IQAir CleanZone 3020 series User manual

Swiss Made
Installation Guide & wner’s Manual
CleanZone® 3020 & 3030 Series
for HVAC Integration
HB_CZ_0407_208 04 01 00
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WARNING:
The installation of the CleanZone
air cleaning system needs to be
performed by a qualified HVAC
contractor.
WARNING:
This installation guide is designed
to assist in the installation. Since
no installation is alike, the installer
needs to take into account all
factors pertaining to the installa-
tion.
2
• TO REDUCE THE RISK O IRE, ELECTRIC SHOCK, OR INJURY TO PERSON(S) OBSERVE
THE OLLOWING:
• This manual covers use in residential installations only. Contact IQAir for informa-
tion on commercial and other uses.
• Installations must be done in accordance with all applicable codes and standards,
including fire-rated construction codes and standards.
• The unit is not designed to provide combustion and/or dilution air for fuel-burning
appliances.
• Do not install in a cooking area or connect directly to an appliance.
• Always disconnect the power cord from electrical outlet before replacing filters,
adding or removing parts and before cleaning.
• When cutting or drilling into wall or ceiling, do not damage electrical wiring or
other hidden utilities.
• This unit must be grounded. The power supply cord has a 3-prong grounding plug
for your personal safety. It must be plugged into a mating 3-prong grounding
receptacle,grounded in accordance with the national electrical code and local codes
and ordinances.Do not remove the ground prong. Do not use an extension cord.
• This unit must be installed in a weatherized location out of direct sunlight and
protected by the elements.
• When the ambient temperature for the unit location is below freezing
(32° – 0°C), the unit must run continuously to prevent condensation.
• Do not attempt to recover in any way the exhaust air from a dryer or a range hood.
This would cause clogging of the filters and constitute a fire hazard. This will also
void the warranty.
• Do not operate this appliance if it has a damaged cord or plug, if the motor fan fails
to rotate, if it is not working properly, if it has been dropped or damaged. Contact
IQAir for repair or replacement part service.
• Use this unit only in the manner intended by the manufacturer. If you have
questions, contact the manufacturer at the address or telephone number listed in
this document.
• Do not use this appliance in areas with very high concentrations of dusts or
powder to prevent the danger of dust explosions.
• Do not use this appliance in explosive areas.
• Only use original IQAir® filters and accessories.
• Do not run any air ducts directly above or closer than 2 ft (0.6 m) to any furnace or
its supply plenum, boiler or other heat producing appliance.
• The ductwork must be be installed in compliance with all local and national codes
that are applicable.
• Keep the power cord away from heated surfaces.
• If the unit is used during construction or renovation, regularly check filters for
prematurely clogged filters.
• Save these instructions for future reference.
Important Safety
Instructions
IQAir welcomes any suggestions
you may have concerning this
manual and/or the product, or
ways to better serve you. Please
contact us at:
IQAir North America, Inc.
CleanZone Assistance
10440 Ontiveros Place
Santa e Springs, CA 90670
Email: [e-mail]
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Table of Contents
3
Important Safety Instructions 2
Modular Housing Concept 4
Tool & Materials Checklist 4
Planning Your Installation 5
Chapter 1 Installation Diagrams 6
Model 3030 6
Model 3020 7
Chapter 2 System Components 8
Model 3030 8
Model 3020 10
How the System Works 12
Chapter 3 CleanZone Assembly 14
Unpacking the Modules 14
Preparing the HyperHEPA Module 15
Connecting the HyperHEPA and Motor Module 16
Placing the HyperHEPA ilter 17
inishing the Module Assembly 17
Attachment of the Air Inlet and Outlet Panels 18
Chapter 4 Electrical Connections 19
Power Cord 19
EAC Terminal Wire 19
Control Panel 19
Chapter 5 Mounting of the Control Panel 20
Mounting for Wall Surface Wiring 20
Mounting for Through Wall Wiring 21
Chapter 6 Control Panel Functions 22
Description of the Control Panel Elements 22
Menu Items 23
ilter Life Monitor 24
New ilter Reset 25
Initial Installer Set-Up of the Control Panel 26
Setting the System Airflow 27
ilter Configuration 28
Password Menu 30
Chapter 7 Replacing Filters 31
Replacing the Micro-Particle ilters 32
Replacing the HyperHEPA ilter 33
New ilter Reset 34
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To assemble the CleanZone system components the following tools are necessary:
Hand tools:
Torx-30 Screwdriver
4mm Hex Ballpoint Screwdriver (supplied in CleanZone Basic Tool Kit)
Crimping tool for quick connect terminals
Power Tools (optional):
Cordless Driver-Drill
Torx-30 Ballpoint Power Bit (supplied in CleanZone Basic Tool Kit)
Torx-30 Power Bit (supplied in CleanZone Basic Tool Kit)
Materials Checklist
The CleanZone components are shipped with all necessary materials to be assembled.The
following list is designed as guide to the other materials that may be required for the instal-
lation:
Ducting
• lex duct (18” recommended) or other ducting from return grille to CleanZone
• Return plenums
• T-wyes and elbows
• Return platform
• Miscellaneous items: cable ties, sheet metal screws, duct mastic, approved duct
tape, plumbers tape
• Insulation for T-wyes, elbows and return plenums when installed in uncondi-
tioned spaces
Electrical
• Two 1
⁄
4-in female quick connect terminals (for 16–14 wire) for the EAC IN wire
connection to the air handling control board.
• Rigid wire to fish control panel wire through wall Mounting
• Chains, straps, threaded bars
4
Modular Housing
Concept
Tool & Materials
Checklist
The IQAir CleanZone air cleaning system is based on a modular architecture that allows
for easy system customization and regular non-palletized shipment.
Each CleanZone system is made up of a motor module and at least one filter module.
Each of these modules is supplied in a separate transport box.
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5
Installation Principle
Single speed 2-3 ton HVAC systems
The CleanZone system is designed to go inline to the residential HVAC return duct in
installations up to airflow rates of 1200 cfm. If the airflow is lower than 1000 cfm, the
CleanZone fan speed should be reduced also. The CleanZone is designed to replace all
existing furnace filters or similar.
Single speed 4-5 ton HVAC systems
In installations, with airflow rates of over 1200 cfm, a filtered bypass (additional Perfect 16)
needs to be installed to make up for the additional HVAC system airflow.The CleanZone is
designed to replace all existing furnace filters or similar.
Multiple speed 2-3 ton HVAC systems
In installations with 2-3 ton multiple speed air handling systems, the CleanZone is designed
to go inline to the residential HVAC return duct. Integration of a excess air bypass duct into
the duct design is necessary to allow excess air to be circulated back to the air cleaning
system on speed setting of less than 1000 cfm. If the maximum airflow of the HVAC
system is lower than 1000 cfm, the CleanZone fan speed should be reduced also.
Multiple speed 4-5 ton HVAC systems
In installations, with airflow rates of over 1200 cfm, a filtered bypass needs to be installed
to make up for the system airflow and the maximum of 1200 cfm supplied by the
CleanZone air cleaning system. This filtered bypass will also serve as a excess air bypass
duct, as it allows recirculation of excess air when HVAC airflow capacity is reduced to
less than 1000 cfm.
L CATI N
• The CleanZone should be located on the return side (upstream) of the air handling
system. Please note that locating the CleanZone on the supply side (down stream)
may cause the motor and/or electronics in the CleanZone to fail due to overheating
or condensation.
• or best performance, the CleanZone should be connected as close to the air
handling system as possible. Duct runs to and from the CleanZone should be held
as short as possible.
• Choose a location that is readily accessible for checking and replacing the filter(s).Allow
at least 241⁄2in. (622 mm) clearance in front of the unit.
• Note that the micro-particle V-bank filters can only be replaced through the square
panels.The HyperHEPA filter can be replaced from all four sides of the unit.
M UNTING
• If positioned on the floor or a platform, anti-vibration pads (supplied with the unit)
should be used to reduce vibration.
• If the unit is suspended,screws must not penetrate through the cabinet. Make sure that
you have the proper equipment to keep the unit secure.
DUCTING
• Installed duct runs should be as straight as possible.
• If flex duct is used, the preferred duct diameter is 18”.
• or best indoor air quality, fiberglass ductboard or fiberglass lined ducts are not
recommended.
• To reduce the possibility of noise from the CleanZone system travelling down to the
return grille, a minimum return duct length of 6 feet is recommended.
ELECTRICITY
• The CleanZone requires a 120 Vac grounded electrical outlet.If an outlet is not available,
have a qualified electrician install one.
Planning your
Installation
When planning the installation of
the CleanZone® system, keep the
following considerations in mind:
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Chapter 1
Installation Diagrams
M DEL 3030
Supply Duct
Furnace
Fresh Air
(Optional)
Return Plenum
Return Air
Return Air
CleanZone®
MERV16
Micro-Particle
Filter Module
Return Plenum
CleanZone®
HyperHEPA®
Nano-Particle
Filter Module
CleanZone®
Motor Module
Perfect16®
ID-Series
Micro-Particle
Filter Module
Supply Duct
Furnace
Fresh Air
(Optional)
Return Plenum
Multiple
Speed
Bypass
Return Air
CleanZone®
MERV16
Micro-Particle
Filter Module
CleanZone®
HyperHEPA®
Nano-Particle
Filter Module
CleanZone®
Motor Module
6Chapter 1
For 2–3 ton basement
installations the following CleanZone
items are recommended:
1 CleanZone 3030
(incl. 2 connection panels)
1 additional connection panel if
multiple speed bypass connection
Preferred Basement Installation
4–5 ton installation with multiple returns (side view)
For 4–5 ton basement
installations the following combination
is recommended:
1 CleanZone 3030
(incl. 2 connection panels)
1 Perfect 16 ID-2225
(incl. 2 connection panels)


2–3 ton installation (side view).
* Multiple Speed Bypass is required for multiple speed HVAC systems.
*
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Perfect16®
ID-Series
Micro-Particle
Filter Module
Supply Duct Furnace
Fresh Air
(Optional)
Return Plenum
Return Air
CleanZone®
HyperHEPA®
Nano-Particle
Filter Module
CleanZone®
Motor Module
Multiple
Speed
Bypass
Perfect16®
ID-Series
Micro-Particle
Filter Module
Supply Duct
Furnace
Fresh Air
(Optional)
Return Plenum
Return Air
Perfect16®
ID-Series
Micro-Particle
Filter Module
Return Plenum
Return Plenum
CleanZone®
HyperHEPA®
Nano-Particle
Filter Module
CleanZone®
Motor Module
7Chapter 1
Installation Diagrams
M DEL 3020
For 2–3 ton basement
installations the following combination is
recommended:
1 CleanZone 3020
(incl. 2 connection panels)
1 Perfect 16 ID-2225
(incl. 2 connection panels)
1 additional connection panel if
multiple speed bypass connection
4–5 ton single or multiple speed installation (bird’s eye view)
For 4–5 ton basement
installations the following combination
is recommended:
1 CleanZone 3020
(incl. 2 connection panels)
2 Perfect 16 ID-2225
(incl. 2 connection panels each)


Preferred Attic Installation
2–3 ton installation (bird’s eye view).
* Multiple Speed Bypass is required for multiple speed HVAC systems.
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Chapter 2
System Components
M DEL 3030
8Chapter 2
Rectangular Connection Panel
Eight Torx-30 screws
Micro-Particle ilter
End Module (MERV 16)
our 4 mm Hex screws
HyperHEPA Middle Module
(Nano-Particle iltration)
Eight 4 mm Hex screws
Motor End Module
Eight Torx-30 screws
Rectangular Connection Panel
Power cord with 3-prong 120 Vac
connector plug with ground
EAC terminal connection cord
Wall control panel cord
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16 (400) 18 (450)
20 (500)
16 (400)
23.69 (601)
19.63 (499)
can be cut and adapted
61.75 (1568)
25.25 (642)
20.75 (527)
61.75 (1568)
21.25 (540)
20.75 (527)
9Chapter 2
Dimensions
All measurements in inch (mm)
Connection Panels
our different connection panels are
available:
• Panel without opening
(to be cut and adapted as neces-
sary by installer)
Order No. 207 30 05 04
• Panel with16” x 20”connection
Order No. 207 30 09 04
• Panel with 16” round connection
Order No. 207 30 06 04
• Panel with 18” round connection
Order No. 207 30 07 04
Connection panel for air inlet
attaches to face of system
Connection panel for air outlet attaches
to face or long side of system
Connection panel for optional
multiple speed bypass
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10Chapter 2
SystemComponents
M DEL 3020
Perfect 16
Micro-Particle ilter
(to be ordered separately)
Rectangular Connection Panel
Eight Torx-30 screws
HyperHEPA End Module
(Nano-Particle iltration)
Eight 4 mm Hex screws
Motor End Module
Eight Torx-30 screws
Rectangular Connection Panel
Power cord with 3-prong 120 Vac
connector plug with ground
EAC terminal connection cord
Wall control panel cord
The CleanZone 3020 was designed to
allow more installation flexibility in
tight spaces. or the CleanZone 3020
to function properly it requires a
Perfect 16 filter for pre-filtration. The
Perfect 16 can be connected to the
CleanZone with as much as 20 feet of
duct distance between the two.
If flex duct is used, 18” diameter is
recommended.
ATTENTI N
ailure to use a Perfect 16 for pre-
filtration of a CleanZone 3020 will
cause the HyperHEPA filter to
become pre-maturely loaded and
can lead to a drastic reduction of
airflow.
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16 (400) 18 (450)
20 (500)
16 (400)
23.69 (601)
19.63 (499)
can be cut and adapted
41.5 (1055)
25.25 (642)
20.75 (527)
41.5 (1055)
25.25 (642)
20.75 (527)
11Chapter 2
Dimensions
All measurements in inch (mm)
Connection panel for air inlet
attaches to face of system
Connection panel for air outlet attaches
to face or long side of system
our different connection panels are
available:
• Panel without opening
(to be cut and adapted as neces-
sary by installer)
Order No. 207 30 05 04
• Panel with16” x 20”connection
Order No. 207 30 09 04
• Panel with 16” round connection
Order No. 207 30 06 04
• Panel with 18” round connection
Order No. 207 30 07 04
Connection Panels
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12Chapter 2
How the CleanZone®
System Works
M DEL 3030
1Polluted air enters through
the inlet panel.
2our filter panels are arranged
in double V shape to eliminate
over 95% of all pollution
particles 0.3 microns and
larger.The large surface area
of 170 square feet of micro-
particle filtration media
ensures a long filter life.
3An aluminum framed filter
element contains 200 square
feet of true HEPA media for
nano-particle filtration.This
filter stage eliminates over
99.97% of all pollution parti-
cles 0.3 microns and larger
and over 99.5% of all particles
down to 0.003 microns.
4The motor module provides
the airflow which is necessary
to overcome the resistance
of the micro-particle and the
HyperHEPA filter.The back-
ward curved radial design of
the fan allows for straight
through and right angle air
duct connection. The digital
motor which drives the fan
saves up to 35% energy.
5The outlet panel can be
attached to the front or side.
1
2
3
4
5
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13Chapter 2
How the CleanZone®
System Works
M DEL 3020
1Polluted air enters through
the inlet panel.
2An aluminum framed filter
element contains 200 square
feet of true HEPA media fo nano-
particle filtration.This filter stage
eliminates over 99.97 % of all
pollution particles 0.3 microns
and larger and over 99.5% of all
particles down to 0.003 microns.
3The motor module provides the
airflow which is necessary to
overcome the resistance of the
micro-particle and the
HyperHEPA filter.The backward
curved radial design of the fan
allows for straight through and
right angle air duct connection.
The digital motor which drives
the fan saves up to 35% energy.
4The outlet panel can be
attached to the front or side.
1
2
3
4
The CleanZone 3020 was designed
to allow more installation flexibility
in tight spaces. or the CleanZone
3020 to function properly it requires
a Perfect 16 filter for pre-filtration.
The Perfect 16 can be connected to
the CleanZone with as much as 20
feet of duct distance between the
two. If flex duct is used, 18” diameter
is recommended.
ATTENTI N
ailure to use a Perfect 16 for pre-
filtration of a CleanZone 3020
will cause the HyperHEPA filter to
become pre-maturely loaded
and can lead to a drastic reduction
of airflow.
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3. Pull module out by pulling on the
plastic bag.
1. Take off the box straps. Carefully open
the box. Do not cut into the box, as this
may damage the contents.
Chapter 3
The individual items that
make up the 3030/3020
Unpackaging the
individual
CleanZone modules
The CleanZone is shipped in the 3020 and the 3030 kits and contains all the essential
items. In addition, there are a number of optional order items. Make sure you have all the
necessary CleanZone components before you start the installation:
CleanZone 3030 items
Contained in the 3030 kit:
1 Micro-particle end module
1 HyperHEPA middle module
1 Motor end module
2 Duct connection panels (for air inlet and air outlet) – your choice must be
specified at time of order.
1 Wall control panel
6 Anti-vibration pads
1 HyperHEPA replacement filter aid (for horizontal installations)
Optional items that may be necessary for your installation:
1 Perfect 16 ID-2225 (needed only for system airflows of over 1200 cfm)
1 Duct connection panel (needed only for multiple speed bypass)
CleanZone 3020 installation
Contained in the 3020 kit:
1 HyperHEPA end module
1 Motor end module
2 Duct connection panels (for air inlet and air outlet) – your choice must be
specified at time of order.
1 Wall control panel
4 Anti-vibration pads
1 HyperHEPA replacement filter aid (for horizontal installations)
Essential additional item:
1 Perfect 16 ID-2225 (for pre-filtration)
Optional items that may be necessary for your installation:
1 Perfect 16 ID-2225 (needed only for system airflows of over 1200 cfm)
14Chapter 3
2. Remove foam corner pieces and turn
the box on one of its long sides.
4. Remove plastic bag and dispose.
DANGER:
Children can easily suffocate inside
plastic bags. Do not leave around.
Dispose of immediately.
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15Chapter 3
6. Remove the cross bar.5. Release the cross bar by turning the
levers both ends.
8. Remove the panel, keeping insulation
in place.
4. Take off the bag with screws. There are
eight of these for the HyperHEPA End
Module (3020 Kit) and eight for the
HyperHEPA Middle Module (3030 Kit).
7. Take off one of the side panels by
removing the eight panel screws with a
TORX 30 bit.
3. Pull out the metal pin, that locked the
two levers into place during transport.
Discard the metal pins, as they do not
need to reinserted.
2. Cut off the red cable ties that fix the
cross bar on both sides of the module.
1. Place the HyperHEPA Module so that
the cross bar with the two levers faces you.
Preparing the
HyperHEPA Module
for Assembly
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10. Carefully remove the HyperHEPA filter.
Attention: It weighs 32 pounds! Set Aside.
9. Remove the HyperHEPA filter by
slightly lifting it and then pulling it out.
4. There are a total of eight screws (2 each
on 4 sides) .
3. With a Hex 4 bit, attach the HyperHEPA
Module with the screws that were in the
bag attached to the cross bar.
2. Align the modules.1. Place the HyperHEPA ilter Module
onto the Motor End Module
1. Place the Micro-Particle ilter Module
onto the HyperHEPA Module. Align the
modules.
Connection of Micro-
Particle Filter Module to
HyperHEPA Module
(CleanZone 3030 only)
Connection of the
HyperHEPA Module
to Motor Module
2. With a Hex 4 bit, attach the HyperHEPA
Module with two each screws on the long
sides.
16Chapter 3
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1. If the air cleaning system will be used in
a horizontal end position insert the filter
HyperHEPA replacement aid on the side
that will be facing the floor.
2. The HyperHEPA filter replacement aid
allows the HyperHEPA filter to be easily
slid in position.
5. Reattach the side panel with eight
TX30 screws.
6. Decide where to place the finger
screws for future filter replacement.
4. Center the cross bar under the cross
members, engage by turning the levers
on both sides.
3. Replace the cross bar by sliding it in
back under the opposing cross members.
2. Ensure that the filter is fully centered
and flush on the internal flange.
1. Re-insert the HyperHEPA ilter.
Placing Horizontal Filter
Replacement Aid
Finishing the Module
Assembly
17Chapter 3
Applies to both CleanZone 3020
and 3030
Applies to both CleanZone 3020
and 3030
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4. Attach the panel with the eight special
screws supplied. Use a TORX 30 bit.
3.Place the outlet panel either on the face
of the motor end module or take off a rec-
tangular side panel, attach it to the face of
the motor end module and attach the
outlet panel in its place.
2. Attach the panel with the eight special
screws supplied. Use a TORX 30 bit.
1. Place the inlet panel on the face of the
V-bank Micro-Particle module (3030) or
the face of the HyperHEPA module (3020)
Attachment of Air Inlet
and utlet Panels
Every CleanZone air cleaning system
needs to be fitted with an air inlet
and an air outlet panel.
our different connection panels are
available:
• Panel without opening
(to be cut and adapted as
necessary by installer)
Order No. 207 30 05 04
• Panel with16” x 20”duct lip
Order No. 207 30 09 04
• Panel with 16” round duct lip
Order No. 207 30 06 04
• Panel with 18” round duct lip
Order No. 207 30 07 04
Inlet Panel
On the CleanZone 3030 the air inlet
panel is attached to the face of
V-bank micro-particle filter module.
On the CleanZone 3020 the air inlet
panel is attached to the face of the
HyperHEPA module.
utlet Panel
On both the CleanZone 3020 and
3030 the air outlet panel can be
attached to any of the rectangular
sides (long sides)of the Motor End
Module.Maximum air flow is achieved
with the outlet panel attached to the
side of the Motor End Module.
18Chapter 3
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The CleanZone 3020 and 3030 feature an
oval electrical connection console, which
features the following items (left to right):
• Power cord with 3-prong 120 Vac
connector.
• EAC IN indicator light
• 2-wire EAC terminal signal wire
• 8-wire control cable with RJ-45
connector
• AN indicator light
• POWER indicator light
Power Cord
The CleanZone has a 3-prong, 120 Vac con-
nector designed to plug into a grounded
120 Vac electrical outlet. If an outlet is not
available, have a qualified electrician install
one. The maximum load of the CleanZone
is 3.8 A. The power cord supplies the
CleanZone with the necessary power for
the fan motor and electronics.When power
is connected,the POWER indicator light will
be on.
EAC Terminal Wire
The EAC signal wire is designed to connect
to the control board of the HVAC system
(air handler). It automatically turns the
CleanZone system fan on and off with the
HVAC system blower. When the EAC signal
wire is energized, the EAC IN indicator light
will light up.
Pull the two-wire cable, labeled “EAC In”
from the CleanZone connection console to
the air handler control board. Shorten as
necessary.
Attach two 1
⁄4-in female quick connect terminals for 16–14 wire to EAC signal wire.
Connect the female quick connect terminals to the two male 1⁄4-in quick-connect terminals
on the control board marked EAC-1 and EAC-2. On some air handling systems, the termi-
nals are labeled EAC and COM.
Control Cable
The control cable is the connection of the
main air cleaning system to the wall control
panel.The CleanZone will not run without a
proper connection to the wall control unit.
Connect the RJ-45 plug of the control
cable to the socket on the back of the wall
control unit.
The AN light will turn on when the
POWER signal and the EAC signals are active
and the control panel is properly connected.
Control Panel
Power Cord
EAC Terminal Wire
Power
cord
EAC IN
light
EAC IN
wire
Control
cable
AN
light
Power
light
19Chapter 4
Chapter 4
Electrical Connections
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5. Pull out any excess cable.
Mounting for Wall
Surface Wiring
4. Push cable through and insert cable
connector into the receptacle.
3. Insert the control cable through the
square center opening on the lower back
of the control panel unit.
2. Drill holes, insert plugs and fix the wall
plate in place with screws.
1. Place the wall bracket on the wall, level
out horizontally and mark either the two
holes which are in a horizontal or vertical
line to one another.
The CleanZone wall control panel
unit can be either mounted with
the control cable located in the
wall or with the control cabled
fixed on the surface of the wall.
The latter option may be pre-
ferred if there are concrete walls
or access inside existing walls is
difficult.
6. Center the wall control panel unit over
the wall plate at a 45° angle.
7. Engage the control panel unit on the
wall bracket and twist into horizontal
position. You may now wish to fix the
cable to the wall using a cable conduit
or cable clamps.
20Chapter 5
Chapter 5
Mounting of the Wall
Control Panel
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