Installation/Operation Manual
Contents
1. READ AND SAVE THESE INSTRUCTIONS MAC 10 LE AC FAN FILTER MODULE INSTALLATION AND SERVICE MANUAL STANDARD RSR RSRE MODELS Mac 10 and VE5 are registered Trademarks of the Envirco U S A US Patents 4 560 395 and 5 470 363 Other patents issued and pending in foreign countries Version 1 Updated 2 5 11 Critical operation conditions of the MAC 10 1 Touching of the HEPA filter will damage it voiding the warranty on the filter The screen is only to protect against an accidental touch of the filter Never place a hand or tool on the filter Never lie filter face flat down on a surface always have filter on its side or back to protect from damage 2 Prior to powering the unit verify that the unit has been plugged into the correct voltage The serial number label on the top of the Mac 10 unit has the required voltage 3 For reorder prepossess the Mac 10 part number and serial number should be recorded This information is located on the serial number label located adjacent to the electrical box If you can t located the Sales Order Number please contact Envirco for this information Part Numbers Covered by this Manual 11194 XXX Mac 10 LE AC 2x4 600x1210mm Standard Filter Mac 10 LE AC 2x4 600x1210mm RSR E Filter Note A Z in the part number indicates that the unit is special This may indicate a size change from standard or a special filter Please contact the factory for part numbers if this is the s2. AC SERVICE MANUAL PAGE 2 Table of Contents Title Page INS YE VELO io OE EO EE ER EE OE ER EO EE EE EE EN 4 FIGURE 1 UNIT DNCRA TING sesse essssesdsessk esel iss e ed sed ese Gee sedes ees eene ee de ge ON een ee ee Ee ed dee 4 2 SERVICE CLEANING THE MAC 10 LE AC PREFILTER FOAM eee eee eee ee sesse uuu 5 FIGURE 2 FOAM PREFILTER CLEANING eee esse ee ee 00000000000000 00000000000000 00000000000000 000 eee 9 3 SERVICE CLEANING THE MAC 10 LE AC PREFILTER G4 PLEATED PREFILTER 6 FIGURE 3 G4 PREFILTER REPILAG EMENT sesde esse esse des dosis de ooie ph b EE de Fo ae e epp a PER dese de de sed de 6 4 SERVICE REMOVAL AND REPLACEMENT OF THE HEPA ULPA FILTER STANDARD UNIT ee ee ee ee ee ee ee ee e seeeerosssseseeeesss 7 FIGURE 4 STANDARD FILTER REPLACEMENT ees 00000000000000 0000000000000000 000 0e0eneeee een oi 5 SERVICE REMOVAL AND INSTALLATION OF THE ROOM SIDE REPLACEABLE GEL SEAL FILTER RSR RSRE uie sesse ese ese ses ee ee ee ee ee ee ee e orrossss 8 FIGURE 5 RSR SHEET METAL FILTER REPLACEMENT eee e eee e eee eese ee sees esse ees sesse ee oe 9 6 SERVICE REMOVAL AND INSTALLATION OF THE MOTOR STANDARD AND RSR MODELS NER 10 FIGURE 6 MOTOR REPLACEMENT ussesssssssssscssscssscsssscssccssssscsssssssscesssesscssssesssscsssssscessesssscsseesssesee 11 7 SERVICE REMOVAL AND INSTALLATION OF THE RSRE MOTOR sees 12 FIGU
3. FILTERS PART NUMBERS 69600S 001HAPXX FILTER HEPA 2X4 9 FRAME 69600S 001UAPXX FILTER ULPA 2X4 9 FRAME WELDED RSR GEL SEAL 69601 001H FILTER HEPA 21X45X3 5 GEL SEAL 69601 001U FILTER ULPA 21X45X3 5 GEL SEAL Optional Accessories Fluorescent lighting lonizing bar A C intake collar 20x20 10 254mm 20x20 127 304 8mm 20x20 14 355 6mm ULPA Filter Standard and RSR Replacement parts are available through your authorized Envirco representative If you cannot locate a representative in your area contact Envirco Parts Dept at ENVIRCO 101 McNeill Road Sanford NC 27330 U S A Tel 919 775 2201 Tel 800 884 0002 Fax 800 458 2379 MAC 10 LE AC SERVICE MANUAL PAGE 17 12 Warranty LIMITED WARRANTY Unless otherwise expressly stated in Envirco s published specifications for the Goods Envirco warrants that that Goods are free from defects in material and workmanship except for services which are warranted to be performed in a competent and diligent manner in accordance with any mutually agreed specifications The foregoing warranty shall apply for eighteen 18 months from the date of shipment from Envirco s facility except for services for which the warranty shall apply for ninety 90 days from the date of performance the Warranty Period Provided Buyer informs Envirco in writing of any breach of warranty prior to the expiration of the applicable Warranty Period Envirco shall as its sole obli
4. Driver Battery Operated Drill with a 5 32 Drill Bit Rivet Hand Tool 05 32 aluminum rivet grip range 126 187 Step 1 Remove unit from ceiling Step 2 Remove the 10 screws holding the HEPA ULPA filter to the lid assembly Step 3 Lift the lid assembly off the HEPA ULPA filter see Figure 3 Remove Filter deflectors using 5 32 drill bit Keep filter deflectors to install in new filter Discard the used filter as per requirements of the applicable regulations Carefully install the filter deflectors into the new filter using the 5 32 rivets Do not touch or place the filter deflectors on the HEPA ULPA media pack This could cause tears in the filter pack Note Before replacing with a new HEPA ULPA filter carefully inspect the new filter for any visible damage Also inspect the gasket in the tee bar to insure a tight seal Replace as necessary Step 4 Replace with the new HEPA ULPA filter and assemble by reversing the above steps ON OFF Switch Lid Screw 10 Lid Assembly Speed Control d ac SS A 8 SCREWS 10X D er Se Wu HEPA ULPA AR Filter N sso Bc P 05 32 RIVET 6X FILTER DEFLECTOR Figure 4 Standard Filter Replacement MAC 10 LE AC SERVICE MANUAL PAGE 7 5 SERVICE Removal and Installation of the Room Side Replaceable Gel Seal Filter RSR RSRE WARNING Disconnect the unit from the electrical power source before attempting any service WARNING The RSR Filter is protected with
5. RE 7 RSRE MOTOR REPLACEMENT iese sees sees ee sees ees eaaa aee ee ee ee 13 FIGURE 8 MOTOR BLOWER COMPONENTS uessscsssessssscssssssscsssscssssssccssscsssesscesssscssecsssesscessesesseesee 13 8 ON OFF SWITCH SPEED AIRFLOW ADJUSTMENT iese sesse sees ee ee ee ee ee 14 FIGURE 9 ELECTRICAL BOX FACE ees essens aee ee eee eee eee eee ee ee ee ee ee ee 14 9 TROUBLE SHOOTINGS uie ees eene ee ee anane eaaa ee ee ee ee ee ee anana eee ee cases 15 10 MAC 10 LE AC WIRING DIAGRAMS wescecssssscscsssescsssccssccsescssesssscssscesscssccssscssssssssssscesseesseessees 16 11 MAC 10 LE AC REPLACEMENT PARTS LIST sesse ees ere ee eene ee ee ee 17 ER WARRANTY ese ee ee ee ee anana eaaa ee ee ee ee ee ee ana ee ee ee ee 18 MAC 10 LE AC SERVICE MANUAL 1 INSTALLATION Note The MAC 10 LE AC Fan Filter Unit is completely assembled at the factory with Step 1 Step 2 Step 3 Step 4 the exception of the optional Va 0 64 cm 20 eyebolts which can be used when hanging the unit from an overhead structure Carefully remove the unit from the shipping carton and inspect for any damage that may have occurred during transportation See Figure 1 Wipe down plastic bag and move unit into clean room Double bagging is available upon request If using rigidly supported grid usually 2 50 mm or wider raise unit through ceiling and lower onto the gasketed grid If using a flexible grid typically supported with wires the unit must be se
6. S EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY NON INFRINGEMENT OR FITNESS FOR A PARTICULAR PURPOSE WHICH ARE HEREBY DISCLAIMED TO THE EXTENT PERMITTED 13 TESTING Each MAC 10 LE AC filter unit is thoroughly tested at the factory before shipment However because of the rigors of shipping ENVIRCO encourages its re test after installation Additional for large installations it is recommended to bench test 5 of the units prior to installation ENVIRCO recommends that the customer contact an independent organization with technicians trained and experienced in performance evaluation and maintenance of clean air equipment Some of the testing procedures performed on the MAC 10 LE AC include PSL challenge of HEPA ULPA filters to assure specified performance along with air velocity measurement and adjustment tests No DOP is used on Mac 10 Filters unless requested MAC 10 LE AC SERVICE MANUAL PAGE 18
7. an expanded metal face screen This is never to be used to handle the filter It is only for protection against an accidental touch of the filter Only handle the filter by the frame Tools Required Phillips Head Driver 3 16 hex head wrench Manpower Required 2 Step 1 Remove the diffuser screen by removing the 6 each 10 32x1 2 screws Step 2 Loosen the six 1 4x20 socket head screws far enough to rotate the filter clip 90 The filter will not drop during this operation Slowly pull the filter away from the knife edge seal taking care not to touch the filter face during this operation It is important to pull the filter slowly away from the seal so that the gel remains in the filter gel track Step 3 Inspect filter for visible damage if damaged set aside for replacement or repair Step 4 Inspect the gel seal if reinstalling the removed filter Determine if the gel has lost its ability to seal if so repair the gel Step 5 Place the filter against the filter sealing surface of the RSR unit Install filter clips and screws The clips can be rotated and angled into place Using the clips as a lever the filter can be seated It is recommended to work either clockwise or counter clock wise around the filter raise the filter into the gel Step 6 Reinstall screen Referenced by Figure 5 on page 9 MAC 10 LE AC SERVICE MANUAL 8 Fan Filter Unit D o D D O a T A Plenum Housing Filter Clip and Screw ty
8. cured to an overhead structure with eyebolts s hooks and chain or 4 20 all thread A roll of high density gasket has been provided for use with ungasketed grids Note special size units are available to fit specific clean room grid systems Have an electrician wire the unit to the appropriate voltage 115V 220V 277V AC according to the wiring diagram in section IX and local electric codes If optional power cord was purchased plug unit into a grounded receptacle The optional power cord is not acceptable for plenum installations Figure 1 Unit Uncrating MAC 10 LE AC SERVICE MANUAL PAGE 4 2 SERVICE Cleaning the MAC 10 LE AC Prefilter foam WARNING Disconnect the unit from the electrical power source before attempting any service Tools Required None Note To keep the filter in top operating condition washing the foam prefilter is recommended every three to six months Step 1 To gain access to the prefilter remove the ceiling panel next to the unit if applicable Step 2 Switch the ON OFF switch to the off position Step 3 Remove the prefilter from the snap in frame See Figure 2 Step 4 Clean the prefilter by hand washing in water with a mild detergent or by using a vacuum cleaner Allow prefilter to dry completely before replacing Step 5 Reassemble by reversing the above steps 20 x 20 Prefilter ON OFF Switch MAC 10 LE AC SERVICE MANUAL 5 E G A P Figure 2 Foa
9. embly from below remove the six screws on the underside of the venturi ring and lower the assembly See Figure 7 Note the baffle does not have to be removed to remove the motor blower assembly Before removal of the motor mount bracket measure the precise location of the bracket on the motor Remove the bracket Replace with the new motor and reassemble by reversing the above steps Set the location of the motor mount bracket as measured see above Step 6 Set the spacing at 0 25 6 35 mm clearance between the blower and the upper motor plate prefilter frame creating a 0 11 2 80 mm overlap between the wheel and the venturi ring When reinstalling the assembly align the plate to insure that the leads will reach the electrical box Referenced by Figures 7 amp 8 on page 13 MAC 10 LE AC SERVICE MANUAL 12 Electrical connectors located in inner prefilter wall Plenum Motor Blower Assy Baffle Assembly Gel Seal Filter Screen Figure 7 RSRE Motor Replacement Motor Venturi Ring Loosen Bolt to remove Motor Blower Wheel Figure 8 Motor Blower Components MAC 10 LE AC SERVICE MANUAL PAGE 13 8 ON OFF Switch Speed Airflow Adjustment All MAC 10 units are equipped with a three position rotary switch which is located on the side of the electrical box See Figure 8 Recommended fan speed during initial start up and operation is the LOW speed As airflow eventually decrea
10. gation and Buyer s sole and exclusive remedy for any breach of this warranty repair or replace re perform the Goods which gave rise to the breach or at Envirco option refund the amounts paid by Buyer for the Goods which gave rise to the breach Any repair replacement or re performance by Envirco hereunder shall not extend the applicable Warranty Period The parties shall mutually agree on the specifications of any test to determine the presence of a defect Unless otherwise agreed upon by Envirco in writing Buyer shall bear the costs of access de installation re installation and transportation of Goods to Envirco and back to Buyer These warranties and remedies are conditioned upon a the proper storage installation operation and maintenance of the Goods and conformance with the proper operation instruction manuals provided by Envirco or its suppliers or subcontractors b Buyer keeping proper records of operation and maintenance during the applicable Warranty Period and providing Envirco access to those records and c modification or repair of the Goods only as authorized by Envirco Envirco does not warrant the Goods or any repaired or replacement parts against normal wear and tear or damage caused by misuse accident or use against the instructions of Envirco Any modification or repair of any of the Goods not authorized by Envirco shall render the warranty null and void EXCEPT AS EXPRESSLY SET FORTH HEREIN ENVIRCO MAKES NO OTHER WARRANTIE
11. ituation CAUTION TO REDUCE THE RISK OF INJURY TO PERSONS INSTALL FAN AT LEAST 2 1M 7 FEET ABOVE THE FLOOR MAC 10 LE AC SERVICE MANUAL READ AND SAVE THESE INSTRUCTIONS WARNING TO REDUCE THE RISK OF FIRE ELECTRICAL SHOCK OR INJURY TO PERSONS OBSERVE THE FOLLOWING A Installation work and electrical wiring must be done by qualified person s in accordance with all applicable codes and standards including fire rated construction B When cutting or drilling into wall or ceiling do not damage electrical wiring and other hidden utilities C If this unit is to be installed over a tub or shower it must be marked as appropriate for the application D Use this unit only in the manner intended by the manufacturer If you have any questions contact the manufacturer ENVIRCO 101 McNeill Road Sanford NC 27330 Tel 919 775 2201 Tel 800 884 0002 Fax 800 458 2379 Email info envirco com ASIAN SALES Building 1 200 Middle Suhong Road Suzhou Jiangsu PRC 215021 Tel 86 512 6258 0031 Fax 86 512 6258 7180 Europe Middle East amp Africa EMEA TRION Div of Ruskin Air Management Ltd European Operations The Cavendish Center Winnall Close Winchester Hampshire S023 OLB UK Tel 44 0 1962 840465 Fax 44 0 1962 828619 E Before servicing or cleaning unit switch power off at service panel and lock service panel to prevent power from being switched on accidentally MAC 10 LE
12. m Prefilter Cleaning 3 SERVICE Cleaning the MAC 10 LE AC Prefilter G4 Pleated Prefilter WARNING Disconnect the unit from the electrical power source before attempting any service Tools Required None Note To keep the filter in top operating condition replacing the pleated prefilter is recommended every twelve months or sooner Step 1 To gain access to the prefilter remove the ceiling panel next to the unit if applicable Step 2 Switch the ON OFF switch to the off position Step 3 Remove the prefilter from the snap in frame The beverage frame has slots that have to be depressed to release the filter from the prefilter housing See Figure 3 Step 4 After removing the new G4 pleated prefilter from the box remove the die cut slots from the beverage board frame and install on prefilter bracket Step 5 Reassemble by reversing the above steps T n 20 x 20 Prefilter ON OFF Switch Figure 3 G4 Prefilter Replacement MAC 10 LE AC SERVICE MANUAL 6 E G A P 4 SERVICE Removal and Replacement of the HEPA ULPA Filter Standard Unit WARNING Disconnect the unit from the electrical power source before attempting any service WARNING The Standard Filter is protected with an expanded metal face screen This is never to be used to handle the filter It is only for protection against an accidental touch of the filter Only handle the filter by the frame Tools Required Phillips Head
13. motor shaft Mark the location of the motor support bracket belly band then loosen the bolt just enough to allow the motor support bracket to slid off the motor Step 10 Using the removed motor mark the new motor with the location of the motor support bracket Step 11 Replace with the new motor and reassemble by reversing the above steps 1 8 Set the spacing at 0 25 6 35 mm clearance between the blower and the upper motor plate prefilter frame This will give a 0 11 overlap between the venturi ring and the blower Referenced by Figure 6 on page 11 MAC 10 LE AC SERVICE MANUAL 9 Prefilter SS Motor j Venturi Ring Blower Wheel ON OFF Switch Figure 6 Motor Replacement MAC 10 LE AC SERVICE MANUAL 7 SERVICE Removal and Installation of the RSRE Motor WARNING Disconnect the unit from the electrical power source before attempting any service WARNING Electrical service should be performed by licensed electricians or authorized Step 1 Step 2 Step 3 Step 4 Step 5 ENVIRCO service technicians To gain access to the motor remove the gel seal filter see Section III Prior to removing motor blower assembly remove blower wheel to expose motor connectors on motor Using an adjustable wrench loosen the two set screws that attach the blower wheel to the motor shaft Disconnect the five and sixteen pin connectors from the motor While supporting the motor blower ass
14. moving devices are operating in or around clean room which disrupt room s airflow pattern Step 3 Check air velocity and if low conduct the Low Air Velocity procedure outlined above Step 4 Conduct smoke and photometer test on HEPA filter Seal or replace HEPA filter as necessary Contact Technical support at ENVIRCO 101 McNeill Road Sanford NC 27330 U S A Tel 919 775 2201 Tel 800 884 0002 MAC 10 LE AC SERVICE MANUAL PAGE 15 10 MAC 10 LE AC Wiring Diagrams Black T Black UL Blue CE Blue L2 e Red Yel G White Yel Grn CND 4 Yel Grn Mac 10 LE AC Three Speed Wiring Diagram Figure 11 Wiring Diagram Speed Control MAC 10 LE AC SERVICE MANUAL PAGE 16 11 MAC 10 LE AC Replacement Parts List ACLE PARTS PART Grommet 63271 Motor 120V 63 64 001 Motor 220V 63 64 002 Motor 277V 63 64 003 Motor Mount Clip 3851 1 001 Venturi Ring 64115 Blower Wheel 64015 Motor Blower Assy 24511 001 24511 002 24511 003 61485 Capicitor Boot 60126 Rocker Switch 63739 002 3 spd switch 63775 Foam Pre filter 20x20 62981 038 30 30 Pre filter 20X20 64125 001 All filter part numbers are based on the standard Mac 10 sizes 2x4 23 63x4 7 63 If the unit in question is not this size or the part number includes a Z contact the factory for replacement filter information STANDARD
15. p 6 Screws typ 6 Knife edge Seal Filter Gel Track Filter Clip O D 2 Oc DO eg YI X DO C 0 Va 20 Cap Screw 10 32 PHP Screws RSR Sheet Metal Filter Replacement Figure 5 MAC 10 LE AC SERVICE MANUAL PAGE 9 6 SERVICE Removal and Installation of the Motor Standard and RSR models WARNING Disconnect the unit from the electrical power source before attempting any service WARNING Electrical service should be performed by licensed electricians or authorized ENVIRCO service technicians Tools Required Phillips Head Driver Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 3 8 10mm Hex Head Wrench Pliers 5 32 0 40 cm Allen wrench To gain access to the motor remove the ceiling panel next to the unit if applicable Switch the ON OFF switch to the off position Remove the prefilter off the prefilter frame See Section Loosen the electrical box cover screws 2 and slide lift off cover Figure 6 Make note of all wire locations for reinstallation later Disconnect 5 pin and 16 pin wire harnesses from the electrical box housing Remove the eight screws to free the motor blower assembly from the lid assembly If using power drivers set the unit to a low torque setting to avoid stripping the sheet metal screws See Figure 6 Using an adjustable wrench loosen the two set screws that attach the blower wheel to the
16. ses due to filter loading fan speed may be increased by moving the rocker switch to the top or MEDIUM position and finally to the HIGH position Periodic airflow velocity readings Per I E S T Specifications should be conducted to determine the filter condition and appropriate fan speed setting Med High Low 3 Speed Switch Electrical Entrance ON OFF Switch Figure 8 3 Speed Switch Adjustment MAC 10 LE AC SERVICE MANUAL PAGE 14 9 Trouble Shooting Unit is not adjustable Step 1 Verify that rotation of the knob on the visual speed control does not change the RPM or Flow Index display on the unit If rotating does nothing remove the electrical box cover and remove the 4 pin connector from the Visual Speed control and install in 180 degrees rotated Again adjust the knob The 4 pin connector is on the 18 31 8 mm white conductor Low Air Velocity Step 1 Check prefilter media replace or clean as necessary Step 2 Adjust visual speed control for higher blower output Step 3 Check power supply for proper voltage amperage and distribution frequency Step 4 Replace HEPA filter if the air velocity remains low High Air Velocity Step 1 Adjust visual speed control for lower blower output Non Laminar Flow and or Excessive Contamination Step 1 Insure that no large obstructions are upstream of airflow pattern Step 2 Determine that no other air
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