Carrier Airaaxcc20a Owners Manual
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AIRA Electronic Air Cleaner Installation, Start-Up, and Operating Instructions NOTE:Read the entire instruction manual before starting the installation. TABLE OF CONTENTS Page SAFETY CONSIDERATIONS...................................................1 INTRODUCTION.....................................................................1-2 PLANNING AN INSTALLATION........................................2-3 · Application...................................................................................2 · Installation Requirements ............................................................2 · Air Conditioning..........................................................................2 · Humidifiers ..................................................................................3 · Outdoor Air .................................................................................3 · Sheet Metal Installation...............................................................3 · Transitions ................................................................................3-4 · Turning Vanes ..........................................................................3-4 · Select Location .........................................................................3-4 · Direction of Airflow Through Air Cleaner ................................3 INSTALLATION......................................................................3-7 · Orientation ...............................................................................3, 5 · Details ..........................................................................................5 · Typical Mounting Positions ........................................................5 · Electrical Installation ..............................................................5, 7 · Furnace Application ....................................................................7 · Fan Coil Application ...................................................................7 SYSTEM CHECKOUT............................................................7-8 MAINTENANCE..........................................................................8 · Washing Cells and Prefilters.......................................................8 TROUBLESHOOTING.........................................................8-11 · Recommended Service Tools ..................................................8-9 · Indication of Electrical Trouble ..................................................9 · Electrical Troubles and Their Conditions .............................9-11 ADDITIONAL CHECKOUT PROCEDURES.......................11 OTHER FACTS YOU SHOULD KNOW.........................11-15 · White Dust .................................................................................11 · Ozone....................................................................................11-12 · High Altitude Operation ................................................12-13, 15 · Airflow Sensor (optional) ....................................................12-13 SAFETY CONSIDERATIONS Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock or other condi- tions 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 pack- aged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warning or cautions attached to the unit. Consult local building codes and National Electrical Code (NEC) for special require- ments.It is important to recognize safety information. This is the safety-alert symbol . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand the signal words DANGER, WARNING, and CAU- TION. These words are used with the safety-alert symbol. DAN- GER identifies the most serious hazards whichwillresult in severe personal injury or death. WARNING signifies hazards which couldresult in personal injury or death. CAUTION is used to identify unsafe practices whichwouldresult in personal injury or product and property damage. INTRODUCTION The AIRA is a duct mounted electronic air cleaner available in 1400 and 2000 CFM models. (See Fig. 1.) Designed to remove airborne particles down to 0.01 microns in size, the AIRA effectively removes such particles as dust, dirt, smoke, pollen, virus, spores, bacteria, and mold from indoor air. Air movement through unit is provided by heating, air condition- ing, or ventilating system blower. As dirty air enters air cleaner, air passes through a metal mesh prefilter. (See Fig. 2.) Prefilters prevents lint, pet hair, and other large particles from entering air cleaner by impingement. It is important that these filters be in place to prevent excessive dirt loading of air cleaner collector cells. These filters extend time between maintenance of air cleaner collector cells. This allows the collector cells to provide clean air for a longer period between washing. Fig. 1ÐAIRA Electronic Air Cleaner A97152 ® Visit www.carrier.com 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. 03AI-RA0 Printed in U.S.A. Form AIRA-1SI Pg 1 6-97 Replaces: New
Prefiltered air then passes through a 2-stage electric cleaner. In the first stage, all airborne particles, even submicron size, are electri- cally charged (positive) as they pass through the ionizer. The ionizer field is setup by a corona discharge emanating from fine, tightly strung wires suspended between 2 adjacent flat plates. In the second stage, charged particles pass into an intense electrical field established between alternately charged and grounded paral- lel plates. Here positively charged particles are attracted to ground plates and are deposited out of the air stream. Air Cleaner Construction The air cleaner is easy to install, operate, and maintain. Its basic components are: 1. CABINET Ð mounts to existing ductwork; houses the col- lecting cells and prefilters. 2. COLLECTING CELLS Ð collect dust, dirt, and other par- ticles in the air. They contain ionizing and collecting sections as described above. Cells must be installed with ionizing wires on air intake side. A spring contact is located on top of each cell and must be in position to make contact with contact board assemblies on bottom of power supply. (See Fig. 3.) 3. PREFILTERS Ð trap large particles before they enter collec- tor cells. 4. POWER SUPPLY ASSEMBLY Ð contains indicating lights, solid state power supply, contact boards, and electrical con- trols including ON/OFF switch and safety interlock switch. It also includes a wiring compartment located at rear of the power supply assembly. PLANNING AN INSTALLATION Step 1ÐApplication This air cleaner is intended to be used in return-air duct of a forced air heating, cooling, and ventilating system.The air cleaner should be installed in system so that all system air is circulated through the air cleaner. The air cleaner will only remove airborne contaminants delivered to it. Maximum perfor- mance is obtained when system blower is set for continuous operation. Never use air cleaner to collect grease or other flammable contaminants. Step 2ÐInstallation Requirements The required location for the air cleaner is in the return-air 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 duct. Before installing the air cleaner consider the application. (See Fig. 9 to 14.) If a transition is required refer to section entitled Transitions. The unit must be readily accessible for periodic inspection and cleaning of prefilters and electronic cells to maintain maximum efficiency and trouble-free operation. Step 3ÐAir Conditioning The air cleaner should be installed upstream of cooling coil. This will keep coil clean and reduce air conditioning coil maintenance. Improved cooling efficiency is the result which directly affects energy costs. If air cleaner is downstream of cooling coil, condensation will form on cooled collector plates when air conditioner cycles. This will allow water droplets to form on collector plates and cause nuisance arcing. Arcing will reduce air cleaner efficiency and reduce life of high-voltage power supply. Table 1ÐComponent Information MODEL AIRAAXCC0014 AIRAAXCC0020 Electrical Input120v, 60 Hz, single phase120v, 60 Hz, single phase DimensionsHXWX D20-1/2 X 7-1/4 X 25 24-1/2 x 7-1/4 x 25 Air Flow Range*350 Ð 1400 CFM *600 Ð 2000 CFM Max Pressure Drop0.11-in. wg @ 1400 CFM0.14-in. wg @ 2000 CFM Cell Weight10 lb each 12 lb each Unit Weight41 lb 46 lb Power Consumption40 watts maximum 48 watts maximum Electrical Output2.5 MA @ 6200 VDC 3.2 MA @ 6200 VDC *Using electronic air cleaner outside specified airflow range is not recommended. Fig. 2ÐAirflow through Unit A97055 1. PRE- FILTER 2. IONIZER 3. COLLECTOR 4. OPTIONAL CHARCOAL AFTER-FILTER 2
Step 4ÐHumidifiers An evaporative humidifier can be mounted upstream of air cleaner. It is best to install atomizing humidifier downstream of air cleaner because hard water salt deposits and water droplets may damage air cleaner. If an atomizing humidifier must be mounted upstream of air cleaner: 1. Mount it as far upstream as possible. (Recommend at least 6 ft.) 2. Install standard disposable furnace filter between humidifier and air cleaner to trap water droplets and hard water salts. Select location that is accessible for inspection and replace- ment. 3. Clean air cleaner more frequently to prevent hard water salt buildup. Step 5ÐOutdoor Air When outdoor air is added to return air duct, sufficient heat should be added to maintain return air temperature at 40ÉF (4ÉC) minimum. Lower temperatures can cause ionizer wire failure. Step 6ÐSheet Metal Installation The electronic air cleaner is adaptable to all new and existing residential forced-air furnace and cooling systems. Step 7ÐTransitions If air duct does not fit air cleaner cabinet opening, gradual transitions are recommended to reduce air turbulence through air cleaner and maximize efficiency. Not more than 20É (about 4 in. per running ft) of expansion should be used on each side of transition fitting. (See Fig. 4.) Step 8ÐTurning Vanes If air cleaner is installed adjacent to a 90É duct elbow, add turning vanes inside duct to improve air distribution across face of air cleaner. (See Fig. 5.) Step 9ÐSelect Location Remember to select a location that is readily accessible for periodic inspection and cleaning. Allow a minimum of 18-in. clearance in front of access panel and 12-in. clearance above power rack cover plate for component removal and service space. For complete dimensions required refer to Fig. 6.Step 10ÐDirection of Airflow Through Air Cleaner NOTE:Air cleaner is set up for left-to-right airflow when facing access door. For right-to-left airflow remove prefilters and cells from cabinet. 1. A plastic positioning spacer is located inside bottom of cabinet and secured to cabinet using No. 6-32 round head Phillips drive thread cutting screw (See Fig. 7.) to index installation of cells in proper position with respect to airflow. 2. Remove screw and reposition spacer in alternate hole at bottom of cabinet. 3. Replace screw to insure plastic spacer is not accidentally knocked out of place during normal maintenance. It must be installed in hole provided closest to air leaving side of cabinet. 4. Seal unused hole with duct tape. 5. Turn cells around, replace in cabinet, and replace prefilters on air entering side.Directional arrows on cell end plates must point in direction of airflow. Only a trained, experienced service person should install this electronic air cleaner. The power supply should be removed before installation. To remove the power supply, remove the 2 screws (See Fig. 8.) in the top front of the cabinet. Remember to keep this hardware for reinstallation of the power supply when the air cleaner installation is complete. A thorough check of the unit installation should be completed before unit operation. INSTALLATION Step 1ÐOrientation Air cleaner can be in any position, except with access door facing down. See Fig. 9-14 for proper air cleaner mounting with variety of furnace installations. Fig. 3ÐView of Major Components A97056 CABINET COLLECTING CELLSPRE-FILTER POWER SUPPLY ASSEMBLY ON-OFF SWITCH CONTACT INDICATING LIGHTS ACCESS DOOR 3
Fig. 4ÐTransition Fitting Installation A97057 AIR CLEANER OPENING MAXIMUM 4 DROP PER LINEAL FOOT FURNACE OPENING AIR FLOW FURNACE AIR CLEANER AIR FLOW20¡ TRANSITION SECTION Fig. 5ÐTurning Vanes Installation A97058 TURNING VANES Fig. 6ÐDimensional DrawingDimensions (In.) MODELABCDEF AIRAAXCC001420-1/2 13-7/8 16-1/4 22-1/2 25 7-1/4 AIRAAXCC002024-1/2 17-7/8 20-1/4 22-1/2 25 7-1/4 A97059 4 1⁄2²20 3⁄4² A F E C 3 1⁄2² 2 3⁄8² 2 1⁄8² 30¡ 5⁄8² 3⁄16² B D 4
Cabinets will support a maximum weight of 400 lb 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. Prior to installing this product: 1. Read rules and instructions carefully for safe operation. Failure to follow them could damage product or cause hazardous condition. 2. Check ratings given on product to make sure it is suitable for your application. Step 2ÐDetails 1. Remove existing furnace filter and discard. 2. Air cleaner cannot remove existing dirt from blower and ducts. Clean area thoroughly before you begin. 3. Remove unit access panel, and slide prefilters and ionizing- collecting cells out of cabinet. Place them safely aside with warranty registration card. Remove any cardboard pieces before proceeding. NOTE:The following is a typical installation of an air cleaner on an upflow furnace. (See Fig. 8 and 11.) You may have to alter the installation to fit your application. 4. Locate cabinet in cold air return duct so that all of return air flows through unit. (See Fig. 8.) If furnace and air cleaner openings are different, use a transition. (See Fig. 4.) 5. Mounting holes are provided for duct work attachment. (See Fig. 8.) The 0.140-in. holes are sized for No. 8 sheet metal screws, or 1/8-in. rivets. If adjoining ductwork is flanged, install screws so that screw heads are inside cabinet. This willprevent damage to prefilters and optional charcoal after-filter during removal and installation after cleaning. 6. After unit has been secured, seal seams air tight with duct tape or caulking. In applications with minimum airflow, it is helpful to seal any openings on power pack assembly or cabinet. 7. Refer to Direction of Airflow. 8. Re-install power supply on top of cabinet. 9. Install prefilters and ionizer-collector cells. 10. Re-install cabinet front panel door assembly. Step 3ÐTypical Mounting Positions Air cleaner can be mounted in any position, except with the access door facing down. Seal all joints in return air system with duct tape between furnace and air cleaner to prevent dust from entering clean airstream and to assure proper operation of electronic airflow sensor. Step 4ÐElectrical 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. Fig. 7ÐPlastic Positioning Spacer and Screw for Right-to-Left Airflow Installation A97060 SCREW SPACER (PLASTIC) Fig. 8ÐInstallation on Upflow Furnace A97061 MOUNTING HOLESSCREW(S) BLOWER COMPARTMENT 5
Fig. 11ÐSide Installation on Upflow Furnace Side installation. Cleaner is mounted vertically, where return air enters side inlet of furnace. A97064 AIR FLOW Fig. 9ÐBasement Furnace Mounted horizontally in return plenum just above furnace. A97062 AIR FLOW Fig. 12ÐOffset Installation If there is less than 7-in. for mounting air cleaner between duct and furnace, move return-air drop. A97065 AIR FLOW Fig. 10ÐDownflow Furnace Mounted horizontally in return duct or plenum just above furnace. A97063 AIR FLOW 6
The following procedures will expose electrical components. Disconnect power between checks and proceed carefully. Electrical shock can cause injury or death. The air cleaner is powered by providing 120v, 60 Hz, 1-phase electrical service to pigtail leads at field wiring compartment (with knock-out holes) located at rear of power pack assembly. (See Fig. 15.) 1. Turn air cleaner off using ON/OFF rocker switch located on front panel. 2. Remove power supply cover plate by removing front door and 2 screws holding assembly to top of air cleaner. (See Fig. 8.) 3. Make wiring connections inside junction box area (field wiring compartment). Remove knock-out and use conduit or other approved methods to supply input power. Connect ground wire to clip. 4. Replace power supply cover plate and secure with screws removed from step 2. 5. Replace door on front of air cleaner. 6. Air cleaner will operate when door is in place, ON/OFF rocker switch is in ON position, and input voltage is present in junction box. The following should be completed to supply input power to air cleaner. Step 5ÐFurnace Application It is recommended to use EAC-1 and EAC-2 terminals when provided by furnace circuit board. These outputs will provide 120 VAC whenever blower motor is energized.Furnace circuit boards without EAC-1 and EAC-2 terminals must use alternate methods to supply 120 VAC to air cleaner (via sail switch, isolation relay, or optional electronic airflow sensor). Air cleaner should only operate when blower motor is running.This unit cannot be powered directly from blower motor leads. Voltages can exceed 190 VAC (120-v motors). This can double with 240-v fan coil motor. Step 6ÐFan Coil Application 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 120v at these terminals. Alternate methods may be needed to convert fan coil supply voltage to 120 VAC input for air cleaner. A 240-VAC to 120-VAC step-down trans- former (40 VA) will be needed in most application. Sail switch, isolation relay, or optional electronic airflow sensor may also be applied when needed. Do not wire directly to multiple speed blower motor. Wiring to multiple speed blower will damage power supply and void warranty. SYSTEM CHECKOUT ADJUST THERMOSTAT SO THAT SYSTEM BLOWER IS OFF. After installing unit, switch ON/OFF rocker switch to ON position.A bright red segment of rocker switch should be visible. Adjust thermostat so system blower is ON. Fig. 13ÐBotton Installation on Upflow Furnace Installation beneath furnace. Cleaner mounts horizontally, where return air enters from below. Raise furnace by installing suitable wood structure and install air cleaner. A97066 AIR FLOW Fig. 14ÐHorizontal Furnace Mounted vertically in return duct as close to furnace as possible. A97067 7
1. Both input indicating light (green) and output voltage light (red) should now be on. 2. Check to assure that both lights go out when the cell access panel is removed, when rocker switch is switched to OFF position, and when system blower is not running. MAINTENANCE Sharp edges. Handle the cells carefully to avoid cuts from the sharp metal edges. Step 1ÐWashing Cells and Prefilters Regular washing is necessary to insure proper performance. A thorough washing every 2 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 carpet, plaster dust, or there is above normal cigarette smoke. (See Fig. 16.) 1. Remove cells and prefilters. a. Push air cleaner ON/OFF rocker switch to OFF. Wait 15 sec. Open access door. b. Carefully remove cells and prefilters, and set aside. c. Avoid damage to cell plates and ionizing wires. 2. Wash in tub. a. Place enough hot water in utility tub to cover cell. Electronic Air Cleaner concentrate solution (Part No. P902-2001) is recommended. (Solution is available from your dealer through the Replacement Components Divi- sion.) As an alternative, 2 to 4 oz of automatic dishwasher detergent (not laundry detergent) can be used. b. Allow cell to soak for 30 minutes. Agitate cell up and down in solution until it appears clean, then remove. c. Repeat with second cell. d. Agitate prefilters up and down in solution until they appear clean.e. With hose, rinse cells and prefilters. Hose should be held about 10 in. from cell plates and at slight angle for better cleaning results. Cell frame should be thoroughly rinsed along edges to dislodge any trapped lint or dirt. Carefully wipe damp cloth or sandpaper (not emery cloth) along ionizing wires. f. Stand cells and prefilters up to drain. Let dry 2 hr. NOTE:We do not recommend washing electronic air cleaner cells in the dishwasher. Not only can collector plates and ionizing wires be easily dam- aged, but dirt from cells and prefilters can permanently stain plastic dishwasher linings. 3. Replace cell and prefilters. a. Replace prefilters and cells in cabinet. Check that arrow on cells points in same direction as air flows through duct. (If you have to force it past the positioning screw on bottom, it is probably in a wrong position.) b. Reposition access door (engage tips on lower edge of door into slots in cabinet). Carefully close door. c. Turn air cleaner switch to ON. TROUBLESHOOTING Procedures in this section should be performed only by qualified service personnel. The following procedures will expose energized electrical components. Disconnect power between checks and proceed carefully. Electrical shock can cause injury or death. Step 1ÐRecommended Service Tools · Screwdriver, 8-in. common with insulated handle (plastic). · Screwdrivers Phillips No. 1 and 2 with plastic insulated handles. · Needle-nose pliers Fig. 15ÐElectrical Installation A97068 GROUND FIELD WIRING COMPARTMENT (COVER PLATE REMOVED) KNOCKOUT PIGTAIL LEADS (120 VAC) 8
· Fluke No. 8021B multimeter or equivalent · Fluke No. 80K-40 high-voltage probe or equivalent. Step 2ÐIndication of Electrical Trouble Air cleaner is equipped with input power LED light (green) and output voltage LED light (red) for indicating proper unit operation. When unit is in normal operation, system blower running, access door in place, control switch in the ON position, and indicating lights go out, there is an electrical problem. If green light goes out there is a problem in the primary circuit. If red light goes out the problem is a shorted secondary. Although failure of indicating lights should not be overlooked, this condition is unusual and rather remote. Step 3ÐElectrical Troubles and Their Conditions Exercise the usual precautions when working with high voltage. When the circuit has been de-energized, always discharge any residual current in the secondary with an insulated handle screwdriver. Electrical shock can cause injury or death. Always ground power supply and ionizing-collecting cell when bench testing. Electrical shock can cause injury or death. PRIMARY CIRCUIT Normal operation Ð For normal operation of electronic air cleaner, system blower should be running and air cleaner switch should be ON. If there is supply line voltage at the service connections and no input voltage to power supply (green light out), outage can be located by checking operation of safety switch and interconnecting wiring with multimeter. Refer to Circuit Diagram, Fig. 17 to check operation of switches. Follow these steps: 1. Assure that circuit breaker controlling air cleaner is in ON position. Main fuse not open. 2. Set multimeter for reading AC voltage at a 200-v full scale for 120-v units. 3. Connect 1 lead of multimeter to load side of interlock switch. Connect other lead to common (white) lead at a convenient place in power supply assembly. Depress switch and measure voltage. If there is no voltage reading, switch is defective and should be replaced. 4. With white lead still connected as in step 3, connect multim- eter test lead to loadside of the ON/OFF switch. ON/OFF switch shall be in ON position. Actuate interlock switch and measure voltage. If there is no voltage reading, ON/OFF switch is defective and should be replaced. SECONDARY CIRCUIT 1. Ionizing-Collecting Cell Cell is electrically energized through a contact terminal located at top center of cell. Ionizing wires and every other collector plate are electrically charged while each interleaving plate is grounded. Fig. 16ÐMaintenance Procedures A97069 REMOVE SOAK RINSE DRIP-DRY REPLACENOTE AIR FLOW DIRECTION ARROW SHOULD POINT TO THE FURNACE OR AIR HANDLER 9
If space between charged and grounded plates is bridged with conductive or semi-conductive material, a short circuit devel- ops. The bridging or short may be caused by damaged plates or foreign material lodged between or on plates. Since cell is periodically removed from unit to wash away collected dirt, it is susceptible to physical damage. Also, cell contains ionizing wires which, due to their function, have to be designed with minimal structural support and are susceptible to breakage. However, trouble related to a shorted collector cell is readily shown by output indicating light and can be quickly isolated by a simple procedure. To determine if a short exists in 1 or both of the collector cells, turn electronic air cleaner OFF and remove both electronic cells from cabinet. Close door and re-power unit. If red performance light comes on, an electrical short exists in 1 or both of the electronic cells. Replace cells in unit, 1 at a time, to determine which cell is shorted. Most troubles in the cell can be visually detected and corrected. (See Table 2.) NOTE:Ionizer collector cells are not designed for field repair. Ionizing wires and insulators can be field replaced. It is not recommended to attempt to replace other cell components, such as collector plates, end plates, ionizer supports. 2. Ionizing Wire Replacement Ionizing wire breakage is minimal because of the constant tension design and fixed location of ionizing wire supports. If necessary to replace a broken wire follow these instructions.Wires are supplied in coiled spring configuration, with clinch nut on each end of wire. Wire replacement requires pair of needle-nose pliers. Exercise caution in removing any broken wires in collector cell. This will prevent accidental shorting of cell and reduce need for further maintenance. Use the following procedure when replacing ionizing wire. Handle with care as parts are sharp. a. Carefully remove all remains of broken wire. b. Grip new wire at each end with your thumb and index finger. While stretching wire to approximately 6 in. allow 1 end of wire to uncoil between your thumb and index finger. c. Place 1 end of wire in slot in stainless steel support on collector cell from front of cell. This support is partially covered by cell brace in front of support. d. Grip other end of ionizing wire with needle-nose pliers and insert terminated end of wire into slot of support bar of opposite end of collector cell. e. Wire should be tight enough to be self supporting and remain suspended between 2 support slots in support bar. Fig. 17ÐCircuit Diagram A97070 12 3 9 46 GN RDO O RBL Y BK 1. Interlock Switch 2. On-Off Rocker Switch 3. 50VA Stepdown Transformer Class-2 24VAC Output 4. High Frequency Oscillator and High Voltage Power Supply Board 5. Output LED (Red) 6. Input LED (Green) 7. Ionizer-Collector Cells 8. Cell to Power Supply Contact 9. Jumper Wire (remove to install optional Air Flow Sensor Kit) LEGEND W Y W/O W/O 5 8 77 10