GeneralAire AC500 Owner's manual

1-248-476-5100
43800 Grand River Avenue
Novi, MI 48375

Table of contents
2
1.1 Unpacking and inspection 2
1.2 Technical data 3
2.1 Planning the installation 4
2.2 Type of installation: Return to Return 4
2.3 Type of installation: Stand-Alone 5
2.4 Installing the unit 6
3.1 General Operating Information 9
4.1 Changing filters 10
4.2 Cleaning unit 10
4.3 Auxiliary relay control module 11
INFORMATION FOR INSTALLERS PAGE
2.Installation Guide
INFORMATION FOR THE HOMEOWNER PAGE
3.Owner’s Operation Guide
GENERAL MAINTENANCE INFORMATION PAGE
4. Maintenance Guide
7
Limited Warranty
Manufacturer
Warranty
You benefit from a limited 7 year warranty
on the motorized impeller and a 5 year
limited warranty against manufacturing
defects on other components. The limited
warranty covers normal usage. It does not
apply to malfunctions or failures as a result
of improper installation, abuse, mishandling
or misapplication or any other circum-
stances outside the manufacturer’s control
or consent.
Warranty from the manufacturer is for parts
only, laborandshipping oftheproduct is not
covered under warranty.
† Warranty doesn’t cover in any way or form
the replaceable Pre-Filter, Carbon Filter or
HEPA Filter.
years
1.1.Unpacking and inspection
Box Content
Includes:
• Whole House AC500
• Power cord, 5 FT
• Plenum seal, 7.5 FT
• Screws, (16) 8 x 32 x 1/2”
• Template
GENERAL INFORMATION PAGE
1.Getting Started
Optional Interlock
11
Contact
For Technical Support
• Toll Free: 1-248-476-5100
Warning:
Instructions listed for interlocking the
filtration unit to a furnace is an example
only. Actual wiring of interlock connection
may vary depending on the system
Wiring the AC500 Air Cleaner
to an ICP 80% or 90 % +%Furnace
Thewiringtogetherofthe GeneralAire AC500 Air cleanerontoanICPelectronic fan
control (EFC) board is as simple as 1-2-3. Control boards on different brands of
furnaces vary but in principal are all quite similar.
Step 1:
Turn-off electric power to furnace and use a
120V coil SPST N/O relay (such as the Relay-
In-Box #RIBU1C L39-103). Mount relay to a _”
knockout.
Step 2:
Wire the HOT EAC terminal on the furnace’s
EFC board to one side of the 120V coil on the
relay. Wire the other side of the 120V coil
back to a spare common terminal on the EFC
board.
Step 3:
Wire 120V HOT from blower door safety
switch (use a spade terminal splitter similar to
Johnstone #G21-414) to one side of the open
contact on the relay (red wires on L38-180).
Wire from the relay to a receptacle you
mount in a 2X4 handy-box on the outside of
the furnace. Wire the common side of the
receptacle to the common terminal on the
furnace EFC board.

4. General Maintenance Information
10
Maintenance
GUIDE
4.1 Changing Filters
After opening the unit’s door, grasp both edges of filter
and pull with equal force to slide out the filter.
4.2 Cleaning
Once a year or as needed, clean the interior of the unit
(Wall and motor plates) using mild non-abrasive soap
and water. It is recommended to use products that are
environmentally friendly.
Troubleshooting Suggestions
Unit does not operate •Is power cord fully inserted in the unit’s
connector?
•Is outlet powered?
•Is door interlock switch operating?
Unit operates only on one speed. Possible loose wire inside electrical box,
contact your local contractor.
Unit vibrates Check for excessive dust builup or missing
balancing weight on the impeller wheel.
M
L
Door
Interlock
Brown
N
Blue
Black
2.5uf
7.5uf
G
Speed
Selection
When should
I Service
my Unit?
service and accessories
Detailed maintenance information is located
on the front decal on motor plate.
PRE-FILTER AND CARBON
FILTER
Replace filters every 3 to 6 months or as
needed.
HEPA FILTER
Replace filter every 1 to 3 years or as
needed. Check regularly to maintain maxi-
mum performance from your HVAC system.
For replacement filters, contact your local
HVAC contractor.
Note
to installer
IMPORTANT : ALWAYS UNPLUG UNIT
BEFORE SERVICING 4.4 Electrical Wiring Diagram
4.3 Troubleshooting
1.2. Technical Data
3
Dimensions and Clearance
installation
Back View
Front View Side View - Clearance
Side View Front View Side View - Clearance
Return Air Plenum and Stand Alone Installations
*
With Collar Mount Kit
Specifications
IMPORTANT INFORMATION
The manufacturer reserves the right to modify a product, without prior notice,
whether in design, color or specifications, in order to offer at all times a qual-
ity product that is highly competitive. • Please consult local authorities to find
out whether the installation of electrical products requires the services of a
certified technician or electrician.
Model AC500
22” (559 mm)
13”
(330mm)
17”
(432 mm)
17”
(432mm)
17”
(432 mm) 12”
(305 mm)
11.587”
(294.5 mm)
Return Air Plenum Installation
12”
(305 mm)
11.587”
(294.5 mm)
22” (559 mm)
* Installation requires kit No.CMK500
Stage 1
Stage 3
Stage 2
Stage 1
Stage 3
Stage 2
Filtration Stage 1 Prefilter (100563)
Filtration Stage 2 Carbon Filter (100512)
Filtration Stage 3 HEPA filter (100562)
Weight 28 lbs (12.7 kg)
Plenum Mount Port Openings 16” x 3.5” (406mm x89mm)
Collar Mount Port Openings 8” (203mm) Round*
Installation type Plenum,Wall* or Floor*Mounted
Electrical Supply 120 VAC @ 60 Hz
Power Consumption 134 W
Certification CCSA US
Air flow data 220-300 CF.M.

Door
Switch
Mode
Selector
•II
• I
Operations
MaximumFiltration
Normal Filtration
3. General Operating Information
9
Function
The Whole House HEPA system is comprised of a ventilator, speed selection
switch, 3 stages of filtration and the cabinet enclosure system. The ventilator
pulls air through the pre-filter and pushes the same air threw the impregnat-
edcarbonpadforodor control and finallythelaststageof filtration is theHEPA
filter which removes 99.97% of particles 0.3µm in size.
Operation Mode Options
The unit features two speeds of operation for your convenience. The speed
selection switch is located on the front of the motor assembly. At lowest speed
the unit will provide 220 CFM of clean air while at highest speed, the unit will
provide 300 CFM of clean air. It is recommended that the unit be operated on
highest speed at all times to maximize the benefits of the HEPA filtration
system. If for some reason the filtration needs are not as important then one
might operate the unit at low speed.
An access door is provided at the front of the unit
to permit access to the filters and speed selection
switch. Opening the latch on the right side of the
unit will permit the door to swing open. A safety
door interlock switch cuts the power to the motors
foryoursafety. If needed the door canberemoved
from the cabinet hinges by holding the top part of
the door with one hand and gently taping on the
bottom edge of the door with the other hand to
release the door from its hinges.
Recommended Operation
The return plenum mount model operates in conjunction with your forced air
heating/cooling system. A forced air distribution system continuously
circulates the same air inside your home. The whole house HEPA filtration
system operates on the principal of bypass filtration, which means that a
portion of the air being returned into the furnace is filtered on each pass. Over
time all the air in the home gets cleaned. It is recommended that the furnace
blower be in operation whenever the filtration system is in operation.
For stand-alone attic installation, the HEPA filtration system must be
operated continuously whenever a part of all the system is located in an
unconditionned space to avoid condensation in the ductwork below freezing
(32°F ,0°C)
Maintenance of the unit should be performed at regular interval to keep the
benefits of the HEPA filtration unit.
Owner’s Operation GUIDE
Return
Air Plenum
Forced Air Heating/Cooling System
Forced Air Heating/Cooling System
To living
space
PAGE 4
2. Information for the Installer
Special
Consideration
For integrated system installation
•Verify clearance on the ductwork to
mount the unit using the Forced Air
heating/cooling system
•Minimum clearance requirements for
maintenance and service
•Electrical power requirements
•Interaction between the HEPA filter unit
and other mechanical devices.
Ducting Flair
System
installation
The Whole House HEPA Filtration system is
designed to install directly onto the return
air plenum of the forced air heating/cooling
system. Choosing this type of installation
eliminates the need to externally duct the
HEPA filter unit to the plenum system. If you
choose this type of installation, it is
recommended that you run the fan on your
forced air system continuously to maximize
its cleaning ability.
TIPS
to installer
The Whole House HEPA Filtration system
does not replace the filter from the forced
air heating/cooling system. Regular
maintenance of this filter is necessary to
permit the good operation of the forced air
heating/cooling system.
Optional collar
system
installation
Using kit no. CMK500 the Whole House
HEPA Filtration system can be converted to
use 8 inch round collars for application
requiring ducting. The kit includes two, 8
inch round collars, two mounting brackets
for wall or floor mounting, installation
guide and fasteners.
2.2 Type of Installation:
Return to Return Integrated System
Installation
GUIDE
2.1 Planning the Installation
The Whole House HEPA unit is a versatile appliance with multiple installations
configuration. It is recommended to take your time in planning the installation.
Several Installations are illustrated herein’ for Whole House filtration applications:
•Return to return integrated with the forced air
heating/cooling system.
•Central draw points using dedicated duct system
•Consult the manufacturer for other special applications.
Ducting Flair System
(Hepa Mounted on Duct)
INSTALLATION SHOULD BE PERFORMED BY A CERTIFIED PROFESSIONAL.
Consult your HVAC product manufacturer if the usage of this product will affect the performance of
your forced air heating / cooling system.
Optional Collar System
(Hepa Mounted on Wall)
Return
Air Plenum
To living
space

2.4 Installing the unit (Continued)
8
Step 3: Mount Hepa Step 3: (Continued)
Installation
GUIDE
figure 2.3b - Unfold the ducting flairs
completly to sandwich the return air plenum
between the ducting flair and the filtration unit.
figure2.3a - Align unit into place.
figure 2.3c - Install unit as usual using all
supplied fastening hardware.
Step 4: Finishing
Tips
to installer
It is recommended that the filtration unit have
a devoted receptacle with 115V. It is not rec-
ommended to connect unit with an extension
cord. If no receptacle is available please call
an electrical contractor to have one installed.
MAKE SURE TO INSTALL
FILTERACCORDING TO
AIR FLOW DIRECTION FOR
MAXIMUM PERFORMANCE
Check for this symbol on each
filters and it is located on the
unit’s motor plate.
figure 2.4b - Replace door and insert power
cord into the receptacle of the filter units and
the other end into wall outlet.
Stage 1: Pre-Filter
Stage 2: Carbon filter
Stage 3: HEPA Filter
figure 2.4a - Remove protective plastic covers
from all filters and replace them in their prop-
er location (Stage 1, 2 and 3).
2.3 Types of Installation: Stand-Alone
5
Installation
GUIDE
Stand Alone
Attic Installation
Ideal for homes without a forced air
heating / cooling system. Allows for air
filtration and circulation throughout
the home.
HEPA system must be operated continuously
whenever a part or all the system
is located in an unconditioned space to
avoid condensation in the ductwork
below freezing (0°C, 32°F).
Stand Alone
Basement Installation
Ductingwillusually consistof onereturn with
grille from one side of the home,
and one supply with grille at the opposite
end of the home.

6
2.4 Installing the unit
Installation
GUIDE
Tools required
•Phillips #2 or Robertson #1
screwdriver
•3/32” drill bit
•Tin snips or metal shear
•Power Drill
Location
Return side connections is to be installed
after the last branch on the return air
plenum and minimum 2 linear ft distance
from furnace.
A 5-ft power cord is supplied with the
unit. If not available a 120VAC outlet
needs to be supplied.
Note:
Refer to the Owner’s Operation Guide
(p.9) for details on how to remove the
unit’s door and filters
Step by step Installation
Steps involved in the preparation of the plenum mount system are
as followed:
figure 2.2b -One cut permits the clean
removal of the insulation piece.
Step 2:
Preparing ducting flairs
Remove the door and filters and proceed to
cut the insulation as illustrated below.
figure2.2a- Cut the insulation along the inside
edge of both inlet and outlet ports to remove
the insulation from the port openings.
Step 1:
Preparing return air plenum
Find a location that satisfies both service and
maintenance requirements and proceed to cut
holes as illustrated below.
figure 2.1a - Tape template to return air
plenum. Cut opening with metal shears and
predrill for the securing screws.
figure 2.1b - Remove template.
figure 2.2c -The unit should look like this
when the foam piece is removed.
2.4 Installing the unit (Continued)
7
Installation
GUIDE
Step 2:(Continued)
Cut the four metal tabs to release the
mounting flairs for the inlet and outlet ports.
figure 2.2j- Bend tabs outward approximately
90 degrees.
figure 2.2h - Apply plenum seal tape all
around both openings on the back of the unit.
figure 2.2i
Step 2:(Continued)
figure 2.2d
figure 2.2e
figure 2.2f
figure 2.2g
Tips
to installer
Interlocking the HEPA filtration unit with
the forced air heating / cooling system is
possible using an auxiliary relay. Refer to
page 11 of this guide for example.
Please consult local authorities to find out
whether the installation of electrical
products requires the services of a certified
technician or electrician.