Home

General AcuAir ® Installation, Operation, & Maintenance

1. 29 Freezing 29 FIELD PENETRATIONS FOR PIPING AND ELECTRICAL 29 TOOS ROC UIC I 29 Material Regultetlas 6 29 EE 29 LATCHES ee apr enixa 31 ACUAIR SINGLE FILTER APPLICATION NON HEPA 32 HEPA FILTER APPLICATION 33 INSTALLATION OF 2 PLEATED PANEL PREJFILTERS 34 Installation of Spring Latches 34 INSTALLATION OF 4 PLEATED PANEL PREJFILTERS 34 Installation of Spring Latches 34 INSTALLATION OF SH SINGLE HEADERED FILTERS 35 Installation Of Latches ents 35 INSTALLATION OF A RIGID DH DOUBLE HEADERED FILTER 35 Installation of Spring Latches 36 HEPA FILTERS taco eeu Sino n s 37 INITIAL START UP odd 38 Blower Motor 38 38 CONTROL DAMPERS INSTALLATION OPERATION AND MAINTENANCE 38 alu dp H Pa 39 Sore ree me 39
2. Form 210 100 IOM MAR 2014 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS File SERVICE MANUAL Section 210 Replaces 210 100 OCT 2013 Dist 3 3a 3b 3c Installation Operation Maintenance AcuAir Hygienic Air Units THIS MANUAL CONTAINS RIGGING ASSEMBLY START UP AND MAINTENANCE INSTRUCTIONS READ THOROUGHLY BEFORE BEGINNING INSTALLATION FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER OPERATION OF THE UNIT Please check www jci com frick for the latest version of this publication 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Page 2 INSTALLATION OPERATION MAINTENANCE Frick BY JOHNSON CONTROLS IMPORTANT READ BEFORE PROCEEDING GENERAL SAFETY GUIDELINES This equipment is a relatively complicated apparatus During installation operation maintenance or service individuals may be exposed to certain components or conditions including but not limited to refrigerants oils materials under pressure rotating components and both high and low voltage Each of these items has the potential if misused or handled improperly to cause bodily injury or death It is the obligation and responsibility of operating service personnel to identify and recognize these inherent hazards protect themselves and proceed safely in completing their tasks Failure to comply with any of these requirements could result in serious damage to the e
3. 026 35778 006 026 35778 023 12 SS knock on Clip Special Order Notchless frames require knock on clips JCI 026 3577 000 12 X 24 18 ga Stainless Stee 026 35777 010 12 X 24 18 ga SS Notchless Special Order 026 35777 006 1 24 X 24 18 ga Stainless Stee AAF 312 600 106 JCI 026 35777 016 24 X 24 18 ga SS Notchless AAF 399 035 005 Special Order Filters are Designated Width x Height x Depth 12 X 24 X 2 24 X 24 X 2 12 X 24 X 4 AAF 140 104 863 026 35723 008 Filters are Designated Width x Height x Depth 24 X 24 X 2 12 X 24 X 4 Single Header NOTICE Typically when filters are supplied by others so are the filter clips NOTICE Filter Pleats Must Be Installed Vertically When Possible Filters are Designated Width x Height x Depth 12 X 24 X 4 AAF 332 510 008 JCI 026 32410 014 Filters are Designated Width x Height x Depth 12 X 24 X 12 SH 24 X 12 X 12 SH 12 X 24 X 12 DH 24 X 12 X 12 DH 24 X 24 X 12 DH Single Header SH Double Header DH 12 X 24 X 12 SH 24 X 12 X 12 SH 24 X 24 X 12 SH 24 X 12 X 12 DH 24 X 24 X 12 DH AAF 331 300 101 JCI 026 35731 007 Clip part is SS not latch wire Total SS Construction Product description must follow p n for entry Product description and size must follow p n for entry Double Header ae ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 oe INSTALLATION Page 33
4. SHOULDER WASHER TUBE EXPANDED ASSEMBLY VIEW SIDE VIEW OPERATING POSITION P STYLE PLUG FAN REMOVE 0 38 0 13 OPERATING POSITION OPERATING POSITION SIDE VIEW BUY OUT ISOLATORS 3 Repeat step two until all isolators are set at the proper elevation and the fan base is level fan base support angle until the desired level is achieved Figure 27 Spring Isolator Setup Frick BY JOHNSON CONTROLS CONDENSATE DRAIN TRAP SIZING All condensate drain connections and floor drains must be trapped at the job site location Failure to properly trap a drain will result in flooding of the drain pan and potential water damage to the air handling unit and other building facilities To design the drain traps reference Figure 28 as well as the total static pressure TSP associated with the main fan and motor as indicated on the applicable AcuAir data drawing DRAIN PAN CONSTRUCTION AcuAir recessed hygienic drain pans are triple sloping and have a minimum depth of 3 at the drain connection Drain pans and pipe stub outlet connection are constructed of 304 Stainless steel unless specified otherwise The cooling coil supports are constructed of material similar to the air unit interior liner and may not be stainless steel MPT RECESSED HYGIENIC OUTLET Figure 29 Drain Pan Detail FIELD PIPING REQUIREMENTS 1 General Every effort must be made in field piping to keep the stre
5. FAN BEARING LUBRICATION INTERVALS BALL BEARING PILLOW BLOCKS Relubrication schedule months SPEED RPM 500 SHAFT DIA 1 2 thru 11 6 6 11546 thru 27 6 6 21176 thru 2 e 3 6 thru 35 6 Relubrication schedule months NENNEN LT 13 6 thru 17 6 1116 thru 23 6 2 6 thru 37 6 2000 p EE RM 1 2 2500 3000 3500 E r 31346 thru 41976 ve v4 TABLE 3 FAN BEARING LUBRICATION INTERVALS SPHERICAL ROLLER BEARING SPLIT PILLOW BLOCKS Relubrication schedule months 15000 2000 2500 EMEN 25 SPEED RPM 500 750 1000 SHAFTDIA J9 176 thru 1 e 6 4 4 2 e thru 21 6 21546 thru 316 42 3 5 472 3 272 Grease to be added at each interval 3500 4000 272 476 thru 4194 4 4 142 4004 4 1 O 57 6 thru 5 5 6 4 2562 221 210 100 1OM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 44 MAINTENANCE SY JOHNSON CONTROLS Lubrication Motor Bearing Lubricant Bearing grease will lose its lubricating ability over time The lubricating ability of grease To avoid damage to motor bearings grease must be kept bearing the speed at which the bearing operates and the your distributor or an authorized Service Center for ad severity of the operating conditions Good results can be ditional information obtained if
6. Foam should be injected into the cavity at a rate of 3 4 brd ft per linear foot of seam This will mean a 15 brd ft can of expanding foam will fill between 4 5 linear feet of AcuAir reconnect seam When filling the reconnect seam from the top inside the AcuAir unit it may be advisable to cover the bottom of the opening with duct tape to prevent the foam from dropping out before it has a chance to expand and attach itself to the cavity walls NOTICE If foam dispensing has stopped for more than 30 seconds replace the nozzle with the extra provided CAULK BASE CHANNEL 5 Inject Foam Prior to Installing Cover SPLIT COVER CAULK BASE SKIN SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS a Page 22 INSTALLATION Frick FOAM KIT 15 USE GUIDELINES ACUAIR UNIT BASE RECONNECT INSULATION Always review and follow the directions provided in your foam kit The below instructions are a general overview meant to Accompany the reference photos Ensure you follow all safety Precautions including wearing protective eyewear and gloves Foam kit 15 assembly instructions Tear open the back of the box Figure 20 Without forcing remove hoses and applicator to full length Figure 21 Ensure gun Safety is on roller is locked toward end of applicator Pull yellow tab to remove black plastic valve lock Discard Figure 22 Activate valves by pulling black st
7. Repeat the installation process with the remaining latches in the other three corners Figure 38 Correctly installed latch AAF 315 004 003 shown as an example 4 Rotate all of the latches outward and insert the filter into the frame making certain that the pleats run vertical 5 After the filter has been placed into the frame grasp the circular end of the latch and rotate it across the corner of the filter Push the end of the latch towards the filter until the latch catches beneath the knockout on the frame Repeat for the remaining latches ACUAIR HYGIENIC AIR UNITS INSTALLATION Frick BY JOHNSON CONTROLS 6 The filter should now be securely installed into the frame see Figure 39 Figure 39 Fully installed filter INSTALLATION OF 4 PLEATED PANEL PRE FILTERS These instructions are for installing 4 panel filters into type 8 holding frames Latches needed for these applications are four 4 clips as indicated in the table on page 32 A single latch should be installed at each of the four 4 corners of the frame The latch fits into the set of knockouts which consists of two 2 rows of three 3 knockouts The row of knockouts closest to the gasketing should be used for filters with a 13 16 single header in combination with a nominal 2 prefilter The second set of knockouts should be used for nominal 4 filters 528 shown as example Installation of Spring Latches 1
8. Figure 18 Split Reassembly Procedure For AcuAir Food Grade and Sanitary Series Units Only Frick INSULATION OF THE BASE RECONNECT SEAM OF AN ACUAIR FOOD GRADE OR SANITARY SERIES UNIT When two AcuAir unit sections are drawn together the base channels of the two sections form an uninsulated cavity that under certain conditions could produce condensation AcuAir provides a ship loose foam insulation kit to fill this cavity as part of the reconnect procedure The insulation may be injected either from the top of the cavity prior to installing the reconnect split cover strip or from underneath the unit provided the reconnect joint is not positioned directly over a support structure cross member Inject the foam into this open seam after the sections are joined and before the seam cover is installed GASKET SPLIT ES O CAULK EDGE OF COVER E pr AFTER ANCHORING BASE SKIN aH 27 Inject Foam Prior Installing Cover CAULK BASE SKIN SPLIT COVER BASE CHANNEL SPLIT TYPICAL JOINT OF TWO SECTIONS WITH FLAT SURFACES Figure 19 Insulation of the Base Reconnect Seam ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 MAR 14 Page 21 Follow the instructions provided by the foam manufacturer for preparing the two part foam mixture and the injection kit Take special note of the 30 second inactivity limit after which the injection nozzle may become permanently clogged
9. Filters The AcuAir unit is supplied with all filter racks in place The filters and filter clips are shipped separately direct from the filter supplier Once the unit is completely installed and thoroughly cleaned the prefilters and final filters should be installed in their respective holding frames Once the final filters have been installed the final filter section and the supply air ductwork should be cleaned and sanitized On units equipped with final filters a final filter pressure gauge is shipped mounted The high pressure tube is connected to the gauge at the factory The secondary port on the gauge needs to be field routed to the ductwork downstream of the final filters using the tubing supplied Cooling Coils All refrigeration coils must be evacuated to remove moisture prior to charging Do not leave system or coils open and idle prior to start up Internal corrosive damage can result Make sure piping is properly supported Evaporators are not designed to support external piping Evaporator piping and distributor tubing is not to be used for support or stepped on during the construction process The use of threading compounds at coil flanges with particles of metals i e copper embedded in the compounds can cause corrosion due to contact of dissimilar metals Verify the compatibility of your construction materials with the coil material of construction Refrigerant sensing devices should be employed in the hygienic
10. START UP AFTER PROLONGED SHUTDOWN 40 DAILY OPERATION AND ROUTINE MAINTENANCE 41 COIL MAINTENANCE eere nennen 41 DAMPER 41 FILTER 0 010 1221 41 ELECTRICAL CONDUIT SEALING REQUIREMENT 42 Sources of Water 42 PREC pe PU 42 UNIT CLEANING AND 42 FAN BEARING 43 Recommended Lubricant for Fan Bearings 43 Proper Interval and Quantity See Tables 1 2 amp 3 43 FAN SEGMENT FAN 1 43 Mounting Hardware and Adjustable Motor Base 43 Motor Condition Visual eee 43 Electrical I8 GKS eee tetur ee decente dede 43 NN 44 INSPECTING V BELTS AND 45 Inspect Sheave 45 Belt Replacement 45 TENSIONING V BELTS 45 General Rules Of Tensioning 45 Simple Tensioning 46 INSTRUCTIONS FOR PIEZOMET
11. 12 X 24 X 12 DH AAF 331 300 102 GL Special Order NOTICE NOTICE HEPA Filters must always be installed with the pleats Non HEPA Filters should be installed with the pleats oriented vertically oriented vertically whenever possible 210 100 IOM MAR 14 Page 34 INSTALLATION OF 2 PLEATED PANEL PRE FILTERS Care should be taken to prevent contamination of the filter media prior to placement in the filter racks Fresh filters should never be placed on dirty surfaces such as roofs or floors These instructions are for installing 2 panel filters into type 8 holding frames Latches needed for these applications are four 4 clips as indicated in the ACUAIR SINGLE FILTER APPLICATION table A single latch should be installed at each of the four 4 corners of the frame The latch fits into the set of knockouts which consists of two 2 rows of three 3 knockouts The row of knockouts closest to the gasketing should be used for nominal 1 filters or filters with a 13 16 single header The second set of knockouts should be used for nominal 2 filters Installation of Spring Latches 1 Insert the straight end of the latch between the two 2 knockouts furthest from the corner 2 Using a moderate amount of pressure force the latch over the third knockout 3 The latch installation should now be complete The latch should now be trapped within the three 3 knockouts but should be able to freely rotate see Figure 38
12. 6 Keep belts free from foreign material which may cause Slip 7 Make V drive inspection on a periodic basis Tension belt Figure 55 Simple Tensioning Procedure when slipping is observed Never apply belt dressing as this will damage the belt and cause early failure Simple Tensioning Procedure 1 Measure the span length K 2 Atthe center of the span K apply a force perpendicular to the span large enough to deflect the belt 1 64 for every inch of span length For example the deflection of a 100 inch span would be 100 64 or 15 5 inches See Figure 55 Frick BY JOHNSON CONTROLS OPERATING AND MAINTENANCE INSTRUCTIONS FOR PIEZOMETER DO NOT PERFORM MAINTENANCE ON THE Piezometer WHEN FAN IS ROTATING Operation of the Piezometer The Piezometer has no moving parts it cannot be turned on or off or adjusted Each of the two rings on the exterior side of the inlet cone are fitted with a 0 25 union brass tee The two tees are the connection points for running pneumatic tubing from the Piezometer to an air pressure gauge This Piezometer will automatically produce a pressure differential signal whenever the fan is moving air Figure 56 Maintenance of the Piezometer Basic Piezometer maintenance requires keeping the eight tiny pressure pickup holes in the flange and throat of the inlet cone free from blockage or debris buildup and periodically checking the tubing and fittings attached outside the Piezometer fo
13. ABOVE THE FINISHED ROOF NUMBER OF LEGS AND DESIGN BY OTHERS UNIT BASE 2 25 STEEL SUPPORT BY OTHERS TYPICAL SUPPORT LEGS BY OTHERS LOCATE AT CENTER OF UNIT WIDTH FOR SUPPORT OF AIR HANDLERS 150 OR WIDER NOTICE UNIT BASE ALL MEASUREMENTS ARE IN INCHES CURBS AVAILABLE IN 12 amp 18 HEIGHTS INSIDE DIMENSIONS ARE 7 LESS THAN O D DIMENSIONS ON 12 HIGH CURBS ce CONSULT ACUAIR ON ALL OTHER APPLICATIONS FOR ACTUAL DIMENSIONS 2 X 4 TREATED WOOD NAILER mM GALVANIZED STEEL SKIN INTERNALLY SUPPORTED Tt SUPPO STD W O CANT 5 50 OPT WITH CANT 8 50 ROOF CURBS ARE NOT RECOMMENDED ON SYSTEMS THAT HAVE ROOM TEMPERATURES BELOW 60 F UNIT SHOULD BE MOUNTED ABOVE ROOF IN THESE APPLICATIONS ab OPTIONAL CANT Figure 7 Generic Roof Curb Support SECTION RECONNECT SHIP LOOSE ITEMS INSTALLATION TOOLS AcuShield Roof Coating To complete the installation of an AcuAir system the Joint Sealing Caulk following tools are required Seal Gasket Tape Drift Pins 1 4 Bolts and Nuts 8 Foot Straight Edge Electrical Conduit Sealing Putty s devel Assorted Open End Wrenches Socket Set Caulk Gun Tape Measure Chain Falls Screw Gun with Nut Drivers Paint Brush or Roller for Applying AcuShield Roof Coating 210 100 IOM MAR 14 Page 12 Roof Curb Assembly Optional 1 When supplied by Johnson C
14. DATA POWER SUPPLY Unit Nameplate V PH CYC Verify V DATA SUPPLY FAN MOTOR RETURN FAN MOTOR Nameplate Volts Amps Volts Amps Run Amps Catalog Number Spec Number Horse Power RPM Nameplate 7 0 Actual Nameplate Actual Frame size Service Factor Jump Skip Frequencies SUPPLY FAN RETURN FAN Manufacture Name Type or Model Number Code or Shop Order Number Serial Number SUPPLY FAN DRIVE KIT RETURN FAN DRIVE KIT Belts Quantity amp ID Number Belt Tension Tag Actual Tag Actual Fan RPM DN Tag Actual Tag Actual other utilities Refrigerant Number Refrigerant Liquid Supply psig Rrefrigerant Gas Suction psig SE Gas Supply Pressure psig Natural Gas or Propane Circle one Hg Steam Pressure psig MAINTENANCE Upon completion of start up the customer assumes responsibility for periodic maintenance of this equipment in order to continue warranty Refer to the Installation Operation and Maintenance Manual provided with this equipment Customer s agent signature Date Frick BY JOHNSON CONTROLS A Actuators 38 Acu Shield Roof Coating 19 airborne contaminants 41 air leakage 26 Alignment 45 alkaline cleanser 41 Ammonia 41 automatic dampers 41 back flushing 47 Base Reconnect Seam 21 belt run in 38 Belt Tension 38 blower bearings 47 boiler pressure 29 bolt holes 13 brass fittings 47 bucket traps 29 burner 39 Bypass Coil 28 C cage nuts 13 clean
15. PSI It is recommended that the steam pressure be reduced to 15 50 PSI or lower for maximum steam coil life and optimum control operation 210 100 IOM MAR 14 Page 26 3 Refrigerant Piping When a cooling coil is supplied all refrigeration piping must be installed in accordance with all state and local codes and standard industry practices There must be sufficient flexibility in the piping so that any vibration from the unit is not transmitted to the building and so that the piping joints at the unit are not stressed All refrigeration lines must be secured to prevent wear or vibration at all operating conditions 4 Evaporator Coils Evaporator coils are designed and tested to a designated maximum allowable operating pressure PSIG It is the contractor s and or customer s responsibility to provide controls and reliefs on the refrigeration system to prevent internal pressures from becoming higher than the tested operating pressure Halocarbon refrigeration coils may not have been fully evacuated or totally dried at the factory It is the cus tomer s contractor s responsibility to provide adequate evacuation of the evaporator coil and ensure that the coil is dry and water free before start up of the system 5 Water or Glycol Coils It is essential that the piping for the system be done so that all lines can be drained and there are no traps or pockets on the system where water or glycol can collect and freeze All piping s
16. SPLIT DETAIL A Acceptable Polyurethane Caulking Manus bond Gray P N 013 02966 001 or Sikaflex Gray P N 013 03317 050 or Sikaflex Champagne P N 013 0331 7 040 DETAIL B SHIPPING SPLIT COVER Figure 13 Split Reassembly Procedure For AcuAir Performance Series Units Only Frick BY JOHNSON CONTROLS ACUAIR PERFORMANCE SERIES ROOF SEALANT PROCEDURE See Figure 14 1 The mechanical joint between sections must be bolted and sealed with polyurethane caulking 2 Acu Shield Roof Coating can be applied after polyurethane caulking is dry and when surface temperature is between 45 F and 108 F Below 45 F extra steps must be taken to keep the polyurethane caulking Acu Shield and metal reconnect surfaces heated for proper application during installation Contact Product Service for further direction 3 Do not apply when inclement weather is imminent within a 24 hour period ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 IOM MAR 14 Page 17 4 Do not apply to wet ice or snow covered surfaces 5 Before applying clean surface with wire brush or solvent wipe not provided 6 Apply Acu Shield Roof Coating with 3 inch wide roller or 3 inch wide paintbrush not provided 7 One quart applied at 45 mils is equal to a 3 inch wide X 33 foot long section 8 Cure time will vary with temperature and humidity Under normal conditions a rubber coating can be expected within a 24 hour period ACU SHIE
17. in Figure 13 using the 10 TEK screws and washers provided Apply a fine bead of caulk to either edge of the split cover and allow time to dry 10 Once the shipping cover is in place and the caulk has had time to set apply the roof coating as shown in Figure 14 11 INSPECT all splits to see if polyurethane caulk was applied and split was bolted properly 12 Reconnect all electrical conduit and wiring at the reconnect junction boxes Use electrical conduit sealing putty to seal all conduit openings into and out of the junction box to prevent the migration of moisture reference the information on page 42 13 INSPECT all splits to see if all electrical and piping connections are complete and correct NOTICE Temporary roof supports and diagonal shipping sup ports should not be removed until the split sections are completely reassembled See Page 18 for Food Grade and Sanitary Connections HOUSING GASKET CCCCCCCCCCCCCQCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC CCCecececececcccececececececccc ccce 9 HEX NUT USE FROM LIFTING LUC 9 SPLIT WASHER 9 FLAT WASHER Figure 9 Base Assembly Attachment Relates to AcuAir Performance Series Unit Only 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ELLE Page 14 INSTALLATION ETC FIELD SEAL BEFORE RECONNECTING SECTIONS EXTERIOR SKIN WITH POLYURETHANE CAULK Nx f TR Hn 25 20 X 75 HEX BOLT WITH 25 FL
18. moving parts This mechanical protection from moving parts is required by UL 1995 See Figure 1 A number of additional safety issues are discussed throughout the manual Please read the complete manual prior to installing operating or servicing the equipment Erick ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 i INSTALLATION OPERATION MAINTENANCE Page 5 DISCONNECT AND LOCKOUT POWER BEFORE SERVICE CONTACT WITH MOVING PARTS CAN CAUSE PERSONAL INJURY OR PROPERTY DAMAGE PRIOR TO OPERATION SECURE THIS ACCESS WITH LOCK BOLT OR SCREW lu M eee LATCH FRONT VIEW LATCH SIDE VIEW Figure 1 Access Door Latch 210 100 IOM MAR 14 Preinstallation Requirements TRAINING amp SAFETY CONSIDERATIONS The AcuAir precision engineered hygienic air systems provided by Johnson Controls Frick utilize the finest in HVACR materials and corrosion protection to deliver dependable consistent and accurate control of temperature and humidity in process rooms This manual provides the information needed for safe installation operation and maintenance Close attention to the instructions and guidelines provided will ensure the longest possible system life and dependable consistent performance Before installing operating or maintaining the system it is recommended that only experienced HVACR contractors operators and maintenance technicians be used
19. new media or when the pressure drop reaches the level recommended by the filter manufacturer Original filter information is provided in the AcuAir project manual 3 Unit Exterior a Visually inspect the unit exterior The seams between panels are factory sealed with silicon and should be re sealed if there appears to be any degradation of the original seal Any scratches to the exterior of the unit should be repainted with the factory supplied touch up paint b Verify the tightness of the door seals If there is any indication of air infiltrating or escaping the unit via the doors the door handles should be adjusted to provide a tighter seal ACUAIR HYGIENIC AIR UNITS MAINTENANCE Frick BY JOHNSON CONTROLS MAINTENANCE INTERVALS Maintenance of the AcuAir system is relatively easy if sufficient consideration is given to the minimum maintenance requirements for keeping air handling units performing to specification These can be easily scheduled using the following easy reference preventative maintenance guide provided in the following Recommended Maintenance Intervals table Before performing any maintenance or inspection make certain that all power has been disconnected locked out and tagged properly RECOMMENDED MAINTENANCE INTERVALS TYPE OF SERVICE START UP WEEKLY MONTHLY X X Check and clean the smoke detector air filter and detector board Check the Ammonia Detector sensor cell Check the seal
20. of the sections to facilitate lifting the the tension in each line for proper load distribution See sections at the factory for securing on truck trailers Lifting lugs Figures 3 and 4 for recommended lifting can be relocated to sides of the individual sections to facilitate 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ay Page 10 INSTALLATION EIC ORK 5092 HOUSING 5059026 5552556 OO 5 5 59550 965605555 SSSR NORE RX 5 lt gt X OOO 2 BASE SKIN Do not lift non base units or subassembly by attaching clevis hooks pins or bolts to casing casing hardware angles tabs or flanges NOTICE Save bolts when removing lifting lugs Bolts will be used for assembly of split units LIFTING LUG PERIMETER CHANNEL S Figure 5 Lifting Lugs When lifting use all lifting lugs to avoid damage and or personal injury Lifting lugs are shown in Figure 5 Do not lift non base units or subassemblies by attaching clevis hooks pins bolts etc to casing casing hardware angles tabs or flanges See CAUTION Lift the air unit only in an upright position Never lift or move a unit on its side or upside down If you do not rig or lift the unit carefully you could damage the unit hurt yourself or others USE CAUTION SU
21. piers or structural steel on which the units are to be located should be rigid and level shim if required Shims should be placed at intervals no greater than 5 feet apart and should not be used to compensate for significant surface slope The sum total of any individual stack of shims should not exceed and are to be used to compensate for surface irregularities only On units more than 150 inches wide the foundation shall support not only the perimeter base channel but also the midpoint of each unit split Reference Figure 6 Consult factory if housekeeping pad is not continuous The AcuAir unit must be secured to the Support structure It is the installer s responsibility to be sure the unit is secured in accordance with applicable building and earthquake codes NOTICE Shims may be used between the AcuAir unit and the supporting structure When shims are used they should be spaced no more than 5 feet apart Shim stacks should not exceed 1 2 inch in height ASSEMBLY HINT Units must typically be SLID into final position Applying grease to the support surface may make this easier ae ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 oe INSTALLATION Page 11 NOTES 1 SEE UNIT INSTALLATION DIMENSION DRAWING FOR UNIT WIDTH LENGTH AND WEIGHT 2 ALTERNATE METHODS OF SUPPORT TO INCLUDE SUPPORT AT ALL SECTION SPLITS SUPPORT DESIGNED AND SUPPLIED BY OTHERS DRAWING FOR REFERENCE ONLY LEGS TO SUPPORT THE FRAME
22. remaining latches Note filter media prior to placement in the filter racks Fresh the orientation of the latch to the knockouts in Figure 44 filters should never be placed on dirty surfaces such as roofs or floors A CAUTION Figure 44 Correct latch knockout configuration After the latches have been installed the frame should be configured like that shown in Figure 45 Pleated filters must be installed with the pleats running vertical whenever possible Figure 45 Frame with 4 latches installed NOTICE The frame contains 2 latches per side none on the top or bottom aL Frick BY JOHNSON CONTROLS ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 1OM MAR 14 Page 37 HEPA FILTERS AIRFLOW S AIRFLOW FILTER RETAINER CLIPS MUST BE ATTACHED TO SIDES ONLY FILTER CLIP INSTALLATION FLAT SEALING SURFACE GASKET SEAL HEPA FILTER HOLDING FRAME GASKET SEAL DETAIL A Figure 47 Installation of Hepa Filters High efficiency particulate air HEPA filters are installed in hygienic air units when extreme control of discharge airborne particles is required These filters are rated on the percentage of 3 micron size particulates they capture In order to achieve the desired filtration success the filter manufacturer checks each filter for integrity prior to shipment For ultimate success the HEPA filters must be handled properly installed cor
23. sections are mounted together to form larger damper assemblies Matching frame members must be tightly welded or bolted together in the field Multiple sections require additional structural support provided on site by others to ensure complete rigidity Horizontally mounted dampers may sag unless supported adequately Blade motion is transmitted between adjacent panels by common blade shaft couplings and Jackshafts It is important that all shafts are accurately aligned otherwise blade edges will bind and prevent a good seal 4 Actuators Operation of dampers may be manual using locking quadrant handles chain operators or other devices For automatic operation electric or pneumatic actuators can be connected to dampers either internally or externally Dampers constructed with multiple panels require individual actuators or Jackshafts Actuators or multiple actuators should be of adequate torque capacity to effectively open and close the damper according to its type size location and aL Frick BY JOHNSON CONTROLS its function in the system relative to air velocity and static pressure requirements 5 Lubrication Before initial operation all moving parts of dampers should be first cleaned and then thoroughly lubricated Dampers furnished with stainless steel side seals should also have the seals lubricated generously Dampers should then be manually operated several times until linkages and blades operate freely
24. seismic isolators Verified fan alignment with unit discharge Adjust with isolation Q Fan bearings properly lubricated Gas Supply is provided up to unit Flue is installed if needed Gas supply pressure is correct Gas line is purged 2 PRV installed if required have reviewed understand and acknowledge the terms and conditions of Johnson Controls start up policies detailed in this document The information that is provided in the prestart up checklist is accurate Authorized Signature Authorized Firm Phone Please FAX to Johnson Controls Frick Service 717 762 8624 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 52 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS START UP PERFORM THE FOLLOWING STEPS IN ORDER Refer to safety standards Ensure all door latches are secured before starting Energize power to the unit disconnect switch 6 Note record motor nameplate Full Load Amp rating Verify correct voltage phase and cycles 7 Immediately verify current draw of each leg of each motor Energize fan motor s briefly bump and check VFD refer to manufactures start up guide for correct fan rotation Inspect doors and latches for air leaks Check operation of dampers Inspect for obvious audible leaks Energize fan motor s Observe fan s for Apply steam to cold coils slowly to prevent damage smooth operation RECORD
25. the following recommendations are used in your With Grease Relief Plug maintenance program A high grade ball or roller bearing grease should be used Es CPAN AN grease E Recommended grease for standard service conditions is 2 Remove grease relief plug Polyrex EM Exxon Mobil 3 Add only the recommended amount of grease Maximum operating temperature for standard motors 4 Reinstall grease relief plug 110 C Shutdown temperature in case of a malfunction 115 C Proper Lubrication Intervals Recommended lubrication GREASE intervals are shown in Table 4 It is important to realize UE that the recommended intervals of Table 4 are based on average use Refer to additional information contained in Tables 5 and 6 Motor Lubrication Procedure Figure 52 GREASE FILLER PLUG Be sure that the grease you are adding to the motor is compatible with the grease already in the motor Consult your distributor or an authorized service center if grease other than the recommended type is to be used Figure 52 Grease Fittings TABLE 4 MOTOR BEARING LUBRICATION INTERVALS 10000 6000 3600 1800 1200 90 OVER 210 280 INCL 180 3600h 9500hr 15000 18000hr OVER 280 TO 360 INCL 180 2200hr 7400hr 12000hr 15 000 hr OVER 360 TO 5800 INCL 180 2200hr 3500hr 7400hr 10 500 Lubrication intervals are for ball bearings For roller bearings divid
26. ANGED LOCKNUT INTERNAL RECONNECT 7 SUPPLIED BY JCI GASKET INSTALLED IN FIELD i bm Figure 10 Cross Section Of Split Wall Assembly AcuAir Performance Series Only GASKET POLYURETHANE CAULK 25 MINIMUM DIA CONTINUOUS POLYURETHANE NO GAPS CAULKING 2 PLACES GASKET SHIPPED LOOSE INTERNAL RECONNECT AND INSTALLED BY CONTRACTOR BASE RECONNECT FLANGE Figure 11 Multi Section Gasket Installation On AcuAir Performance Series Units ae ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 oe INSTALLATION Page 15 INSULATION OF THE BASE RECONNECT SEAM OF ACUAIR PERFORMANCE SERIES UNIT When two AcuAir unit sections are drawn together the base channels of the two sections form an uninsulated cavity that under certain conditions could produce condensation AcuAir provides a ship loose foam insulation kit to fill this cavity as part of the reconnect procedure NOTICE On the Performance Series air units this insulation must be IF FOAM DISPENSING HAS STOPPED FOR MORE THAN injected from underneath the unit after the sections have 30 SECONDS REPLACE THE NOZZLE WITH THE EXTRA been securely joined PROVIDED INJECT THE FOAM INTO THE OPEN SEAM AFTER THE AIR UNIT SECTIONS HAVE BEEN SECURELY RECONNECTED Follow the instructions in the section FOAM KIT 15 USE GUIDELINES o
27. Belts If Ordered Installation and Start Up Manual ifting Lugs Filters amp Filter Clips Typically Shipped Separately FILTER SECTION HEPA Filter Latches ship loose and or attached to HEPA filter frames NOTICE Shortage of field installed items must be reported within ten 10 days after receipt of order STORAGE Short term storage is considered six 6 months or less from date of shipment Storage maintenance during this time period is usually limited to the following Indoor Storage 1 Store units in dry indoor protected area on a firm flat surface to prevent unit distortion 2 Protect units from excessive vibration and accidental impact 3 Do not store other equipment on top of or inside unit Outdoor Storage Whenever possible unit should be stored indoors or under cover If unit must be stored more than 1 week outdoors Johnson Controls Frick recommends the following guidelines 1 Cover all floor openings and secure all doors 2 Tarp unit to protect unit from dust rain snow and rodents Tarp over the roof and down the side to the base channel and secure ACUAIR HYGIENIC AIR UNITS INSTALLATION Frick BY JOHNSON CONTROLS 3 Store on level surface If unit must be raised off ground supports under base channel and base channel cross supports at maximum interval of 5 feet 4 Fan wheels should be rotated by hand 90 every month Lightly lubricate bearings every two 2 months 5 A200 wa
28. ER 47 Operation MM TNR T 47 c EH 47 RECOMMENDED MONTHLY SERVICE 47 RECOMMENDED MAINTENANCE INTERVALS 48 SPARE PARTS RECOMMENDATIONS 48 MAINTENANCE 48 ACUAIR FACTORY START UP ASSISTANCE 50 ACUAIR AIR HANDLER PRESTART UP CHECKLIST 51 PRESTART UP For Site 51 STARTS UP xiii M Dn Es ndo see a 52 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Page 4 INSTALLATION OPERATION MAINTENANCE Frick BY JOHNSON CONTROLS INTRODUCTION This manual in combination with the appropriate controls related manuals provides the information necessary to safely install and start up Frick AcuAir equipment Due to the custom nature of the AcuAir products there may be areas beyond the scope of this manual If there are any questions about a special application lacking the required information please contact the installing contractor or your local Frick Sales Office SAFETY The customer is responsible for providing qualified and trained personnel to install and operate the equipment Consult all local building occupational safety electrical gas and other codes applicable to the installation A variety of optiona
29. ERIOR SKIN HCS NC GR5 25 X 75 WITH FLANGE LOCKNUT NC 25 20 EXTERNAL RECONNECT 25 MINIMUM DIA CONTINUOUS POLYURETHANE CAULKING 2 PLACES Figure 17 Multi Section Gasket Installation On AcuAir Food Grade and Sanitary Series Units 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 20 INSTALLATION BY JOHNSON CONTROLS 3 Do not apply roof coating when inclement weather is 7 One quart applied at 45 mils is equal to a 3 inch wide x imminent within a 24 hour period 33 foot long section 4 Do not apply to wet ice or snow covered surfaces 8 Cure time will vary with temperature and humidity Under normal conditions a rubber coating can be expected within 5 Before applying clean surface with wire brush or solvent a 24 hour period wipe not provided 6 Apply Acu Shield Roof Coating with a good quality synthetic bristle paintbrush not provided DO NOT use silicone caulking on field recon nects or on shipping split covers CAULK ALONG RECONNECT HOLE LOCATION NOTICE Only use caulking shipped with unit SHIPPING SPLIT COVER DETAIL A SHIPPING SPLIT COVER Shipping split attachment angles come attached to each side of split Reattach with provided hardware Acceptable Polyurethane Caulking Manus bond Gray P N 013 02966 001 or Sikaflex Gray P N 013 03317 050 or Sikaflex Champagne P N 013 03317 040 DETAIL B SHIPPING SPLIT COVER
30. HEPA FILTER APPLICATION AcuAir HEPA Filter Frames 24 X 24 14 ga Galvanized 026 35789 001 24 X 12 14 ga Galvanized 026 35789 002 12 X 24 14 ga Galvanized 026 35789 003 24 X 24 14 ga Stainless Steel 026 35790 001 24 X 12 14 ga Stainless Steel 026 35790 002 12 X 24 14 ga Stainless Steel 026 35790 003 Filters are Designated Height x Width x Depth A EPA H x W x D Opposite of RE dims Filter Pleats Must Be Installed Vertically 23 375 X 23 375 X 11 5 AAF 905 000 029 Special Order 23 375 X 11 375 X 11 5 AAF 92A20H1T2A0 Special Order 11 375 X 23 375 X 11 5 AAF 91A20H1T2A0 Special Order Filters are Designated Height x Width x Depth HCA H x W x D Opposite of Ashrae dims Filter Pleats Must Be Installed Vertically 23 375 X 23 375 X 11 5 AAF 905 000 128 Special Order 23 375 X 11 375 X 11 5 AAF 92A20H1T2HO Special Order 11 375 X 23 375 X 11 5 AAF 91A20H1T2H0 Special Order o Non HEPA Filters in HEPA Frames Filters are Designated Width x Height x Depth MERV 13 Rigid w Gasket ALS Filter Pleats Must Be Installed Vertically When Possible 24 X 24 X 12 DH AAF 331 300 107 GL Special Order 12 X 24 X 12 DH AAF 331 300 108 GL Special Order Filters are Designated Width x Height x Depth MERV 14 Rigid w Gasket ALS Filter Pleats Must Be Installed Vertically When Possible 24 X 24 X 12 DH AAF 331 300 101 GL Special Order
31. ION 210 100 MAR 14 Page 23 Figure 26 Fresh Air Intake Plenum and Hoods Preassembled in the Factory required The plenum assembly must be securely screwed to the unit 12 Replace the access panel being sure that all screws are in place NOTICE Any penetration of cabinet skin will cause water and air leakage Thoroughly seal any screw piping or electrical holes with appropriate sealant Self tapping screws are not weathertight 210 100 IOM MAR 14 Page 24 FAN HOLD DOWN SPRING ISOLATOR SETUP OPTIONAL ACUAIR HYGIENIC AIR UNITS ee eee Frick BY JOHNSON CONTROLS INSTALLATION Place tubes on studs and place shoulder washer shoulder up on studs Place one 1 nut on each stud and tighten it on shoulder washer If fans are supplied with internal spring isolation they will be bolted down see Figure 27 for unit shipping After the unit Is in place assembled and leveled the fan mounts can be Place remaining nuts on studs and tighten to lower nut to lock in place disassembled by removing two 2 nuts and one 1 washer from each side Remove tubes from wire and discard wire NUTS SHOULDER WASHER SHIPPING POSITION SIDE VIEW SHIPPED POSITION SHIPPING POSITION SIDE VIEW 1 Remove the 7 8 nut as shown in the operating position view 2 Loosen the 7 8 jam nut between the isolator housing and the
32. Insert the straight end of the latch between the two 2 knockouts furthest from the corner 2 Using a moderate amount of pressure force the latch over the third knockout Repeat the installation process with the remaining latches Frick BY JOHNSON CONTROLS 4 Insert the filter into the frame making sure that the pleats are vertical 5 After the filter has been placed into the frame grasp the loose end of the latch and place it over the filter frame so that the latch secures the filter into the frame see Figure 41 Repeat for the remaining latches Figure 41 Place the end of the latch over the filter frame securing the filter to the frame 6 The filter should now be securely installed into the frame see Figure 42 INSTALLATION OF SH SINGLE HEADERED FILTERS These instructions are for installing single header rigid filters into type 8 holding frames Care should be taken to prevent contamination of the filter media prior to placement in the filter racks Fresh filters should never be placed on dirty surfaces such as roofs or floors Latches needed for these applications are four 4 clips as indicated in the table on page 32 A single latch should be installed at each of the four 4 corners of the frame The latch fits into the set of knockouts which consists of two 2 rows of three 3 knockouts The row of knockouts closest to the gasketing should be used for nominal 1 filters or filters wi
33. LD ROOF COATING CAULKING PROVIDED ROOF x c L BBB B BBBBBBBBAAALCIAIa AaAuaamnIALA SD HOUSING SPLIT Provided with ship loose items in fan section see table in Section Receiving amp Inspection Figure 14 Outdoor Split Roof Sealant Procedure AcuAir Performance Series Only 210 100 IOM MAR 14 Page 18 ACUAIR HYGIENIC AIR UNITS INSTALLATION Frick BY JOHNSON CONTROLS FOOD GRADE AND SANITARY CONNECTIONS RECONNECT INSTALLATION PROCEDURE 1 Position sections on level surface 2 Install the foam gasket on one of the mating surfaces of one of the sections to be reconnected as indicated in Figure 17 Gasket material and caulk are shipped loose in boxes located in the blower section of the air unit 3 Apply a bead of polyurethane caulk to either side of the foam gasket and across the lower reconnect flange as indicated in Figure 17 ASSEMBLY HINT It may be advantageous to install gasket material on the ends of the sections while the sections are still on the truck This will allow the crane to set the sections as close as possible during the lift 4 Attach hand winches to either side of the base via relocated lifting lugs and pull the sections together Bolt the base flanges per Figure 15 ASSEMBLY HINT It may be advantageous to locate the first AcuAir unit section in its
34. N CONTROLS GENERAL SPLIT UNIT REASSEMBLY Units which are shipped in sections must be installed on a proper foundation and carefully assembled to provide the required unit performance AcuAir units are assembled in one piece in our factory and split prior to shipping AcuAir units must be level for reassembly All bolts nuts washers split covers and polyurethane caulking if required can be found in supply fan section All splits are identified with welded let yc uem ters on the base channel A A B B for A A example to indicate which sections are to match up for reassembly REMOVABLE LIFTING LUGS You will be provided with removable lifting lugs along either the width or length of the various sections of the unit Lifting lugs may be repositioned prior to lifting Once the sections have been placed as close as possible to each other remove any lifting lugs in the reconnect split A hand actuated winch or a come along can be used to bring the unit sections together for final bolting Attach the hand winch or come along to each side of the base using the lifting lugs relocated to the alternate side locations and draw the sections together ELECTRICAL WIRING PIPING It is the installer s responsibility to reconnect all internal and external electrical or piping splits All wires are colored and or numbered to designate which wires should be joined at each split Before turning on power check all electrical circuits
35. P WITH FOAM 3 APPLY ESCUTCHEON AS SHOWN GLOSSY SIDE 4 USE POLYURETHANE CAULK Of COIL 4 7 INTERNAL EXTERNAL ESCUTCHEON ESCUTCHEON CAULKEDGE AN CLEAN AREA WHERE ESCUTCHEON WILL BE APPLIED WITH ALCOHOL amp CLEAN RAG PART PART NUMBER Caulking Gray 013 03317 050 Champagne 013 03317 040 Champagne Touch up 044 03504 000 Spray Paint Figure 36 Penetrations Details Use only metal cutting hole saws and or blades to make penetrations through panels Never use a cut ting torch due to foam insulation p ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 Eren INSTALLATION Page 31 FILTER INSTALLATION TABLE OF CONTENTS ACUAIR MATRIX AAF FILTERS AND AAF FRAMES LATCHES 32 INS TALLATION OF 2 PLEATED PANEL FILTERS md eonun a 34 INSTALLATION OF 4 PLEATED PANEL 34 INSTALLATION OF SH SINGLE HEADERED RIGID FILTERS 35 INSTALLATION OF A DH DOUBLE HEADERED RIGID FILTER 0 eee cece cece eee eee ee eee eee eee eee eee 35 INS TON 39 FILTER LATCHES Use with a 2 pleated panel filter prefilter or with a s
36. PPORT STRUCTURE INFORMATION AcuAir systems may be shipped in two or more sections These sections must be anchored to a suitable support structure concrete pads concrete piers or structural steel capable of supporting the total system operating weight plus a significant safety margin as determined by a qualified structural engineer The weight the support structure must support and the anchoring requirements will vary with live loads expected snow ice buildup seismic and wind loading See Figures 6 and 7 for AcuAir unit support methods If the support structure is in the form of two or more parallel steel beams the beams should be sized in accordance with standard engineering practices The structure must be capable of supporting the shipping weight of the unit as provided on the order related documents In addition it must also be able to carry any operating duty related loads such as water or refrigerant within the cooling and heating coils possible frost on the cooling coils any applicable flooded refrigerant LDO7923A surge vessel and associated piping snow loads that could accumulate on the roof horizontal wind loads etc It is recommended that the structure be designed for at least 110 of the operating weight of the system distributed as a uniform load over the longitudinal beams allowing for a maximum deflection of 1 360 of the length not to exceed 1 2 The support structure whether concrete pads concrete
37. See page 25 for help designing the drain piping 5 Consult the refrigeration contractor as to how much space is required for the coil piping A minimum walk space of 30 should be left between the final field piping to any object 6 As with any large equipment placement consideration of maintenance service and part component replacement should be allowed when designing space for the unit 210 100 IOM MAR 14 Page 8 Installation RECEIVING amp INSPECTION Frick AcuAir units are inspected and tested prior to shipment ensuring a high quality product Upon receipt of the unit s inspect for any damage that may have occurred during shipment Upon delivery compare items on the bill of lading with the items on the shipment to verify all parts have been received Any shortage breakage or damage noticed at time of delivery should be indicated on the carrier s freight bill and signed by the driver or carrier s representative Damage noticed after delivery should be reported to the carrier at once Request their inspection of the shipment and fill out a concealed damage inspection report Located on the inside of fan section access door is a handwritten list of field install items shipped with the unit Items typically shipped loose include FAN SECTION Acu Shield Roof Coating see Figure 14 optional Thermal Break Gasketing see Figures 9 11 15 amp 17 Split Reconnect Hardware Nuts bolts polyurethane xtra Fan
38. UAIR HYGIENIC AIR UNITS INSTALLATION 210 100 MAR 14 Page 29 FIELD PENETRATIONS FOR PIPING AND ELECTRICAL CONNECTIONS Use only metal cutting hole saws and or blades to make penetrations thru panels Never use a cutting torch due to foam insulation NOTICE For small sizes such as 1 2 iron pipe 1 2 conduit or 5 8 O D copper and smaller it is acceptable to use caulk instead of a grommet NOTICE Electrical conduits must be sealed internally to prevent airflow and moisture condensation Tools Required Drill motor Pilot starter bit Hole saws approximately 212 314 amp 472 diameter for holes Power cords as required Material Required Neoprene grommet 212 314 4 5 or 512 as required Cold galvanized paint Touchup spray paint champagne P N 044 03504 000 for outdoor unit exterior only Caulk P N 013 03317 050 aluminum gray or 013 03317 040 for outdoor units with champagne paint X acto knife Clean up supplies Procedure See Figure 36 Penetration Details 1 Make sure any components bulkheads or other obstructions are disconnected from panel inside and out 2 Layoutlocation and dimensions of hole opening to be cut Do this on both sides of double wall panels 3 Carefully cut correct hole size for the application in panel ensuring cuts on both sides line up and a smooth clean cut is made 4 Paint raw edges of sheet metal with cold galvanized paint 5 S
39. air system These sensors should be selected and located based on the refrigerant within the system When the refrigerant is ammonia the sensors work well when placed inside the AcuAir unit immediately downstream of the cooling coil Examine your environment If structure equipment or other elements of your facility show rust or corrosive effects the evaporator coils are not likely to be impervious to the same effects of the environment Consider this when formulating your maintenance program GAS HEAT START UP 1 Close the manual gas shutoff valve external to the burner Turn off the electrical power to the furnace Set the temperature to the lowest possible setting Set the burner controls to the OFF position Wait five minutes to clear out any gas Then smell for gas including near the floor 6 Set the burner controls to the ON position ACUAIR HYGIENIC AIR UNITS OPERATION 210 100 MAR 14 Page 39 7 Close the door on the front of the gas manifold 8 Open the manual gas valve external to the furnace 9 Turn on the electrical power supply to the furnace 10 Set the controls to the desired temperature NOTICE This heater is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand NOTICE There is an approximate 30 second delay between controls energizing and burner firing Figure 48 AcuAir Direct Fired Gas Burn
40. amp CONTROLS WALL OBJECT OR OBSTRUCTION Figure 2 AcuAir System to Wall Spacing Requirements Generic unit layout shown here Please consult the order specific unit layout drawing before beginning site engineering NOTES 1 The minimum distance from the exhaust fan housing to any sensitive object in the discharge air stream is 2 fan diameters Any closer and the object may be damaged The minimum recommended distance from the exhaust fan housing to an airflow obstruction such as a wall is 4 fan diameters for a single fan and 6 fan diameters for two stacked exhaust fans 2 The minimum distance from an access door in the open position to an object is the door width i e 24 plus 8 3 The minimum distance from any electrical enclosure to an object is 48 The installation of the AcuAir unit must be in accordance with the codes of the authorities having jurisdiction 4 The AcuAir hygienic unit will have sections under both positive and negative pressure with respect to ambient during normal operation When piping the individual drain pan outlets to a common drain line AcuAir recommends individual p traps The piping design should take into account the pressure inside the specific section and the elevation required to create the necessary trap
41. asket 12 p Periodic Inspections 41 Pieziometer 47 plenum 23 prefilters 39 48 pressure gauge 39 PRESTART UP 51 R Recommended Maintenance Intervals 48 reconnect seam 15 reducing bushing 29 Refrigerant Piping 26 return piping 28 roof curbs 12 run in procedure 38 S seals 39 sensing devices 29 Sensing devices 39 shaft retainers 6 Sheave Alignment 45 sheaves 45 SH filter 35 Shipping Bolts 29 shutdown 40 silicone caulking 16 20 Split Reassembly Procedure 16 Split seams 13 spring isolation 24 Spring Latches 34 start up 38 52 steam coil 25 steam manifolds 29 Steam traps 29 T thermal expansion 25 tools 11 Troubleshooting 49 V V belts 45 vibration 26 Vibration 6 W Warranty 28 Erick ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 INSTALLATION OPERATION MAINTENANCE Page 55 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 56 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS Form 210 100 2014 03 JOHNSON CONTROLS Supersedes 210 100 IOM 2013 10 Jj K 100 CV Avenue Subject to change without notice Waynesboro PA 17268 1206 USA Published in USA 03 14 GUI 50 Johnson Phone 717 762 2121 FAX 717 762 8624 2014 Johnson Controls Inc ALL RIGHTS RESERVED Control S www jci com frick
42. at saturated steam temperature Inverted bucket traps should incorporate thermostatic air vents Make return connection full size as required and reduce only at trap Do not use reducing bushing on coil return connection Flexible Connectors VIFB Only Return steam condensate headers hot water supply and return headers must be free to float A flexible connector MUST be installed as close as possible to the coil to accommodate a minimum of 1 2 expansion movement of the headers Failure to install connectors will restrict expansion of the headers This can result in bowing of tubes bending of fins interference with damper operation or eventually tube breakage Freezing Conditions NOTICE Antistratification baffles are standard on all IFB and VIFB coils mounted in units The outside air and return air must be thoroughly mixed before passing over the coil When air below 32 F enters only part of the coil it creates a greater hazard than when the airflow entering the coil is of a uniform temperature Coils used in series with respect to the airflow must have individual controls with ample space between the coils for sensing devices when required Coils with two or more rows are more sensitive to freezing than single row coils On 100 O A capable applications locate low limit at least 24 downstream of leaving edge of VIFB IFB casing Low limit element must cross both face and bypass areas parallel to headers AC
43. at this procedure for each of the hoods HOODS 4 Carefully remove excess polyurethane caulking from around the flange of the hood SHEET METAL SCREWS NOTICE Any penetration of cabinet skin will cause water and air Figure 32 Connection of Weather Hood s to Unit leakage Thoroughly seal any screw piping or electrical holes with appropriate sealant Self tapping screws are not weather tight Figure 33 Weather Hood Installation 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ay Page 28 INSTALLATION EIC HORIZONTAL AND VERTICAL TUBE STEAM HEAT COIL WITH INTEGRAL FACE AND BYPASS DAMPERS STEAM IN ACTUATOR FACE DAMPERS CLOSED BYPASS OPEN NN Ai 2 de STEAM OUT LI i a 4 a Li y m Figure 34 Integral Face and Bypass Coil Horizontal Tubes Steam Shown The Vertical Tube Integral Face and Bypass VIFB or the Integral Face and Bypass IFB operates with full steam pressure or water flow at all times when the air is at or below 7 35 F This prevents freeze up and temperature stratification tat STEAM IN A CAUTION VIFB lower header must be free to float After the coil has been piped remove the yellow colored bolts to allow header to float Always support on the coil connections when installing fittings A CAUTION VIFB Warranty will be voided should return piping on ACTUATOR lower header inlet and return on two r
44. by Johnson Controls This is a limited training which is adequate for most job sites Additional training for maintenance crews or site owners is available at extra cost Contact your sales representative for pricing Factory Start up Assistance will not include Piping of the gas supply lines to the unit or setting of gas regulators external to the unit Wiring any connection of electrical power required to operate the equipment Wiring or installation of external control devices This includes items shipped separately such as sensors valves gages etc Wiring remote panels to the unit Drainpipe plumbing and heat tape installation on drainpipe Piping pneumatic tubing runs required by room pressure sensing controls Wire connections at unit shipping splits Air balancing of the room supply return and exhaust air NOTE Your factory technician will attempt to set control systems to deliver balanced room conditions but absolute verification of air volumes and final adjustment is up to others Filter installation Piping of refrigerant lines or valves settings of refrigerant line regulators Assembly and installation of ship separate mechanical such as hoods Assembly or installation of ductwork or diffuser systems Our factory service technicians are committed to providing customer satisfaction Due to travel restrictions they are limited as to the amount of tools that can be carried on a given trip Please take the time to rev
45. can be repaired in the field 210 100 IOM MAR 14 Page 38 Before attempting to start up and operate any electrical cooling equipment such as an AcuAir system unit it Is essential that all personnel associated with it have a basic knowledge of how and why the unit operates in normal conditions The following description outlines a standard unit s general features operation and controls An AcuAir system Hygienic air unit is an engineered heat transfer device that provides some or all of the listed functions cooling dehumidification pressurization filtration heating exhaust and condensation control Each unit is engineered and designed for a specific application Safeties and controls vary with each AcuAir system installation and may be interfaced with ancillary equipment or system controls All operators should be thoroughly trained in an integrated cooling system s sequence of operations and safeties INITIAL START UP After installation of the AcuAir unit controls and necessary ancillary and auxiliary equipment the entire system should be verified before placing the hygienic system on line for the first time Specifically the following prestart measures must be completed to ensure the readiness of the AcuAir system Do not attempt any inspection or maintenance unless the electrical supply has been completely disconnected and locked out Inspection Do not start the unit until the following inspections ver
46. ce belts as a matched set Used belts will always be longer because of stretcthing and new belts should never be installed singly on a matched drive Follow the steps below to replace belts 1 Release the tension on the belts by loosening the adjusting nuts on the fan motor 2 Remove old belts and verify the sheave alignment with a straight edge 3 Install the new belts on the sheave Never place the belts on the sheaves by using a screw driver to pry the belt over the rim of the sheave TENSIONING V BELTS amp SHEAVES General Rules Of Tensioning 1 Correct belt tensioning data is located on V belt Drive Kit Label which is mounted on inside of fan access door 2 Adjust the belt tension using the adjusting nuts on the motor mount 3 The ideal tension is the lowest tension at which the belt Will not slip during start up 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ay Page 46 MAINTENANCE EIC ALIGNMENT USING STRAIGHTEDGE A Straightedge touching sheaves at points indicated by arrows ALIGNMENT USING STRING B Cord tied to shaft Cord touching sheaves at points indicated by arrows Figure 54 Sheave Alignment 4 Inspect tension after The first 24 hours of operation One week of operation BELT New belt tension will drop rapidly during the first few hours of operation INCH OF SPAN 5 Overtensioning shortens belt and bearing life
47. cetus 12 PERFORMANCE GRADE CONNECTIONS 13 REASSEMBLY PROCEDURE FOR SPLIT UNIT PERFORMANCE SERIES 13 INSULATION OF THE BASE RECONNECT SEAM OF AN ACUAIR PERFORMANCE SERIES UNIT 15 ACUAIR PERFORMANCE SERIES ROOF SEALANT 17 FOOD GRADE AND SANITARY CONNECTIONS 18 RECONNECT INSTALLATION PROCEDURE 18 ACUAIR FOOD GRADE OR SANITARY SERIES ROOF RECONNECT FINISH 19 INSULATION OF THE BASE RECONNECT SEAM OF AN ACUAIR FOOD GRADE OR SANITARY SERIES UNIT 21 FOAM KIT 15 USE GUIDELINES ACUAIR UNIT BASE RECONNECT INSULATION 22 ACUAIR FRESH AIR INTAKE PLENUM 23 FAN HOLD DOWN SPRING ISOLATOR SETUP OPT 24 CONDENSATE DRAIN TRAP SIZING 25 DRAIN PAN 25 FIELD PIPING REQUIREMENTS 25 DUCT CONNECTIONS trie roc aues cen eaan 26 WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR FRESH AIR OPENING 27 HORIZONTAL AND VERTICAL TUBE STEAM HEAT COIL WITH INTEGRAL FACE AND BYPASS DAMPERS 28 Shipping Bolts VIFB 29 Piping Suggestions VIFB and IFB 29 Flexible Connectors VIFB
48. e if all electrical and piping connections are complete and correct NOTICE Temporary roof supports and diagonal shipping supports should not be removed until the split sections are completely reassembled INTERIOR WALL PANEL ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 1OM MAR 14 Page 19 ACUAIR FOOD GRADE OR SANITARY SERIES ROOF RECONNECT FINISH 1 The mechanical joint between the unit sections must be bolted and sealed with polyurethane caulking prior to applying the roof coating 2 Acu Shield Roof Coating can be applied to the roof reconnect after any exposed polyurethane caulking is dry and when surface temperature is between 45 F and 108 F Below 45 F extra steps must be taken to keep the polyurethane caulking Acu Shield and metal reconnect surfaces heated for proper application during installation Contact Product Service for further direction Interior Finish Caulking to be DOW RTV 732 Food Grade Caulk CAULK RAW EDGES OF SPLIT ANGLES SPLIT REATTACHMENT ANGLE Figure 16 Cross Section Of Split Wall Assembly POLYURETHANE CAULK NO GAPS GASKET SHIPPED LOOSE AND INSTALLED BY CONTRACTOR BASE RECONNECT FLANGE EXT
49. e the listed lubrication interval by 2 For 6205 and 6806 bearings For 6807 bearings consult oil mist lubrication MN410 Relubrication interval for 6205 bearing is 1 550 hr Using grease lubrication Relubrication interval for 6806 bearing is 720 hr Using grease lubrication TABLE 5 MOTOR BEARING SERVICE CONDITIONS SEVERITY OF SERVICE AMBIENT TEMP MAX ATMOSPHERIC CONTAMINATION TYPE OF BEARING STANDARD CLEAN LITTLE CORROSION DEEP GROOVE BALL BEARING SEVERE MODERATE DIRT CORROSION BALL THRUST ROLLER gt 50 C OR EXTREME CLASS H INSULATION SEVERE DIRT ABRASIVE DUST ALL BEARINGS LOW TEMPERATURE lt 30 C CORROSION Special high temperature grease is recommended NOTE that high temperature grease may mix with other grease types Thoroughly clean bearing and cavity before adding grease Special low temperature grease is recommended TABLE 6 MOTOR BEARING LUBE INTERVAL MULTIPLIER SEVERITY OF SERVICE MULTIPLIER O STANDARD SEVERE 05 1 0 5 EXTREME LOW TEMPERATURE Frick BY JOHNSON CONTROLS INSPECTING V BELTS AND SHEAVES Before a new set of V belts are installed inspect the condition of the sheaves Dirty or rusty sheaves impair the drive s efficiency and abrade the belts which result in premature failure See Figure 53 Inspect and clean sheaves replace worn or damaged sheaves Worn sheave grooves are one of the principal causes of premature belt failure Clean dirty dus
50. eck power to and from starter Check damper end switch if applicable 210 100 1OM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 50 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS ACUAIR FACTORY START UP ASSISTANCE Responsibilities of Parties in Coordinating Factory Start up Attention Factory Sales Reps Project Engineers Installing Contractors Project Owners Factory start up assistance is often included in the purchase price of AcuAir equipment When factory start up assistance is sold with the equipment it is crucial for all parties involved in the completion of any project to understand and carry out their respective responsibilities prior to scheduling factory start up personnel The purpose of factory start up assistance is to provide final testing and calibration to ensure that the equipment is functioning in compliance with the design specifications of the factory order It does not include installation or assembly of any components shipped separately from the factory The factory start up assistance includes one trip of a factory technician who will provide this service It is our policy to bill additional time and travel expenses of any additional labor or expenses incurred in the event that the unit is not completely ready when the factory technician arrives The included factory start up assistance is available Monday through Friday except holidays during normal and reasonable working hours Customers with nar
51. ed As a rule of thumb filters should be replaced when the air pressure drop across them becomes double the pressure drop when newly installed 210 100 IOM MAR 14 Page 42 Finish and Sealing AcuAir units utilize a food grade caulk for air and water sealing on the interior and exterior The sealing on the units should be inspected and repaired as necessary NOTICE It is important that food grade sealant be used when repairing or replacing unit caulking ELECTRICAL CONDUIT SEALING REQUIREMENT The AcuAir hygienic unit has the potential to operate with internal air humidity and external ambient temperatures conducive to forming condensation These factors make it important that measures be taken to eliminate risk of water and ice collecting where it has the potential to cause damage or faulty operation Before initial start up of the AcuAir hygienic unit a thorough inspection of all conduit openings should be made and any compromised openings resealed Follow up inspections should be performed as indicated on the recommended maintenance schedule Sources of Water or Ice Water may enter the inside of the electrical conduit and door switches by either of two methods through unsealed conduit ends and flexible conduit pigtails prior to the AcuAir unit factory wiring being reconnected on site or by humidity migrating into unsealed conduits that are open to the inside the AcuAir enclosure Humidity that migrates into an electrical c
52. elect appropriate grommet for new panel hole and cut out appropriate hole diameter for penetration with an X acto knife 6 After paint dries Install grommet into panel hole opening 7 Apply sealant all around new hole opening behind lip of grommet on both sides of panel 8 Run pipe or conduit through grommet and make appropriate connections 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS a Page 30 INSTALLATION Frick 9 All modified panels must provide integrity equal to original equipment specifications 10 Reconnect any components bulkheads or other fixtures that were disconnected from panel in step 1 11 Thoroughly clean up inside and outside air unit WATER amp STEAM COILS DX REFRIGERANT COILS NOMINAL ESCUTCHEON ESCUTCHEON JCI PARTNO OD 10 55 CONNECTION OD 0 500 175 0 625 550 0 875 550 OD 30 1 125 815 60 60 60 60 0 125 60 02814910006 60 02814910007 60 1 02814910008 60 1 02814910009 60 2375 0120 60 2 60 60 200 60 1 375 1 000 250 60 1 625 1 315 300 60 2 125 1 875 2 625 3 125 2 3 5 2 875 028 14910 010 028 14910 011 028 14910 012 2875 025 APPLY RING OF CAULKING TO BACKSIDE OF PROCEDURE ESCUTCHEON 1 CUT HOLE LARGER THAN MATTE SIDE FOR BOTH INTERIOR AND PIPE O D WITH HOLE SAW N EXTERIOR ESCUTCHEON 2 FILL GA
53. er GAS HEAT SHUTDOWN 1 Set the controls to lowest setting Turn off the electrical power supply to the furnace Set the burner controls to the OFF position 2 3 4 Close the manual gas shutoff valve external to the furnace m EN il eim Oe Rl SENE 4 4 a TATEM he A G DEI TF Ys Figure 49 AcuAir Gas Burner Wrapper 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS E ET Page 40 OPERATION Frick 24 Hour After 24 hours of operation under load the following services should be performed 1 Examine the unit for any unusual noise or vibration 2 Readjust fan belt tension if required START UP AFTER PROLONGED SHUTDOWN It is imperative that maintenance personnel conduct a thorough start up before running the unit after a prolonged shutdown At minimum the following checks must be preformed 1 Clean any debris from guards fans eliminators heat transfer coils and filters 2 Turn the fan s by hand to ensure rotation without obstruction 3 Verify and if necessary adjust the fan belt tension See Belt Replacement and Tensioning section 4 Prior to start up lubricate the fan shaft and motor bearings The ball bearings are factory lubricated but should be relubricated if the unit has been sitting on site for more than a year before start up 5 Check the locking collar on each fan shaft bearing and tighten if necessary 6 Verify the voltage and current of all three
54. er lubrication intervals and the amount of grease added should be altered Always lubricate bearings prior to extended shutdown or storage and rotate shaft monthly Recommended Lubricant for Fan Bearings A Lithium Petroleum base grease conforming to an NLGI Grade consistency is normally used Lubricant must be free of any chemical impurities such as free acid or free alkali dust rust metal particles or abrasives This light viscosity low torque grease is rust inhibited and water resistant has a temperature range of 30 F to 200 F with intermittent highs of 250 F Lubricate bearings as required by the severity of required duty Proper Interval and Quantity See Tables 1 2 amp 3 ACUAIR HYGIENIC AIR UNITS MAINTENANCE 210 100 1OM MAR 14 Page 43 FAN SEGMENT FAN MOTOR Keep the motor clean dry and properly lubricated at all times Blow dust and dirt out of windings periodically using low pressure 50 psig air Figure 51 Figure 51 ODP Open Drip Proof TEFC Totally Enclosed Fan Cooled Mounting Hardware and Adjustable Motor Base Inspect for loose parts Inspect for damage Motor Condition Visual Inspect for leaky bearing seals Inspect for damage Inspect for dirt dust amp debris in air vents on motor housing Electrical Checks Inspect all electrical terminations Inspect conduit fittings and clamps for damage or looseness Inspect operating amperage and compare to nameplate TABLE 1
55. final position and attach it to the support structure before pulling the next section into position against it 5 The factory installed unit reconnect flanges will be joined using 14 bolts and nuts shipped loose in a container in the blower section of the unit All bolt holes require a bolt CAULK EDGE OF COVER AFTER ANCHORING BASE SKIN 75 GR5 HEX BOLT ew e USE FROM LIFTING LUG es 9 2 De E If bolt holes do not align it may be due to racking during transit to job site Use a Jack to lift one side until holes on the wall of the opposite side align Bolt this wall together and then remove jack from opposite side As the unit settles the out of square racking caused during transit should realign Continue assembly with bolting other side base and roof making use of a drift pin to align the holes Bar clamps may be needed to align the roofs together If bar clamps are needed use wood for protection in between the bar clamp and unit 6 Check to see if all bolts are secured properly and apply polyurethane caulk to all exterior seams per Figures 18 ASSEMBLY HINT It is recommended that the base flange bolts be only loosely fitted prior to fitting all 1 4 reconnect external flange bolts Once all of the 1 4 flange bolts are in place tighten the base flange bolts and finish tightening all of the reconnect flange bolts This sequence will help make alignment of the reconnect flange holes a bit easier 7 Appl
56. for continuity UNIT INTERIOR FLOOR FORMED INTERNAL CHANNEL CHANNEL FLANGE A 8 x 11 5 2 250 NOTICE FLANGE WIDTH CAN VARY LOCATE OUTSIDE EDGE OF CURB ANGLE USING THE A DIMENSION FROM THE BACK SIDE OF THE PERIMETER CHANNEL Figure 8 Roof Curb Detail Frick BY JOHNSON CONTROLS ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 MAR 14 Page 13 PERFORMANCE GRADE CONNECTIONS REASSEMBLY PROCEDURE FOR SPLIT UNIT PERFORMANCE SERIES ONLY 1 Position sections on level surface 2 Install the foam gasket on one of the mating surfaces of one of the sections to be reconnected as indicated in Figure 11 Gasket material to be shipped loose ASSEMBLY HINT It may be advantageous to install gasket material on the ends of the sections while the sections are still on the truck This will allow the crane to set the sections as close as possible during the lift 3 Apply polyurethane caulk on either side of the foam gasket and across the lower reconnect flange as indicated in Figures 9 and 11 4 Attach hand winches to either side of the base via relocated lifting lugs and pull the sections together Bolt base per Figure 9 ASSEMBLY HINT It may be advantageous to locate the first section in it s final position and attach it to the support structure before pulling the next section into position 5 Install the reconnect flange attachment hardware starting from the middle of the botto
57. g power to AcuAir system Always disengage and lock out power before allowing interior inspections To prevent foreign objects from being sucked into rotating fan blades never allow operation with the doors open Enclosed space inspections Inspections of coils filters etc requires machinery lockout and the use of a lookout buddy at a minimum consult your internal safety policy and OSHA requirements for additional recommended safety procedures Vibration and noise Discontinue or stop machinery that emits unusual vibration and noise The source must be investigated identified and corrected before testing or placing the system back in operation ACUAIR HYGIENIC AIR UNITS Page 6 INSTALLATION Frick BY JOHNSON CONTROLS Wet Surface Precautions Poorly maintained and wetted machinery requires care to avoid electrical shocks from inadequate or loose field wiring and connections All personnel must lock out and tag machinery before working on the unit Proper safety precautions such as the use of insulating soles and gloves and a trained lookout buddy are indispensable Ice formation in cold weather can present slip and fall hazards Icing safety procedures should be mandatory when the daily ambient temperature falls below 40 F AcuAir systems typically serve in a continuous duty capacity and must be properly sited installed and connected in the field by others to appropriatel
58. hould be pitched away from the unit coil The piping should be installed in a manner which Will allow the coil to be filled with an antifreeze solution if necessary ACUAIR HYGIENIC AIR UNITS INSTALLATION Frick BY JOHNSON CONTROLS DUCT CONNECTIONS See Figures 30 and 31 Make duct connections to the casing by screwing flanged ducts directly to the casing with self tapping sheet metal screws Duct connections to collar type openings can be made with S cleats or overlapping joints Apply polyurethane caulking around the duct connection It is important to seal all duct connections to prevent air leakage and system performance problems It is recommended that all duct connections to the AcuAir unit be insulated to minimize condensation CAULKING E SHEET METAL SCREW Figure 30 Detail of Duct Connection REMOVE SHIPPING COVER PRIOR TO INSTALLING DUCT WORK Figure 31 Connection of Duct ae ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 oe INSTALLATION Page 27 WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR FRESH AIR OPENING POLYURETHANE See Figures 32 and 33 CAULKING 1 Apply polyurethane caulking to the flange of the hood 2 Align the hood over the opening Check for adequate clearance to doors and other openings on the air handling unit 3 Attach the hood to the unit using sheet metal screws through the unit casing On openings requiring multiple hoods repe
59. iew this document to be sure that all facets of project construction and completion are assigned and understood by all participants When the project is complete please fill out and send the following AcuAir Prestart up Check List Erick ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 INSTALLATION OPERATION MAINTENANCE Page 51 ACUAIR AIR HANDLER PRESTART UP CHECKLIST Name of Installing Contractor Unit Tag Qualified Technician s Name Unit Model Frick Sales Order Unit Serial Job Name Job Site Location Job Site Contact and Phone PRESTART UP For Site Records GENERAL UNIT INSPECTION Identify and perform appropriate lockout tag out and safety rules For details on points below see appropriate section of Installation Operation Maintenance manual provided with each air handler For VFD equipped air handlers refer to the VFD forms for additional start up requirements Unit inspected for damage interior and exterior Condensate drain properly trapped Unit installed on flat and level surface Outdoor unit mounted UNE Air hoods installed properly within roof slope limitations where applicable Package Installed According to 090 400 SB Proper Installation Q Terminal screws and wiring connections secure of Electronic Equipment in control electric and Air Modulator panels All shipping splits sealed and secured properly Verify that all ductwork is complete and available for ful
60. ify operational readiness Avoid accidents or equipment failure by rectifying any unsatisfactory condition Inspect general condition of unit e g structural integrity anchors supports etc Confirm that all conduit openings through the walls of the AcuAir unit as well as conduit openings into electrical panels are sealed with electrical putty Confirm drive assembly condition and alignment of motor bearings collars and fan shaft Confirm proper belt condition and tension See Mainte nance section Verify there are no obstructions at the fans and fan guards Verify the correct rotation of the fans Understand and prepare for first 24 hour operation mea sures e g new belt run in procedures See New Belt Run in section Understand and prepare the unit prestart up checklist See Appendix A for the prestart up form Blower Motor Drives 1 Mechanical Tightness a Verify tightness of fan bearing bolts b Verify tightness of blower wheels to shafts ACUAIR HYGIENIC AIR UNITS OPERATION Frick BY JOHNSON CONTROLS c Verify tightness of blower motor and sheave d Verify tightness of all motor mounting bolts 2 Belt Tension a Adjust belt tension if slipping is evident b Verify belt tension after 50 hours of operation and again after 100 hours of operation NEW BELT RUN IN During initial start up of new belts a belt run in procedure is recommended During start up follow these inst
61. in conjunction with formal training on the AcuAir system s design and features Reading and understanding of this manual should serve as the minimum application specific training requirement AcuAir system installation operation and maintenance involves heavy rotating machinery operating at high speed and high voltage Normal operations and maintenance procedures may require working at elevations enclosed space entry or use of hand and power tools Taking these considerations into account along with the hygienic nature of AcuAir applications it is clear that safety should always be the top priority We recommend that every AcuAir system user analyze and develop an installation specific safety regime that takes into account such variables as specific site system features personnel qualifications hazard identification etc The following elements of operational safety are recommended for inclusion in every client s AcuAire system safety plan requirements NOTICE Configure all power switches and controls to provide an open safe circuit before and during maintenance pro cedures until the system is cleared by management for normal on line operations For extended shutdowns it is recommended that a qualified technician remove fuses from fused disconnect panels or otherwise open the circuit in an accepted secure manner Fans All fan covers guards and shaft retainers if any must be in place before applyin
62. ing putty of all electrical conduit openings both inside the air handler as well as inside all electrical enclosures SPARE PARTS RECOMMENDATIONS Johnson Controls Frick recommends that customers maintain an inventory of spare parts for the AcuAir air unit By maintaining this inventory of spare parts change out requirements can be immediately satisfied during preventative maintenance inspections EVERY 3 EVERY 12 MONTHS MONTHS X X X X X It is also advisable to reorder parts prior to taking existing spares from inventory This policy helps prevents downtime due to forgotten spare parts order placement The type and recommended stock level for recommended part is listed in the order specific documentation provided after the AcuAir air unit is shipped from the factory Frick BY JOHNSON CONTROLS ACUAIR HYGIENIC AIR UNITS 210 100 1OM MAR 14 MAINTENANCE Page 49 Troubleshooting Symptom Probable causes and Corrections Motor doesn t start Motor starts but quits shortly after Cooling doesn t come on Steam valve doesn t modulate Direct fired burner doesn t light Check and gap pilot assembly 3 16 gap Indirect fired burner doesn t light Exhaust fan doesn t start Check MOA module to see if in AUTO green light if on red light if fuse is blown Check blower door switch Check smoke ammonia detectors if applicable Check end switch on OA dampers if applicable Check fuses Check ove
63. ingle header SH rigid filter final Filter either one installed in a standard type 8 filter frame Use with a 4 pleated panel filter Prefilter installed in a standard type 8 filter frame Use with a 12 DH Double Headered Rigid Filter installed in a standard type 8 filter frame Use with a 2 pleated panel pre filter in a smooth notch free type 8 style filter rack AAF 312 100 002 L 2 Use with a 4 pleated panel pre filter in a smooth notch free type 8 style filter rack AAF 312 100 004 L 4 Use with a 12 rigid DH final filter in a smooth notch free type 8 style filter rack Used to attach HEPA Filters to Holding Frame NOTICE JCI P N 391 008 101 Galv JCI P N 391 008 100 Stainless Typically when filters are supplied by others so are the Figure 37 Filter Latches filter clips 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ELLE Page 32 INSTALLATION EIC ACUAIR SINGLE FILTER APPLICATION NON HEPA FILTER 4 Pleated 12 Rigid Final Filter Double Header Style Filter Holding Clips to be used 2 Pleated Panel Panel 12 Rigid Final Filter with Filter Styles Prefilter Prefilter Single Header Style Filter Clip and Frame AAF Part Number JCI Part Number Description Filter Holding Clips C70 Stainless Steel AAF 315 004 003 026 35778 000 2 SS Knock on Clip AAF 312 100 002 Special Order JCI 026 35778 007 026 35778 024 Special Order
64. inuous bead of polyurethane caulking on the face of each vertical hood flange and across the face of the top flange 6 The Plenum and hood assembly can be lifted using the lifting lugs provided on the top if the plenum 7 On the blank wall of the plenum is an access panel This panel can be removed to provide access to the inside of the plenum when attaching it to the fresh air opening on the AcuAir unit 8 Apply continuous beads of polyurethane caulking on the face of the plenum flanges The caulking should be on the outside of the factory drilled attachment screw holes This caulking will prevent rain water from reaching the attachment screw penetrations once the plenum Is mounted to the AcuAir unit See Figure 23 Site Applied Caulk to Seal the Plenum to the AcuAir Unit Factory Drilled Tapper Screw Holes Fresh Air Plenum Caulking Figure 23 Applying Caulk to Plenum 9 Using a crane lift the plenum with mounted hoods into position for attaching to the AcuAir unit 10 The two outer legs under the plenum must rest securely on site structural supports 11 When the plenum is plumb and level use the screws that were provided to attach the plenum section to the AcuAir unit The screws are shipped loose and can be found in the blower section The predrilled holes indicated in the plenum frame show the location and number of attachment points ACUAIR HYGIENIC AIR UNITS INSTALLAT
65. l airflow Unit installed with proper clearances Clean air filters installed properly and secured Visually inspect roof curb for tight seal around unit Damper linkage is tight and in correct power off position All shipping bolts and other material have been removed Fan VIEB Energy Recovery Wheel Damper Pipe chase floor sealed at penetrations All shipped loose parts installed Pneumatic tubing for room pressure sensors is in place Controls installation complete Filter gauge is installed in supply ductwork and set to zero 5j Paste Verify all plastic spacers have been removed between door and door frame El init centroloahrelisSecessiblor Catwalk adderet Verify Energy Recovery Wheel turns freely and wheel segments are fully engaged All field wiring complete and inspected Installer has cleaned out interior All wiring and tubing connections made at shipping splits Correct line voltage is supplied at disconnect 2 All field piping connections complete 7 Fan Inspection Verify that bearings and locking collars have properly tightened setscrews bolts and nuts Fan wheel properly aligned tight on shaft and freely moving Sheaves properly aligned and tight on shaft Verified fan base isolators and thrust restraints for proper adjustment NOTE Do not remove functional bolts from Belt tension adjusted properly per drive package label on fan
66. l safety features are available from the manufacturer it is the responsibility of the owner to determine If the unit is equipped with all of the safety devices required for the particular application Safety considerations include 1 The accessibility of the equipment to non service personnel 2 The provision of electrical lockout switches 3 Maintenance procedures 4 Automatic control sequences Users and installers of this equipment should be aware of all recommended safety procedures and information such as AMCA publication 410 90 Safety Practices Never open an access door while air unit is in operation WARRANTY NOTICE For Warranty Support with the Frick AcuAir unit contact Frick Service at 717 762 2121 A fan even though locked out electrically can rotate in a seemingly insignificant air flow During maintenance the impeller should be secured to restrict rotation Verify that the restrictive device is removed before putting the fan back into service Equipment wired to automatic control devices may start without warning resulting in personal injury or property damage In many instances a unit will have multiple elec trical connection points To prevent unforeseen startup prior to beginning work on a hygienic air unit always lock out all power supplies Always replace any protective covers removed for ser vicing Always replace bolts or locks on latches of access doors that provide access to areas with
67. legs of the fan motors The current should not exceed the rated service factor After prolonged shutdowns the motor insulation should be checked with a Megger Tester prior to restarting the motors 7 Start the fan s and verify proper rotation as indicated by sticker on unit aL Frick BY JOHNSON CONTROLS MAINTENANCE DAILY OPERATION AND ROUTINE MAINTENANCE The unit should be inspected cleaned and lubricated on a periodic basis The required services and recommended frequency for each are summarized in the Operation and Maintenance Schedule in this manual A daily AcuAir system operations log is a good method to assure that no problems develop that may go unchecked Entries to this log should be made once each shift Any notations should be entered as they occur or internal policy dictates It is essential that the maintenance manager examine notations from the previous 24 hours on a daily basis As weather and safety dictate a visual check of the AcuAire unit should be made once each shift daily at a minimum to examine operating conditions Unusual leaks noise vibration part damage failures or vandalism should be logged and investigated immediately Corrective action should be initiated immediately Components of the AcuAir unit should also be part of the daily operational checks for the AcuAire system unit In particular filtration performance is important to satisfactory and problem free AcuAir sy
68. m angle working around to the middle of the top angle making use of a drift pin to align the holes Bar clamps may be needed to align the roofs together If bar clamps are needed use wood for protection in between the bar clamp and unit 6 Split seams that have internal access to both sides of split will be reattached with bolts and nuts Split seams with internal access to only one side of split will have cage nuts 25 MINIMUM DIA CONTINUOUS POLYURETHANE CAULKING REQ D BOTH SIDES OF SPLIT PRIOR TO REASSEMBLING INTERNAL RECONNECT AcuAir Performance Series Only RECONNECT HOUSING AND HARDWARE NOT SHOWN THIS SIDE FOR CLARITY 9 HEX BOLT USE FROM LIFTING LUC 75 FLAT WASHER 0 2 0 2 22 2 2 2 on the blind side and bolts installed from accessible side All bolt holes require a bolt 7 If bolt holes do not align it may be due to racking during transit to Job site Use jack to lift one side until holes on the wall of the opposite side align Bolt this wall together and then remove jack from opposite side As the unit settles the out of square racking caused during transit should realign 8 Oncethe sections are drawn together and the reconnect flanges are aligned and attached apply two parallel beads of caulk along either side of the reconnect seam on the exterior of the AcuAir unit as shown in Figure 13 9 Install the shipping split covers as shown
69. mples showing an AcuAir system installed next to a wall PRELIMINARY FIELD PIPING DESIGN CONSIDERATIONS All AcuAir systems require strongly supported and properly anchored field piping NO field piping is to be supported by the AcuAir system itself Wind loading temperature variation etc must be considered to allow for movement between the system adjoining building ducting and field piping A qualified cooling system design engineer should provide final field piping plans and specifications Before finalizing piping installation plans it is recommended that related plans for system and plant expansion be discussed with your refrigeration system designer and Johnson Controls Fricke sales representative Incorporating appropriate pipe and Opening sizes now for existing and future needs allows for easier installation in the future ae ACUAIR HYGIENIC AIR UNITS 210 100 IOM MAR 14 oe INSTALLATION Page 7 WALL OBJECT OR OBSTRUCTION COOLING COIL SEE NOTE 4 CONNECTIONS COIL PULL SEE NOTE 5 AMMONIA DETECTOR FLOOR DRAIN CONN TYPICAL PLAN VIEW RETURN AIR RIGHT HAND LOW SIDE DIRECT FIRED BURNER ROOF SLOPE HIGH SIDE s FRESH AIR CONTROLS PLAN VIEW P 1 WEATHER PIEZOMETER GAUGE A HOODS SMOKE DETECTOR SEE NOTE 2 FLAT PREFILTERS SEE NOTE3 CAS TRAIN
70. n page 21 for preparing the two part foam mixture and the injection kit Take special note of the 30 second inactivity limit after which the injection nozzle may become permanently clogged Foam should be injected into the cavity at a rate of 3 4 bd ft per linear foot of seam This will mean a 15 bd ft can of expanding foam will fill between 4 5 linear ft of AcuAir reconnect seam 25 MINIMUM DIA CONTINUOUS POLYURETHANE CAULKING REQ D BOTH SIDES OF SPLIT PRIOR TO REASSEMBLING INTERNAL RECONNECT HOUSING AcuAir Performance Series Only GASKET CCCCecececcecececececcececec ecc ccce CCCCCCCCCCCCCCQCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCC RECONNECT HOUSING AND HARDWARE NOT SHOWN THIS SIDE FOR CLARITY e M ag Foam Injected From Underneath Figure 12 Foam Injection Underneath Base Assembly Attachment Relates to AcuAir Performance Series Unit Only 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ay Page 16 INSTALLATION EIC NOTICE Do not use silicone caulking on field reconnects or on shipping split covers Only use caulking shipped with unit 10 16 SS TEK SCREW W EPDM WASHER TYP SHIPPING SPLIT COVER CAULK SHIPPING SPLIT CAULK ALONG SCREW HOLE LOCATION NOTICE Shipping split covers ship with the air handler installed to one side of the re connect Remove cover and install across the split as shown on Detail A amp B SHIPPING
71. n should include but not limited to the following areas 1 Blowers Motors and Drives a Shut down the unit and disconnect all electrical power Touch all of the blower bearings The bearings should be slightly warmer than the air passing over them and they should all be approximately the same temperature If any of the bearings are noticeably warmer than the other bearings or if any of the bearings are too hot to touch grease should be applied via the grease fitting The bearings should be greased in accordance with the included Blower Bearing Lubrication Guidelines b Verify the tightness of the blower bearing bolts the blower motor and pulleys and the motor mounting bolts c Inspect the blower belt tension The belts should be tensioned in accordance with the included Blower Belt Tension Guidelines Visually inspect the belts for indica tions of wear Replace the belts if there is evidence of cracking fraying or uneven wear 210 100 IOM MAR 14 Page 48 2 Filters a Visually inspect the prefilters intermediate filters if applicable and final filters if applicable If the prefilter media appears damaged in any way or if the media becomes wet the prefilters should be changed im mediately If the intermediate filter media or final filter media appears damaged the filters should be changed immediately Filters should normally be replaced when the static pressure drop through the media is double that of
72. onduit that is then exposed to outdoor temperatures below the dew point of the air will condense into water and drain to the lowest location possible If those outdoor temperatures are cold enough this water may then turn into ice Plug Vertically Down Plug All Conduit Conduit Openings At wa Wall Penetrations All Door Switches 4 Many Plug All Gas Wrapper Panel Conduit Openings Figure 50 Required Putty Locations ACUAIR HYGIENIC AIR UNITS MAINTENANCE Plug All Junction Box Conduit Openings Typical 2 Boxes Plug All Control Panel Conduit Openings Frick BY JOHNSON CONTROLS Remedy In order to eliminate the collection of condensed water inside electrical conduit panels and instrumentation it is very important that electrical conduit openings are adequately sealed Each sealed opening restricts the further migration of humidity and the potential for water collection and damage The example in Figure 50 highlights the important locations for sealing electrical conduit This representation is not to be considered all inclusive but rather a representation of the typical locations requiring sealing putty UNIT CLEANING AND SANITATION The unit should be thoroughly cleaned at regular intervals Your chemical supplier should be consulted when picking the proper cleaning chemicals DISCONNECT ALL ELECTRICAL POWER BEFORE CLEAN ING THE UNIT Before cleaning any capped drain pipes should be uncapped and motors
73. ontrols AcuAir roof curbs ship either fully welded or in pieces If bolted curb construction bolt together 2 Curb must be level shim if required Shims at fractions of inch should be placed at intervals no greater than 5 feet apart Shims are not intended to compensate for roof pitch Individual stacks if shims should not exceed 1 2 in height On large units with splits remember to shim at the split s midspan see Figure 8 3 The installer is responsible to secure the roof curb to the building structural support in accordance with local building and earthquake codes 4 Seal all roof curb joints and seams with a suitable sealer polyurethane caulk to prevent water leakage Roof Curb Installation 1 Verify that the curb is level and secured to the roof 2 Verify that there is adequate height between the base of the unit and the roof to allow for drain trapping 3 Install a 1 8 thick neoprene gasket on the top of the curb to provide a seal between the unit and the roof curb If the unit or unit sections must be slid into place a polyurethane sealant may be used in lieu of the gasket 4 Lift the unit in place 5 The installer is responsible to secure installation in accordance with the local building and earthquake codes EXTERIOR WALL PANEL STRUCTURAL PERIMETER CHANNEL SEE NOTE BELOW E m M Lg ROOF CURB 2x2x0 25 CURB ANGLE ACUAIR HYGIENIC AIR UNITS INSTALLATION Frick BY JOHNSO
74. ow header not include flexible connector s and if lower header s bolts are not removed prior to use STEAM OUT NOTICE See the IFB and VIFB coil unit manufacturer s for Figure 35 Vertical Integral Face and Bypass Coil Face additional piping details A custom IOM is created for Mounted Actuator Shown each AcuAir order and the IFB and VIFB coil unit manu facturer s information is included in this document that is available after the air handler is built and shipped Frick BY JOHNSON CONTROLS Shipping Bolts VIFB Only Headers whether return steam condensate or hot water supply and return are securely bolted to lower mounting brackets to prevent damage to header and tubes during shipment and piping of the coils These bolts MUST be removed before applying steam or hot water but after all piping connections are made Piping Suggestions VIFB and IFB NOTICE See Field Penetrations for Piping and Electrical Con nections Steam and hot water field piping must be supported separately after the flexible connector to isolate piping strains and additional expansion from the coils Internal steam manifolds and piping should be insulated Steam traps should be sized for three times the calculated condensate loading at the coil design conditions The calculation should be based on the pressure differential across the trap not the boiler pressure Traps should be of types that pass condensate and vapor
75. product improvement the information contained in this docu ment is subject to change without notice While Johnson Controls Frick makes no commitment to update or provide current information automatically to the manual owner that information if applicable can be obtained by contacting the nearest Frick Factor or the nearest Frick Sales office It is the responsibility of operating service personnel to verify the applicability of these documents to the equipment in question If there is any question in the mind of operating service personnel as to the applicability of these documents then prior to working on the equipment they should verify with the owner whether the equipment has been modified and if current literature is available External wiring unless specified as an optional connection in the manufacturer s product line is NOT to be connected inside the micro panel cabinet Devices such as relays switches transducers and controls may NOT be installed inside the micro panel NO external wiring is allowed to be run through the micro panel All wiring must be in accordance with Johnson Controls Frick s published specifications and must be performed ONLY by qualified Johnson Controls Frick personnel Johnson Controls Frick will not be responsible for damages problems resulting from improper connections to the controls or application of improper control signals Failure to follow this will void the manufacturer s warranty and cause se
76. quipment and the property in which it is situated as well as severe personal injury or death to themselves and people at the site This document is intended for use by owner authorized operating service personnel It is expected that this indi vidual possesses independent training that will enable them to perform their assigned tasks properly and safely It is essential that prior to performing any task on this equipment this individual shall have read and understood this document and any referenced materials This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question SAFETY SYMBOLS The following symbols are used in this document to alert the reader to areas of potential hazard DANGER indicates an imminently A DANGER hazardous situation which if not avoided will result in death or seri ous injury WARNING indicates a potentially A WARNING hazardous situation which if not avoided could result in death or serious injury CAUTION identifies a hazard which ACAUTION could lead to damage to the ma chine damage to other equipment and or environmental pollution Usually an instruction will be given together with a brief explanation NOTICE or ASSEMBLY HINT is used NOTICE to highlight additional information which may be helpful to you CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous
77. r this application are four 4 clips as indicated in the table on page 32 Two latches should be attached on each side of the frame The latches should only be installed two 2 per side of the frame There should be no latches used on the top or bottom This is done to match the holes in the filter frame used to secure the latch to the filter See Figure 43 for the sets of knockouts that should be used for the latches DO NOT USE USE THESE Figure 43 Correct Use of Knockouts 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS ay Page 36 INSTALLATION EFC Installation of Spring Latches 5 Insert the rigid DH filter into the frame While holding the filter in the frame grasp the loop on the end of the latch and pull it until it stretches over the header and rests into the pre drilled hole in the header of the filter see Figure 46 Repeat 2 Using a moderate amount of pressure force the latch over this with the remaining latches the third knockout 1 Insert the straight end of the latch between the knockouts furthest from the corner 6 The filter should now be securely installed into the frame 3 The latch installation should now be complete The latch should now be trapped within the three 3 knockouts Figure 46 Spring latch should be pulled and fastened in hole in the header of the filter A CAUTION Care should be taken to prevent contamination of the 4 Repeat the latch installation with the
78. r wear or damage In addition periodically back flushing each line gently with compressed air may help to blowout debris in the line and pressure pickup holes It is important and necessary to keep the inside surface of the cone clean especially in a one inch radius immediately around the pressure pickup holes In the unlikely event that the pneumatic tubing on the Piezometer is damaged simply remove the damaged section and replace with a comparable type of tubing NOTICE PRESSURE DIFFERENTIAL ON TUBING IS LESS THAN 1 PSIG In the unlikely event that one of the brass fittings which is sweated to the Piezometer breaks loose from the Piezometer simply remove that fitting and replace it with a straight coupling fitting of similar construction Do not attempt to resolder the fitting to the Piezometer ACUAIR HYGIENIC AIR UNITS MAINTENANCE 210 100 MAR 14 Page 47 There are four pickup holes on each piezometer ring Elimination of one of them will not adversely affect the performance of most Piezometer CONNECT TO HIGH PRESSURE SIDE CONNECT TO LOW PRESSURE SIDE Figure 56 Plenum Fan Tap Location And Connection Illustration NOTICE For help with setup and calibration of Piezometers and Transducers contact Johnson Controls Frick AcuAir service 717 762 2121 RECOMMENDED MONTHLY SERVICE Johnson Controls Frick recommends that the unit undergo a thorough monthly inspection The inspectio
79. rap up and insert strap into slit marked in yellow on back of box Hoses will partially fill with chemicals Hold unit upside down move roller to on position Towards hoses and dispense foam Adjust roller to increase decrease flow If dispensing is stopped for more than 30 seconds replace nozzle with the extra provided Foam can be trimmed painted sanded or plastered after curing completely Figure 22 Pull Yellow Tab to Remove the Valve Lock Figure 20 Opening the Foam Kit Box Frick BY JOHNSON CONTROLS ACUAIR FRESH AIR INTAKE PLENUM 1 The fresh air intake plenum and hoods will be shipped as an assembly on smaller cfm units The plenums will arrive with one set of hoods unmounted for larger cfm units 2 The plenums and all hoods are assembled in the factory prior to preparing for shipment Not all of the attachment screws are installed in hoods that will ship unattached 3 For those unit arriving with unattached hoods reattach the hoods starting with a hood in the bottom position first Use the factory attached hoods as a model as well as the existing screw holes to finalize locations 4 When a set of detached hoods is shipped separately one hood will have an opening in the side for mounting the fresh air temperature sensor Be sure to locate this hood such that the sensor wiring on the unit can reach this mounting location 5 Prior to placing the hood in the mounting position apply a cont
80. rectly and the final installation verified 1 HEPA filters must be handled such that neither the air entering nor the air leaving side of the filters are subjected to poking pressures Sharp objects may directly compromise the filtration media General concentrated pressure may compromise the media by forcing it against the internal aluminum pleat separators If unprotected HEPA filters are placed on dirty surfaces prior to installing them in the AcuAir unit filter frames they become subjected to unnecessary contamination and possibly long term hygienic compromise SEE DETAIL A FILTER CLIPS INSTALLED 2 In order for HEPA filtration to properly control discharge air particulate count bypass air must be eliminated AcuAir HEPA filters include gaskets to seal between the filter and the filter rack During the installation process it is important to verify the cleanliness of both the gasket and the filter frame to assure a continuous seal HEPA filters must be installed with the filter pleats running vertically Contrary to the installation of other rigid filters where vertical pleats are a best practice for HEPA filters this orientation is a must 3 Although the HEPA filter manufacture inspects every HEPA filter prior to leaving the factory it is necessary to scan HEPA filters after installation to verify that there are no pinhole leaks and no bypass air Most pinhole leaks and bypass holes
81. rious damage to property or injury to persons NOTE For Product Warranty Support call 717 762 2121 Frick BY JOHNSON CONTROLS ACUAIR HYGIENIC AIR UNITS INSTALLATION OPERATION MAINTENANCE Page 3 210 100 IOM MAR 14 TABLE OF CONTENTS INTRODUCTION 111 4 WARRANTY rabie 4 PREINSTALLATION REQUIREMENTS TRAINING amp SAFETY CONSIDERATIONS 6 PRELIMINARY SITE LAYOUT CONSIDERATIONS 6 PRELIMINARY FIELD PIPING DESIGN CONSIDERATIONS 6 INSTALLATION 8 STORAGE cotta n cR M Eon 8 5 ER 8 Outdoor 8 Storage of Units with Ammonia Sensors 8 8 SUPPORT STRUCTURE INFORMATION 10 SECTION RECONNECT SHIP LOOSE ITEMS 11 INSTALLATION TOOLS a 11 GENERAL SPLIT UNIT REASSEMBLY 12 REMOVABLE LIFTING 12 ELECTRICAL 12 Roof Curb Assembly 12 ROOT
82. rloads Check power to coil on starter Check power from starter to motor Check fan belts Check tubes to airflow switch to be clean Check power through air flow switch Check rotation of fan Check MOA module to see if in AUTO green light if on red light if fuse is blown Check setpoint for cooling Check OA lockout setpoint lockout should be below OA Temp Check power to valve Check setpoint for heat Check OA lockout setpoint lockout should be above OA Temp Check output for steam valve Check setpoint for heat Check OA lockout setpoint lockout should be above OA Temp Check MOA module to see if in AUTO green light if on red light if fuse is blown Check burner safety circuit Eg High gas pressure switch Low gas pressure switch high temp limit burner door switch Check to make sure OUTSIDE air dampers are open and RETURN dampers are shut Check burner airflow switch Check and clean UV scanner Check gas supply Check setpoint for heat Check OA lockout setpoint lockout should be about OA Temp Check MOA module to see if in AUTO green light if on red light if fuse is blown Check blower on burner Check lockout alarm on Honeywell control Check burner airflow switch Check low fire end switch on burner damper motor Check spark rod and flame rod Check pilot assembly Check MOA module to see if in AUTO green light if on red light if fuse is blown Check disconnect switch on fan Check overload Ch
83. rosion by washing and rinsing frequently The water used to wash the coils should be analyzed prior to use to determine its suitability It should not contain dissolved chemicals or organisms Contact a specialist to test the water ACUAIR HYGIENIC AIR UNITS MAINTENANCE 210 100 MAR 14 Page 41 then follow his recommendations Establish and follow a regular testing and treatment schedule Further need for cleaning or repair of an AcuAir system coil should be left to the judgement of a certified or factory trained service person Contact the local AcuAire representative if a coil or its connections appears to have been significantly damaged Do not allow ice buildup If a coil remains partially frosted after a defrost it is unlikely to ever completely clean itself in a subsequent defrost If a coil is allowed to build ice into a solid block the ice can cause stresses to develop which are capable of breaking coil tubes and piping NEVER take shortcuts to clear ice from a coil by applying an open flame to melt ice or frost DAMPER MAINTENANCE 1 General Maintenance Dampers require proper maintenance in order to function correctly Blade shafts linkages stainless steel side seals if applicable and other moving parts should be periodically cleaned and lubricated A light molybdenum oil in aerosol cans is preferable since the jet nozzle permits pinpointing the stream of lubricant where required It usually con
84. row time constraints resulting in excessive overtime for factory start up technicians will be invoiced for the additional overtime hours incurred Customers requiring Saturday or Sunday start up of equipment will be billed at a weekend rate Weekend and holiday start up of equipment is NOT included in the sell price of the equipment If you require a weekend start up consult your factory sales representative for scheduling availability and cost Factory start up assistance should be requested at least two weeks prior to the start up date A request for start up assistance Is initiated by completing the AcuAir Prestart up Checklist E mail fax or mail the checklist to the factory per the instructions noted at the bottom of the checklist Once the checklist is received a factory representative will work with you to determine the best available date that a factory technician can be at the Job site Factory Start up Assistance will include Testing and calibration of all AcuAir control components provided by Johnson Controls Tuning of control system parameters and verification that control points are held within acceptable tolerance Adjustment and testing of gas burners Test and verification of all AcuAir safety and limit controls provided by Johnson Controls The factory start up technician will provide a basic control system review basic troubleshooting training and instruction regarding any AcuAir operator interface controls provided
85. ructions 1 Listen and look for unusual noise or vibration 2 After shutting down and locking out the starter check the bearings and motor If they feel hot the belt tension may be too tight 3 Run the drive under full load for 24 hours of continuous operation Running the belts under full load allows them to seat themselves into the grooves 4 After running the drive verify the tension of the belts Re tension to the recommended values This run in procedure will reduce the future need for re tensioning and will help extend the life of the belts CONTROL DAMPERS INSTALLATION OPERATION AND MAINTENANCE 1 Location Wall or panel openings for dampers must be properly sized Do not force a factory damper into undersized field ductwork or attempt to fill an oversized opening This Will bend the frames causing air leakage Dampers must also be installed plumb and square Twisted and distorted frames develop stresses causing linkage to bind and correlating improper blade operation All control damper seams must be caulked air and watertight 2 Obstructions Configuration of damper frames permits the use of screws rivets or welding to attach damper s to ducts or housings Fastener ends must not protrude in any way which can interfere with blade movement Correctly mounted dampers allow free and smooth operation from completely closed to fully open 3 Multiple Assemblies Where dampers consist of more than one section
86. s strictly based on that extended by the manufacturer and is irrespective of when the air unit is placed into active service Lifting amp Handling The unit will ship as specified on unit submittal either assembled as a subassembly collection of parts or as individual sections When lifting individual AcuAir sections weight may not be evenly distributed causing the section to be unbal anced or top heavy To prepare for safely lifting the air unit estimate the approximate center of gravity Internal placement of components may cause the weight to be unevenly distributed with more weight in the coil and fan areas Removable lifting lugs are provided to rig the unit sections into place Spreader bars are required to prevent damage to the ae ACUAIR HYGIENIC AIR UNITS 210 100 1OM MAR 14 oe INSTALLATION Page 9 SPREADER BARS MUST BE WIDER THAN THE UNIT WIDTH TO PREVENT DAMAGE TO THE HOUSING Figure 3 Recommended Lifting With Four Lifting Points SPREADER BARS MUST BE WIDER THAN THE UNIT WIDTH TO PREVENT DAMAGE TO THE HOUSING RIGGING INSTRUCTIONS FOR LIFTING AIR HANDLERS WITH LIFTING LUGS USE SPREADER BARS AND CABLES AS INDICATED DO NOT USE A FORKLIFT ALL LIFTING LUGS MUST BE USED TO AVOID DAMAGE Figure 4 Recommended Lifting With Multiple Points cabinet and protruding components during a lift The lugs are placement on site supports Use all lifting lugs provided Adjust positioned at the face
87. should be draped with plastic During cleaning the following components should NOT be directly sprayed with water Motors Damper Motors Bearings Pitot Tubes Filters and Electronic Sensors NOTICE High pressure water has the potential to dislodge caulk and sealing putty It is important to thoroughly inspect all seam caulking and electrical conduit sealing putty following a sanitary wash down Plug All Smoke Detector Enclosure Electrical Conduit Openings Plug All Starter VFD Panel Conduit Openings Frick BY JOHNSON CONTROLS FAN BEARING LUBRICATION Standard fan configurations ship with fan bearings factory lubricated ready for start up The fan should be turned off and locked out to prevent accidental start up of the fan during lubrication procedures Also secure sheaves before servicing the unit to ensure that the fan cannot freewheel Failure to do so may result in severe personal injury Proper lubrication of bearings helps to assure maximum bearing life Generally lubricate bearings every 1 000 hours of operation or more frequently when exposed to wet location wide temperature variety or severe atmospheric conditions Add grease with manual grease gun until a light bead of grease appears at the bearing grease seal or refer to lubrication frequency in the Tables 1 2 amp 3 Observation of the condition of the grease expelled from the bearings at the time of re lubrication is the best guide as to wheth
88. sing solutions 41 codes 12 coil connections 25 Coils 29 coil section 41 condensate drain 25 Cooling Coils 39 Cure time 20 D damper bearings 48 damper frames 38 damper linkage 48 Drain pan 25 drain trapping 12 duct connections 26 ductwork 38 E extended shutdowns 6 F fan belt tension 40 fan covers 6 Fans 6 Fan Section 8 fan shaft 40 field piping 6 25 filter 34 ACUAIR HYGIENIC AIR UNITS INSTALLATION OPERATION MAINTENANCE Index Filter Latches 31 Filter Section 8 final filters 39 flanged ducts 26 flexible connector 29 foam kit 22 foundation 6 frame 36 fresh air intake plenum 23 frost blockages 6 G gas manifold 39 gas shutoff valve 39 General Maintenance 41 glycol 26 grease 43 44 47 grease fittings 44 Grease Relief Plug 44 guards 6 H heater 39 HEPA 8 HEPA Filters 31 37 hood 27 hoods 23 hot water supply 29 HVACR contractors 6 inspection 47 Inspection 38 Inspection Checklist 41 installer 12 Intake Hoods 23 J Jack 13 Jackshafts 38 L latches 36 Latches 34 Lifting amp Handling 8 lubrication 43 Lubrication 39 Lubrication Intervals 44 M Mechanical Tightness 38 Motor Bearing Lubricant 44 motor bearings 40 210 100 MAR 14 Page 53 210 100 IOM MAR 14 ACUAIR HYGIENIC AIR UNITS Frick Page 54 INSTALLATION OPERATION MAINTENANCE BY JOHNSON CONTROLS N neoprene g
89. sses to a minimum on the coil connections a Allow for thermal expansion and contraction of all field piping b Do not rely on the coil connections to support the weight of the field piping c Design piping to minimize transmittal of vibration through the piping to the unit coils ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 MAR 14 Page 25 FACTORY SUGGESTED P TRAP GUIDELINES N SLOPE 1 8 PER FT MIN 3 2 MM CONFIGURATION 1 TSP NEGATIVE PRESSURE TRAP 25 4 MM 4 TSP H 2 HOT CHANNEL 7 COIL SUPPORT 1 MIN 1 TSP MIN POSITIVE PRESSURE TRAP 55 4 MM MIN 25 4 MM TSP MIN TSP FAN TOTAL STATIC PRESSURE Figure 28 Condensate Drain Trap Sizing LE UNIT HOUSING REFRIGERANT CONNECTION ge s STUB DRAIN DRAIN PAN D 2 Steam Piping When a steam coil is supplied the steam piping must be installed in accordance with state and local codes and accepted industry practices Please refer to the supplied piping diagram for specific information Prior to shipment steam coils are pressure tested for a maximum operating pressure of 150
90. stem unit operation COIL MAINTENANCE An AcuAir air unit s operational readiness is dependent on the condition of the coil Coils that are dirty blocked from airflow or physically damaged may affect overall heat transfer capability of the AcuAir system to a significant degree Periodically conduct a visual inspection of the coil section and refrigerant line connections Remove any airborne debris that may have collected on the face of the coils themselves Refrigerant could share the air stream with food products and personnel As such proper maintenance of coils to prevent corrosion and leaks is essential to prevent product loss and to ensure the safety of plant personnel A typical refrigerated food processing facility sparkles with stainless steel food contact surfaces and clean work spaces However evaporators that are suspended overhead trapping airborne contaminants and corrosive elements in the coils are usually not so sparkly Dirty coils are unsanitary They must be cleaned regularly with simple gentle wash and rinse procedures For all coils chlorine based cleansing solutions acidic cleansing solutions and highly alkaline cleansing solutions are hazardous to the coil s integrity Use a mildly alkaline cleanser Consult with your chemical supplier and read the Material Safety Data Sheet for your cleansing solution NOTICE Air units move air and airborne contaminants across the coil Protect the coil from cor
91. tains an evaporating solvent and dries to a nonoily film which will not attract dirt For dampers located in difficult or impossible to reach locations field access panels doors are required as installed by others 2 Periodic Inspections All automatic dampers should be checked and serviced on a regular schedule The recommended interval is monthly and should never exceed three months Malfunctioning dampers can lead to improper control of space temperatures excessive infiltration and increased energy costs 3 Inspection Checklist At a minimum include the following items in scheduled inspections Observe damper motors and actuators through an operating cycle to check for defects and binding Inspect mounting bolts for integrity Adjust actuator linkages so those dampers open and close fully for given stroke Verify tightness of closed blades readjust linkage for any blades that may not close fully Replace any damaged blades clean operating parts Inspect blade edge and side seal replace as necessary Inspect pins straps bushings etc for wear and replace as required Lubricate all moving part contact points and side seals Inspect caulked joints between the damper frames and the main structure repair if the possibility of air or water leakage exists FILTER MAINTENANCE Both pre filters and final filters should be visually inspected at regular intervals and should be replaced when they appear dirty or damag
92. th a 13 16 single header The second set of knockouts should be used for nominal 2 filters Installation of Latches 1 Insert the straight end of the latch between the two 2 knockouts furthest from the corner 2 Using a moderate amount of pressure force the latch over the third knockout ACUAIR HYGIENIC AIR UNITS INSTALLATION 210 100 MAR 14 Page 35 3 The latch installation should now be complete The latch should now be trapped within the three 3 knockouts but should be able to freely rotate Repeat the installation process with the remaining latches 4 Rotate all of the latches outward and insert the SH filter into the frame The bulk of the filter should be inserted through the frame protruding out the backside Only the header of the filter should be contacting the flange of the frame 5 After the filter has been placed into the frame grasp the circular end of the latch and rotate it across the corner of the filter Push the end of the latch towards the filter until the latch catches beneath the knockout on the frame Repeat for the remaining latches Figure 42 Fully installed filter 6 The filter should now be securely installed into the frame see Figure 42 INSTALLATION OF A RIGID DH DOUBLE HEADERED FILTER These instructions are for the installation of a Rigid DH Double Headered filter nominal 12 deep double header into a type 8 holding frame The latches needed fo
93. tt light bulb needs to burn continually in each section to prevent water condensation inside unit 6 Inspect and ventilate each section every 2 weeks to pre vent them from getting musty and to ensure that unexpected problems are addressed immediately Special care may be required for electrical or electronic components Storage of Units with Ammonia Sensors Ammonia detection electrochemical sensors are subject to degradation when stored in warm or humid conditions Special storage measures recommended Chemical cell gas sensors Ammonia Detectors inside AcuAir hygienic units are sensitive to storage temperatures and humidity The electrochemical sensor begins to degrade immediately upon manufacture The degradation process is worsened in the presence of warm to hot temperatures as well as high humidity For this reason gas detector sensor cell warranty is strictly based on time lapse from the date it is purchased from the manufacturer and irrespective of the date the AcuAir unit is placed into active duty For optimal sensor life involving storage Remove the electrochemical sensor cell Place the cell in a zip lock style storage bag Store the bag with the cell in a refrigerator between 35 F and 40 F Following these procedures does not extend warranty on any chemical sensor cell NOTICE Gas detector electrochemical sensor cells are a degrad ing component irrespective of active service Warranty on these sensor cells i
94. ty or rusty sheaves Feel sheave grooves wear gloves or use a rag for nicks or burrs and file them smooth Belts should ride in sheave grooves so that the top of the belt is Just above the highest point of the sheave If the grooves are worn to the point where the belt bottoms out a clue check for shiny groove bottoms the belts will slip and burn If the groove walls are dished out the bottom corners of the belt will quickly wear off and cause rapid failure Check groove wear by sight touch or with a groove gauge If grooves are dished out 1 32 or more replace the sheaves DISHING OF GROOVE SIDEWALLS SHORTENS BELT LIFE ORIGINAL GROOVE DISHING BELTS SHOULD LOW RIDING BELTS RIDE LIKE THIS INDICATE WORN GROOVES Figure 53 Sheave Inspection Inspect Sheave Alignment NOTICE An incorrectly aligned sheave can substantially shorten belt life or overload blower and motor bearings short ening their life expectancy A belt tensioned too tightly can overload the motor electrically causing nuisance tripping of the motor overloads and or motor failure and or shaft failure Sheave adjustment should be verified by placing a straight edge across the sheave faces so that it touches all four points ACUAIR HYGIENIC AIR UNITS MAINTENANCE 210 100 1OM MAR 14 Page 45 of contact Ordinarily a misalignment of more than one half of one degree one eighth inch in one foot
95. will adversely affect belt life Improper sheave alignment produces uneven wear on one side of the belt causes the belt to roll over in the sheave or throws all the load on one side of the belt stretching or breaking the cords on that side After the proper operating tension has been applied to the belts verify the following Parallel position of the sheave shafts Correct alignment of sheave grooves Sheave alignment and parallelism of shafts is very important Proper alignment helps equalize the load across the entire belt width thereby reducing wear and extending belt life Figure 54 shows how to align a synchronous drive properly using a straightedge A or a piece of string B After aligning the sheaves verify the rigidity of the supporting framework Shafts should be well supported to prevent distortion and a resulting change in the center distance under load Do not use spring loaded or weighted idlers Alignment Using A Straightedge Preferred Place a straightedge against the outer edge of the sheaves Figure 54 A shows the four points where the straight edge should touch the sheaves The straight edge should cross the sheaves at the widest possible part of the sheave Alignment Using A String Tie a string around either shaft and pull it around and across the outer edge of both sheaves Figure 54 B shows how the string should touch four points when the drive is properly aligned Belt Replacement Always repla
96. y gasket tape to either side of the section joint on the interior floor of the unit as indicated in the details of Figure 15 8 Center the split cover over the gasket tape and the joint to be covered Attach the cover using the 12 TEK screws It may be necessary to predrill holes through the base flange for the TEK screws 9 Seal the edges of the split cover with beads of caulk as shown in Figure 15 10 Inspect all splits to see if polyurethane caulk was applied and split was bolted properly Interior Finish Caulking to be DOW RTV 732 Food Grade Caulk BASE CHANNEL 75 ZINC HEX NUT 75 PLTD USE FROM LIFTING LUG LOCK WASHER 75 PLTD FLAT WASHER BOTH SIDES 1 5 X 1 5 X UNIT I D 0 5 3 XUNIT I D SPLIT COVER 12 24 x 1 25 TEK SCREW W EPDM WASHER CAULK POLYURETHANE BASE SKIN CHANNEL amp SPLIT TYP JOINT OF TWO SECTIONS WITH FLAT SURFACES Figure 15 Base Split Reassembly Procedure 4112 24 x 1 25 SCREW GASKET TAPE 0 25 X 1 25 GASKET TAPE 0 25 X 1 25 POLYURETHANE SPLIT COVER INTERNAL WALL W EPDM WASHER SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT aL Frick BY JOHNSON CONTROLS 11 Reconnect all electrical conduit and wiring at the reconnect junction boxes Use electrical conduit sealing putty to seal all conduit openings into and out of the junction box to prevent the migration of moisture reference the information on page 42 12 Inspect all splits to se
97. y sized and installed wiring for electrical power and controls air ducting refrigerant lines and fuel piping The engineering plans piping layouts etc for all peripheral field work should be detailed in accordance with local and governing codes and the best industry standards and practices If you have any comments or questions regarding this manual or the AcuAir system you are urged to call your installing contractor and or sales representative PRELIMINARY SITE LAYOUT CONSIDERATIONS All AcuAir systems must be located to minimize the effect of exhaust air recirculation Prevailing winds other structures or even other air handling units can cause exhausted air to be drawn back into the AcuAir unit Short cycling air in this manner can create an excess cooling load condensation load or in cold climates frost blockages It is the owner s responsibility to properly locate each system and consult with a qualified engineer before laying out structural or foundation supports and installing the AcuAir system Sufficient access must always be available to allow adequate airflow to the AcuAir system fresh air inlet and exhaust louvers In general AcuAir systems should always be placed on concrete pads piers or structural steel so that exhaust air discharge of the fan orifice is at or above the elevation of nearby walls structures and equipment For other minimum spacing requirements see the generic layout in Figure 2 for exa

General AcuAir ® Installation, Operation, & Maintenance

Contents

Download Pdf Manuals

Related Search

Related Contents

General AcuAir &reg; Installation, Operation, &amp; Maintenance

Contents

Download Pdf Manuals

Related Search

Related Contents

General AcuAir ® Installation, Operation, & Maintenance