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Air Quality Engineering Smokemaster Technical information
S U P P L Y I N G
C L E A N
A I R
T O
I N D U S T R Y
AutoClean
In-Duct Self Cleaning
Electronic Air Cleaner
The new AutoClean from Air Quality Engineering, Inc.,
is a self washing in-duct electronic air cleaning system. The AutoClean will
effectively remove a broad range of contaminants including dust, soot, pollen,
tobacco, and cooking smoke from the air. One, Two or Four electronic cells,
operated by high voltage power supplies remove airborne contaminants at
efficiencies as high as 99 percent and at rates starting at 1000 cfm. Dynamic Wash
system is the state-of-the-art in maintenance free air cleaning.
7140 Northland Drive North, Brooklyn Park, MN 55428-1520 USA
FAX: (763) 531-9900 EMAIL: info@air-quality-eng.com WEB SITE: www.air-quality-eng.com
TOLL FREE: 1-800-328-0787
Air Quality Engineering Inc., has a policy of continuing product improvement and reserves the right to make changes
in design and specification without notice.
Before you get started please review the following:
Purchase Date: _____________________
Serial Number: _____________________
Customer Technical Support:
To contact Air Quality Engineering use:
Mail:
Air Quality Engineering
7140 Northland Drive N.
Brooklyn Park, MN 55428
USA
Phone: 1.800.328.0787
763.531.9823
Fax:
763.531.9900
e-mail: info@air-quality-eng.com
web:
www.air-quality-eng.com
Copyright
Air Quality Engineering, Inc. copyrights this manual with all rights reserved. Under the copyright laws, this
manual may not be reproduced in any form, in whole or in part, without the prior written consent of Air
Quality Engineering, Inc.
 2004
Disclaimer
All statements, technical information and recommendations in this manual or related documents are
believed reliable, but the accuracy and completeness thereof are not guaranteed or warranted, and they
are not intended to be, nor should they be understood to be representation or warranties concerning the
products described.
Specifications are subject to change without notice.
2
TABLE OF CONTENTS
PAGE
HOW AIRBORNE CONTAMINATION IS REMOVED
3
DIMENSIONS
4
SPECIFICATIONS
6
PLANNING THE INSTALLATION
7
ASSEMBLY & INSTALLATION
10
CHECKOUT
16
MAINTENANCE
18
TROUBLE SHOOTING
21
PARTS IMAGES & PART NUMBERS
24
WARRANTY
27
HOW AIRBORNE CONTAMINATION IS REMOVED
A process called “Electrostatic Precipitation” traps airborne contaminants. The fan draws particulate
laden air successively through the prefilter, the cell ionizing section and the cell collector section. The
ionizing section imparts an electrical charge to the individual particles that are then drawn by electrostatic
forces to the oppositely charged collector plates. Cleaned air is then discharged back into the room.
The electronic cells must be washed periodically to maintain efficient performance.
3
DIMENSIONS
AutoClean 2000
AutoClean 4000
AutoClean 8000
1.50
METRIC CONVERSION
Ins. to mm
Lbs. to kgs.
Ins. w.g. to kPa
CFM to m³/h
Ft² to m²
AutoClean 2000
AutoClean 4000
AutoClean 8000
FORMULA
Ins. x 25.4
Lbs. x .455
Ins. w.g. x .2488
CFM x 1.6992
Ft² x .0929
SHIPPING
WEIGHT
Lb.
Kg.
290
390
600
131.5
177.0
272.2
INSTALLED
WEIGHT
Lb.
Kg.
240
340
530
108.9
154.2
240.4
5
SPECIFICATIONS
- IMPORTANT THE SPECIFICATIONS GIVEN IN THIS PUBLICATION DO NOT INCLUDE NORMAL MANUFACTURING TOLERANCES.
THEREFORE, THIS UNIT MAY NOT MATCH THE LISTED SPECIFICATIONS EXACTLY. ALSO, THIS PRODUCT IS TESTED
AND CALIBRATED UNDER CLOSELY CONTROLLED CONDITIONS AND SOME MINOR DIFFERENCES IN PERFORMANCE
CAN BE EXPECTED IF THOSE CONDITIONS ARE CHANGED.
SPECIFICATIONS
Cabinet:
16 gauge welded steel cabinet with a powder coat finish.
Instrumentation:
Indicator Light – Light indicates that the collector cells are energized properly.
Electrical Rating:
AutoClean In-place Wash Electronic Air Cleaner-120V/240V, 60 Hz; or 220-240V, 50 Hz
Ambient Temperature Rating:
Airflow through cells: 125°F [52°C] max., 40°F [5°C] min.
Power Ratings:
MODEL
AutoClean 2000
AutoClean 4000
AutoClean 8000
Pre/post Filter:
AIR CLEANER
ON CYCLE
MAX.
NOM.
NOM.
W
W
VA
90
55
75
90
70
85
140
120
170
WASH CYCLE
MAX.
NOM.
NOM.
W
W
VA
145
105
170
145
105
170
145
105
170
2000: 2 x 41022 2’ x 2’ aluminum mesh filters.
4000: 4 x 41022 2’ x 2’ aluminum mesh filters.
8000: 8 x 41022 2’ x 2’ aluminum mesh filters.
Primary Filter Options:
2000: 1 x 38010 ~ 24”h x 24”w x 10.75” deep or 2 x 38003 ~ 24”h x 12”w x 10.75” deep
4000: 2 x 38010 ~ 24”h x 24”w x 10.75” deep or 4 x 38003 ~ 24”h x 12”w x 10.75” deep
8000: 4 x 38010 ~ 24”h x 24”w x 10.75” deep or 8 x 38003 ~ 24”h x 12”w x 10.75” deep
Optional Carbon Filter:
Custom carbon modules available
Optional Blower Module:
Custom blower modules available
Optional Enclosure and Mounting:
Optional outdoor weather enclosure and mounting skid available
Air Quality Engineering, Inc., has a policy of continuing product improvement and reserves the right to make
changes in design and specifications without notice.
6
PLANNING THE INSTALLATION
outdoor air. The Standard recommends as much
as 50 CFM per person ventilation air where people
are smoking, such as in a cocktail lounge. These
recommended outdoor air quantities may be
reduced if air cleaning is provided. However, the
Standard recommends that “in no case shall the
outdoor air quality be less than five CFM per
person.”
INTRODUCTION
Clean air is the subject of numerous laws and
regulations. Typical requirements in the United
States are those put out by the Occupational
Safety and Health Administration (OSHA). Private
groups, such as the American Society of Heating,
Refrigeration and Air Conditioning Engineers
(ASHRAE), have also published numerous
recommendations.
The reduction in outside ventilation air required
represents the potential for savings through the
use of clean recirculated air. This potential for
savings can be achieved by a system that reduces
particulate and gaseous contaminants to within the
ASHRAE recommended limits.
Normally, clean air is defined in regulations and
recommendations as air having a limited amount
of contaminant in it, commonly expressed as parts
per million or milligrams per cubic meter.
Approved counteractions are intended to lower or
eliminate the amount of contaminants in the air.
One of the more common methods of achieving
this goal is through the use of air cleaners.
The AutoClean helps to provide this clean,
recirculated air by removing particulate
contamination (visible smoke). The reduction in
outdoor air used, of course, means a reduction in
the amount of heating or cooling required. This
reduces both operating cost and equipment wear.
AIR CLEANER SIZING
The AutoClean air cleaner is usually sized
according to the capacity of the air handling
system and the desired efficiency. See Fig. 3.
Remember that the air cleaner must meet the
needs of the user. You are encouraged to use
your experience and judgment in the application of
this data keeping in mind local codes and
minimum air requirements.
The ASHRAE Standard 62-81, Natural and
Mechanical Ventilation, gives recommended
quantities of ventilation air in terms of 100 percent
Airflow recommendation with pressure drop and efficiency rating:
F 61 A
3
cfm
M / hr
1000
1699
1500
2548
2000
3398
2500
4248
3000
5296
F 61 B
3
cfm
M / hr
2000
3398
3000
5097
4000
6796
5000
8495
6000
10,194
F 61 C
3
cfm
M / hr
4000
6896
6000
10,194
8000
13,592
10,000
16,990
12,000
20,388
Efficiency
(Percent)
99
99
95
90
80
Water Pressure Drop
In.
KPa
0.06
0.015
0.12
0.030
0.22
0.550
0.33
0.830
0.49
0.122
Efficiency ratings based on National Bureau of Standards Dust Spot Method and American Society of Heating, Refrigerating and Air-Conditioning
Engineers Standard 52-76, using atmospheric dust.
FIGURE 3 – AutoClean ELECTRONIC AIR CLEANER CAPACITY AND EFFICIENCY
COMMERCIAL APPLICATIONS
2. Capacity cubic feet per minute (cfm) of
equipment and system.
When deciding on the number of air cleaners
required for applications such as a restaurant,
bowling alley, store, bar or lounge, several
conditions must be considered. They are:
3. Method of calculation-must be forced air,
distributed evenly to all parts of the controlled
area with the required air changes per hour.
1. Air to be cleaned of dust, tobacco smoke,
greases, etc. These conditions may require a
higher efficiency in the electronic air cleaner
installation.
4. Maximum number and average number of
people that will occupy controlled area.
7
LOCATION AND POSITION
5. The percent operating efficiency required of
the electronic air cleaner. The AutoClean
efficiency should be from 85 to 95 percent
depending on the application and purpose.
See Efficiency Chart, Fig. 3.
Because air-handling systems vary greatly in
arrangement and style, factors such as location,
air distribution, transitions, etc., require careful
consideration.
The AutoClean cabinet must be mounted in a
horizontal duct in an upright position with the
washing manifold above the electronic cells.
Locate the cabinet in the return air duct so that the
face of the electronic cell is at right angles to the
airstream.
Contact an Air Quality Engineering Representative
for assistance on commercial sizing.
INDUSTRIAL APPLICATIONS
Sizing is determining how many air cleaning units
are required to maintain a desired level of air
quality. The process to sizing an industrial
application involves roughly figuring the number of
air cleaners needed and then modifying the figures
according to the specific characteristics of each
application.
For ambient air cleaning, the estimated number of
electronic air cleaners may be determined by the
relationship of air volume to the needed air
changes per hour.
An alternative method for calculating the estimated
number of electronic air cleaners can be used if it
is possible to measure the generation rate of the
contaminants and the allowable level of
contamination.
To use either method of calculation, contact an Air
Quality Engineering Representative for assistance
on industrial sizing.
FIGURE 4 – TYPICAL INSTALLATION
CENTRAL DETERGENT SYSTEM FOR
MULTIPLE AIR CLEANERS
Regardless of the method used to calculate the
number of units needed to produce clean air, the
physical conditions of the space to be cleaned
may either limit this number or demand that more
units be installed. For ambient air cleaning, it is
important to establish a uniform airflow pattern
throughout the entire space. Limitations to the
calculated sizing may be a lack of space for
mounting areas or the number of units may
interrupt normal building operation; that is, a unit
cannot be mounted where an overhead crane will
smash into it or where stand mountings seriously
interrupt building traffic patterns. The number of
units required by air volume and air changes per
hour might need to be increased when the shape
of a structure is such capturing and air distribution
is not possible according to the sizing calculations
that effective.
When the installation includes two, three or four
AutoClean air cleaners, they can be positioned so
that the wash detergent can be pumped from a
centrally located bottle. Maximum horizontal
distance from air cleaner cabinet to detergent
bottle is 20 ft., maximum vertical distance is 7 ft.
8
Depending on the installation, it may be necessary
to incorporate some or all of the precautions
mentioned below:
TRANSITIONS
When adapting the duct to fit the air cleaner, use
gradual transitions in duct size to prevent
turbulence and to increase efficiency.
1. Outdoor air intakes should be hooded or
louvered to provide adequate protection from
rain and snow. The type of hood used will
depend upon the installation and expected
weather.
Duct transitions should not exceed 20 degrees
(about 4” per lineal foot) on each side of a fitting.
2. Outdoor air intakes should always be
equipped with a “bird screen.”
3. At times it may be desirable to install a prefilter
ahead of the electronic air cleaner. This is
done to remove contaminants that could be
harmful to the air cleaner or might cause
excessively fast dirt buildup or arcing in the
electronic cell.
WATER DAMAGE PROTECTION
If the installation is going to be overhead, provide
a sheet metal pan with a drain under the entire
AutoClean cabinet. This is important in case of
water leaks in the ductwork or in the case of a
plugged drain.
Fig. 5: TYPICAL INSTALLATION WITH TURNING VANES IN
AIR DUCT
OUTDOOR AIR
When outdoor air is added to the return air duct,
sufficient heat must be added to maintain a
uniform a temperature between 50°F and 125°F.
Two methods are recommended:
Make certain a drainpipe of sufficient size and
slope is roughed-in to the bottom of the air cleaner
cabinet at the planned location.
1. Baffles. Mixing baffles should be used to mix
the outdoor air and the return air before it
enters the air cleaner.
Make certain the cooling coil is installed
downstream from the air cleaner cabinet to
prevent condensation and chilled air (cooler than
40°F [5°C]) from entering the cell.
2.
AIR CONDITIONING
Preheat Coil. If large amounts of outdoor air
are used, it must be heated. An appropriate
control system should be used to control the
heating element (electric strip heater, steam
coil, etc.).
HUMIDIFIERS
Location of the system humidifier is important to
the operation of the air cleaner.
An evaporative type humidifier may be installed
between the furnace warm air duct and the return
air duct without affecting the electronic air cleaner.
Outdoor air intakes should be protected to prevent
the introduction of unnecessary contaminants.
9
ASSEMBLY & INSTALLATION
- IMPORTANT This section includes information for the sheet metal, plumbing and electrical installation. Make certain
each person involved with the installation is aware of the appropriate subsections in the manual.
- INSTALLATION CHECK LIST -Transitions
-Turning Vanes
-Components Assembled
Electronic Cells
-Wiring
-Activated Carbon Filters Required?
-Hot Water Supply Line
-Pressure Regulator Required?
-Water Strainer
-Drain Connected
-Check Packing Materials Before Discarding
- CAUTION Do NOT connect the power source until after the air cleaner is completely assembled.
If the air cleaner must be turned on for an electrical check, be extremely careful in avoiding electrical
shock. Also, take care to avoid the air cleaner’s moving parts.
UNPACKING
Remove all shipping cardboard and banding.
Be sure to inspect the packaging material before
discarding it.
4. Drain connection.
WHEN INSTALLING THIS PRODUCT
6. Sequence controller.
5. Water strainer.
7. Accessories, if ordered.
1. Read these instructions carefully. Failure to
follow them could damage the product or
cause a hazardous condition.
2.
PLACEMENT OF THE AIR CLEANER
Depending on the placement of the air cleaner
(roof top for example) a lifting crane might be
necessary. Make sure that the air cleaner and
components are properly supported before
lifting.
After installation is complete, check out
product operation as provided in these
instructions.
All components are individually packaged and
shipped in one large box. Before proceeding,
carefully open each carton and visually check for
possible damage to the air cleaner components.
If placing on a rooftop make sure there is proper
clearance between the rooftop and the air
cleaner. This can be achieved with mounting
beams or by keeping the lifting supports in
place.
1. Cabinet with control box mounted.
2. Electronic cell (1-8 cartons depending on
model ordered).
If the air cleaner is installed in a location
where water damage is possible, install a
sheet metal pan with drain under the air
cleaner cabinet and sloped ductwork.
3. Legs with leveler screws and mounting
bolts.
10
c.
SHEET METAL INSTALLATION
Air Distribution and Ductwork
The AutoClean operates most efficiently when
all system air is delivered across the electronic
cell at a uniform velocity. Turning vanes should
be added to any return airdrop upstream from
the air cleaner. See Fig. 5.
Use caulking compound (not furnished)
to seal the flange joints and all ductwork
joints on both the inlet and outlet sides.
Seal all joints for at least 3 ft. from
cabinet.
FILTER PLACEMENT
1. Slide prefilters into shield channels and push
all the way to the back of the cabinet.
Gradual transitions to the AutoClean cabinet are
recommended in all ductwork larger or smaller
than the cabinet opening. If transitions are
used, they should not exceed 20 degrees (4”
rise per linear ft.
Install the Air Cleaner
Mount the AutoClean Air Cleaner as Follows:
1. Fabricate and install the necessary vanes
and transitions.
2. Set the cabinet in position.
a. If feet are used, mount the feet on the
AutoClean cabinet and adjust all four
feet-leveler screws. The bottom of the
cabinet must be level. This will provide
for proper drainage of water from the
bottom of the cabinet. Maximum
adjustment is 1 ¼ in. for each leveler
screw.
FIGURE 6 – CORRECT CELL ORIENTATION IN
AutoClean
2. Insert the electronic cells into the cabinet
with THIS SIDE OUT label facing the door
opening. Make certain the arrow stamped
on the cell points downstream. See Fig. 6.
b. If hanging brackets are used, make
certain the brackets are strong enough
to hold the cabinet and the cabinet is
attached firmly to the brackets.
c.
3. Close the door.
Leave clearance above the control box
to remove the cover and apply a wrench
to the water strainer.
3. Ductwork preparation
a. Drill clearance holes for sheet metal
screws in the cabinet flanges which will
not cause leaking. Remember that the
ductwork must be water-tight near the
cabinet.
b. Fasten the duct to the inside of the
cabinet flange opening with sheet metal
screws.
11
PLUMBING INSTALLATION
Model
AutoClean 2000
AutoClean 4000
AutoClean 8000
Recommended
Min. Water
Pressure during
Wash
psi
kPa
25
25
25
172.4
172.4
172.4
Recommended
Hot Water Tank
Size (Minimum)
Hot Water per
Wash
Washes per
unit of
detergent
Gallon
Liter
Gallon
Liter
Gallon
Liter
40
50
100
151.4
189.3
378.5
35
60
112
132.5
227.1
423.9
20
10
6
5.3
2.6
1.6
Recommended
wash water
temperature
125 to 160 deg F
( 52 to 71 deg C)
Maximum water flow
rate @ 30 psi (206.8
kPa)
Gal /
min
4
7
14
Liter / min
15.1
26.5
53.0
Figure 7 – Hot Water and Detergent Requirements
Connect the Hot Water Supply
Connect the Detergent Bottle
Plumbing must comply with applicable codes
and regulations. The hot water supply line from
the heater to the air cleaner should be ¾”
copper pipe for AutoClean 2000 and AutoClean
4000 and 1” for the AutoClean 8000.
FIGURE 8 – TYPICAL INSTALLATION FOR
HOT WATER SUPPLY
1. Install the water strainer (supplied) in the hot
water line ahead of the water valve. See
Fig. 8. The strainer protects the valves and
washing jets from clogging.
2. Attach the pressure regulator valve (if water
pressure is over 75 psi ) to the water
strainer.
3. Connect a faucet, if desired, for checking
water temperature.
FIGURE 9 – CONNECTING DETERGENT
BOTTLE TO THE CONTROL BOX
1. Insert the plastic hose (supplied) over the
metal tube. See Fig. 9. Fasten the hose
with a clamp.
2. Insert the hose into the bottle. Make certain
the filter screen rests on the bottom of the
bottle.
Connect the Drain
Connect the drain spud (2 inch) in the base of
the AutoClean cabinet to the waste drain. Use a
water trap or check the valve to prevent sewer
odor from entering the air cleaner base and
spreading through the air system. Follow local
codes. Test may have to be preformed to check
total water quality after air cleaner is installed.
3. Place the bottle on the hanger.
4. Close the top of the bottle with the stopper
provided to prevent debris from falling into
the detergent.
NOTE: Multiple hoses can be inserted into a
detergent bottle. Maximum horizontal distance
from the air cleaner to the detergent bottle is 20
ft., maximum vertical distance is 7 ft.
12
Follow figures 10, 11 12, and 13 for making all
the appropriate electrical connections.
Figures 10 and 11 are of the internal wiring
diagrams for each unit.
Figures 12 and 13 are of the total wiring
diagrams for the units. Notice the three boxes
surrounding the Unit, Timer, and HVAC system.
All wires that appear outside of these boxes
need to be added by the installer.
ELECTRICAL INSTALLATION
All wiring must comply with applicable local
codes and ordinances. The power supply to the
AutoClean air cleaner must be 120V or 240V, 60
Hz, or 220-240V, 50 Hz. Refer to the AutoClean
nameplate for the proper voltage for your air
cleaner. Use color-coded wires and attach all
connections with solderless connectors or to the
screw type terminals.
FIGURE 10 – INTERNAL WIRING SCHEMATIC FOR AUTOCLEAN 2000 AND 4000
13
FIGURE 11 – INTERNAL WIRING SCHEMATIC FOR AUTOCLEAN 8000
14
FIGURE 12 – WIRING SCHEMATIC FOR TYPICAL HVAC SYSTEM
15
FIGURE 13 – WIRING SCHEMATIC FOR EXHAUST FAN SYSTEM
CHECKOUT
3. Check over the installation for correct sheetmetal, plumbing and electrical work.
- IMPORTANT Before putting the AutoClean In-Place Wash
Electronic Air Cleaner into service, check through
the following items to be sure it is properly
installed.
4. Turning vanes should be used in duct elbow to
provide even air distribution across the cell.
5. When it is necessary to change the duct size
close to the air cleaner, use gradual transitions
to reduce turbulence.
2. If outdoor air is used, care must be taken to
prevent direct delivery of cold outside air
across the electronic cell. Preheat the air in
some manner or mix with return air.
GENERAL COMPONENT
INSPECTION
16
1. Check for proper orientation of the
electronic cells, protective screens and
spray shield. Airflow arrows must point
downstream. Protective screens must be
on both sides of the electronic cells.
CHECK THE ELECTRONIC CELLS
AND THE POWER SUPPLY
2. Be sure that the electronic cells, protective
screens and spray shields are clean, dry
and free of foreign objects.
Check the indicator light on the power door. It
should be on. With the power supply energized,
momentarily open the access door. When the
door opens the indicator light should go out.
With all components in place and the access
door closed, energize the system fan and turn
on the electronic air cleaner.
3. Be sure the spray manifold is located in the
cabinet with nozzles pointed toward the
cells.
If the power supply and electronic cells do not
check out properly in this procedure, refer to the
TROUBLESHOOTING section for additional
checks.
CHECK THE JUNCTION BOX
CONNECTIONS
CHECK THE AUTOMATIC WASHING
CYCLE
Check all electrical connections to make certain
they are correct and complete. Refer to the
hookup diagrams (Figures 9 through 13).
The wash cycle for the electronic cell is
controlled by the built-in sequence timer and the
washing assembly is operated by a motor. The
wash cycle may be manually activated by
pressing the button. Remove and visually check
cell and screens for dirt.
CHECK THE PLUMBING
CONNECTIONS
Check to be sure all plumbing work including
the hot water supply and the drain are correct
and will not leak!
The manifold motor operates a cam and gear
assembly to slowly move the manifold (water
pipe and spray nozzles) during the wash cycle.
Make sure there is complete coverage of the
cells during a wash cycle.
SEQUENCE TIMER OPERATION
SYSTEM SHUT DOWN - 1MIN, WASH - 2MIN, RINSE - 5 MIN, DRY - 45 MIN
EAC POWER SUPPLY
SYSTEM FAN
DETERGENT PUMP
HOT WATER VALVE
DETERGENT VALVE
MANIFOLD MOTOR
SYSTEM HEATING
SYSTEM COOLING
0
2
4
6
8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60
TIME (MINUTES)
OPERATES AT DEMAND OF PRIMARY CONTROL
CIRCUIT OFF
CIRCUIT ON
Figure - 14 - Sequence Timer Operation
17
MAINTENANCE
- CAUTION Always disconnect the power to the AutoClean before working on or near the air cleaner.
WHEN TO WASH THE ELECTRONIC
CELLS
While the cells in the electronic air cleaner are
being washed, a musty, dirty odor combined with
the characteristic odor of the detergent may be
noticed. This is caused when the accumulated dirt
on the cells is washed off by the detergent and hot
water spray. It will disappear after the washing is
complete.
To maintain peak performance and efficiency, the
electronic cells and spray shields in the electronic
air cleaner must be washed regularly. This
washing is necessary to remove the dirt particles
accumulated during the air cleaning process.
The cells and screens should be visually checked
for dirt or lint. Experience will probably be the best
indicator of how often the cells and screens should
be cleaned. For example, when operating in a
thick smoke or particularly dirty atmosphere, the
cells may need washing twice a week. If the dirt
accumulation is light, the period between
washings can be lengthened.
AUTOMATIC WASHING CYCLE
The cell wash cycle for the electronic air cleaner is
controlled by a built-in timer sequence and may be
activated by a master clock. The washing
assembly is operated by a motor. NOTE: For 50
Hz models, the timing will be about one-fifth
longer.
Make sure that enough hot water is available for
washing throughout the entire cycle. In
installations with multiple electronic air cleaners, it
may be necessary to stagger the timing of the
wash cycles. This is to assure adequate water
pressure for washing.
FIGURE 15 – PN 38010, ELECTRONIC CELL
COMPONENTS. DIMENSIONS IN INCHES
[MILLIMETERS SHOWN IN BRACKETS].
MANUALLY STARTING A WASH
CYCLE
The electronic air cleaner is equipped with an
automatic wash control box. When an extra wash
cycle is desired, it may be manually started by
pushing the labeled button.
NOTE: The complete cycle takes about 70
minutes. For the first 15 minutes when water is
being sprayed in the electronic air cleaner, the
heating or cooling system is automatically turned
off.
18
REPLENISH THE DETERGENT SUPPLY
WASHING THE CELLS OUTSIDE THE
ELECTRONIC AIR CLEANER
After routine washing, a noticeable buildup may
remain on some parts of the cells. This is normal
and has only a negligible effect on performance.
- IMPORTANT Replenish the detergent supply in the bottle before
it is completely empty. If detergent is allowed to
dry in the bottom of the hose or bottle, the hose
may become plugged.
After a long period of service, perhaps every one
to three years, the electronic cells should be
removed from the cabinet and given an extra
thorough washing. In many areas, professional
cell cleaning services are available or they may be
returned to Air Quality Engineering for a
professional cleaning.
Replenish the detergent supply as follows:
1. Remove the stopper and hose from the nearly
empty bottle.
The spray shields may be washed along with the
electronic cells. Before doing this, however,
remove the lint from the screens to prevent getting
lint caught in the electronic cells.
2. Insert the hose into a new, full bottle or refilled
bottle. Make certain that the filter screen at
the end of the hose rests on the bottom of the
bottle.
REMOVE THE CELLS AND THE
SCREENS
3. Hang the bottle on its hanger or replace it
where the first bottle was placed.
1. Use care to avoid damage to the collector
plates when handling and washing the cells.
4. Close the top of the bottle with the stopper
provided to prevent debris from falling into the
detergent.
2. Pull the handle to slide the cells out. Note the
direction of the airflow arrows on the cells.
3. Pull the screen out. Vacuum or dust loose dirt
in the cell or screen tracks.
NOTE: Maximum horizontal distance from the air
cleaner to the detergent bottle is 20 ft. [6.1 m].
Maximum vertical distance from the air cleaner to
the bottle is 10 ft. [3.0 m].
MANUALLY CLEANING CELLS
Depending on the type of contaminant, different
cleaners will be required. Smokemaster liquid
detergent will be adequate to remove almost any
type of dust, dirt, pollen and tobacco smoke. A
cleaner, such as AQE’s welding detergent part
number 45026, will remove metal oxides such as
those produced by welding. A cleaner, such as
AQE’s degreaser part number 45031, will remove
greases associated with kitchen hoods.
Smokemaster has 1 gal. [3.8 L] bottles and 55 gal.
[208.0 L] drums of liquid detergent available.
MANUALLY CLEANING
CLEANING THE SPRAY SHIELDS
The spray shields in front of the electronic cells
help stop lint and other large particles. It’s a good
idea to check these shields periodically to be sure
they are not overloaded.
- CAUTION -
At intervals of about one year, the spray shields
should be removed to clean off the accumulated
lint. An overloaded shield screen can restrict the
airflow through the heating or cooling system.
Do not splash the cleaning solution in your eyes
and avoid prolonged contact with your skin. Keep
the detergent and solution out of the reach of
children. Be sure to follow the cleaning solution
label instructions for use or storage.
The shields may be cleaned in several ways:
- spray with a garden hose
- vacuum or
- knock the dirt off onto a paper by striking the
screen against the floor.
1. Mix the cleaning solution according to the
label instructions.
19
other short in the charging section, is indicated by
the status light on the power door. Broken wires
must be replaced. Remove all parts of the broken
wire and temporarily use the cell short of one wire
until it can be replaced as directed below. See the
PARTS LIST to order wires.
2. Soak the cells for the time indicated on the
cleaning solution label. Before removing the
cells, slosh them around several times.
3. Rinse the cells with a fine spray.
4. Soak the cells and let the water drain. If the
water draining from the cells feels slippery,
they need more rinsing.
To replace the ionizing wires, remove the
electronic cell from the cabinet and proceed as
follows:
5. Inspect the cells for cleanliness. If any dirt
remains, it probably indicates that the cells
should be washed more frequently. Repeat
this soaking procedure, if needed, to get the
cells clean.
1. Remove all of the broken wire from the cell
mounting brackets. See Fig. 16.
2. Install the new wire.
a. Insert the “T” end of the ionizing wire into
the keyhole spring until the hooked end
can be secured in the mounting bracket
hole.
REPLACE THE ELECTRONIC CELLS
AND THE SPRAY SHIELDS
1. Replace the electronic cell so that the arrow
on the handle-side of the cell points in the
direction of the airflow.
Use a long nose pliers and carefully pull the
spring until the hooked end can be secured in
the mounting bracket hole.
2. Insert the spray shields in the channels
provided.
3. Replace and close the power door.
NOTE: The just washed cell may be replaced in
the cabinet even though it is still wet. The system
light may come on during the normal drying
period.
IONIZING WIRE REPLACEMENT
The fine wire electrodes in the charging section of
the electronic cell may break or become damaged.
During operation, a broken or deformed wire
generally causes a short to ground, possibly with
visible arcing or sparking. This condition, or any
FIGURE 16 – METHOD OF REPLACING THE
IONIZING WIRE
20
TROUBLE SHOOTING
WARNING!
The following instructions are intended for qualified service personnel only.
Dangerous line voltage circuits are exposed during this procedure. Disconnect
the power before servicing the unit. Voltage may exceed 10,000 Vdc. Make sure
meter to be used has appropriate voltage rating.
Before beginning this section make sure to review the checkout and maintenance
sections!
Make sure all wiring is connected properly reference figures 8, 9, 10, and 11.
FIGURE 18 - SEQUENCE CONTROLLER
FIGURE 17 - CONTROL BOX COMPONENTS
Indicator light flickers / Unit makes zapping noises
Some flicker is inherent in neon indicator lights and is not an indication that anything is wrong. If the
indicator light blinks off and back on and is accompanied by a clicking or zapping noise that is frequent, it
is an indication that the electronic collector cell(s) may be dirty or damaged. A wash cycle should be
performed to clean the cell. An occasional blink or snapping is normal.
If the wash cycle does not eliminate the noise remove the cells and investigate them looking for bent
collector fins or a large particle stuck in a cell. Also check the contacts on the cells and inside the unit for
a possible bad connection.
Remove any particles taking care not to bend the collector plates or break any ionizing wires.
If any ionizing wires are broken reference the parts list for replacement.
If a collector plate is bent causing the arcing (bug zapper noise), one may attempt to bend the plate back
to an original position with a duckbilled pliers. Care must be used as further damage can be caused by
stretching the aluminum plates, which can render the cell unrepairable. Air Quality Engineering will
21
evaluate cells at no charge and provide free repair estimates. This is highly recommended before
untrained personnel attempt repairs. Please contact Air Quality Engineering at 1-800-328-0787 for
assistance.
Indicator light is NOT on
Check to see if the wash system is operating. The indicator light should not be lit when the wash system
is activated.
Check to see if the cell access door is closed properly. The indicator light will not be lit if the door is open
and the electronic cells will not be energized.
Be sure the electrical connections have been made properly per Figure 10 & 11, particularly that a lead
was made from the fan motor to terminal 16A on the sequence controller. This supplies power to the
sequence controller when the fan is operating which in turn supplies power to the power supply.
Remove the electronic collector cell(s) and close the door. If the light comes back on, there is a short in
at least one collector cell. A short can be a result of the cell(s) being excessively dirty, a large piece of
contaminant shorting the fins, or a physical damage such as a collector fin being bent out of shape and
touching an adjoining fin. The wash cycle may be run to clean the cells if they appear dirty. Visually
inspect the cell for large particulate that may be bridging two adjoining collector fins or for physical
damage. If damage is identified, repairs should only be performed by trained personnel as improper
repairs may result in unrepairable damage. Please contact Air Quality Engineering, Inc. at 1-800-3280787 for assistance. Cells may be returned for free repair estimates.
If the indicator light does not come on with the cells removed and the door closed, use a voltmeter to
confirm that there is indeed voltage at the input of the power supply. If there is voltage at the power
supply, but no indicator light, the power supply should be replaced. The indicator light itself has a very
low failure rate.
Water not Flowing
There are two valves in series. The first valve (the one on the left) is an open/closed valve while the
second valve is a flow control valve (meaning its positions are fully open/partially open). Check to make
sure the first valve is getting energized (it is fail closed). One should hear a clicking from the solenoid
during as the sequence controller engages and disengages the solenoids. If this is not occurring one
could check this by manually taking apart the hot water solenoid, or a new assembly might have to be
installed.
Detergent not Flowing
During the wash cycle the valves should open and close allowing detergent to be pumped from the
container and sprayed from the manifold jets. If the detergent is not being sprayed check for the following:
If the detergent supply bottle is empty. If the detergent supply tube is restricted. If the detergent pump is
running. The detergent pump makes a significant amount of noise and should be audible while it is
running.
If the pump is not running, check to make sure it is receiving voltage, if not, the sequence controller has
an LED indicator for the detergent pump, if the LED does not light, sequence controller may need to be
replaced. If it does light, but pump does not run, the pump may need to be replaced.
22
Too much detergent being used
The length of time the detergent pump is on during the wash cycle can be manually changed on the
sequence controller by rotating the potentiometer.
Mechanical wash system not working (the nozzles are not turning or not
traversing along the cells, during the wash and rinse cycle.)
The manifold motor operates both the rotation and traversing motion of the jets. Check to see if the
manifold motor is operating.
If the motor is still not operational check to see if it is getting voltage.
If no voltage is getting to the motor trace wiring back and find the break.
If voltage is getting to the motor and still no movement is coming from the motor the motor will need to be
replaced. Reference the parts list for replacement.
Make sure that the linkage is not being stopped by an obstruction.
Nothing happens when the start button is depressed
Check inside the NEMA box of the sequence controller to see if the LED lights light up when you push the
start button. If they do, the sequence controller is not properly wired to the AutoClean. Check the
electrical schematics for proper wiring.
If the LEDs do not light up when the start button is depressed, check to see that voltage is being supplied
to the sequence controller. If voltage is present, but the LEDs won’t light, replace the sequence
controller.
Fan will not turn off during a wash cycle
If the fan does not turn off reference the wiring diagram to make sure it wired properly. The fan relay coil
should be energized or de-energized by terminal 15 of the sequence controller.
23
PARTS IMAGES & PART NUMBERS
24
ITEM NO.
DESCRIPTION
1
Spray Shield, Pre/Post Filter 24 5/8” x 24” x ¼”
Industrial Cell Full Size
Industrial Cell Half Size
Ionizing wires for Industrial Cell sold in 5 pack
Sequence Controller
Manual Start switch
Power Supply Assy
Detergent Valve & Solenoid Assy
Detergent Pump
Water Valve & Solenoid Assy.
Water Strainer
Manifold Motor
Liquid Detergent (1 gal. [3.78 L])
Liquid Detergent-55 gal. [208.2 L] drum
Cell Coat
Cell Coat Refill
Welding Smoke Detergent (5 Gal)
Industrial Cell Cleaning Kit
Degreaser (5 Gal.)
2
Not Shown
3
4
5
6
7
8
Not Shown
9
Not Shown
Not Shown
Not Shown
Not Shown
Not Shown
25
120V, 60 HZ
41022
38010
38003
38005
45008
45011
45023
45024
45026
66666
45031
PART NO.
240V, 60 HZ
41022
38010
38003
38005
45008
45011
45023
45024
45026
66666
45031
220-240V, 50 HZ
41022
38010
38003
38005
45008
45011
45023
45024
45026
66666
45031
26
CERTIFICATE OF WARRANTY
THREE-YEAR LIMITED WARRANTY
Air Quality Engineering, Inc. (AQE), warrants to the original purchaser, subject to the conditions below, that if the
“Product” covered by this warranty should fail to perform by reason of improper workmanship or material, AQE will
during the period of three (3) years from the date of original purchase either (i) replace the product or (ii) provide all
necessary parts to repair the product without charge. The decision to replace the product or the necessary parts
shall rest solely with AQE. This three-year limited warranty does not apply to main filter elements. AQE will replace
without charge the main filter elements during the period of thirty (30) days from the date of original purchase if the
main filter elements fail to perform by reason of improper workmanship or material. This warranty is valid only under
the following conditions:
CONDITIONS
1.
REGISTRATION: The purchaser’s completion and mailing of the Registration Card to Air Quality Engineering,
Inc., 7140 Northland Drive North, Minneapolis, Minnesota 55428-1520 within 30 days of original purchase.
2.
AUTHORIZATION: The purchaser will contact AQE at (763) 531-9823 for authorization, returned goods number
(RGA) and the shipping address. AQE will direct the purchaser to either return the necessary parts or the
product at AQE’s option.
3.
PROPER DELIVERY: The shipping, freight prepaid or delivery of the parts or the product to AQE in either its
original carton or in a carton assuring similar protection of the product with the returned goods number (RGA)
clearly displayed on the outside of the carton.
4.
UNAUTHORIZED REPAIR: A showing by the original purchaser that the product has not been altered, repaired
or serviced by anyone other than an authorized service technician using genuine AQE parts.
5.
UNAUTHORIZED PARTS: A showing by the original purchaser that the product has had only genuine AQE
parts and filters used in its operation and maintenance.
6.
SERIAL NUMBER INTACT: A showing by the original purchaser that the serial number has not been altered or
removed.
7.
MISUSE: A showing by the original purchaser that the product has not been involved in an accident, freight
damaged, misused, abused or operated contrary to the instructions contained in the Owner’s Manual.
Air Quality Engineering, Inc.’s, sole responsibility shall be to repair or replace the product within the terms stated
above. AQE SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL DAMAGES RESULTING FROM ANY BREACH
OF WARRANTY, EXPRESS OR IMPLIED, APPLICABLE TO THIS PRODUCT. Some states do not allow the
exclusion or limitation of consequential damages so this limitation may not apply to you.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, AND THE WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY EXCLUDED BEYOND
THE THREE-YEAR DURATION OF THIS WARRANTY. Some states do not allow limitations on how long an implied
warranty lasts so the above limitation may not apply to you.
This warranty gives you specific legal rights and you may also have other rights that vary from state to state.
AIR QUALITY ENGINEERING, INC.
7140 NORTHLAND DRIVE NORTH
MINNEAPOLIS, MINNESOTA 55428-1520
TOLL FREE: 1-800-328-0787
TELEPHONE: (763) 531-9823
FAX: (763) 531-9900
MANUFACTURER & WORLDWIDE DISTRIBUTOR OF SMOKEMASTER® AIR CLEANING SYSTEMS
Printed in the USA
27
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