Honeywell PS1202C User manual

INSTALLATION INSTRUCTIONS
69-1137EF-03
PS1202C, PS2402C
Replacement Power Supply Kits
for Electronic Air Cleaners
APPLICATION
These kits replace the power supplies with solid-state
performance indicators (SSPI) used in the F50, F52,
F57, and F90 Electronic Air Cleaners. See Table 1. Each
kit includes the power supply and leadwires.
CAUTION
Electric Shock Hazard.
Can cause electrical shock or equipment
damage.
Disconnect power before removing or installing
power supply board.
Table 1. Power Supply Replacement Guide.
Supply
Model Voltage
Nominal Size of
Electronic Cell(s) P5 Ionizer
Current (mA)
LED Board
Jumper
Position Replacement Power
Supply (OS no.)
Air
Flow
Switch(in.) (mm)
F50E 120 Vac 16 x 25 406 x 635 1.65 2 (1.65) PS1202C00 No
20 x 20 508 x 508 1.65 2 (1.65)
20 x 25 508 x 635 2.1 1 (2.1)
240 Vac 16 x 25 406 x 635 1.65 2 (1.65) PS2402C00
20 x 20 508 x 508 1.65 2 (1.65)
20 x 25 508 x 635 2.1 1 (2.1)
F52E (One
Cell) 120 Vac 20 x 12-1/2 508 x 318 1.05 4 (1.05) PS1202C00
220-240
Vac, 50 Hz 1.05 4 (1.05) PS2402C00
F52E (Two
Cell) 120 Vac 20 x 25 508 x 635 2.1 1 (2.1) PS1202C00
220-240
Vac, 50 Hz 2.1 1 (2.1) PS2402C00
F57A (Two
Cell) 120 Vac 20 x 25 508 x 635 2.1 1 (2.1) PS1202C00
220-240
Vac, 50 Hz 2.1 1 (2.1) PS2402C00
F57B (One
Cell) 120 Vac 20 x 12-1/2 508 x 318 0.9 3 (1.29) PS1202C03
220-240 Vac 0.9 3 (1.29) PS1202C03 with 203365
F90A (Two
Cell) 120 Vac 20 x 25 508 x 635 2.1 1 (2.1) PS1202C03
220-240
Vac, 50 Hz 2.1 1 (2.1) PS1202C03 with 203365
F90B (One
Cell) 120 Vac 20 x 12-1/2 508 x 318 0.9 3 (1.29) PS1202C00
220-240
Vac, 50 Hz 0.9 3 (1.29) PS2402C00
F52F (One
Cell) 120 Vac 20 x 12-1/2 508 x 318 1.05 4 (1.05) PS1202C00 Yes
220-240
Vac, 50 Hz 1.05 4 (1.05) PS2402C00
F52F (Two
Cell) 120 Vac 20 x 25 508 x 635 2.1 1 (2.1) PS1202C00
240 Vac 2.1 1 (2.1) PS2402C00

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
69-1137EF—03 2
INSTALLATION
When Installing this Product…
1. Read these instructions carefully. Failure to follow
them could damage the product or cause a hazard-
ous condition such as electrical shock.
2. Check the ratings given in the instructions and on
the product to make sure the product is suitable for
your application.
3. Installer must be a trained, experienced service
technician.
4. After installation is complete, check out product
operation as provided in these instructions.
WARNING
Electric Shock Hazard.
Safety Hazard.
Can cause electrical shock or equipment
damage.
Disconnect power before removing old power
supply board and installing replacement power
supply board. When servicing the F57 or F90,
stand on a stable work platform or ladder.
Fig. 1. Power supply location on F50E Two-Cell Air
Cleaners.
To Remove Old Power Supply
Board And Performance Indicator
Board
NOTE: It is advisable to observe the location of lead-
wires on the power supply to be replaced.
Tagging the lead-wires as they are removed
will help to correctly reconnect them.
Open access door or grille. See Fig. 1 through 5.
Open power box.
Remove W8600E terminal block and wiring. Save
screws for future use.
On the F90, remove the power supply assembly as
follows:
— Open the cover by pulling the two latches located
on the front of the cover and swinging the cover
down until it hangs (see Fig. 5).
— Remove the two prefilters and the two cells from
the channel guides.
— Loosen the screws holding the power supply
assembly cover plate and remove the cover plate.
See Fig. 6.
— Loosen the two screws on the inner wall of the
power supply assembly and three screws on the
top of the assembly. Slide the power supply
assembly toward the center of the air cleaner and
disconnect the two Molex connectors and the one
quick connect connector. See Fig. 6.
— Remove the power supply assembly to a table or
work bench to replace the power supply.
Disconnect the red ionizer and black collector leads at
the board quick connects.
Disconnect remaining input leads at the quick
connects.
Remove and set aside the sheet metal screws holding
the power supply board in place. Remove the
performance indicator board by clipping the four plastic
standoffs with diagonal cutters, or squeezing the ends
of the standoffs to release the board. Remove and
discard the board.
M33489
2
ONE-CELL MODEL
1

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
369-1137EF—03
Fig. 2. Power supply location on F50 One Cell.
Fig. 3. Power supply enclosure location on F52 Air
Cleaner. Open to access power supply.
Fig. 4. Power box location on F57 Air Cleaners. Open
to access power supply.
Fig. 5. Opening the F90A Cover.
M33489
2
ONE-CELL MODEL
1
CELL CONTACT PLATES
CELL LATCH CELL
PLASTIC CELL HOOKS
HINGE PREFILTER
TEST
BUTTON
(ON DOOR) POWER
SUPPLY
ENCLOSURE
INTERLOCK
SWITCH
ON-OFF SWITCH
WITH NEON LIGHT
M11514A
M2364

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
69-1137EF—03 4
Fig. 6. Removing F90A Power Supply Assembly.
Install New Power Supply
When replacing the power supply, refer to the
appropriate wiring diagram. See Fig. 7 through Fig. 20.
Install new W8600E terminal block and wiring using
screws removed previously.
When replacing the power supply, reuse the lead wires
remaining in the air cleaner when removing the old
power supply board and performance indicator board.
Note that the F52 uses a mounting plate that has a
rubber bumper; turn over the power supply and pry the
rubber bumper off the bottom.
Align the mounting holes and mount the new power
supply in the air cleaner using the sheet-metal screws
removed earlier. Orient the terminal strip (on selected
models) so that pin 1 is at the top.
IMPORTANT
Do not splice ionizer and collector leads. These
leads must be unbroken to avoid electrical shock
through the connector or tape covering the
splice.
Route the remaining leads so the red ionizer and black
collector leads are separate from the power supply and
light leads. Route all leads around, rather than over,
the power supply board. Keep all leads away from high
voltage leads. On single-cell, duct mounted cleaners,
route the performance indicator output lead (4-wire
thermostat cable) to the rear of the power supply
assembly.
Connect the leads to the quick-connect terminals on
the new power supply. See Fig. 7 through Fig. 20.
Route the leads through the cable clamp and hook the
cable clamp to the tab on the left front of the power
supply. Push down the tab to hold the cable clamp in
place. See Fig. 24.
M2422B
ELECTRONIC
AIR CLEANER
POWER BOX
POWER BOX
SECURING
SCREWS (5)
POWER BOX COVER
POWER BOX COVER
SECURING SCREWS (5)
NOTE: SCREWS ONLY NEED TO BE
LOOSENED, NOT REMOVED.

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
569-1137EF—03
Fig. 7. Past electronic air cleaner (F50A&E, F52E) with W8600E—internal schematic.
RED BLACK
TRAY
SHORTING
BAR
TEST
BUTTON
JUNCTION BOX
COLLECTOR
IONIZER RED
BLACK
1
LINE VOLTAGE
POWER SUPPLY
BROWN
BLACK
BROWN
BLACK
ON-OFF SWITCH YELLOW
YELLOW
1
2
3
4
1
2
3
4
TERMINAL STRIP
FRONT BACK
TO
W8600
WALL
PANEL
RED
IONIZER
BLACK
COLLECTOR
M33491
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2 P1, P2 TERMINALS ON 120V MODELS ONLY. POWER CONNECTIONS ON 240 V MODELS ARE TO QUICK-CONNECTS ON POWER
SUPPLY TRANSFORMER. BROWN LEAD GOES TO TOP TERMINAL AND BLACK LEAD TO BOTTOM TERMINAL.
3 ONE-CELL UNIT SIMILAR, BUT WITH JUST ONE CELL.
4 ON ONE-CELL, DUCT-MOUNTED UNITS, SSPI OUTPUT LEAD IS A 4-WIRE CABLE.
4
3
BLACK
BROWN
BLACK
1
2
3
4
P19
P12
P13
P17
P15
P14
LED CIRCUIT
BOARD
2
POWER SUPPLY
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
69-1137EF—03 6
Fig. 8. Recent electronic air cleaner (F50A&E, F52E) with W8600E—internal schematic.
RED BLACK
TRAY
SHORTING
BAR
TEST
BUTTON
JUNCTION BOX
COLLECTOR
IONIZER RED
BLACK
1
LINE VOLTAGE
POWER SUPPLY
BROWN
BLACK
BROWN
BLACK
ON-OFF SWITCHYELLOW
YELLOW
1
2
3
4
1
2
3
4
TERMINAL STRIP
FRONT BACK
TO
W8600
WALL
PANEL
RED
IONIZER
BLACK
COLLECTOR
M33492
GREEN
RED
BLUE
YELLOW
GREEN
RED
BLUE
YELLOW
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION
AS REQUIRED.
2 P1, P2 TERMINALS ON 120V MODELS ONLY. POWER CONNECTIONS ON 240 V MODELS
ARE TO QUICK-CONNECTS ON POWER SUPPLY TRANSFORMER. BROWN LEAD GOES
TO TOP TERMINAL AND BLACK LEAD TO BOTTOM TERMINAL.
3 ONE-CELL UNIT SIMILAR, BUT WITH JUST ONE CELL.
4 ON ONE-CELL, DUCT-MOUNTED UNITS, SSPI OUTPUT LEAD IS A 4-WIRE CABLE.
4
3
BLACK
BROWN
BLACK
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
2
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
769-1137EF—03
Fig. 9. Retrofitted electronic air cleaner (F50A&E, F52E) with W8600E—internal schematic.
RED BLACK
TRAY
SHORTING
BAR
TEST
BUTTON
JUNCTION BOX
COLLECTOR
IONIZER RED
BLACK
1
LINE VOLTAGE
POWER SUPPLY
BROWN
BLACK
BROWN
BLACK
ON-OFF SWITCH YELLOW
YELLOW
1
2
3
4
1
2
3
4
TERMINAL STRIP
FRONT BACK
TO
W8600
WALL
PANEL
RED
IONIZER
BLACK
COLLECTOR
M33493
2
GREEN
RED
BLUE
YELLOW
GREEN
RED
BLUE
YELLOW
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2 P1, P2 TERMINALS ON 120V MODELS ONLY. POWER CONNECTIONS ON 240 V MODELS ARE TO
QUICK-CONNECTS ON POWER SUPPLY TRANSFORMER. BROWN LEAD GOES TO TOP
TERMINAL AND BLACK LEAD TO BOTTOM TERMINAL.
3 ONE-CELL UNIT SIMILAR, BUT WITH JUST ONE CELL.
4 ON ONE-CELL, DUCT-MOUNTED UNITS, SSPI OUTPUT LEAD IS A 4-WIRE CABLE.
5 CABLE WITH WIRES TO W8600 TERMINAL STRIP IS CONNECTED TO J2 ON THE RPI DRIVER.
4
3
BLACK
BROWN
BLACK
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
69-1137EF—03 8
Fig. 10. Recent internal schematic for F52F Electronic Air cleaner with W8600E and AFS.
Fig. 11. Retrofitted schematic for F52F Electronic Air Cleaner with W8600E and AFS.
BLACK
1
2
3
4
1
2
3
4
TERMINAL STRIP
FRONT BACK
TO
W8600E
WALL
PANEL
W4 W2 W1 W3
AIRFLOW SWITCH BOARD
ORANGE
GRAY
VIOLET
BLACK
1 INTERLOCK SWITCH.
2 OUTPUT REDUCTION JUMPER.
3 AIRFLOW SWITCH DISABLE JUMPER.
4 ONE-CELL UNIT SIMILAR, BUT WITH JUST ONE CELL.
5 P1, P2 TERMINALS ON 120V MODELS ONLY. POWER CONNECTIONS ON 240V MODELS ARE TO
QUICK-CONNECTS ON POWER SUPPLY TRANSFORMER. BROWN LEAD GOES TO TOP TERMINAL
AND BLACK LEAD TO BOTTOM TERMINAL.
M33494A
2
4BLACK
RED
CONTACT
BOARD
RED IONIZER
BLACK COLLECTOR
BLACK
5
BLACK BLACK
BROWN
BLACK
GREEN
3
1
BLACK
WHITE
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
POWER SUPPLY
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1
BLACK
B4
R3
Y2
G1
W4 W2 W1 W3
AIRFLOW SWITCH BOARD
ORANGE
GRAY
VIOLET
BLACK
1 INTERLOCK SWITCH.
2 SHORTING BAR.
3 AIRFLOW SWITCH DISABLE JUMPER.
4 W8600E REMOTE PERFORMANCE INDICIATOR DRIVER.
5 NEON LIGHT. M33495A
5
BLACK
4
BLACK BLACK
BROWN
LINE VOLTAGE
BLACK
GREEN
3
1
GREEN
YELLOW
RED
BLUE
BLACK
RED
CONTACT
BOARD
RED IONIZER
BLACK COLLECTOR
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1
2

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
969-1137EF—03
Fig. 12. Past F57 120V model electrical schematic.
P19 P12 P13
P5
SSPI
D24 D22 D26
P17 P15 P14
1
RED IONIZER
BLACK COLLECTOR
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2 LEFT CELL AND CONTACT BOARD ON
TWO-CELL AIR CLEANER ONLY.
3 INTERLOCK SAFETY SWITCH.
M33498A
3
2BLACK
RED
TEST
BUTTON
CONTACT
BOARD
BROWN
VIOLET
BLUE
RED
ON
HI
MED
LO
HI
MED
LO
OFF
FAN
MOTOR
PERFORMANCE
SWITCH
BLACK
BLACK
WHITE
ORANGEBLACK
L1
(HOT)
L2
PUSH BUTTONS WIRING TERMINALS
ON-OFF/3-SPEED FAN SWITCH
CHECK
(RED)
RED
WHITE
WHITE
WHITE
WASH
(YELLOW)
ON
(YELLOW) RED
RED
SSPI PRINTED WIRING BOARD ASSEMBLY
GREEN
YELLOW
BLUE
BROWN ORANGE
WHITE
RED
GROUND
GREEN
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1

PS1202C, PS2402C REPLACEMENT POWER SUPPLY KITS FOR ELECTRONIC AIR CLEANERS
69-1137EF—03 10
Fig. 13. Recent F57 120V model electrical schematic.
Fig. 14. Retrofitted/original equipment F57 120 Vac model electrical schematic.
1
RED IONIZER
BLACK COLLECTOR
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2 LEFT CELL AND CONTACT BOARD ON
TWO-CELL AIR CLEANER ONLY.
3 INTERLOCK SAFETY SWITCH.
M33496A
2BLACK
RED
TEST
BUTTON
CONTACT
BOARD
BROWN
VIOLET
BLUE
RED
ON
HI
MED
LO
HI
MED
LO
OFF
FAN
MOTOR
3
PERFORMANCE
SWITCH
BLACK
BLACK
WHITE
ORANGEBLACK
L1
(HOT)
L2
GROUND
PUSH BUTTONS WIRING TERMINALS
ON-OFF/3-SPEED FAN SWITCH
WHITE
RED
ON
(YELLOW)
WHITE
RED
WASH
(YELLOW)
WHITE
RED
CHECK
(RED)
1 2 3 4 5 6 7
RPID BOARD
J1
J2
1
2
3
4
5
6
P1
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1
1
RED IONIZER
BLACK COLLECTOR
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS
AND OVERLOAD PROTECTION AS REQUIRED.
2 LEFT CELL AND CONTACT BOARD ON
TWO-CELL AIR CLEANER ONLY.
3 INTERLOCK SAFETY SWITCH.
4 REMOVE J8 SHORTING BAR. CONNECT BLACK
LEADS FROM PERFORMANCE SWITCH TO J8.
5 CABLE WITH WIRES TO W8600 TERMINAL STRIP
IS CONNECTED TO J2 ON THE RPI DRIVER.
M33497A
2BLACK
RED
TEST
BUTTON
CONTACT
BOARD
BROWN
VIOLET
BLUE
RED
ON
HI
MED
LO
HI
MED
LO
OFF
FAN
MOTOR
3
4
5
PERFORMANCE
SWITCH
BLACK
WHITE
ORANGEBLACK
L1
(HOT)
L2
PUSH BUTTONS WIRING TERMINALS
ON-OFF/3-SPEED FAN SWITCH
CHECK
(RED)
WASH
(YELLOW)
WHITE
RED
WHITE
RED
WHITE
RED
ON
(YELLOW)
BLACK
GROUND
POWER SUPPLY
2
P4
P1
P2
J3
J4
J8
P3
2.1mA
1.65mA
1.29mA
1.05mA
0.9mA
0.25mA
P5
T1
U4
8150V
7500V
P8
E6
E4
E5
E3 E1
E2
J1