Carrier EACA Installation And Operation Manual

Electronic Air Cleaner

Sizes 00!4, 0020, & 2020

Manual for:

Installation o Operation o Maintenance

CAUTION: Read installation instructions and rules carefully for safe operation,

Exercise the usual precautions when working with high voltage,

Form # IM-EACA-01 Date t/03

Table of Contents

Safety Considerations & Introduction

Unit spedflcations

Facts you should know about your new Electronic Air Cleaner

1) Regular dusting & "white dust"

2) Ozone

3) Air flow sensor operation

4) High akitude applications

Replacing the ionizing wires

Common Q & A

Maintenance of your Electronic Air Cleaner

1) Removing the cells and prefllter

2) Washing the cells and prefllter(s)

3) Replacing the cells and prefiiter(s)

Common troubleshooting techniques

Installation instructions ( for use by authorized HVAC

contractors)

Technical troubleshooting flowchart

Replacement part list

List of figures

Figure 1

Figure 2

Figure 3

Table 1

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Air flow sensor diagram

Reducing ozone in high altitude applications

Cleaning the ionizing-collector cells

Symptoms of excessive arcing or zapping

Unit dimensions

Technical specifications

Typical HVAC system configurations

Sheet metal transitions

Turning vanes from improving air flow

Proper installation of cell spacer

Proper mounting diagram

Wiring the unit to the input power source

Electrical schematic diagram

Testing the power supply output

Troubleshooting flowchart

Unit p a r t s diagram

Page

1

2

4

4

5

6

7

8-9

10

10

11

11

12

15-29

29-30

31-32

Page

5

6

10

12

13

15

16

18

18

19

21

22

26

28

29-30

31-32

NOTE: Read the entire instruction manual before startinc 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 Z_ .When you

see this symbol on unit or in instructions and manuals, be alert to potential for

personal injury.

Understand the signal words DANGER, WARNING, and CAUTION. 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 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.

This manual provides information for location, installation, operation and
service. Before installation and use of the air cleaner, carefully read these

instructions to insure maximum benefits from the unit and to avoid needless
service costs that can result from improper installation.

mNTRODUCTmON

Thiselectronicair cleaneris technicallyknownas a two-stageelectrostatic

precipitator. The air cleaneris designedto removeairborneparticulates,
includingdust,dirt,smoke,pollen,virus,spores,bacteriaandmold,fromindoor

air.

Airmovementthroughtheunitis providedbythe heating,airconditioningor
ventilatingsystemblower.Asdirty air entersthe air cleaner,the air passes

throughametalmeshprefilter.Theprefilterpreventslint,pethairandotherlarge

particulatesfromenteringtheaircleaner.Htitsimportantthatthesefiltersbein
placeto preventexcessivedirtloadingoftheaircleanercollectorcells.These

filters extendthe time betweenmaintenanceof the air cleanercollector

cells.Thisallowsthe ionizing-collectorcellsto providecleanairfor a longer
periodbetweenwashings.

Theprefilteredairthenpassesthroughatwo-stageElectronicAirCleaner.Inthe
first stage,allairborneparticulate,evensubmicronsize,are electronically

charged(positive)astheypassthroughtheionizer.Theionizerfieldissetupby
a coronadischargeemanatingfromthefine,tightlystrungwiressuspended

betweentwoadjacentflatplates.Inthesecondstage,thechargedparticulate
passesthroughan intenseelectricalfield establishedbetweenalternately

chargedandgroundedparallelcollectorplates.Here,the positivelycharged
particulateisattractedtothenegativelygroundplatesandremovedfromtheair

stream.
Foraunitdiagramandacompletelistingofallparts,pleaseseepage31-32.

POWER ]RAY ASSEMBLY

COVER ON-OFF SWITCH

fND_CATING

CELL
CON[ACT

POWER TRAY

ASSEMBLY

CABINET

COLLECIiNG CELL(S)

UNiT SPECiFiCATiONS

This air cleaner is easyto install, operate and maintain. Its basic components

arethe:

Cabinet
Mounts to existing ductwork; houses the ionizing-collecting cells and

prefilters.

IonizingoCoHector Cells
Collect the dust, dirt and other particulates in the air. They contain the
ionizing and collecting sections as described on page 2. The cells must be

installed with ionizing wires on the air intake side. A spring contact is located
on the top of each cell and must be in position to make contact with the
contact board assemblies on the bottom ofthe power tray assembly.

Prefilters

Trap large particulates before it enters the ionizing-collector cells.

Power Tray Assembly
Contains the indicating light, solid state power supply, contact boards and
electrical controls including ON/OFF switch and safety interlock switch.

Awidng compartment is provided at the rear of the tray allowing the option to

permanently wire the unit directly to a furnace control.

Air Flow Sensor (AFS)

Installed on certain models, this part brings the unit on by sensing the
movement of air within the duct.

How to identify Which Air Cleaner Modem you own

The model number and serial number for your Electronic Air Cleaner can be
found on the data label located on the inside of the access door. This serial

number will be aten (10) digit number.

3

FACTS YOU SHOULD KNOWABOUTYOUR NEW

ELECTRONIC AiR CLEANER

Dusting and "White Dust"
Your new Electronic Air Cleaner will efficiently clean and filter your household
air. Unfortunately, it will not eliminate the need for regular dusting of your
furniture and belongings. Due to the design of all duct-mounted air cleaners,
they can only clean the air that reaches the air cleaner. Therefore, if the

particulates are not being carried to the air cleaner in the air stream, the air

cleaner cannot remove them from your home.

Occasionally a "white dust" may be noticed in bedrooms or newly furnished

rooms. This is mainly composed of lint which, because it is heavier than other

particulates, settles before it reaches your unit.. This "white dust" is not mixed
with airborne dirt particles, therefore, it is clean and has no staining or soiling

properties. However, running the furnace blower continuously, day and night,
will help reduce this from occurring.

Ozone

Under normal operating conditions all Electronic Air Cleaners produce

minute quantities of ozone as an incidental by-product. In fact, all electronic

products, such as televisions, cordless phones and refrigerators, produce
some amount of ozone. The average homeowner can detect the smell of

ozone concentrations as low as 25 to 100 ppb (parts per billion). The design of
this unit has been tested and ozone production is approximately half of the

published permissible limits established by the Environmental Protection
Agency. These limits recommend that the concentration of indoor ozone not

exceed 50 ppb. Ozone is not harmful in these concentrations. In fact, the

ozone level in major cities can sometimes reach as high as 100 ppb on a
summer day. The addition of optional charcoal after-filters can help reduce

this.

Normally, a new unit will produce more ozone than one that has been in

operation for several weeks. This is due to sharp corners or manufacturing

burrs on the ionizing-collecting cell(s) and is normal. As the Electronic Air

Cleaner arcs and zaps, the voltage is vaporizing these areas and tends to

round them off. This is part of the breaking-in period of ownership and the

issue is self-correcting. Also, high-altitude locations can be more susceptible
to noticing the presence of ozone.

An ionizing-collecting cell that has been damaged or bent (the designed
spacing between electrically charged and ground components has been

decreased) may also produce an abnormal amount of ozone.

Turn OFF power and install lockout tag before beginning any maintance procedure.

How the Air How Sensor Works (Available on specific modems)
The electronic AFS was designed to provide an efficient and reliable method

of controlling the operation of the air cleaner when the dealer is unable to
wire the unit directly into the furnace blower. The electronic AFS utilizes a

thermistor that heats up to approximately 130°R The AFS then stabilizes at
this temperature and when the furnace blower turns on and air flows through
the ductwork, the same vacuum effect pulls cooler air over the hot surface.
This air movement cools down the thermistor and this cooling down effect

allows the electronic AFS to understand that the furnace blower is moving air

and the Electronic Air Cleaner must turn on to provide air cleaning.

If the air cleaner is installed in a location that is dusty and dirty, the sensor on
the AFS can become coated with dirt and lint. This coating can insulate the

AFS and keep it from operating properly. To clean the thermistor, take a

cotton swab dipped in rubbing alcohol and carefully insert it into the hole

located on the right hand side of the power pack assembly (when facing the

unit). The hole is 3/16" in diameter and is located on the front of the power
tray assembly. Carefully twirl the cotton swab between your fingers, making

sure the tip is lightly in contact with the g[_ disc, cleaning this coating from
the thermistor.

Figure 1

H_h Altitude Operation

Because the air is less dense at higher altitudes, there is a possibility of

nuisance arcing. The homeowner can quickly and easily correct this

condition.

1. Turn the unit OFF and turn offcircuit breaker.

2. Remove the two screws that secure the cover to the power tray and
remove it from the unit. (The entire power supply tray may be removed

from the cabinet by removing two screws from inside the cabinet.) Do

not lose these screws.

3. Locate the jum per terminal (see figure 2).

4. With a pair of needle nose pliers, carefully adjust the jumper settings

from HIGH to MED. Ensure that the jumper is firmly seated in the
terminal.

5. Replace the power tray cover and secure it with the two screws.

6. Replace the access door and turn the unit ON.

This procedure will slightly reduce the output voltage, minimize arcing and

reduce ozone production. If the condition does not improve, repeat the
above procedure and move the jumper setting from MED to LOW. If this

does not correct the situation, contact your local HVAC dealer.

All Electronic Air Cleaners are produced at the factory with the jumpers set in
the HIGH position. However, the output voltage may be lowered in any

situation where the unit is arcing excessively or there is excessive ozone
production.

Figure 2

REPLACING THE _ON_ZJNG WIRES

Ionizing wire breakage is minimal because of the constant tension design
and fixed location of the ionizing wire supports. When an ionizing wire

breaks, the efficiency of the Electronic Air Cleaner will decrease slightly.
However, the unit will continue to operate with broken ionizing wires as long

as the broken wires have not caused a short circuit of the unit. Remove all
loose and broken wires as soon as they are identified.

Although the replacement of the ionizing wires can be attempted by a

homeowner, it is recommended that a qualified HVAC contractor be
contacted for replacement parts and/or servicing. Wires are supplied in a
coiled spring configuration, with a clinch nut on each end of the wire.
Replacement requires a pair of needle nose pliers. Exercise caution in
removing any broken wires in the collector cell. This will prevent accidental

shorting of the cell and reducethe need for further maintenance.

Use the following procedure when replacing an ionizing wire.

1. Ensure that all power to the Electronic Air Cleaner is OFF, remove the

access door and remove the ionizing-collector cells from the unit.

2. Carefully remove all remains of the broken wire.

3. Grip the new wire at each end of the wire with your thumb and index

finger. While stretching the wire to approximately 6" allow one end of
the wire to uncoil between your thumb and index finger.

4. Place one end of the wire in the slot of the stainless steel support on

the collector cell from the front of the cell. This support is partially
covered bythe cell brace in front of the support.

5. Grip the other end of the ionizing wire with needle nose pliers and

insert the terminated end of the wire into the slot on the support bar of
the opposite end of the collector cell.

6. The wire should be tight enough to be self supporting and remain

suspended between the two support slots in the support bar.

Common Questions and Answers

Q. Why isn't my air cleaner cleaning my air?

A. The air cleaner is most likely working just like it was designed.

However, many factors can affect the performance of the unit. Are cold air
registers located in the ceiling? If so, it will be difficult for the air flow to
carry heavier particulates to the air cleaner. Ifthe dirt doesn't getto the air
cleaner, it can't be removed from the air. Are both the Red and Green lights
illuminated? If not, then the unit may be in need of servicing. Contact your

local HVAC dealer for assistance.

Q. It still isn't cleaning my air the way I want it to. What can I do?

A. We recommend that you run the blower continuously so that the air

movement will carry the dirt to the air cleaner. Unfortunately, there will

always be some dirt that is left behind on the appliances, furniture, etc.

Regular dusting is recommended to stir up these pockets of dust so that

they can enter the airstream and be removed by the Electronic Air Cleaner.

Q. When I turn on my Electronic Air Cleaner, the lights come on for a couple

of seconds and then turn off. The air cleaner isn't working!

A. The air cleaner is fine as long as both the Red and Green lights are

coming on. Try turning the HVAC blower OFF and then turning the
Electronic Air Cleaner on. This should solve the problem.

Q. What is the zapping noise I'm hearing from my unit? Should I be

concerned?

A. The zapping or popping noise that you are hearing is the sound of larger

particles being "vaporized" by the ionizing-collector cell. This is normal

and is no cause for alarm. As your HVAC system blower moves the air
through the ductwork and aNows the Electronic Air Cleaner to clean the

air, the noise will diminish. However, there will always be instances when

larger particles enter the ionizing-collector cell.

Q. Should Ihear this zapping noise all the time?

A. All Electronic Air Cleaners will occasionally zap or pop as larger particles

pass through the ionizing-collector cells. However, if the sound is
constant or is repetitive in nature, then a large particle may have become

lodged in the ionizing-collector cells and they may require cleaning. If
cleaning the ionizing-collector cells does not stop the noise and there

are no large particles trapped in the ionizing-collector cells, then the

cause could be a broken/loose ionizing wire, bent collector plate or
other mechanical reason. Please contact your local HVAC dealer for

assistance.

Q. What if Wno longer hear any popping or zapping noises coming from

my unit? Is it still cleaning the air?

A. If the zapping noises stop and the air cleaner is not in need of

servicing, then one of two situations has occurred. First, the Electronic

Air Cleaner has successfully removed all larger particles from the air

and is cleaning microscopic particles which do not cause the zapping
noise. Second, the blower and/or HVAC system is not running and air
is not flowing through the ductwork. The Electronic Air Cleaner cannot
remove particles if the air stream is not moving.

Q. I lost power to my home during a storm. Should I worry about the

Electronic Air Cleaner?

A. The most common problem associated with power outages is the unit

will not turn on properly after power is restored. Wfthe Red and Green
light come on for a couple of seconds and then go off, the unit is
OK. Just turn the HVAC blower off, turn the unit ON and then turn the

blower back on. Wfthe Red and/or Green light does NOT come on
after a storm, the power supply in the Electronic Air Cleaner may be

short circuited. Contact a local HVAC contractor for further
information.

Q. My installer told me to keep my HVAC system blower running all the

time, but I don't want to increase my power bill. What should I do?

A. It is recommended that you keep your HVAC system blower running

all the time to achieve the maximum air cleaning efficiency. This will
allow the Electronic Air Cleaner to do what it is designed to do, which

is clean the air. Remember that if the air does not reach the air cleaner,
it cannot be cleaned. On average, your Electronic Air Cleaner will use

the same amount of electricity as a 55W light bulb. The energy usage

of the HVAC system blower will depend on the age of your system,
energy costs in your regional location and other variables. The best

solution is to try running the HVAC system blower in continuous mode

for a month or two to estimate your annual energy costs and base

your final decision on what you feel most comfortable with.

MAINTENANCEOFYOURELECTRONICA_RCLEANER

WASHINGCELLSANDPREFILTERS

Regularwashingis necessary to ensure proper performance. A thorough

washing once every two months will be adequate for most installations.

More frequent washing (once a month) may be necessary on some
installations (new homes for example) where there is new carpeting, plaster

dust, or excessive cigarette smoke (Figure 3).

To remove ceils and prefilter

1. Push air cleaner switch to the OFF position. Wait 15 seconds. Open door
access panel.

2. Carefully remove cells and prefilter(s) and set aside in a safe place.

3. Do not drop the ionizing-collector cell. This could cause damage to the
cell plates or ionizing wires and cause excessive arcing and noise.

10

To wash cemmsand prefilter(s)

We suggest that you follow the instructions below to properly and

thoroughly clean your collector cells.

1. Place enough hot water in a utility tub to cover the first cell. Dissolve 2
to 4 oz. of granulated automatic dishwasher detergent (not laundry
detergent) in the water.

2. Allow the cell to soak for 30 minutes. Agitate it up and down in the
solution until it appears clean and remove.

3. Repeat with second cell.

4. Agitate the prefilters up and down in the solution until they appear
clean.

5. With a hose, rinse the cells and prefilters. The hose should be held
about 10" from the cell plates and at a slight angle for better cleaning

results. Be careful not to spray the ionizing wires directly with the

hose. The water pressure can cause the wire to snap and break. The
cell frame should be thoroughly rinsed along the edges to dislodge
any trapped lint or dirt. Carefully wipe a damp cloth or sandpaper (not
emery cloth) along the ionizing wires.

6. Stand cells and prefilters up to drain. Let dry two hours. You may
experience a slight discoloration of the aluminum collector cells after

washing. This is a normal chemical reaction and will not harm your

unit or affect its performance.

To replace celms in air cleaner

1. Replace prefilter and cells in cabinet. Check that arrow on cells points

in same direction as air flows through the duct. (If you have to force it
past the positioning screw on bottom, it is probably in the wrong
position.)

2. Replace access door (engage tabs on lower edge of door into slots in
cabinet). Carefully close door.

3. Turn air cleaner switch to ON.

11

COMMON TROUBLESHOOTING TECHNIQUES

SYMPTOM

Rapid arcing or zapping

Excessive ozone smell

Excessive ozone smetl

Hissing or sizzling noise

Green LED light is not ON

Red LED light is not ON

POSSIBLE CAUSES

Broken or toose ionizing wire(s)

Dirty ionizing-collector ce_l

Damaged or bent collector p_ates

Dirty inst_lator caps on ionizing-
collector cell

Air cleaner is wired directly to a

120V power source

Loose high voltage connections

Radio or tetevision interference

Poor electrical contact

No power available

Loose widng at ON/OFF switch

Defective ON/OFF switch

ON/OFF switch not in ON position

Loose wiring within power pack
assembly

Broken or shorted electdca_
component

Excessive dirt build up on ionizing

wires

CORRECTIVE ACTION

Remove broken or loose wire and
replace with new wire

Clean as outlined on page 10-11

Straighten prates with needlenose
pliers or replace entire ionizing-

collector ceil.

Clean with warm soapy water and
rinse weE_

Qualified HdAC contractor must
instafi AFS or rewire air cleaner

To the HdAC system blower

Repair or replace the component

Uncommon occurance --
check for good common ground

for air c_eaner

Ensure that there is a good
connection between the top of
the ionizing-collector cell and the

bottom of the contact board
assembly

Contact HdAC contractor

Reset circuit breaker
Replace fuse

Check for secure connectior_

Replace ON/OFF switch

Turn the unit ON

Check for secure connections
Contact HVAC contractor

Contact HdAC contractor

Clean wires with alcohol and
allow to dry thoroughly before

turning the ur_it ON

Contact board assemblies are Replace contact board assembly
corroded or carbonized

Broken ionizing wire Remove broken wire and replace

with new wire

Dirty ionizing-collector cell Clean as outlined on page 10-11

Foreign object located between Remove object from ionizirlg-
collector plates collector ceil

Damaged or bent collector plates Straighten with a pair of needle-

nose pliers or replace cett

Insulators are corroded or
carbonized

Table 1

12

Replace insulators or ionizing-
co,rector cet_

UNiT D_MENS_ONS =All dimens{ons in inches (ram)

EACA

Inches MM Inches MM Inches MM Inches MM Inches MM Inches MM Inches MM

0020 24-!/4 6!6 !7-7/8 453 20-!5/16 531 22-1/2 572 24-7/8 632 7-!/8 18! 21-7/16 545

0014 20-!/4 5!4 !3-7/8 352 !6-!5/16 429 22-1/2 572 24-7/8 632 71/8 18! 21-7/16 545

2020 24-!/4 6!6 !7-7/8 453 20-!5/16 531 19 483 21-3/8 543 7-!/8 18! !8-5/8 473

13

Only a trained, experienced serviceman
should install this electronic air cleaner.

A thorough checkout of the unit installation

should be completed before unit
operation. Electrical shock can cause
sedous injury or death.

14

TECHNICAL SPECiFiCATiONS

(Specifications subiect to change without notice.)

MODEL NUMBER-EACA 0014 0020 2020

DIMENSIONS (IN) 20 1/4 x 7 1/8 x 24 7/8 24 1/4 x 7 1/8 x 24 7/8 24 1/4 x 7 1/8 x 2! 3/8

AIR FLOW SENSGR INSTALLED NQ NO YES

ELECTRICAL INPUT !20V, 60 Hz, 1 PH !20V, 60 Hz, 1 PH 240V, 60Hz, 1PH

MAXIMUM RATED AIR FLOW 1400 CFM 2000 CFM !400 CFM

(2380 m_/hr.) (3400 m3/hr.) (2380 mhr)

MAXIMUM PRESSURE DROP ,11 inch w.g. ,14 inch w.g. ,11 inch w.g.

@! 400 CFM @ 2000 CFM @ ! 400 CFM

CELL WEIGHT (2 CELLS IN EACH UNIT) !0 Ibs. each !2 Ibs. Each 9 Ibs. Each

(4,45 kg) (5,45 kg) (4,!0 kg)

UNIT WEIGHT 32 Ibs 361bs 36 Ibs.

(14,6 kg) (!6.4 kg) (! 6,4 kg)

MAXIMUM POWER CONSUMPTION 40 watts 48 w_[ts 40 watts

ELECTRICAL OUTPUT 2.5mADC 3.2 mADC 2.5 mADC

@ 6200 kVDC @ 6200 kVDC @ 6200 kVDC

CLASSIFICA-[IQN UL/CUL UL/CUL UWCUL

15

TYPICAL MOUNTING POS_T_ONS

Shaded illustrations are for positioning use only

BASEMENT FURNACE
(LOWBOY)

Mounted horizontally in return
plenum -iust above the furnace

COUNTERFLOW FURNACE
Mounted horizontally in return

duct -iust above the furnace

SPACE SAVER FURNACE
(HIGHBOY)

Side installation. Cleaner is
mounted vertically, where

return air enters side inlet of

furnace.

_AIR CLEANER

OFFSET INSTALLATION

Ifthere is less than 7qn. for mounting the air cleaner
between the duct and the furnace, move the return air drop.

SPACE SAVER (HIGHBOY)
Installation beneath furnace. Cleaner

mounts horizontally, where return air
enters from below. Raise furnace by

installing a suitable wood structure and
install air cleaner.

HORIZONTAL FURNACE
Mounted vertically in return duct as close to

the furnace as possible

16

PLANN1NG TH E 1NSTALLATION

Application
The air cleaners are used in forced air heating cooling and ventilating systems. The

air cleaner should be installed in the system so that all the system air is circulated
through the air cleaner. The air cleaner will only remove the airborne contaminants

delivered to it. Maximum performance is obtained when the system blower is set for
continuous operation.

installation Requirements

The best location for the air cleaner is in the return air duct next to the blower

compartment, in this location, the blower motor and cooling coils will be kept clean.

DO NOT INSTALL THE AIR CLEANER

IN THE DISCHARGE AIR DUCT.

Before installingthe air cleaner, consider the application and type of HVAC system
present. Refer to the section entitled Typical Mounting Positions,

for the most common types if a transition between the ductwork and air cleaner is

required, refer to section entitled Transitions. The unit must be readily accessible

for periodic inspection and cleaning of the prefikers and electronic cells to maintain

maximum efficiency and trouble-free operation.

Air Conditioning
The air cleaner should be installed upstream of the cooling coil. This will keep the

coil clean and reduce air conditioning coil maintenance. Improved cooling
efficiency is the result and directly affects energy costs. A clean coil, will reduce

utility costs. If the air cleaner is downstream of the cooling coil, condensation will
form on the cooled collector plates when the air conditioner cycles. This will allow
water droplets to form on the collector plates and cause nuisance arcing. Arcing will

reduce air cleaner efficiency and reduce the life of the high voltage power supply.

Humidifiers

An evaporative humidifier can be mounted upstream of the air cleaner. It is best to

install an atomizing humidifier downstream of the air cleaner because hard water
salt deposits and water droplets may damage the air cleaner. If an atomizing

humidifier must be mounted upstream of the air cleaner:

1. Mount itas far upstream as possible. (Recommended at least 6 feet.)

2. Install a standard disposable furnace filter between the humidifier and
the air cleaner to trap water droplets and hard water salts.

3. Clean the air cleaner more frequently to prevent a hard water salt

buildup.

Outdoor Air

When outdoor air is added to the return air duct, sufficient heat should be added to

maintain the return air temperature at 40°F (4°C) minimum. Lower temperatures can
cause ionizer wire failure.

17

Atomizing Humidifiers
If an atomizing humidifier is installed, it must be mounted downstream of

the air cleaner.

1. Mount the humidifier as far downstream as possible. It is recommended a
distance of at least 10 feet to reduce the possibility of excessive arcing

as water droplets pass through the Electronic Air Cleaner.

2. Install a standard disposable furnace filter between the humidifier and

the air cleaner totrap water droplets and hard water deposits.

3. Clean the air cleaner more frequentlyto prevent a hard water buildup.

Sheet Metal _nstallation

The Electronic Air Cleaner is adaptable to all new or existing residential
forced air furnace and cooling systems.

Transitions
If the air duct does not fitthe air cleaner cabinet opening, gradual transitions

are recommended to reduce air turbulence through the air cleaner and
maximize efficiency. Not more than 20 °
(about 4" per running foot) of expansion

should be used on each side of the

transition fitting (Figure 4).

Outdoor Air
When outdoor air is added to the return air
duct, sufficient heat should be added to
maintain the return air temperature at 40°F

(4°C) minimum. Lower temperatures can
cause ionizer wire failure.

NR OL_NE_)

Figure 4

If the air cleaner is installed adjacent to a

90 ° duct elbow, add turning vanes inside
the duct to improve air distribution across
the face of the air cleaner (Figure 5).

Failure to follow the recommendation can

reduce the efficiency of the Electronic Air

Cleaner.

t-; .....

rlgu_e 5

18

SELECT LOCATION FOR A_R CLEANER

Remember to select a location that is readily accessible for periodic

inspection and cleaning of this air cleaner. Allow a minimum of 24"

clearance in front and 12" clearance above the air cleaner for component

removal and service space. For complete dimensions required refer to the

section entitled UNiT D_MENS_ONS.

DiRECTiON OFAIR FLOW THROUGH THE A_R CLEANER
This air cleaner is set up for left to right air flow when you are facing the

access door.

For right to left airflow, follow these directions:

1. Remove the prefilter(s) and cells from the
cabinet. A plastic positioning spacer is

located inside the bottom of the cabinet.
This spacer is secured to the cabinet using

a #6-32 round head Phillips drive thread
cutting screw to assure installation of the

cells in the proper position with respect
to airflow (Figure 6).

2. Remove the screw and reposition the
spacer in the alternate hole at the bottom of

the cabinet. Figure 6

3. Replace the screw to insure the plastic spacer is not accidentally
knocked out of place during normal maintenance. It must be installed in
the hole provided closest to the air leaving side of the cabinet. Seal the

unused hole with duct tape.

4. Remove the cell handle and reattach to the opposite end of the cell. Turn
cells around, replace in cabinet and replace prefilters on the air
entering side. The directional arrows on the cell end plates must point in

the direction of air flow.

19

_NSTALLAT_ON

PHYSICAL iNSTALLATiON OF THE AIR CLEANER

This Electronic Air Cleaner can be installed in any position, except with the
access door facing down. The section entitled TYPICAL MOUNTING

POSITIONS show examples of proper air cleaner mounting with a variety of

furnace installations.

Prior to installing this product...

1. Read rules and instructions carefully for safe operation. Failure to follow

them could damage the product or cause a hazardous condition.

2. Check the ratings given on the product to make sure it is suitable for your
application.

3. Select a location for the air cleaner.

4. Remove the old furnace filter and discard.

5. The air cleaner cannot remove existing dirt from the blower and ducts.
Clean the areathoroughly before you begin.

6. Remove unit access panel, and slide the prefilters and ionizing-collecting
cells out of the cabinet. Place them safely aside with the warranty and

registration card.
NOTE: The following is a typical installation of the air cleaner on a
highboy furnace. You may have to alter the installation to fit your
particular application.

2O

7. Locate the cabinet in the cold air return duct so that all of the return air
flows through the unit (Figure 6). If the furnace and air cleaner openings

are different, use atransition (Figure 4).

8_

Mounting holes are provided for
ductwork attachment (Figure 7). The

.140" holes are sized for #8 sheet
metal screws, or 1/8" rivets. If the
adjoining ductwork is flanged, install

the screws so that the screw heads

are inside the cabinet. This will prevent
damage to the prefilters

during removal and installation after

cleaning.

9. After the unit has been secured, seal
seams air tight with duct tape or

caulking.

Figure 7

ATTENTION: On Electronic Air Cleaners that have the air flow sensor

installed at the factory, be especially careful not to cover the air flow

sensor orifice when sealing the air cleaner and ductwork. This hole is

located on the right hand side of the enclosure that holds the power
pack assembly (when facing the unit). The hole is 3/16" in diameter and

is located on the front of the power tray assembly. In applications with
minimum air flow, it is helpful to seal any openings on the power tray
assembly or cabinet. This will increase the velocity of air flowing over the
air flow sensor, enabling the air flow sensor to turn the Electronic Air
Cleaner on and off. The only opening required for actuation of the

air flow sensor is the 3/16" diameter hole previously described.

10. Refer tothe section entitled D_RECT_ON OF A_R FLOW.

11. Install prefilters and ionizer-collector cells.

12. Reinstall power tray assembly intothe cabinet.

13. Reinstall unit access panel.

21

ELECTRICAL INSTALLATION

All wiring must comply with applicable local and national codes.

Be sure all incoming power is OFF before beginning any procedures.

The following instructions are for use by qualified personnel only.

The following procedures will expose hazardous live parts. Disconnect power between checks and

proceed carefully. Electrical shock can cause iniury or death.

The Electronic Air Cleaner (without the AFS installed at the factory) is designed to take advantage of the integrated
accessory control panel available on most furnaces. The 120V Electronic Air Cleaner tap on the furnace will provide

power to the air cleaner only when the circulating air blower is in operation,

Read the instructions in the furnace installation manual carefully before attempting installation or operation, Failure to

follow these instructions may result in improper installation and therefore void warranty

An optional(on 120v model) electronic air flow sensor kit is available if the air cleaner is not equipped with an AFS. This
air flow sensor will sense the air movement within the duct and turn the Electronic Air Cleaner on and off acco rdingly,

Figure 8

WIRING PROCEDURE
This air cleaner is powered by providing power to pigtail

leads at field wiring compartment (see knocbout holes)
located at the rear of the power pack assembly (See Fig.

8).
1, Turn air cleaner OFF using ON/OFF switch located on

front panel.

2, Remove power pack cover plate by removing front

door and two screws holding assembly to the top of
theair cleaner.

3, Make wiring connections inside junction box area

(See Fig. 8), Remove knock-out and use conduit or

other approved methods to supply input power
Connect groundwireto dip,

4, Replace the power supply cover plate and secure with

screws removed from step 2.

5. Replace the unit door to the front of the air cleaner.

6, Air cleaner will now operate when door is in place,

ON/OFF rocker switch is in the ON position and input
voltage is present in the junction box. The following

should be completed to supply input power to the air
cleaner.

FURNACE APPUCATION
It is recommended to use EAC 1 and EAC 2 terminals
when provided by the furnace circuit board, These

outputs will provide 120 vac whenever the blower motor
is energized.

Furnace circuit boards without EAC 1 and EAC 2
terminals MUST use alternate methods to supply to

supply power to the air cleaner. Options include Sail
Switch, Isolation relay or Optional AFS (Air Flow Sensor).

Air cleaner should only operate when blower motor is
running.

This unit cannot be powered directly from blower motor

leads. Voltages can exceed 190vac for 120 v, motors or
possibly double with 240 v fan coil motors,

FAN COIL APPLICATION of 0014 or 0020 Models (120-v.)
If EAC 1 and EAC 2 terminals are provided by fan coil

circuit board refer to fan coil data to determine voltage
output. Most fan coils do not provide 120w. at these

terminals, Alternate methods may be needed to convert
fan coil supply voltage to 120w. for the cManen A 240-v to

120w step down transformer (60 v.) will be needed in most
applications, Sail Switch, Isolation relay or Optional AFS

(Air Flow Sensor) may also be needed.
FAN COILAPPLICATION of 2020 Model (240-v.)

The Model 2020 is a 240 v. power supply model designed

to match your fan coil. To install this model with a 240-v. fan
coik

This unit cannot be powered directly from blower motor
leads. Back EMF (electro magnetic field) voltages can

reach 400vac for 240 v fan coil motors,

1, Turn air cleaner OFF using ON/OFF rocker switch

located on front panel.

2, Remove power pack cover plate by removing front

door and two screws holding assembly to the top of the
air cleanen

3, Make widng connections inside junction box area (See

Fig. 8). Remove knock out and use conduit or other
approved methods to supply input power Connect

ground wire to clip,

4, Replace the power supply cover plate and secure with

screws removed from step 2.

5. Replacethe unit door to the front of the air cleanen
6, Air cleaner will now operate when door in place,

ON/OFF rocker switch is in the ON position and input
voltage is present in the junction box,

22

SYSTEM CHECKOUT

1. The HVAC system blower should be turned OFR

2. Switch the ON/OFF rocker switch to the ON position. The bright red

segment of the rocker switch should be visible.

3. Inspect both the Green INPUT POWER light and the Red CELL

ENERGIZED light:

If the unit has an AFS installed, the lights should go out in
approximately 20 to 60 seconds. This is the normal time for the
electronic air flow sensor to complete its stabilization period. Both

lights will come back on when the HVAC system blower begins to
operate. See the section entitled HOW THE A_R FLOW SENSOR
WORKS for more information

o If the unit is wired directly to the HVAC system blower, the lights will not

come on until the blower begins to operate. In this case, the electronic
air cleaner will stay on as long as the ON/OFF switch is in the ON
position and the blower is operating.

o If the unit is wired directly to a dedicated 120V power source, the lights

will come on immediately and stay on for as long as the ON/OFF
switch is in the ON position, regardless of the HVAC system blower
operation. This type of installation is NOT recommended due to the
excessive production of ozone. See the section entitled FACTS YOU

SHOULD KNOW ABOUT YOUR ELECTRONIC AiR CLEANER -
OZONE for more information.

4. Wait approximately one (1) minute and turn the HVAC system blower

ON. Most thermostats have a setting that will allow you to run the fan
manually. If not, then set the thermostat so that either hot or cold air

begins to flow through the ductwork.

5. The Green INPUT POWER light and Red CELL ENERGIZED light should

come on, if the unit is wired directly to a dedicated 120V power source,

the lights will already be on and will not be affected by the HVAC system

blower operation (see Step 3).

6. Check to make sure that the Red CELL ENERGIZED light goes out when

the following conditions occur:

o Cell access panel is removed
o Rocker switch is switched to the OFF position
o HVAC system blower is not running.

23

TROUBLESHOOTING

Recommended Service Tools

* Screwdriver, 8" common with insulated handle (plastic)

Screwdrivers Phillips #1 and #2 with plastic insulated handles
Needle nose pliers

Multimeter

o High voltage probe

indication of Electrical Trouble

The air cleaner is equipped with a Red CELL ENERGIZED light for indicating

proper unit operation. When the unit is in normal operation (with the HVAC

system fan running, access door in place and rocker switch in the ON

position) and the Red CELL ENERGIZED light is not lit, the problem is a

shorted secondary. Although failure of the indicating light itself should not

be overlooked, this condition is unusual and rather remote.

24

PRIMARYC_RCU_TWiTHFURNACEBLOWEROPERATING

If there is supply line voltage at the connections and no input voltage to the
power supply, the outage can be located by checking operation of the

safety switch and the interconnecting wiring with a multimeter. Refer to
Circwt Diagram, (Figure 9) to check operation of the switches.

Following these steps to test for proper operation of the circwt board and
power supply assembly:

1. Ensure that the circuit breaker controlling the furnace blower is in the ON

position and the main fuse is not open.

2. The power supply board has a builtqn internal fuse to protect the 24V

transformer. It can be checked visually by inspecting the fuse. If the fine

wire inside the fuse is broken, tMs indicates a problem in the 24V circuit of

the power supply board. Do NOT replace this fuse. The entire power

supply board must be replaced. The purpose of the fuse is not to protect
the power supply board, but to function as a troubleshooting feature of
the product and to protect the transformer from damage.

3. If the fuse is NOT blown, check the ON/OFF switches and safety interlock
switch for proper engagement and operation. This can be completed

using a volt ohm millimeter on a scale that will measure ohms as low as

1.0. If you are using the recommended meter previously mentioned in
this manual, set the meter to read 200 ohm and proceed with Steps 4
through 6.

4. Remove the fuse. Connect one lead to the test pin located directly beside
the wire that connects the ON/OFF switch to the power supply board.

Connect the other lead to the fuse connection closest to the front panel.

5. Turn the ON/OFF switch to the ON position and depress the safety

interlock switch. The meter should have the capability of reading levels
as low as 1.0 ohm.

6. If there is no reading on the meter, begin the process of elimination by

disconnecting the wire from the test point and connecting it to the
terminal with the blue wire located on the safety interlock switch. Depress
the safety interlock switch. If the reading on the meter is greater than 1.0

ohm, the safety interlock switch is defective and must be replaced. If the

reading on the meter is less than 1.0 ohm, the ON/OFF switch is defective

and must be replaced.

25

SECONDARYCiRCUiT
IONIZmNG-COLLECTINGCELL

Thecelliselectricallyenergizedthroughacontactterminallocatedatthetopcenter

of thecell,Theionizingwiresand alternatingcollectorplatesareelectrically
chargedwhiletheinterleavingplatesaregrounded,

Ifthespacebetweenthechargedandgroundedplatesisbridgedwithconductive
orsemi-conductivematerial,ashortcircuitdevelops,Thebridgingorshortmaybe
causedby damagedplates,or foreign materiallodged between/onthe
components,Sincethecellshouldbeperiodicallyremovedfromtheunittowash
awaycollecteddirt itissusceptibletophysicaldamage,Thecellalsocontainsthe
ionizingwireswhich,dueto theirfunction,havebeendesignedwithminimal
structuralsupportandaresusceptibleto breakage,However,troublerelatedto a
shortedcollectorcellisreadilyshownbytheRedCELLENERGIZEDlightandcan
bequicklyisolatedbyasimpleprocedure,

Todetermineifashortexistsinoneorbothofthecollectorcells,turntheElectronic
AirCleanerOFFandremovebothelectroniccellsfromthecabinet,Shutthedoor

andrepowertheunit,IftheRedCELLENERGIZEDlightcomeson,anelectrical
shortexistsinoneorbothoftheelectroniccells,Replacethecellsintheunit,oneat

atime,todeterminewhichcellisshorted,
Mosttroublesinthecellcanbevisuallydetectedandcorrected(page12-Table 1),

NOTE: The ionizer collector cells are not designed for field repair, Ionizing wires and
insulators can be field replaced, It is not recommended that you attempt to replace
other cell components (i,e, Collector plates, end plates, ionizer supports),

EACA-0014 & 0020

W BL / Safe_yinl_d_cks_l_h

EACA-2020

2 ON _ OFF R_c_,_I _wi_h

I 240V 3 _0 VA S_#t_OWn /"r_l_fo_r_le_

i 4 HIg_ Frequ_:_ ,p_w_r_upply

_ontact Board _em_y

Figure 9A Figure 9B

26

CHECKING THE POWER SUPPLY

If the output light remains out with the collector cells removed from the
cabinet, the power supply is defective. Specific problems on the power tray

assembly can be isolated by using a mukimeter and high voltage probe to
check the output voltages.

To check the secondary circuit, a high voltage meter is required. See the

section entitled RECOMMENDED SERVICE TOOLS. To check for proper
operation, it is imperative that the procedure be followed as outlined below:

1. Make sure the furnace blower is operating, the control switch is on and
in put voltage is 120 volts, 60 Hz.

2. Remove front door assembly panel.

3. Remove power pack access cover.

4. Check the high voltage contact board assembly(s) for damage or carbon

tracking.

5. Make connections from the high voltage probe to the multimeter in
accordance with the operator's manual. The meter should be set for
reading DC voltage on the 20 volt full scale.

6. Attach the high voltage probe ground lead to the cabinet. While
depressing the safety switch lever, touch the ionizer wire support bar

with end of the high voltage probe (Figure 10). The meter reading should

be 6.2 kVDC _+.2 kVDC.

7. If no voltage is measured, remove the first cell and check the second cell.

The meter should read 6.2 kVDC _+.2 kVDC.

8. If proper vokage is measured, the first cell is shorted. Refer to Table 1, on
page 12.

27

g_

If no voltage is present, remove the second cell. Install cell number one
and measure voltage as described above. If voltage is present, the

second cell, which is now out of the cabinet, is shorted. Refer to Table 1

on page 12.

10. If no voltage is present, remove both cells and measure the power
supply output. While depressing the safety switch, touch the end of the

high voltage probe to either the front or rear contact board assembly
(Figure 10). The meter should read 6.2 kVDC or higher.

11. If no voltage is present, check the power supply. Set the multimeter for

reading AC voltage at 200 volt full scale and attach meter test leads.

12. While depressing the safety lever, touch the two transformer output lead
junctions to the power supply board with the meter leads and read the

meter.

13. If there is no output voltage from 24 volt transformer, replace the 24 volt
transformer and power supply board.

/ J

/ /

Figure 10

28

TROUBLE SHOOTING THE DUCT MOUNT ELECTRONIC AiR CLEANER

Is the unit operating?

Yes

Is red light on?

Yes

No

Is the furnace blower on?

,_yes

Is input AC power available? _

}yes

No

Is the safety interlock system OK? _'

t

No

Is ON/OFF switch working?

L Yes

N_r YesIs cell dirty or defective? _'

_No

No

Are contact boards OK? _'

,_yes

No

Is the power supply wiring OK? _'

Jryes

Yes

Is power supply defective? _'

_:No

Is transformer defective? t Y_s

Is cell crackling and snapping?

_NO

Is cetl sizzling?

29

WARNING:
The following steps will expose hazardous live parts. Disconnect power between checks

and proceed carefully.

1. Replace any blown fuses and reset any tripped breakers.

2. Repair or replace any loose wires or bad connections.

3. Inspect AFS for proper location and operation.

1, Check that the access door is not open or aiar.

2. Repair or replace any loose wires or bad connections.

3. Replace defective momentary contact switch.

4. Inspect AFS for proper location and operation.

1. Ensure that ON/OFF switch isturned ON.

2. Repair or replace any loose wires or bad connections.

3. Replace defective ON/OFF switch.

4. Inspect AFS for proper location and operation.

1, Remove anyobiects between adiacent collector plates.

2. Replace corroded or carbonized insulators.

3. Replace any broken ionizing wires.

4. Wash dirty cells..

1. Replace contact board if contacts are corroded and carbonized.

2. Replace any defective wires.

3. With alcohol, clean dirt build-up on contacts and let dry thoroughly.

I1. Repair or replace any loose wires or bad connections.

I1. Replace high frequency power supply.

defective

1, Replace power supply.

2. Replace transformer.

1. Wash dirty cell, including any powder build-up on ionizing wires.

2. Straighten any bent plates.

3. Replace any broken or loose ionizing wires.

1. Ensure good contact between cell and contact boards.
Replace defective contact boards..

- I Repe_t these

30

CONI"ACT

31

EACA PARTS UST

REE DESCRiPTiON NO.,

1. Power Tray Assembly (W/AFS) 120V

1A. Power Tray Assembly ON/AFS) 240V

1B. Power Tray Assembly (W!O AFS) 120V

2. High Frequency Power Supply

3. Electronic Air Flow Sensor (Optional)

4. ON/OFF Switch

5. interlock Switch

6. Cabinet Assembly

7. Pre-Filter (2/package)

8. Cell, Ionizing-Collecting

9. ionizing Wire Assembly (FullSet/package)

10 Front Panel Assembly

11. Contact Board Assembly (2/package)

12. Charcoal Filter (optional, not shown)(2/package)

13. Stepdown Transformer 120V to 24V (0014 & 0020)

13A. Stepdown Transformer 240V to 24V(2020)

14. insulator (6/package)

15. Cell Key (not shown)

16. Power Tray Cover

32

FhleoYear Mmited Warranty - This Product is warranted to be free from defects in material and

workmanship, lfDefect appearswithinFive years fromthedateoforiginalinstal]ation, whetherornotactuai

use begins onthat date, product is warranted. If product installation criteria meets this standard, a newor
remanufactured part, at the manufacturer's sole option, to replace any defective part will be provided

without charge for the part itself; PROVIDED the defective part is returned to the distributor through a
qualified servicing dealer.

Limited Labor Allowance - If service call on this unit must be made in the first 120 days from original date of
installation a $2500 (USD) labor allowance will be given. If Power Supply must be replaced in the first 120

days after original installation date a $50.00 (USD) labor allowance will be given.

THIS WARRANTY DOES NOT INCLUDE LABOR OR OTHER COSTS-OTHER THAN THAT SPECIFIED
ABOVE incurred for diagnosing, repairing, removing, installing, shipping, servicing or handling of either

defective parts or replacement parts. Such costs may be covered by a separate warranty provided by the

installer.

THIS WARRANT"/APPLIES ONLY TO PRODUCTS IN THEIR ORIGINAL INSTALLATION LOCATION AND

BECOMES VOID UPON REINSTALLATION.

MMITATIONS OF WARRANTIES ALL IMPLIED WARRANTIES (INCLUDING IMPLIED WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY) ARE HEREBY LIMlTED IN DURATION

TO THE PERIOD FOR WHICH THE LIMITED WARRANTY IS GIVEN. SOME STATES DO NOT ALLOW

LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE MAY NOT APPLY TO YOU.

THE EXPRESSED WARRANTIES MADE tN THIS WARRANTY ARE EXCLUSIVE AND MAY NOT BE
ALTERED, ENLARGED, OR CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON

WHATSOEVER.

ALL WORK UNDER THE TERMS OF THIS WARRANTY SHALL BE PERFORMED DURING NORMAL
WORKING HOURS. ALL REPLACEMENT PARTS, WHETHER NEW OR REMANUFACTURED, ASSUME AS

THEIR WARRANTY PERIOD ON LYTHE REMAINING TIME PERIOD OF THIS WARRANTY.

THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR:

1. Normal maintenance as outlined in the installation and servicing instructions or owners manual including
filter cleaning and/or replacement and lubrication.

2. Damage or repairs required as a consequence of faulty installation, misapplication, abuse, improper
servicing, unauthorized alteration or improper operation.

3. Failure to start due to voltage conditions, blown fuses, open circuit breakers or other damages due to the
inadequacy or interruption of electrical service.

4. Damage as a result of floods, winds, fires, lightning, accidents, corrosive environments or other

conditions beyond the control of the Manufacturer.

5. Parts not supplied or designated bythe Manufacturer, or damages resulting from their use.

6. Manufacturer products installed outside the continental U.S.A. Alaska, Hawaii, and Canada.

7. Electricity or fuel costs or increases in electricity or fuel costs from any reason whatsoever including
additional or unusual use ofsupplemental electric heat.

8. ANY SPECIAL INDIRECT OR CONSEQUENTIAL PROPERTY OR COMMERCIAL DAMAGE OF ANY

NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or consequential
damages, so the above may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which may vary from state
to state.

Part Number 155587-005, 1/03

Manufacturerreservesther}ghttodis¢ont}nue,orchangeat any time, specifications or designs w}thout notice and without incurring ob}igations.

Form No IM-EACA-01 Catalog No. 63EA-CA1 Pri_sted Jn U.S.A. 1-03 Replaces: EACA-1SI & II EACA-14-1