Aprilaire 5000 User's Manual
Contents
1. creating better clearance in tight mounting applications FIGURE 3 Clearance for Inner Housing Removal It is important to leave enough room to remove and re install the Inner Housing Allow Clearance for Removal of Inner Housing for Filter Replacement FIGURE 4 Note Air Cleaner outer housing can support up to 400 Ibs 90 1158A FIGURE 6 Airflow Ak Left side install shown 90 1160A FIGURE 8 Airflow 90 1162A FIGURE 5 Se Airflow Left side install shown 90 1159A FIGURE 7 Minimize Angles Where Possible 90 1161A FIGURE 9 Airflow 90 1163A Size Plenum Box to fit outer housing without door 17 3 4 x 28 1 8 See Figure 1 for complete dimensions INSTALLING THE OUTER HOUSING AND INNER HOUSING ASSEMBLY AA WARNING 120 Volts may cause serious injury from electrical shock Leave power disconnected until installation is complete 1 Turn the system OFF at the thermostat by changing the mode selector to OFF FIGURE 10 this may be a switch or a pushbutton depending on the type of thermostat 2 Disconnect power service to the furnace or air handler 3 Remove air cleaner power pack door assembly and pull inner assembly out of the outer housing 4 Remove the media carton and the cardboard inserts and strapping used to hold the media from the inner housing on On retrofit applications remove and discard the existing filt2. Install a 2 1 step down transformer to get 120 volt service Use the instructions provided with the transformer to ensure it is properly installed Do not use ground as the common connection for the outlet B Follow the instructions For 120 volt equipment without EAC terminals above except double the number of wraps around which the Model 51 is clamped 2 Press the power cord into the slot in the side of the power pack door so that the plug is directed toward the installed outlet 3 Install the door on the housing with the inner assembly installed in the housing Place the bottom of the door on the lower door retainer then swing the door toward the upper door retainer and snap into place 4 With the door ON OFF switch in the OFF position plug the door into the installed outlet AA CAUTION Do not plug the air cleaner into an outlet that is always live The outlet must only be live when the furnace air handler blower is operating Failure to properly wire the outlet can result in excessive ozone production 5 Restore power to the furnace air handler 6 Turn on the heating or continuous fan whichever uses the slowest fan speed and verify that the blue light on the door is not on see Figure 15 7 Turn ON the door switch 8 Verify that the blue light on the door turns on see Figure 15 9 If the light is on turn off the heating or fan and verify that the light on the door turns off If the light turns off install
3. abrasive dish scrubber clean each of the nine ionizer wires Even if the wires don t appear dirty clean each one Do not use steel wool as this material readily sheds 4 Replace the control electrode in the ionizer frame return the inner assembly to the outer housing reinstall the door and turn the ON OFF switch to the ON position 5 Return the thermostat Fan and Mode selectors to their appropriate settings CLEAN THE INNER ASSEMBLY Dust will collect on all parts of the air cleaner which is normal e Clean the inner housing and ionizer frame once a year Procedure 1 Use a vacuum with a brush attachment or a cloth to wipe off collected dust on the inner housing and ionizer frame 2 Return the inner assembly to the outer housing reinstall the door and turn the ON OFF switch to the ON position 3 Return the thermostat Fan and Mode selectors to their appropriate settings FIGURE 16 Maintenance E Bus Bar Be d EEE KAS SG N lonizer KOS d Wires Control Electrode A NTN EEA EEk ek ZB aww be ZOOS A E EEA EEE Eka EEEk Lk ee _A lonizer Frame Control Electrode Media Ground Contacts Inner Housing lonizer Frame ei Control Electrode d Ground Contact 90 1151 10 APPLICATIONS WITH A HUMIDIFIER An Aprilaire Automatic Humidifier can be mounted upstream from the air cleaner AA CAUTION Do not install an atomizing humidifier upstream from the a
4. Model 5000 Electronic Air Cleaner Installation Instructions SAFETY INSTRUCTIONS Read the safety and installation instructions carefully They will help ensure a correct and SAFE installation of the Aprilaire Electronic Air Cleaner Dimensions Maintenance Recommendations A WARNING 120 Volts may cause serious injury from electrical shock Disconnect power to the furnace air handler before starting installation Leave power disconnected until installation is completed Arcing in electrical components may cause an explosion Do not install unit where explosive gasses will be present Sharp edges may cause injury from cuts Use care when cutting and handling sheet metal To reduce the risk of electrical shock this equipment has a grounding type three prong plug This plug will fit only into a grounding type power outlet If the plug does not fit into the outlet contact qualified personnel to install the proper outlet Do not alter this plug in any way To reduce the risk of electrical shock locate product so that the power cord can be plugged into an electrical outlet without the use of an extension cord AA CAUTION To prevent component failure do not install the air cleaner on the warm air supply or in an area where the temperature may exceed 140 F This may include areas above heat exchangers in downflow furnaces or above exhaust flues in lowboy furnace cold air returns The air cleaner must be installed
5. R 1 2 HP USE FOR WRAP DOES MOTORS OR MOTORS LESS GE LARGER THAN 1 2 HP NOT MORK TROUBLESHOOTING GUIDE ON OFF switch not in ON position Turn switch ON Light does not Air cleaner not plugged in Plug in air cleaner come on at all after Insufficient current to activate Wrap blower common wire around relay bracket more see 90 seconds Model 51 relay Figure 14 on page 7 for wire wrapping method Furnace air handler not running Turn blower on by making a heat call or turning Fan ON Ensure components are dry Excessive humidity run cooling to lower humidity levels a Ensure that all 9 ionizer wires are held at both ends Over current or arcing detected Look for foreign object contacting ionizer wires or buss bar Light flashes on then off quickly Door not fully installed ensure door is latched into top and bottom retainer Insufficient current to sustain Model Wrap blower common wire around relay bracket more see 51 relay Figure 14 on page 7 for wire wrapping method Loose connection in outlet junction box Check wire nuts screw terminals and crimped connectors for or at furnace air handler EAC terminal loose wires Use only fully insulated crimped connectors Light stays on after Outlet in which air cleaner is plugged ree a blower stops running See Step 1 in Wiring and Start Up section page 6 Outlet in which air cleaner is plugged is continuously live See Step 1 in Wir
6. ation is complete If the light on the door does not turn on and off as described continue with Step 10 10 If the light stays on after the blower has stopped running the outlet is continuously live and must be rewired in accordance with Step 1 11 If the light flashes on then turns off or if the light does not come on at all refer to the TROUBLESHOOTING section on page 8 FIGURE 12 FIGURE 13 IT IS COMMON TO SEE SPADE ETETE TERMINALS ON THE HVAC i LINE EQUIPMENT CONTROL i VOLTAGE CENTER CIRCUIT BOARD REFER TO THE i dd USE ONLY FULLY INSULATED INSTRUCTIONS PROVIDED dda EE FITTINGS FEMALE QUICK WITH THE MODEL 51 FOR DISCONNECTS SHOWN WIRING DETAILS HVAC Equipment BLK Control Center MODEL 51 Circuit Board y RELAY EAC o ES DO LL NEUTRAL EZ Zb d GND GND GRN BOX 3 PRONG OUTLET WIRED TO HVAC SYSTEM EAC HVAC EQUIPMENT WITH 120 VOLT SERVICE IN CONDUIT HVAC EQUIPMENT 90 1155 90 1156 HVAC ee CONTROL CENTER B MODEL 51 SOLD SEPARATELY FIGURE 14 FIGURE 15 lt a rilaire rilaire ELECTRONIC AIR CLEANER ELECTRONIC AIR CLEANER MODEL 5000 l MODEL 5000 i Deoa apri airar media a Uses Apr aite media E Unit OFF Unit ON ONE WRAP TWO WRAPS INCORRECT Blue Light OFF Blue Light ON USE FO
7. er and filter housing Thoroughly clean the blower blower compartment and evaporative coil 90 1348 Support Air Cleaner to Prevent With the airflow label on the outer housing pointing toward the furnace air Torque on Outer Housing handler see Figure 10 attach the outer housing to the furnace air handler EO 7 Provide support for the housing as shown in Figure 10 if the unit is to be FIGURE 11 installed on the side of an upflow furnace Ba egazti air handler see example of this type of COATED MEDIA S RETAINER POSTS installation in Figure 6 PLEAT TIPS erauno A TRIP Seal the perimeter of the inlet and outlet SF connections with mastic caulk or tape as desired DO NOT USE SILICON BASED CAULK MEDIA GROUND CONTACT OR oe co Open the inner housing and install the media pr 3 4 MIN Use the instructions provided on the carton of the media 10 After installing the media close the inner housing Check the media ground strip to he INCORRECT ensure it is properly contacting the pleats IF THE ALUMINUM FRAME OF THE MEDIA GROUND gure see Figure 11 If not remove the ground STRIP BENDS IN TOWARD strip by removing the ground contacts and THE PINK SEAL FLIP THE E Ge GROUND STRIP OVER reposition as shown in Figure 11 Verify that the holes in the media ground contacts go over the ground contact retainer posts 11 Check to make sure tha
8. flat surface with the control electrode facing up see Figure 16 2 Slide the control electrode out of the ionizer frame and wipe with a clean cloth or vacuum with a brush attachment 3 Return the thermostat Fan and Mode selectors to their appropriate settings REPLACE THE MEDIA The media attracts and neutralizes ionized particles Most homes require replacement of the media once a year How quickly build up occurs will depend on many factors including lifestyle construction details and environment e Check the media 6 months after initial installation If the media appears dark grey or brown replace it and check the media for replacement every 6 months thereafter e Replace the media no less often than once per year e Always use Genuine Aprilaire Model 501 Replacement Media The Model 5000 is designed to work only with Genuine Aprilaire 501 Replacement Media Use of other media will damage your Model 5000 Electronic Air Cleaner Procedure Follow the instructions on the 501 media carton CLEAN THE IONIZER WIRES Particles will normally build up on the positively charged ionizer wires during operation The ionizer wires should be cleaned to maintain the highest level of filtration e Clean the ionizer wires at least once a year Procedure 1 Lay the inner assembly on a flat surface with the control electrode facing up see Figure 16 2 Slide the control electrode out of the ionizer frame and set it aside 3 Using 200 grit sandpaper or an
9. ing and Start Up section page 6 Large crack hole in media Replace media Poor connection between media Remove ground strip and reinstall as shown in Figure 11 ground strip and media on page 5 Produces an Poor contact between control Push in control electrode so it fully seats in the ionizer frame ozone smell electrode and ground contact see Figure 16 on page 10 With the inner assembly installed in the outer housing bend up Ground contacts not touching ground contacts 2 media ground contacts 1 control electrode door liner ground contact so they are at least 3 4 higher than the top of the inner housing Refer to Figure 11 and Figure 16 Media ground contacts not Remove ground contacts and reinstall as shown in Figure 11 fully installed on page 5 Large crack hole in media Replace media Poor connection between media Remove ground strip and reinstall as shown in Figure 11 ground strip and media on page 5 Poor contact between control Makes a buzzing electrode and ground contact sound or causes TV interference Push in control electrode so it fully seats in the ionizer frame With the inner assembly installed in the outer housing bend up Ground contacts not touching ground contacts 2 media ground contacts 1 control electrode door liner ground contact so they are at least 3 4 higher than the top of the inner housing Refer to Figure 11 and Figure 16 Media ground contacts not Remove gr
10. ir cleaner rilaire P O Box 1467 e Madison WI 53701 1467 e Phone 800 334 6011 e Fax 608 257 4357 www aprilairepartners com 10007971 2 14 Printed in U S A B2701048B 2014 Aprilaire A division of Research Products Corporation
11. ound contacts and reinstall as shown in Figure 11 fully installed on page 5 MAINTENANCE RECOMMENDATIONS Whenever performing maintenance on the air cleaner turn off the HVAC system then turn off and unplug the air cleaner Before performing any maintenance item listed below 1 At the thermostat turn the Fan to Auto this is done with a switch or a button on the thermostat refer to thermostat Operating Instructions for details and the Mode Heat Off Cool to Off also done with a switch or a button at the thermostat refer to thermostat Operating Instructions for details 2 Turn the ON OFF switch on the air cleaner door to the OFF position 3 Unplug the door remove the door from the outer housing and then pull the inner assembly out of the outer housing CLEAN THE CONTROL ELECTRODE Most homes will require cleaning of the control electrode once a year while a few homes may require cleaning more often The primary purpose of the control electrode is to develop a good ionization field but it does attract particles and will filter out larger particles like pet hair Check this item 6 months after initial installation to determine how often it should be cleaned in the future e f build up of larger particles that parially block the airflow is occurring clean the control electrode every 6 months e f there is only dust build up occurring clean the control electrode every 12 months Procedure 1 Lay the inner housing assembly on a
12. t Door gt pz 12 e 31 with Door e 23 7 8 Er 24 5 8 a G EE 18 3 8 15 1 2 17 3 4 Zi T Inlet Side Front Outlet Side eo Return Duct Connection Furnace Connection COMPONENTS FIGURE 2 Model 5000 Electronic Air Cleaner Inner Housing Assembly CS GZ aw N y if gt l gt E a gt Kw WL Power Pack Door Assembly On Off Switch Control Electrode lonizer Frame Inner Housing Outer Housing with Door Retainers 501 Media 90 1152 LOCATING THE AIR CLEANER The Model 5000 can be installed in a variety of ways The figures below show some of the possibilities The air cleaner may be installed on the left or right side of the air handler If installed on the right the ON OFF switch will be on top and the nameplate will be on the bottom Remove the nameplate and rotate it 180 to read properly Bottom Return in upflow Highboy installation Figure 4 Inline in duct horizontal or vertical installation Figure 5 Side Return in upflow Highboy installation Figures 6 amp 7 Compact Side Return in upflow Highboy installation Figures 8 amp 9 Either of the methods shown in Figures 6 and 7 will result in a narrower footprint
13. t the ionizer frame is fully installed onto the inner housing and that the control electrode is inserted fully into the ionizer frame 12 Insert the inner assembly ionizer frame and inner housing into the outer housing 13 Continue with WIRING AND START UP on page 6 WIRING AND START UP AA WARNING 120 Volts may cause serious injury from electrical shock Leave power disconnected until installation is complete 1 Install a grounded earth ground 120 volt single receptacle outlet in accordance with NEC Standards and local codes into which the EAC will be plugged This outlet is to be live only when the furnace air handler blower is running For equipment with EAC terminals A Install a single receptacle outlet to the furnace air handler wired as shown in Figure 12 B Use a marker or label to identify the outlet as EAC USE ONLY For 120 volt equipment without EAC terminals A Use an Aprilaire Model 51 Current Sensing Relay to wire a single receptacle outlet as shown in Figure 13 Refer to the instructions provided with the Model 51 for details on wiring requirements B For blowers that are 1 2 hp or larger clamp the Model 51 around the common wire of the blower see Figure 14 C For blowers that are less than 1 2 hp clamp the Model 51 around two wraps of the common wire as shown in Figure 14 D Use a marker or label to identify the outlet as EAC USE ONLY For 240 volt equipment without EAC terminals A
14. where the ambient air temperature remains between 32 F and 140 F 0 C and 60 C Installation must conform to all applicable codes Do not install an atomizing humidifier upstream of the air cleaner Water or mist will cause power supply to shut down Do not plug the air cleaner into an outlet that is always live The outlet must only be live when the furnace air handler blower is operating Failure to properly wire the outlet can result in excessive ozone production TABLE OF CONTENTS Safety Instructions Specifications Components Locating the Air Cleaner Installing the Outer Housing and Inner Housing Assembly Wiring and Start Up Troubleshooting Guide Applications with a Humidifier SPECIFICATIONS TABLE 1 Model 5000 Specifications 0 3 0 4 pm Particle Filtration Efficiency 347 fpm 94 Replacement Media Model 501 Airflow Capacity up to 2000 CFM maximum Electrical Voltage 120 VAC 15 50 60 Hz Electrical Current Power Consumes less than 50 watts with high voltage active Max Equipment Weight Cabinet will support 400 Ib static load TABLE 2 Model 5000 Initial Airflow Resistance inches w c Airflow CFM 1400 1600 FIGURE 1 Dimensions of the Model 5000 Electronic Air Cleaner zr 28 1 8 withou
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