Aprilaire 4200 User manual

Model 4200 & 4400 Media Air Cleaners
Installation Instructions
1. High voltage may cause serious
injury from electrical shock.
Disconnect power to the
furnace/air handler before
starting installation.
2. Sharp edges may cause injury
from cuts. Use care when cutting
and handling sheet metal.
WARNING
1. 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.
2. Installation must be done by a qualified heating and air conditioning
professional. Read instructions thoroughly before beginning installation.
3. Do not install air cleaner downstream of a UV light. UV lamps will cause
degradation of the filtering media.
CAUTION
SPECIFICATIONS
TABLE 1 – Initial Airflow Resistance (inches w.c.)
Model Airflow (CFM)
800 1000 1200 1400 1600 1800 2000
4200 .09 .12 .16 .20 .25 .30 .35
4400 .09 .13 .17 .22 .26 .31 .37
Electrical:
Voltage: 18-30 VAC
Max Current: 2A (maximum low-voltage current for fan control)
MERV (Minimum Efficiency Reporting Value) @ 347 fpm: 13
Airflow Capacity: up to 2000 CFM maximum
Replacement Media: 4200: Model 213 with SelfSeal™
4400: Model 413 with SelfSeal™
Max. Equipment Weight:
Cabinet will support 400 lb. static load
Air Cleaner and LED Base Operating Environment:
Temperature: 0°F – 140°F
Humidity: 0-90% non-condensing
Air Cleaner Control Operating Environment:
Temperature: 20°F – 120°F
Humidity: 0-90% non-condensing
Do not wire to EAC terminals of HVAC system. These terminals
are 120 Volts and will damage the Air Cleaner Control.
CAUTION
DIMENSIONS
TABLE 2 – Dimensions (inches)
Model ABCDE F GH JK
4200 19-3/4 25-3/8 21-3/16 6-3/4 27-3/8 21-3/16 19-3/4 22-1/16 27-11/16 23-5/8
4400 15-7/16 28-1/16 23-7/8 6-3/4 30-1/16 23-7/8 15-7/16 17-3/4 23-3/8 19-5/16
A
B
without DOOR
C
DE
with Door
F
G H
JK
90-1333

INSTALL THE AIR CLEANER CABINET
1. Leave sufficient space in front of the air cleaner for the removal of
the filtering media (see Figure 1).
2. DO NOT INSTALL DOWNSTREAM OF A UV LIGHT. UV lamps
will cause degradation of the filtering media.
3. Figures 2-4 show typical applications. Note position of LED Base.
LOCATING THE AIR CLEANER
29"
FIGURE 1 – Filtering Media Clearance
90-1317
Airflow AirflowAirflow
30°max
45°max
**
*
FIGURE 4 – Highboy Upflow Installation
90-1320
Airflow
*
FIGURE 2 – Horizontal Installation
90-1319
*Leave 4-1/2” above LED Base to allow for installation of the Air Cleaner Control.
Airflow Airflow
*
*
FIGURE 3 – Highboy Installation
90-1318
*Leave 4-1/2” above LED Base to allow for installation of the Air Cleaner Control.
*Leave 4-1/2” above LED Base to allow for installation of the Air Cleaner Control.
2

2. Remove the air cleaner door from the outer housing and pull out the filtering media
and Air Cleaner Control.
3. If replacing an existing filter, remove the filter and thoroughly clean the blower
compartment.
4. Use screws (field supplied) to mount the outer housing to the furnace/air handler.
There is no inlet or outlet side on the outer housing (the outer housing can be mounted on the left or right side of the
furnace/air handler), but the LED Base is to be located at an accessible location.
NOTE FOR UPFLOW INSTALLATIONS: Provide support under the outer housing to ensure the quality of the seals (see Figure 5).
5. Mount the return ductwork to the outer housing.
6. Seal all connections using mastic, foil tape or silicone based caulk.
7. Install the filtering media – use the instructions provided on the cartridge to ensure that it is installed in the proper orientation;
the outlet side of the filtering media is the expanded metal.
8. Install the door.
INSTALLATION
LED Base
shown with
cover
FIGURE 5
90-1317
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.
WARNING
1. Disconnect power to the furnace or air handler at the electrical service panel.
The electronic controls that are included with the air cleaner are
used to circulate air through the air cleaner, monitor filter life
and inform the user that the air is being cleaned. Users can turn
on the blower for a set period of time or adjust it so that the
blower is on, either as part of a heating/cooling call or blower
only, for a set number of minutes per hour. This requires the
Air Cleaner Control to be mounted in an accessible location,
and requires 18-22 gauge (standard thermostat cable) wires
to be run between the air cleaner components and the HVAC
components.
The Air Cleaner Control can be mounted:
• Option 1: near the thermostat – see pages 4-5.
• Option 2: on the air cleaner in the LED Base,
as shown in Figure 6 – see page 6.
• Option 3: near the HVAC equipment – see page 7.
Control
LED Base
INSTALL THE AIR CLEANER CONTROL
FIGURE 6 – Air Cleaner Control Mounted on the Air Cleaner
90-1334
3

1Run a 3-conductor cable between the LED Base and the
low voltage controls of the HVAC equipment.
2Remove the cover from the LED Base and wire the
LED Base to the low voltage controls of the HVAC
equipment as shown in Diagram 1. Replace the cover
on the LED Base.
3Remove the backplate from the Air Cleaner Control and
install the backplate near the thermostat. Use the wire
opening in the wall behind the thermostat to make sure
there is not a wall stud between the thermostat and
desired mounting location.
4Run a 5-conductor cable between the thermostat and
Air Cleaner Control.
5Wire the thermostat to the Air Cleaner Control as
shown in Diagram 2 or Diagram 3. Diagram 2 is for
standard, single thermostat systems; Diagram 3 is
for two-transformer systems such as radiant heat with
forced air cooling. Replace the Air Cleaner Control on
the backplate.
OPTION 1 – INSTALL THE AIR CLEANER CONTROL NEAR THE THERMOSTAT
R
FURNACE OR AIR
HANDLER
C
G
Y
W1
COOLING OR
COMPRESSOR
L1 L2
120
VAC
24
VAC
HEAT OR AUX.
HEAT
FAN
GSW
GF
C
R
LED BASE
SEE NOTE FOR
HEAT PUMPS AND
RADIANT HEAT
SYSTEMS
NOTE: IF THERE IS NO AUXILIARY HEAT OR IF THERE IS ONLY RADIANT HEAT,
DO NOT WIRE THE EQUIPMENT TO THE W TERMINAL OF THE LED BASE.
NEW WIRE
EXISTING
WIRE
LEGEND
WIRE NUT
BA
FROM THERMOSTAT
NOT USED
DIAGRAM 1 – Wiring the LED Base to the HVAC Equipment
90-1328
Wall Stud
FIGURE 8
90-1321
4
3
5
FIGURE 7
90-1321
12
4

R
THERMOSTAT
G
Y
W
COOLING
HEATING
FAN
GSWGFC
R
AIR CLEANER CONTROL
DISCONNECT EXISTING WIRE FROM
THERMOSTAT G (FAN) TERMINAL AND
USE WIRE NUT TO CONNECT TO GF
WIRE FROM AIR CLEANER CONTROL
NEW WIRE
EXISTING
WIRE
LEGEND
WIRE NUT
BA
C
NOTE 1: IF THE TRANSFORMER COMMON IS NOT AVAILABLE, USE THE SUPPLIED BATTERIES
TO POWER THE AIR CLEANER CONTROL.
NOTE 2: IF THERE IS NO HEAT OR AUXILIARY HEAT OUTPUT WIRED ON THE THERMOSTAT,
JUMPER THE GS AND W TERMINALS ON THE AIR CLEANER CONTROL.
SEE NOTE 1
TO HVAC EQUIPMENT
SEE NOTE 2
NOT USED
DIAGRAM 2 – Single Transformer Systems
90-1332
RC
THERMOSTAT
Y
G
RH
W
COOLING
HEATING
FAN
GSW
GF
C
R
AIR CLEANER CONTROL
NEW WIRE
EXISTING
WIRE
LEGEND
WIRE NUT
BA
R
C
TO RADIANT/
HYDRONIC
HEAT SYSTEM
TO FORCED
AIR COOLING
SYSTEM
SEE NOTE
NOT USED
DISCONNECT EXISTING WIRE FROM THERMOSTAT G (FAN)
TERMINAL AND USE WIRE NUT TO CONNECT TO GF WIRE
FROM AIR CLEANER CONTROL
NOTE: IF THE TRANSFORMER COMMON IS NOT AVAILABLE, USE THE SUPPLIED BATTERIES TO POWER
THE AIR CLEANER CONTROL. USE ONLY THE FORCED AIR COOLING SYSTEM TRANSFORMER
TO POWER THE AIR CLEANER CONTROL IN TWO TRANSFORMER SYSTEMS.
DIAGRAM 3 – Two Transformer Systems
90-1331
OPTION 1 – INSTALL THE AIR CLEANER CONTROL NEAR THE THERMOSTAT (CONTINUED)
5

90-1322
R
FURNACE OR AIR
HANDLER
C
G
Y
W1
COOLING OR
COMPRESSOR
L1 L2
120
VAC
24
VAC
HEAT OR AUX.
HEAT
FAN
GSW
GF
C
R
DISCONNECT EXISTING WIRE FROM
FAN TERMINAL AND USE WIRE NUT
(FIELD SUPPLIED) TO CONNECT TO
GS WIRE FROM LED BASE
NEW WIRE
EXISTING
WIRE
LEGEND
WIRE NUT
BA
FROM THERMOSTAT
SEE NOTE FOR
HEAT PUMPS AND
RADIANT HEAT
SYSTEMS
NOT USED
LED BASE
NOTE: IF THERE IS NO AUXILIARY HEAT OR IF THERE IS ONLY RADIANT HEAT,
DO NOT WIRE THE EQUIPMENT TO THE W TERMINAL OF THE LED BASE,
AND JUMPER THE GF AND W TERMINALS ON THE LED BASE.
OPTION 2 – AIR CLEANER CONTROL MOUNTED ON THE AIR CLEANER
1Run a 5-conductor cable between
the LED Base and the low voltage
controls of the HVAC equipment.
2Remove the cover from the LED Base
and wire to the low voltage controls
of the HVAC equipment as shown in
Diagram 4.
3Connect the supplied cable to the
Air Cleaner Control and LED Base
then slide the Air Cleaner Control
into place.
90-1321
FIGURE 9
DIAGRAM 4 – Wiring the LED Base to the HVAC Equipment
FIGURE 10
90-1329
12
3
6

LED BASE
AIR CLEANER CONTROL
GSW
GF
C
RBA
GSWGFC
RBA
NOT USED
NOT USED
R
FURNACE OR AIR
HANDLER
C
G
Y
W1
COOLING OR
COMPRESSOR
L1 L2
120
VAC
24
VAC
HEAT OR AUX.
HEAT
FAN
GSW
GF
C
R
DISCONNECT EXISTING WIRE FROM
FAN TERMINAL AND USE WIRE NUT
(FIELD SUPPLIED) TO CONNECT TO
GS WIRE FROM LED BASE
NEW WIRE
EXISTING
WIRE
LEGEND
WIRE NUT
BA
FROM THERMOSTAT
SEE NOTE FOR
HEAT PUMPS AND
RADIANT HEAT
SYSTEMS
NOT USED
LED BASE
NOTE: IF THERE IS NO AUXILIARY HEAT OR IF THERE IS ONLY RADIANT HEAT,
DO NOT WIRE THE EQUIPMENT TO THE W TERMINAL OF THE LED BASE,
AND JUMPER THE GF AND W TERMINALS ON THE LED BASE.
1Remove the backplate from the Air Cleaner Control, and install
the backplate at the desired location for the Air Cleaner Control.
Do not install the Air Cleaner Control on supply ductwork.
2Run a 5-conductor cable between the Air Cleaner Control and
the LED Base.
3Run a 5-conductor cable between the LED Base and the low
voltage controls of the HVAC equipment.
4Remove the cover from the LED Base and wire the Air Cleaner
Control to the LED Base as shown in Diagram 5. Replace the
Air Cleaner Control on the backplate.
5Wire the LED Base to the HVAC equipment as shown in
Diagram 6. Replace the cover on the LED Base.
FIGURE 11
DIAGRAM 5 – Wiring the Air Cleaner Control to the LED Base
DIAGRAM 6 – Wiring the LED Base to the HVAC Equipment
OPTION 3 – INSTALL THE AIR CLEANER CONTROL NEAR THE HVAC SYSTEM
90-1321
90-1330
90-1329
7
2
1
3
4
5
4

RESEARCH PRODUCTS CORPORATION
P.O. Box 1467 • Madison, WI 53701-1467 • Phone: [phone] • Fax: [phone] • www.aprilairepartners.com
10007820 3.08
B2701034A
©2008 Research Products Corporation
Printed in U.S.A.
1. Restore power to the HVAC equipment.
2. Set the thermostat mode to OFF and fan to AUTO.
3. The display on the Air Cleaner Control should look like Figure 13.
• Verify that there is no activity in the “FILTERING” portion of the display.
4. Press the “Event Clean” button on the Air Cleaner Control.
• Verify that the blower starts.
• Verify that the “FILTERING” portion of the display sequences (Figure 14).
• Verify that the LEDs on the LED base are sequencing on and off
(Figure 15).
5. Press the “Event Clean” button again to cancel the operation.
6. Return the thermostat Mode and Fan to the desired setting.
Refer to the Owner’s Manual for details on the operation of the
Air Cleaner Control.
INSTALL THE AIR CLEANER CONTROL
START UP
Filtering bars
will sequence on / off
LEDs will
sequence on / off
FIGURE 13
FIGURE 14 FIGURE 15
90-1322
90-1322
90-1322
SET UP
Jumper
FIGURE 12
90-1338
FILTER LIFE INDICATOR – SETTING THE REPLACEMENT FREQUENCY
Set the jumper on the back of the Air Cleaner Control circuit board, as
shown in Figure 12, to the desired frequency for filter changes.
TABLE 3 – Filter Change Frequency
Jumper
Position Filter Change Setting
OFF One calendar year (365 days)
A 6570 hours of use (9 months of continuous blower run time)
B 4380 hours of use (6 months of continuous blower run time)
C 2190 hours of use (3 months of continuous blower run time)
The factory default setting is OFF.