Carrier EACA 0014, EACA 2020, EACA 0020 Manual For Installation, Operation & Maintenance

EACA

Electronic Air Cleaner

Sizes 0014, 0020, & 2020

Installation • Operation • Maintenance

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

Exercisetheusualprecautionswhenworkingwithhighvoltage.

Form# EACA-1SI/IIEACA-14-1 Date 07/02

Manual for:

Table of Contents Page

SafetyConsiderations&Introduction1

Unitspecifications2

Facts you should know about your new Electronic Air Cleaner

1) Regular dusting & "white dust" 4

2) Ozone 4

3) Air flow sensor operation 5

4) High altitude applications 6

Replacing the ionizing wires 7

CommonQ&A 8-9

Maintenance of your Electronic Air Cleaner 10

1) Removing the cells and prefilter 10

2) Washing the cells and prefilter(s) 11

3) Replacing the cells and prefilter(s) 11

Common troubleshooting techniques 12

Installation instructions ( for use by authorized HVAC
contractors) 15-29

Technicaltroubleshootingflowchart29-30

Replacementpartlist 31-32

List of figures Page

Figure 1 Air flow sensor diagram 5

Figure 2 Reducing ozone in high altitude applications 6

Figure 3 Cleaning the ionizing-collector cells 10

Table 1 Symptoms of excessive arcing or zapping 12

Unit dimensions 13

Technical specifications 15

Typical HVAC system configurations 16

Figure 4 Sheet metal transitions 18

Figure 5 Turning vanes from improving air flow 18

Figure 6 Proper installation of cell spacer 19

Figure 7 Proper mounting diagram 21

Figure 8 Wiring the unit to the input power source 22

Figure 9 Electrical schematic diagram 26

Figure 10 Testing the power supply output 28

Troubleshooting flowchart 29-30

Unitpartsdiagram 31-32

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 attachedto 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 words and These
words are used with the safety alert symbol. identifies the most

DANGER, WARNING, CAUTION.

DANGER

serious hazards which will result in severe personal injury or death.

WARNING could
CAUTION would

personal injury or product and property damage. is used to highlight

signifies a hazard which result in personal injury or death.

is used to identify unsafe practices which result in minor

NOTE

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.

1

INTRODUCTION

This electronic air cleaner is technically known as a two-stage electrostatic
precipitator. The air cleaner is designed to remove airborne particulates,
including dust, dirt, smoke, pollen, virus, spores, bacteria and mold, from indoor
air.

Air movement through the unit is provided by the heating, air conditioning or
ventilating system blower. As dirty air enters the air cleaner, the air passes
through a metal mesh prefilter.Theprefilter prevents lint, pet hair and other large
particulates from entering the air cleaner. It its important that these filters be in
place to prevent excessive dirt loading of the air cleaner collector cells. These
filters extend the time between maintenance of the air cleaner collector
cells.This allows the ionizing-collector cells to provide clean air for a longer
period between washings.

The prefiltered air then passes through a two-stage Electronic Air Cleaner. In the
first stage, all airborne particulate, even submicron size, are electronically
charged (positive) as they pass through the ionizer. The ionizer field is set up by
a corona discharge emanating from the fine, tightly strung wires suspended
between two adjacent flat plates. In the second stage, the charged particulate
passes through an intense electrical field established between alternately
charged and grounded parallel collector plates. Here, the positively charged
particulate is attracted to the negatively ground plates and removed from the air
stream.

For a unit diagram and a completelistingofallparts,pleasesee page 31-32.

2

UNIT SPECIFICATIONS

This air cleaner is easy to install, operateand maintain. Its basic components
are the:

Cabinet

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

Ionizing-Collector 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 of the 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. A
power cord at the rear of the tray allows the unit to be connected to a
standard 120V outlet. A wiring compartment isprovided at the rear ofthe tray
allowing the option to permanently wire the unit directly to a furnace control.

Air Flow Sensor (AFS)

Installed on certain models, this part controls the operation of the unit by
sensing the movement of air within the duct. This helps to reduce power
usage and prevents the possible buildup of ozone within the duct.

How to Identify Which Air Cleaner Model youown

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 a ten (10) digit number.

3

FACTS YOU SHOULD KNOW ABOUT YOUR 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.

4

How the Air Flow Sensor Works (available on specific models)

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°F. The AFS then stabilizes at
this temperature and when the furnace blowerturns on andair 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 understandthat the furnace bloweris 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 grey disc, cleaning this coating from
the thermistor.

AFS TROUBLESHOOTING

It is recommended that the following procedure only be performed
by an authorized HVAC contractor. Failure to do so may expose an
individual to personal injury

1. Make sure the furnace blower is not operating, the rocker switch
is OFF and the circuit breaker is turned OFF or cord is
disconnected.

2. Remove the access door.

3. Remove power tray assembly.

4. Locate the AFS. It is a circuit board with a small grey disc
connected to the circuit board by two(2) silver wires (similar to
Figure 1). Carefully bend the thermistor so that it is located in the
center of the opening and approximately 1/8" from the inside edge
of the power pack assembly.

5. Reinstall the power tray assembly and access door.

5

High 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. Disconnect cordor turn off circuit 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 jumper 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 withthe 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 atthe factory with the jumpersset 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.

6

REPLACING THE IONIZING 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 reduce the 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 remainsof 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 by the 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.

7

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, manyfactors 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 get to 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 cleanerisn'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 allows 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 I hear 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.

8

Q. What if I no 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. If the 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. If the 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.

9