 Cfm), 016 (500 to 1800 Cfm), and 020 (700
to 2000 Cfm).
These plate-type air cleaners are designed for use with residen
tial and light commercial forced-air heating and/or cooling sys
tems. They may be installed in a vertical or horizontal section
of a t5rpical return-air duct system.
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.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service, mainte
nance, or use can cause explosion, fire, electrical shock or other
conditions which may cause personal injury or property dam
age. Consult a qualified installer, service agency, or your dis
tributor or branch for information or assistance. The qualified
installer or agency must use factory authorized kits or accesso
ries when modifying this product. Refer to the individual in
structions packaged with the kits or accessories when
installing.
Follow all safety codes. Wear safety glasses ar,
Use quench.ing cloth for brazing operations,
guisher available. Read these instructions tho)|
low all warning or cautions attached to the uns
building codes and National Electrical Code (NEC) for special
requirements. ^
It is important to recognize safety inf
safety-alert symbol A. When you see this
and in instructions or manuals, be alert to the pot
sonal injury.
Understand the signal word—DANGER, WARNING, or CAU
TION. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result
in severe personal injury or death. WARNING signifies hazards
that could result in personal injury or death. CAUTION is used
to identify unsafe practices, which would result in minor per
sonal injury or product and property damage.
CABINET
The cabinet includes an electrical junction box and a power
safety interlock, and houses the air cleaner components. These
components are:
1.
Mechanical prefilters—Expanded aluminum mesh first-
stage filter that removes lint and larger dust particles.
2.
Cell assemblies—Cells consist of combined ionizer and
collector.
Ionizer part of cell has tungsten wires (that receive posi
tive charge) mounted between grounded aluminum chan
nels, and supported by glazed ceramic insulators.
31KAX
Electronic Air Cleaners
Fig. 1—Model 31KAX
Collector part of cell consists of alternately charged collec
tor plates.
The electronic air cleaner components are (see Fig. 3):
1. A power door assembly.
2. IWo prefilters.
, 3. A cabinet containing two air-cleaning cell assemblies.
4. A parts bag including: electrical bushings, plug buttons,
wire chase and airflow label.
Power Door Assembly
The power door assembly consists of:
1. Unit operation light, ON-OFF switch, and door attach
ment knob—all installed on door cover.
2. Door base plate contains a solid-state power pack that
converts 120 VAC to high voltage DC (A240V Conversion
Kit, P/N 31KAX900---001-- is available). All wiring
mounted internally. A line-voltage disconnect (male plug)
and high-voltage bus-bar are mounted on the base plate
externally. Four screws must be removed to expose the
power pack and wiring.
The supply circuit to the power pack, which is wired across the
furnace air blower, is controlled by an ON-OFF power switch.
With the power switch ON (assumingpower door in placed and
air blower operating), 120 VAC ±10% single-phase, 60-Hz power
is applied to the power pack (240V Conversion Kit transformer
converts 240V to 120 V AC). Output of the power pack assembly
is approximately 7300 VDC.
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 7a 9a
PC 101 Catalog No. 533-134 Printed in U.S.A.
Form 31KAX-8SI
Pg1
12-91 Replaces: 31KAX-1 SI
Page 2
16-7/8
.REAR MOUNTING FLANGE
A
---------------------------
ELECTRICAL ENTRANCE
S-1/2 FOR DUCT APPLICATION
Jr
►
OPERATION ,KNOB
LIGHT
ON/OFF SWITCH
LOGO
Table 1—Dimensions (In Inches)
Model
31KAX012
31KAX016
31KAX020
A
24-3/4
27-1/4
31-1/2
B
21-3/4
24-1/4
28-1/2
C
19-1/2
22
26-1/4
REMOVABLE
POWER DOOR
ELECTRICAL ENTRANCE (5/8" DIA.)
FOR FURNACE APPLICATIONS)
Fig. 2—Dimensional Drawing
Table 2—Component Information
Model
Air Volume Range 300-1400 500-1800
Electrical Data (input
to power door)
Eiectrical Data (output
to collector cell)
Approx Ship. Wt. 120V 50 54
31KAX012 31KAX016 31KAX020
120 volts,
single phase, 60 Hz
120 volts—1.0 milliamps @ 7300 VDC
120 volts,
single phase, 60 Hz
Table 3—Pressure Drop At Various Airflows
31KAX012 31KAX016 31KAX020
CFM
300 0.005 500
400 0.010
600 0.020 800
800 0.030
1000 0.050 1200
1100 0.060
1200 0.065 1600
1300 0.075
1400 0.085
NOTE: Using the electronic air cleaner on air
for 012-size unit, 500 cfm for 016-size units,
Pressure Drop
Inches wc CFM
600 0.025 800 0.013
1000 0.028 1200 0.023
1400 0.045 1600 0.038
1700 0.070 1900
1800 0.080 2000 0.050
Pressure Drop
Inches wc
CFM
0.010 700
0.020 1000
0.035 1400
0.065
duct systems designed for airflows lower than 300 cfm
or 700 cfm for 020-size units, is not recommended.
1800 0.045
700-2000
120 volts,
single phase, 60 Hz
Pressure Drop
Inches wc
0.010
0.018
0.030
0.048
A91466
57
Fig. 3^View of Major Components
A91467
Page 3
Installation consists of the following:
STEP 1. Locating Unit
STEP 2. Installation
STEP 3. Electrical Connections
STEP 4. Startup and Adjustments
In addition, the following sections are also included:
STEP 5. Maintenance and Routine Service
STEP 6. Service Guide
STEP1. LOCATING UNIT
Fig. 4 shows the air cleaner in the return-air duct of some typi
cal furnace installations, with or without air conditioning.
Other methods of installing the unit are permissible if the de
sign criteria outlined in this section is observed.
A. Planning an Installation
When planning an installation, consider the following:
Upflow Application
RETURN
Furnace Side Application
HORIZONTAL
FURNACE
Downflow Application Horizontal Furnace Application
Fig. 4—Typical Applications
Page 4
- CUT OUT FOR STANDARD FURNACE
- CUT OUT FOR SUPER FURNACE
---------
CUT OUT FOR STANDARD FURNACE
---------CUT OUT FOR SUPER FURNACE
Fig. 5—Opening Detail
- CUT OUT FOR STANDARD FURNACE
- CUT OUT FOR SUPER FURNACE
1. Air cleaner is approved only for indoor installation. If out
door installation is used, unit must be housed in weather
proof 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 indicate.
A 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 of 16 ins. of clearance in front of unit for
cleaning and maintenance.
A CAUTION
Never use air cleaner to collect grease or other flammable
contaminants.
4. Air outlets and returns must not be blocked with furni
ture, drapes, or other objects.
5. Air cleaner should be installed where all air circulated by
system will pass through it.
B. Humidifiers
An evaporative, supply-duct-mounted humidifier may be in
stalled without affecting the electronic air cleaner. A bypasstype evaporative humidifier should be installed so that the
moist air does not contact the air cleaner. When an atomizingtype humidifier is used, it should always be installed in the
supply-air system.
2. A standard, disposable furnace filter must be installed be
tween humidifier and air cleaner 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.
Temperatures lower than 40 F can cause ionizer wire failure un
der certain conditions.
NOTE: The maximum operating temperature of the electronic
air cleaner is 125 F.
STEP 2. INSTALLATION
NOTE: See Fig. 4 for suggested installation positions.
A CAUTION
Tiirn off all power to the furnace before beginning any
procedures.
Proceed as follows to install electronic air cleaner:
1. Remove and discard existing furnace mechanical filters.
They are not required when using an electronic air cleaner.
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
A CAUTION
If an atomizing-t3rpe humidifier is installed upstream from
the air cleaner, the efficiency of the electronic cells will be
decreased by high humidity, salts, and minerals, and serv
ice problems will result.
If the bypass-type humidifier must be used upstream from the
air cleaner, the following precautions should be taken:
1. Humidifier must be installed as far from air cleaner as
possible.
Fig. 6—Electronic Air Cleaner Installation
Page 5
Fig. 7—Installing Baffles if Needed
for Opposite Airflow
from cleaner casing by pulling it towards you. This motion
disengages power supply connector.
3. Slide out prefilters and air cleaner cells.
4. For Model 016 electronic air cleaner furnace side applica
tion, cut open return knockout at the side of the furnace
cabinet. For Models 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 re
moving (4) screws in the back of the air cleaner. Be sure all four
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 two holes on furnace casing. See Fig. 6.
7. Secure the unit with (2) screws using screws provided 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.
A CAUTION
If flanged sheet metal ducts are metal-screwed to the unit
casing, do not use screws longer than 1/2-in.
Fig. 9—Line-to-Line Wiring Diagram
A 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-l duct reduc
tion ratio (3-ins. of duct length for every 1-in. of reduction
in size).
WIRE CONN.
BLK
-Hg
-------
WHITE <
------------
WHITE
BLK
INTERLOCK
(DO NOT BYPASS)
I FIELD WIRING
FIELD WIRED GROUND
TRANSFORMER ASSY.
FOR FIELD CONN. WHT
3
POWER
SWITCH
Fig. 10—Wire Routing
ON 208/240 UNITS ONLY
UNIT
OPERATION LIGHT
A89116
Page 6
POWER SUPPLY (12OV-6OHZ-10)
POWER SUPPLY (12OV-6OHZ-10)
BLK
FAN RELAY FAN SWITCH FAN MOTOR
-»X-
-ll-
HH
WHT
OR
RED
-r
0 WIRENUT, FACTORY SUPPLIED
-------------
120-V FIELD WIRING
Fig. 11—Single-Speed Furnaces
POWER SUPPLY (120V-60H2-10)
WHT OR RED
BLK
6 SAIL SWITCH
GRD or (FIELD SUPPLIED)
iHU <p\
I
I I
*
YEL OR WHT I GRN | BLK
ELECTRONIC
AIR CLEANER
0 WIRENUT, FACTORY SUPPLIED
-----------
120-V FIELD WIRING
A91474
-T-
1
TO "G" ON
THERMOSTAT-
TO "C” ON
THERMOSTAT-
1 AIR CLEANER RELAY BLK
I (FIELD SUPPLIED)
0 WIRENUT, FACTORY SUPPLIED
--------------
(20-V FIELD WIRING
---------------
24-V FIELD WIRING
L—*-
Fig. 12—Multispeed Direct-Drive Furnaces
With Field-Supplied Air Cleaner Relay
FURNACE
EAC1 EAC2
TERMINAL
BOARD
I QBD
YEL OR WHT I G^N | BLK
ELECTRONIC
AIR CLEANER
0 SCREW TERMINAL
(g) WIRENUT, FACTORY SUPPLIED
-----------
120-V FIELD WIRING
GRD
■¡G^N
YEL
OR
■WHT
ELECTRONIC
AIR CLEANER
A91475
Fig. 13—Multispeed Direct-Drive Furnaces
With Field-Supplied Sail Switch
FAN COIL
TERMINAL
GROUNDED EAC1
NEUTRAL
YEL OR WHT SRN BLK
0
240 V*
EAC2
BOARD
ELECTRONIC
AIR CLEANER
Fig. 15—Fan Coils with Printed-Circuit Control Board
OR
Fig. 14—Furnaces With Printed-Circuit
Control Board
EAC 2
EAC 1
I 00000
YTUTirA 30 VA
TO 120-V
ELECTRONIC
AIR CLEANER
‘NOTE: 240V IS SUPPLIED BETWEEN TERMINALS
0 SCREW TERMINAL
0 WIRENUT, FACTORY SUPPLIED
------------120 V FIELD WIRING
TRANSFORMER
EAC1 AND EAC2. EAC2 IS ENERGIZED ONLY
WITH THE FAN MOTOR.
OR
240:120-V
6
EAC 2
EAC 1
@
TO 240-V
ELECTRONIC
AIR CLEANER
(WITH 240-V
CONVERSION KIT
INSTALLED)
A91477
A914S9
Page 7
A CAUTION
Do not baffle off any portion of the entering-air side of the
air cleaner.
9. Seal all joints on downstream side of air cleaner to prevent
infiltration of contaminated air.
STEP 3. ELECTRICAL CONNECTIONS
All wiring must comply with applicable local and national
codes. Determine best power wiring routing (see Section A for
Internal Connections and Section B for External Connections).
A CAUTION
Be sure all
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.
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 cabi
net, down side channel, and through bushing in side chan
nel 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 screw provided.
8. Connect power leads as follows:
Single speed furnaces—Electronic air cleaner is wired in par
allel with fan motor. See Fig. 11.
Multispeed direct-drive furnaces—If the air cleaner 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 Pig. 12 or 13.
Furnaces with printed circuit control module—Electronic air
cleaner is wired to furnace terminals EAC-1 and EAC-2. See
Fig. 14 for wiring connections'.
9. Connect ground wire to base unit ground.
NOTE: For non-corporate furnaces, wire unit using conduit and
strain relief the wires.
incoming power is off before beginning any
A CAUTION
Be sure all internal wiring connections are tight before unit
is operated.
B. External Electrical Connections
1. Attach power supply conduit to hole in top of electronic air
cleaner. Do not use extension cord to connect to electrical
power source.
2. Cut electronic air cleaner wires to 6-in. long; strip ends.
Connect power leads to black and white pigtails extending
from female receptacle, using field supplied wirenuts. See
Fig. 9.
NOTE: Do not connect aluminum conductor to electrical con
nections of the electronic air cleaner (copper wire only).
3. Connect power leads as follows:
4. Connect electronic air cleaner ground wire (green) to ap
propriate supply ground.
5. Replace cover of junction box.
Single-speed furnaces. Electronic air cleaner is wired in paral
lel with fan motor. See Fig. 11.
Multispeed direct-drive furnaces. If the air cleaner 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.
Furnaces with printed-circuit control module. Electronic air
cleaner is wired to furnace terminals EAC-1 and EAC-2. See
Fig. 14 for wiring connections.
Fan-coil units. Electronic air cleaner (120-v) must be wired to
fan-coil circuit board terminals EAC-1 and EAC-2 only as
shown in Fig. 15. Terminals EAC-1 and EAC-2 supply 240-vac.
Terminal EAC-1 is energized continuously; terminal EAC-2 is
energized only with the fan motor.
C. Final Assembly
A CAUTION
Be sure all field electrical connections are tight before unit
is operated.
1. Slide prefilters and air cleaner cells into cabinet.
NOTE; Units are shipped for air entering the right-hand side of
the air cleaner. Reverse the position of the prefilter and the air
cleaner cells in the cabinet for air entering the left-hand side of
the air cleaner as indicated in Fig. 8. Be sure all airflow arrows
are pointing in the direction of the airflow through the air
cleaner and that the prefilter is on the entering-air side.
2. Check contact spring location: cell contact springs must be
relocated for left-hand units. Remove screw holding con
tact spring to cells and reinstall at opposite end (See Fig.
17). Be sure all airflow arrows are pointing in the direction
of the airflow through the air cleaner and that the
prefilters are on the entering-air side.
3. Deform prefilter guide on side opposite prefilters so that
prefilters may not be reinstalled incorrectly.
4. Replace power door by first inserting bottom tab into place
on bottom edge of door opening. Push top of door and
guide door attachment knob screw into threads. Tirn knob
clockwise until screw engages threads in casing. Tbrn knob
clockwise until door is secure. Ensure good electrical con
tact between power door and unit components.
5. Unit can be installed with airflow through cabinet in ei
ther direction. Apply airflow decal (provided) to cabinet,
observing actual airflow direction. See Fig. 17.
STEP 4. STARTUP AND ADJUSTMENTS
The electronic components of the unit convert the incoming
VAC to VDC power supply. Unfiltered, contaminated air passes
through an aluminum mesh prefilter which removes larger air
borne particles and distributes the air uniformly across the ion
izer-collector assembly. The air passes through the ionizer and
is charged with 7300 VDC. The ionizer imparts a positive elec
trical charge to the remaining contaminants. As the air contin
ues through the collector section, the charged contaminants are
attracted to the alternately charged collector plates. The
charged contaminants are electrostatically held by the collec
tor, thus purifying the airstream.
1. Ensure that entire electronic air cleaner is clean, dry, and
free of foreign objects.
2. Restore power to system.
3. Move ON-OFF switch on power door to ON position.
4. Set room thermostat to start blower.
Page 8
u
Corporate Electronic Condensing Upflow
Gas Furnace
TRANSFORMER
A91490
B.
Corporate Continuous Pilot
Gas Furnace
ELECTRONIC
AIR CLEANER
TERMINALS
Corporate Induced Draft
and HSI Condensing Furnace
Fig. 16—Internal Furnace Electrical Connections
for Electronic Air Cleaners
8
Page 9
A89420
Fig. 17—Final Assembly Detail
5. Check to see if operation light is glowing. This indicates
proper power to the cells.
NOTE: Leave these Installation Instructions with the owner to
enable the owner to perform maintenance and routine
service.
STEP 5. MAINTENANCE AND ROUTINE SERVICE
Your new electronic air cleaner requires periodic maintenance
for optimum performance. You may perform this service or have
your serviceman handle it for you.
Cleaning of the cell assembly and prefilter is required two or
three times a year. Frequency will depend on size of home, num
ber of occupants, smoking habits, etc.
The odor of ozone may be noticeable during operation of an
electronic air cleaner. A somewhat higher ozone generation rate
during the first week or two of operation may be caused by sharp
edges on some of the new high-voltage parts. Normal use dulls
these sharp edges in a short time.
The odor of ozone is detectable by an average person at levels as
low as 0.003 to 0.010 parts per million (PPM). The concentra
tion of ozone produced in a home by an electronic air cleaner
ranges from 0.006 to 0.020 PPM. Average concentrations of
ozone in the air of major cities range from 0.020 to 0.040 PPM
and even higher. This is well above the level produced by an
electronic air cleaner.
Because normal maintenance (cleaning) is so simple, most
homeowners will choose to personally perform the necessary
operations.
Clean the unit where dust from air cleaner cells will not soil car
pets or the floor.
A CAUTION
Before removing the electronic cells, be sure to deenergize
the system fan to avoid any possibility of circulating un
filtered air back into the system.
To gain access to the prefilter and air cleaner cells, simply push
power switch to OFF position and remove the power door. Lay it
to one side. Pull out the first-stage prefilters and vacuum from
entering-air side, or wash in detergent and water. Let dry thor
oughly. Reinstall. Do not spray prefilters with any filter
coatings.
A. Cleaning the Cell
For optimum performance, the electronic cells must be washed
regularly to remove the dirt cleaned from the air. The required
frequency of cell washing varies from one environment to an
other, depending on a large number of variables. In nearly all
cases, the correct period is between 1 and 6 months. Where
building infiltration and internal generation of dust is low, as in
a smaller home, washing every 5 or 6 months may be adequate.
Where there is considerable infiltration, cooking, dust, tobacco
smoking, more frequent washing will be required. If a very
heavy buildup of dirt is found on the collector plates, or the cell
is not clean after washing, it should be cleaned more often. If
there is only light dirt on collector plates, the period between
washings can probably be lengthened. The electronic plate cells
may be washed a number of different ways, depending on homeowner preference.
1. Automatic Dishwasher Washing—The easiest and most
convenient way to remove the accumulated dirt from the
plate-t5q>e electronic cells is to wash them in an automatic
dishwasher.
a. Place electronic cells on sides with ionizer section
down (airflow arrows pointing up) on lower rack of
dishwasher.
A CAUTION
Use care to avoid damage to the collector plates when plac
ing the cells in the dishwasher.
NOTE: For some dishwashers with a center spray arm, it may
be necessary to remove the top basket to fit one or both cells
inside.
b. Use detergent in accordance with dishwasher manufac
turer’s instructions.
c. Allow dishwasher to run through its complete wash cy
cle. You may also allow it to run through its complete
dry cycle, although this is not necessary.
A CAUTION
The electronic cell will be very hot at the end of the dish
washer’s cycle. Allow it to cool before handling. Hot water
may accumulate in the tubes supporting the collector
plates. Tip the cells so that these tubes will drain.
d. Dry ceils completely before turning on power to air
cleaner. This can be done by replacing cells in cabinet
and letting fan on system furnace or air handler run ap
proximately 30 minutes before turning on power to air
cleaner.
e. With some dishwashers it may be necessary to rerun
complete cycle or rinse cycle after cells are removed if
homeowner notices dirt stains or residue inside
dishwasher.
2. Manual Washing—The electronic cells may be washed
manually by soaking them in a solution of automatic dish
washer detergent.
a.
Provide suitable container large enough to hold one or
both cells.
b.
Select automatic dishwasher detergent that dissolves
readily in hot water. Depending on local water condi
tions, some brands may form a precipitation or scum. If
a noticeable scum floats to surface, try another brand.
The brand the homeowner finds gives the best results
in his dishwasher will probably give best results wash
ing the electronic cells.
Page 10
A CAUTION
Do not splash detergent solution in eyes, and avoid pro
longed contact with skin. Keep detergent and solution out
of reach of children.
c. Before placing cells in washing container, pour in de
tergent. Use approximately 3/4 of cup per cell if con
tainer is about size of cell. Add enough very hot water to
cover cell or cells.
d. After detergent has completely dissolved, place elec
tronic cell (or cells) in container.
e. Soak cells for 15 to 20 minutes, slosh several times, and
remove.
f. Rinse cells with fine water spray.
g. Fill wash container with clean, hot water and soak cells
for 5 to 15 minutes.
h. Remove cells and let water drain from them. If water
draining from them feels slippery, detergent still re
mains. Repeat rinsing until water from them no longer
feels slippery. Inspect for cleanliness.
i. When both cells have been washed and thoroughly
rinsed, check cells for broken wires and bent collector
plates. If none are found, replace electronic cells and
prefilter in cabinet. Observe proper airflow arrows on
cabinet and cells.
j. Dry cells completely before turning on power to air
cleaner. This can be done by letting fan on system fur
nace or air handler run for approximately 30 minutes
before turning on power to air cleaner.
STEP 6. SERVICE GUIDE
A CAUTION
Procedures in this section should be performed only by
qualified service personnel.
A CAUTION
1. During troubleshooting procedures, dangerous linevoltage circuits are exposed. Use care to avoid hazard of
electrical shock or damage to equipment.
2. Although not lethal, high-voltage output of power sup
ply can produce painful shock.
3. Be sure to properly ground air cleaner and its compo
nents before testing.
4. Do not touch any portion of air cleaner when energized.
Tools and Equipment
Servicing the electronic air cleaner can be accomplished with
only a few tools;
1. Screwdrivers: Long shank, plastic or rubber handles (two
required).
2. Needlenose pliers for stringing ionizing wires.
3. High-voltage jumper cord.
4. High-voltage tester: range to 12 KVDC.
5. Grounding wire.
ELECTRICAL TROUBLESHOOTING GUIDE
The following troubleshooting procedure is a simplified ap
proach to aid the serviceman in repairing any malfunction in
the electronic air cleaner. By following this troubleshooting
procedure, and operation light, the malfunction can be isolated
to certain areas in the electronic air cleaner.
NORMAL OPERATION
For normal operation of an electronic air cleaner, the system
blower should be running and the air cleaner switch should be
“ON.” This will allow the unit to be energized and cause the
light on the power door to glow. Occasional arcing by an elec
tronic air cleaner is normal (the light on the power door will
flicker). This can result when lint or large particles of dirt are
not stopped by the prefilters. The dirtier the electronic air
cleaner becomes, the more likely occasional arcing will occur.
Continuous arcing may indicate cleaning is necessary. (See
cleaning procedures.) The electronic air cleaner should operate
only when the system blower is running.
ISOLATING MALFUNCTIONS
Switch on the electronic air cleaner and energize the blower sys
tem. (See operation of an electronic air cleaner.) If the light does
not glow, remove the cells and replace the door. If the light
glows with the cells removed, the problem is within the cell or
cabinet. Proceed to steps 1 thru 3. However, if the light does not
glow, proceed to steps 4 thru 10.
It may be necessary to perform steps 1 through 3 after complet
ing steps 4 through 10 if there was a malfunction in both
sections.
1. Check spring on cell to see if it is bent, sprung, or de
formed. Check to see that it makes good contact with door.
(Repair or replace.)
Check male and female plug and receptacle and associated
2.
wire connection on power door and cabinet for damage and
proper wiring.
Check air cleaner cells, visually inspecting for:
3.
Heavy dirt accumulation (Wash cells—see cleaning
procedures).
Bent collector plates (Straighten).
b.
Broken ionizer wires (Replace).
Ionizer springs broken or bent (Replace).
d.
1. Check to see that ionizer springs are seated prop
erly in place. Improper seating may cause arcing.
Insulators cracked or broken (Replace).
1. Deterioration of metal around insulator indicates
defective insulator (Replace insulator).
Ionizer grid deformed (Repair or replace).
f.
Check for short between high-voltage contact (found in center
of rectangular ceramic insulator) and frame of cell, with ohmmeter. Resistance should be infinite, (open circuit)
If the light does not glow when cells are removed:
4. Remove power door from unit and check for power to air
cleaner cabinet. This can be accomplished with a volt
meter. Being careful to avoid electrical shock, check out-
10
Page 11
ELECTRICAL TROUBLESHOOTING FLOW CHART
put at the receptacle with voltmeter. Reading should be
approximately 120 volts (240 for 240V conversions).
During normal operation, power to the cabinet should only be
activated while system blower is operating. DO NOT operate
electronic air cleaner when blower is off, to avoid building up an
undesirable concentration of ozone.
5. Remove access panel on power door and visually check to
see that all wire connectors are firm and that wires are not
broken. (Repair or replace with 18-gauge wire minimum.)
6. Inspect ceramic insulators for dirt or damage. (Clean or re
place.) Deterioration of metal around insulator indicates
defective insulator (Replace).
a. Inspect for visual damage (Replace.)
A WARNING
A possible shock hazard exists. Do not allow arcing for a
prolonged period of time. The power supply output can be
checked with a high-voltage voltmeter. The output should
read between 9000 and 11000 VDC. If the output is below
7500 VDC, replace the power supply.
A91482
7. Check switch and light circuit by applying electrical power
to plug on power door. This can be accomplished with
jumpers from cabinet receptacle. Attach grounding wire
between power door base and cabinet.
A WARNING
A possible shock hazard exists. Be careful not to short out
the power supply. The buss bar and contact plate carry live
high voltage current on - 7300 VOC, 1 MA
The L.E.D. light circuit output can be checked with a voltme
ter. The reading should be 4VAC.
8. Check power supply. (See Fig. 18.)
a. Place screwdriver on ground plate (access panel) and at
same time move shank portion of screwdriver towards
high-voltage output of power supply. If arcing occurs
when screwdriver comes within approximately 1/8 in.
of power supply, then power supply is operating prop
erly. If no arcing occurs, power supply is defective. (Re
place power supply.)
b. Use high voltage tester. Voltage output should be be
tween 9000 and 11000 VDC.
11
Page 12
PROBLEM
Operation light off
Unit snaps or arcs continuously
Humming noise
Air cleaner does not clean dirt
Radio or TV interference
White dust on furnishings
TROUBLE ANALYSIS CHART
POSSIBLE CAUSES REMEDY
Shorted cells
Defective light
Defective power supply
Blower not operating
Cells wet either due to high humidity or from washing
Line voltage too high
Cells need cleaning
Broken ionizer wire
Broken contact spring on cell
Broken insulator in cell
Broken insulator in power door
Foreign material lodged in ionizer or between plates
Bent plates
Improper wiring connections
Loose ionizer wires
Ionizer wires not centered
Excessively dirty ionizer or collector
Deformed contact spring on cell
Lack of power to cells because of improper alignment of contact spring cells
to power door
Defective interlock plug or receptacle
Air volume too great Reduce air volume to design CFM.
Leaks in ductwork on clean air side of air cleaner
Dirty air not being delivered to air cleaner
Uneven air distribution across face of unit. Uneven air distribution across
face of unit may be indicated by uneven loading pattern of dirt in collector
section of air cleaning cells. The entering-air side of collector stage should
be evenly covered with dirt. In the case of the two cell units, each cell
should have an even loading pattern.
Accumulation of foreign particles lodged in ionizer section
Unit improperly grounded
Ground line of supply line voltage not properly grounded Correct.
Loose ionizer wires
Loosely connected components or primary-voltage wiring Tighten.
Defective power pack
Dents in collector section or ionizer section Straighten.
Improper contact between power door & cells Adjust alignment of contact spring.
Weak-station/poor ground
Defective insulator
This dust can be described as “clean dirt” and is composed mainly of lint,
which because of its weight settles out of the living space before it
reaches the air returns. It is “white” because the submicron dirt particles,
which normally would color it and render it invisible, have been removed
from the air space.
See “Electrical Troubleshooting
Guide” section.
Energize blower.
Cells will dry.
Adjust line voltage.
Clean cells.
Replace wire.
Replace spring.
Replace insulator.
Replace insulator.
Remove object.
Straighten.
Correct.
Replace or repair.
Center wires between plates.
Clean.
Adjust spring.
Adjust alignment or replace spring.
Replace.
Seal.
Check return-air grilles for obstruc
tion by furniture, drapes, etc. Re
move.
Install turning vanes of air baffles.
CAUTION: Do not block off any of
the entering-air side opening to the
unit.
Remove.
Provide good ground to power pack.
Replace.
Replace.
Add E.M.I./R.F.I. filter, in power line.
Replace.
This problem requires no solution. It
is visible evidence that the air
cleaner is cleaning up the staining
and soiling dirt particles from the
living space.
Copyright 1991 Carrier Corporation, Indpls., IN 46206
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book 1 4
Tab 7a 9a
PC 101 Catalog No. 533-134 Printed in U.S.A. Form 31KAX-8SI Pg12 12-91 Replaces: 31KAX-1 SI
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