Honeywell 208414, 208415 Installation Instructions Manual

Page 1

208414, 208415 Replacement Power Supply

Kit for Electronic Air Cleaner

INSTALLATION INSTRUCTIONS

APPLICA TION

These kits replace the power supplies with W8600E solidstate performance indicators (SSPI) used in the F50F and F58F Electronic Air Cleaners. See Table 1.

NOTE: The W8600E Remote Performance Indicator

driver circuit board has been calibrated with the power supply in this kit. False wash indications will occur if used with a different power supply.

Table 1. Power Supply Replacement Guide.

Nominal Size

(in.) (mm)

F50F 120 Vac, 60 Hz 16 x 20 406 x 508 1.33 208414G

16 x 25 406 x 635 1.65 208414B 20 x 20 508 x 508 1.65 208414B 20 x 25 508 x 635 2.10 208414A 20 x 12-1/2 508 x 318 1.05 208414C

220/240 Vac, 50/60 Hz

F58F 120 Vac, 60 Hz 20 x 25 508 x 635 2.10 208414A

20 x 12-1/2 508 x 318 1.05 208415C

NOTE: Use the 120 Vac replacement power supply

indicated in Table 1 when servicing the F50F or F58F electronic air cleaners which have been modified with the 203365A transformer kit to operate at 220/240 Vac.

Ionizer Current Replacement Power Supply

(mA) (OS No.)

INST ALLATION

When Installing this Product…

1. Read these instructions carefully. Failure to follow

them could damage the product or cause a hazardous condition such as electrical shock.

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

3. Installer must be a trained, experienced service technician.

4. After installation is complete, check out product operation as provided in these instructions.

W ARNING

ELECTRIC SHOCK HAZARD. SAFETY HAZARD. CAN CAUSE ELECTRICAL SHOCK OR EQUIPMENT DAMAGE

Disconnect power before removing old power supply board and installing replacement power supply board.

T o Remove Old Power Supply Board

NOTE: It is advisable to observe the location of

leadwires to be replaced on the power supply. Tag the leadwires as they are removed to help you correctly reconnect them.

■■ Open access door. See Fig. 1.

■■ Open power box.

X-XX UL

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

REMOVING COVER FROM POWER BOX.

M5676A

Fig. 1. Remove cover from power box.

■■ Disconnect the leads from 1, 2, 3, 4, P1, P2, P3, P4,

P5, P12, P14, P17, P18 and P21 on the old power supply. See Fig. 2 through 5.

Install New Power Supply

■■ When replacing the power supply, reuse the remain-

ing leadwires in the air cleaner when removing the old power supply.

■■ Install W8600E terminal block and wiring supplied

with this kit using screws previously removed.

■■ Align the mounting holes and mount the new power

supply in the air cleaner, using the sheetmetal screws removed earlier. Orient the power supply so P1 and P2 are toward the front (closest to the switch and neon light).

■■ Route the remaining leads so the P3 and P4 leads

are separate from the low voltage leads. Route all high voltage leads around, rather than over, the power supply board. Low voltage leads can go over the power supply board.

■■ Connect leads to the terminals on the new power supply.

IMPORTANT

■■ Plug the electronic air cleaner directly into the correct

NOTE: To reduce the risk of electric shock, this product

Do not splice ionizer and collector leads. These leads must be unbroken to avoid electrical shock through the connector or tape covering the splice.

voltage and frequency outlet or reconnect power for directly wired devices. See Fig. 3 or 4 for internal schematic. The air cleaner will operate properly at any fan speed on a multispeed or modulated speed system wired with conduit or plugged in.

has a grounding type plug that has a third (grounding) pin. This plug will only fit into a grounding type power outlet. If the plug does not fit into the outlet, contact a qualified electrician to install the proper outlet. Do in any way.

not

change the plug

POWER SUPPLY

M5764

Fig. 2. Power supply location on F50F and F58F.

■■ Remove and discard W8600E terminal block and

wiring. Set aside screws for future use.

■■ Remove and set aside the sheetmetal screws holding

the board in place.

■■ Discard the old power supply.

CHECKOUT

CA UTION

The following instructions are for use by qualified personnel only.

With all components in place, turn on the air cleaner switch and energize the system blower. Check the following points of operation:

1. The neon light next to the on-off switch is on. If a W8600E is part of the installation, check the wall panel and make sure the ON LED is lit. The W8600E CHECK LED will come on if there is a problem with the high voltage power supply.

2. Turn off the system blower. The neon light should go off after a few seconds. The neon light shows that the air cleaner is energized and the high voltage power supply is working properly.

3. Turn on the system blower. With the air cleaner energized, push the test button. A snapping sound indicates that the collector voltage is present on the cell. The W8600E CHECK LED will come on when the test button is held down.

4. With a multispeed blower, repeat steps 1 through 3 for each fan speed.

5. If operation is not as described, refer to the Troubleshooting and Service section.

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

INTERNAL SCHEMATIC FOR ELECTRONIC AIR CLEANER WITH W8600E.

BLACK COLLECTOR

RED IONIZER

BLACK

P12

P21

TERMINAL STRIP

FRONT BACK

TO W8600E WALL PANEL

1 INTERLOCK SWITCH. 2 OUTPUT REDUCTION JUMPER. 3 AIRFLOW SWITCH DISABLE JUMPER. 4 RESISTOR FOR W8600 WASH INDICATION THRESHOLD. PRESENT ON POWER

SUPPLIES MANUFACTURED WITH DATE CODE 9430 AND EARLIER. 5 ONE-CELL UNIT SIMILAR, BUT WITH JUST ONE CELL. 6 P1, P2 TERMINALS ON 120V MODELS ONLY. POWER CONNECTIONS ON 240V MODELS ARE TO QUICK-CONNECTS ON POWER

SUPPLY TRANSFORMER. BROWN LEAD GOES TO TOP TERMINAL AND BLACK LEAD TO BOTTOM TERMINAL.

P17

BLACK

P18

R43

P14

POWER SUPPLY

BLACK

GREEN

BROWN

BLACK

RED

ORANGE

GRAY

VIOLET BLACK

WHITE

TEST BUTTON

BLACK

W4 W2 W1 W3

GREEN

AIRFLOW SWITCH BOARD

CONTACT BOARD

M15096

Fig. 3. Internal schematic for F50F and F58F Electronic Air Cleaner with W8600E.

BLACK COLLECTOR

BLACK

BLUE

RED

YELLOW

GREEN

1 INTERLOCK SWITCH. 2 SHORTING BAR. 3 AIRFLOW SWITCH DISABLE JUMPER. 4 W8600E REMOTE PERFORMANCE INDICIATOR DRIVER. 5 NEON LIGHT.

5 3 2 1

E4 E3

ORANGE

GRAY

VIOLET

BLACK

W4 W2 W1 W3

AIRFLOW SWITCH BOARD

POWER SUPPLY

P1 BLACK

RED IONIZER

BROWN

RED

BLACK

Fig. 4. Retrofitted schematic for F50F and F58F Electronic Air Cleaner with W8600E.

TEST BUTTON

BLACK

CONTACT BOARD

WHITE

GREEN

M15097

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

BLACK COLLECTOR

BLACK

TEST BUTTON

RED IONIZER

BLACK

RED

CONTACT BOARD

E4 E3

BLUE

RED

YELLOW

GREEN

1 INTERLOCK SWITCH. 2 SHORTING BAR. 3 AIRFLOW SWITCH DISABLE JUMPER. 4 W8600E REMOTE PERFORMANCE INDICIATOR DRIVER. 5 TOP TERMINAL ON TRANSFORMER 6 INPUT POWER. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. 7 NEON LIGHT.

5 3 2 1

Fig. 5. Retrofitted schematic for 220/240 Vac F50% Electronic Air Cleaner with W8600E.

TROUBLESHOOTING AND SERVICE

W ARNING

ELECTRIC SHOCK HAZARD. CAN CAUSE PERSONAL INJURY OR EQUIPMENT DAMAGE.

The following procedures expose hazardous live parts. Disconnect from power between checks and proceed carefully. These instructions are only for use by qualified personnel.

Tools And Equipment

Troubleshooting the electronic air cleaner requires:

• Needle nose pliers for stringing ionizer wires and inserting edge connectors.

• Test meter.

Although a meter is needed for some steps, the primary diagnostic tools are the See Fig. 6.

neon light

and the

test button

ORANGE

GRAY

VIOLET

BLACK

W4 W2 W1 W3

AIRFLOW SWITCH BOARD

Test Button

When pushed, the to ground. The resulting arcing sound indicates that high voltage is being supplied to the collector. The solid state power supply controls current flow to the collector. On air cleaners with a W8600E, the CHECK LED will come on when the

BROWN

BLACK

test button

BLACK

test button

is held down.

BLACK

GREEN

WHITE

BLACK

L1 L2

220/240V 50/60 Hz

M15098

shorts from collector voltage

COLLECTOR TERMINAL

IONIZER TERMINAL

COLLECTOR TERMINAL

Neon Light (On Power Box)

The neon light is powered through the power supply and is on when the power supply output voltage is normal.

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M6155

Fig. 6. Use an ohmmeter to check the electronic cells

for short circuits.

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

Check Led (Air Cleaners With W8600E)

The CHECK LED is on the W8600E. It lights to indicate the following problems: excessive dirt loading (beyond that required to activate the WASH LED), partial shorting

The solid state power supply assembly has no field serviceable components. If troubleshooting indicates a power supply or solid state performance indicator problem, replace the entire power supply assembly.

of the collector, continuous ionizer or collector arcing, power supply failure, excessive ionizer current, or any condition causing a major reduction in high voltage.

Troubleshooting Procedure

The electronic air cleaner Troubleshooting chart shows how to quickly isolate an air cleaner problem. The primary

Power Supply

diagnostic tools are the Some steps require a meter. See Fig. 7.

W ARNING

ELECTRIC SHOCK HAZARD. CAN CAUSE PERSONAL INJURY.

Always turn off power and remove access door before removing the power box or its cover.

TROUBLESHOOTING AIR CLEANERS WITH SOLID STATE PERFORMANCE INDICATOR.

START

MAKE SURE ELECTRONIC CELL(S) ARE CLEAN, DRY AND PROPERLY INSTALLED. MAKE SURE PREFILTER(S) ARE IN CABINET SLOT FARTHEST FROM FURNACE.

TURN ON ELECTRONIC AIR CLEANER AND SYSTEM FAN.

TO USE THIS CHART:

FOLLOW THE STEPS IN ORDER; DO NOT SKIP AROUND.

EACH TIME YOU ISOLATE AND FIX A PROBLEM, GO BACK TO START.

REPEAT ALL THE STEPS UNTIL THE AIR CLEANER CHECKS OUT OK.

THESE SERVICING INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL ONLY. TO REDUCE RISK OF ELECTRIC SHOCK, DO NOT PERFORM ANY SERVICING OTHER THAN CONTAINED IN THE OPERATING INSTRUCTIONS UNLESS YOU ARE QUALIFIED TO DO SO.

neon light

and the

WARNING

RISK OF ELECTRIC SHOCK

test button

CHECK NEON LIGHT.

CORRECT WIRING.

WIRING NOT OK

CHECK WIRING BETWEEN W8600E AND AIR CLEANER. USE MAX NO. 18 4-WIRE THERMOSTAT CABLE CONNECTED 1(G) TO 1(G), 2(Y) TO 2(Y), 3(R) TO 3(R), AND 4(B) TO 4(B).

WIRING OK

REPLACE W8600E.

FOR POWER SUPPLY REPLACEMENT, SEE FORM 69-0776.

W8600E HAS THREE LIGHT-EMITTING DIODES (LEDS): ON, WASH, AND CHECK.

W8600E OPERATION CAN BE CHECKED SEPARATELY. SEE W8600E INSTRUCTIONS.

PUSH TEST BUTTON AND LISTEN FOR SNAPPING SOUND.

OFF

CHECK ON LED IN W8600E

OFF

DEPRESS AND HOLD DOWN TEST BUTTON. CHECK LED IN W8600E SHOULD COME ON

TURN OFF AIR CLEANER AND REMOVE CELL(S) ONLY (NOT PREFILTERS). CLOSE ACCESS DOOR AND TURN ON AIR CLEANER.

WASH LED IN W8600E SHOULD COME ON.

OFF

ELECTRONIC AIR CLEANER AND W8600E ARE OK.

YES

Fig. 7. Troubleshooting air cleaners with solid-state performance indicator.

PUSH TEST BUTTON

OFF

AND LISTEN FOR SNAPPING SOUND.

TURN OFF AIR CLEANER AND REMOVE CELL(S) ONLY (NOT PREFILTERS). CLOSE ACCESS DOOR AND TURN ON

AIR CLEANER.

CHECK NEON LIGHT.

INSPECT CELL(S) FOR:

BENT COLLECTOR

• PLATES BROKEN IONIZER

• WIRES DIRT ON INSULATORS

• DAMAGED IONIZER

• OR COLLECTOR CONTACT TABS

YES

REPAIR OR REPLACE CELL(S).

WITH OHMMETER, CHECK FOR SHORT BETWEEN:

••CELL FRAME AND IONIZER SECTION CELL FRAME AND COLLECTOR SECTION

CELL SHORTED

REPLACE CELL.

CELL OK.

YES

OFF

INFINITE RESISTANCE

REPLACE LIGHT ASSEMBLY.

WARNING

THIS STEP EXPOSES DANGEROUSLY HIGH VOLTAGE. ONLY A QUALIFIED SERVICE TECHNICIAN SHOULD ATTEMPT THIS STEP.

CHECK FOR CORRECT INPUT VOLTAGE ACROSS P1 AND P2 TERMINALS ON POWER SUPPLY.

FIX WIRING.

TURN OFF AIR CLEANER, REPLACE CELLS(S) AND DISCONNECT FOUR W8600E LEADS AT AIR CLEANER. REPLACE ACCESS DOOR.

TURN ON AIR CLEANER. PUSH TEST BUTTON AND LISTEN FOR SNAPPING SOUND.

REPLACE POWER BOX OR POWER SUPPLY.

AIR CLEANER OK. TURN OFF AIR CLEANER AND RECONNECT W8600E LEADS 1(G) TO 1(G), 2(Y) TO 2(Y), 3(R) TO 3(R), AND 4(B) TO 4(B).

YES

M5609E

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

Modification To Reduce Ozone Odor

W ARNING

ELECTRIC SHOCK HAZARD. CAN CAUSE PERSONAL INJURY.

Always disconnect power before opening the power supply cover.

The electronic air cleaner generates a small amount of ozone in normal operation. During the first or second week of operation, the amount may be higher because of sharp edges on some of the new high voltage metal parts. Normal use quickly dulls these edges.

The average person can detect the odor of ozone in concentrations as low as 0.003 to 0.010 parts per million (ppm). The electronic air cleaner contributes 0.005 to

0.010 ppm of ozone to the indoor air. The U.S. Food and Drug Administration and Health and Welfare Canada recommend that indoor ozone concentration does not

outdoor

exceed 0.050 ppm. As a comparison, the level in major cities is sometimes as high as 0.100 ppm.

However, if desired, the ozone generated by the air cleaner can be reduced in one of two ways:

ozone

1. Install an activated carbon filter downstream from the air cleaner. Make sure particles from the air filter cannot fall into the air cleaner.

W ARNING

ELECTRIC SHOCK HAZARD. CAN CAUSE PERSONAL INJURY.

Only a trained service technician should perform the following procedure.

2. This will reduce ozone production about 20 to 25 percent and reduce efficiency about seven to ten percent, depending on actual airflow delivered by the furnace blower.

a. Unplug or disconnect power supply to the air

cleaner. b. Open the access door. c. Remove the power box cover. See Fig. 1. d. Locate J5 shorting bar on the power supply.

See Fig. 8. Remove the shorting bar and

reinstall on only one pin.

NOTE: The ozone will be reduced, but the shorting

bar is available for reinstallation if needed.

e. Replace the power supply cover and access

door. Turn on the power. f. Repeat the checkout procedure before leaving

the job.

J5 SHUNT IN OZONE REDUCTION POSITION

J5 IN NORMAL POSITION

E4 E3

M15099

Fig. 8. Move J5 shorting bar to reduce ozone production about 20 to 25 percent.

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

LIMITED TWO-YEAR WARRANTY

Honeywell warrants this product to be free from defects in the workmanship or materials, under normal use and service, for a period of two (2) years from the date of purchase by the consumer. If, at any time during the warranty period, the product is defective or malfunctions, Honeywell shall repair or replace it (at Honeywell’s option) within a reasonable period of time.

If the product(s) is defective, please contact:

a) the dealer from whom you purchased it, or b) the local Honeywell Authorized Repair Station, or c) the local Honeywell Home and Building Control Office, or d) the Honeywell Customer Assistance Center toll free at 1-800-468-1502, or e) package the defective cell, power supply or other component with care, along with a bill of sale, receipt, or other

dated proof of purchase, and a short description of the malfunction, and ship it, prepaid, to the following address:

Honeywell, Inc. Return Goods Department 1050 Berkshire Lane Plymouth, MN 55441-4437

This warranty does not cover removal or reinstallation costs. This warranty shall not apply if it is shown by Honeywell that the defect or malfunction was caused by damage that occurred while the product was in the possession of a consumer.

Honeywell sole responsibility shall be to repair or replace the product within the terms stated above. HONEYWELL SHALL NOT BE LIABLE FOR ANY LOSS OR DAMAGE OF ANY KIND, INCLUDING ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING, DIRECTLY OR INDIRECTLY, FROM ANY BREACH OF ANY WARRANTY, EXPRESS OR IMPLIED, OR ANY OTHER FAILURE OF THIS PRODUCT. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation may not apply to you.

THE WARRANTIES SET FORTH HEREIN ARE EXCLUSIVE, AND HONEYWELL EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, IMPLIED OR STATUTORY, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF MERCHANTABILITY, WORKMANSHIP, OR FITNESS FOR A PARTICULAR PURPOSE.

This warranty gives you specific legal rights, and you may have other rights which vary from state to state. If you have any questions concerning this warranty, please write our Customer Assistance Center, Honeywell Inc.,

P.O. Box 524, MN27-2164, Minneapolis, Minnesota 55440-0524 or call toll-free at 1-800-468-1502, Monday-Friday, 7:00 a.m.-5:30 p.m. Central time. In Canada, Honeywell Limited/Honeywell Limitee, 155 Gordon Baker Road, North York, Ontario M2H 3N7.

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208414, 208415 REPLACEMENT POWER SUPPLY KIT FOR ELECTRONIC AIR CLEANER

Home and Building Control

Honeywell Inc. Honeywell Plaza P.O. Box 524 Minneapolis, MN 55408-0524

69-1136—1

69-1136—1 J.H. Rev. 11-97

Home and Building Control

Honeywell Limited-Honeywell Limitée 155 Gordon Baker Road North York, Ontario M2H 3N7

Printed in Mexico