FRICK AcuAir Hygienic Air Handling Installation Operation and Maintenance Guide
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Form 210.100-IOM (JUL 2018) INSTALLATION - OPERATION - MAINTENANCE File: Replaces: Dist: SERVICE MANUAL - Section 210 210.100-IOM (JUL 2017) 3, 3a, 3b, 3c 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.johnsoncontrols.com/frick for the latest version of this publication. 210.100-IOM (JUL 2018) Page 2 ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 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 equipment 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 individual 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 DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution. Usually an instruction will be given, together with a brief explanation. CAUTION NOTICE NOTICE (or ASSEMBLY HINT) is used to highlight additional information which may be helpful to you. CHANGEABILITY OF THIS DOCUMENT In complying with Johnson Controls policy for continuous product improvement, the information contained in this document 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. WARNING 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 serious damage to property or injury to persons. NOTE: For Product Warranty Support, call 717-762-2121 ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 210.100-IOM (JUL 2018) Page 3 TABLE OF CONTENTS INTRODUCTION START-UP SAFETY............................................................................. 4 WARRANTY....................................................................... 4 INITIAL START-UP............................................................37 Blower, Motor, Drives......................................................37 NEW BELT RUN-IN ...........................................................37 Filters..............................................................................37 Cooling Coils....................................................................37 START-UP AFTER PROLONGED SHUTDOWN..................... 38 PREINSTALLATION REQUIREMENTS TRAINING & SAFETY CONSIDERATIONS............................ 6 PRELIMINARY SITE LAYOUT CONSIDERATIONS................. 6 PRELIMINARY FIELD PIPING DESIGN CONSIDERATIONS..... 6 INSTALLATION RECEIVING & INSPECTION................................................. 8 STORAGE........................................................................... 8 SUPPORT STRUCTURE INFORMATION............................. 10 SECTION RECONNECT SHIP LOOSE ITEMS...................... 11 INSTALLATION TOOLS..................................................... 11 GENERAL SPLIT UNIT REASSEMBLY................................. 12 REMOVABLE LIFTING LUGS.............................................. 12 ELECTRICAL WIRING/PIPING............................................ 12 Roof Curb Assembly (Optional)........................................12 Roof Curb Installation......................................................12 PERFORMANCE GRADE CONNECTIONS........................... 13 REASSEMBLY PROCEDURE FOR SPLIT UNIT PERFORMANCE SERIES ONLY....................................... 13 RECONNECTION ATTACHMENT AND SEALING PROCEDURE................................................................. 14 INSULATION OF THE BASE RECONNECT SEAM OF AN ACUAIR PERFORMANCE SERIES UNIT.......................... 15 ACUAIR PERFORMANCE SERIES ROOF SEALANT PROCEDURE........................................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................ 25 CONDENSATE DRAIN TRAP SIZING.................................. 26 DRAIN PAN CONSTRUCTION............................................ 26 FIELD PIPING REQUIREMENTS......................................... 26 DUCT CONNECTIONS........................................................27 WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR FRESH AIR OPENING.................................................... 28 FILTER INSTALLATION TABLE OF CONTENTS.................... 30 FILTER LATCHES............................................................... 30 ACUAIR SINGLE FILTER APPLICATION (NON-HEPA).......... 31 HEPA FILTER APPLICATION.............................................. 33 NON-HEPA FILTERS IN HEPA FRAMES............................. 33 Installation of 4” Pleated Panel (Pre)Filters..................... 34 Installation of SH Single Headered Filters....................... 34 Installation of a RIGID DH Double-Headered filter.......... 34 HEPA FILTERS.................................................................. 36 MAINTENANCE DAILY OPERATION AND ROUTINE MAINTENANCE........... 39 COIL MAINTENANCE........................................................ 39 DAMPER MAINTENANCE................................................. 39 FILTER MAINTENANCE.....................................................40 ELECTRICAL CONDUIT SEALING REQUIREMENT...............40 Sources of Water or Ice.................................................. 40 Remedy.......................................................................... 40 TEMPERATURE SENSOR CALIBRATION............................40 Two calibration methods are:......................................... 40 UNIT CLEANING AND SANITATION................................... 41 WHITE RUST AND WET STORAGE STAIN OF GALVANIZED STEEL...................................................... 41 FAN BEARING LUBRICATION............................................ 42 Recommended Lubricant for Fan Bearings..................... 42 Proper Interval and Quantity - See Tables 1, 2 & 3......... 42 FAN SEGMENT-FAN MOTOR............................................ 42 Mounting Hardware and Adjustable Motor Base............. 42 Motor Condition (Visual)................................................. 42 Electrical Checks............................................................. 42 Lubrication...................................................................... 43 INSPECTING V-BELTS AND SHEAVES............................... 44 TENSIONING V-BELTS AND SHEAVES.............................. 44 OPERATING AND MAINTENANCE INSTRUCTIONS FOR PIEZOMETER................................................................ 46 RECOMMENDED MONTHLY SERVICE............................... 46 MAINTENANCE INTERVALS.............................................. 47 RECOMMENDED MAINTENANCE INTERVALS................... 47 SPARE PARTS RECOMMENDATIONS................................ 47 TROUBLESHOOTING ACUAIR FACTORY START-UP ASSISTANCE...................... 49 ACUAIR AIR HANDLER PRESTART-UP CHECKLIST............ 50 PRESTART-UP (For Site Records)..................................... 50 APPENDIX 210.100-IOM (JUL 2018) Page 4 ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 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 optional 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. CAUTION Users and installers of this equipment should be aware of all recommended safety procedures and information such as AMCA publication 410-90-Safety Practices. CAUTION 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. CAUTION 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. CAUTION 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 electrical connection points. To prevent unforeseen startup, prior to beginning work on a hygienic air unit, always lock out all power supplies. CAUTION Always replace any protective covers removed for servicing. CAUTION Always replace bolts or locks on latches of access doors that provide access to areas with moving parts. This mechanical protection from moving parts is required by UL 1995 (See Figure 1). CAUTION A number of additional safety issues are discussed throughout the manual. Please read the complete manual prior to installing, operating, or servicing the equipment. ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 210.100-IOM (JUL 2018) Page 5 1.25 1.50 DANGER 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 LATCH FRONT VIEW Figure 1 – Access Door Latch LATCH SIDE VIEW 210.100-IOM (JUL 2018) Page 6 ACUAIR® HYGIENIC AIR UNITS INSTALLATION PREINSTALLATION REQUIREMENTS TRAINING & 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. CAUTION Before installing, operating, or maintaining the system, it is recommended that only experienced HVACR contractors, operators, and maintenance technicians be used (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 AcuAir® system safety plan/ requirements: NOTICE Configure all power switches and controls to provide an open, safe circuit before and during maintenance procedures, 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 applying power to an 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. 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 appropriately 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 examples showing an AcuAir® system installed next to a wall. PRELIMINARY FIELD PIPING DESIGN CONSIDERATIONS CAUTION 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. 210.100-IOM (JUL 2018) Page 7 ACUAIR® HYGIENIC AIR UNITS INSTALLATION SEE NOTE 1 SEE NOTE 4 SMOKE DETECTOR FLAT PREFILTERS FLOOR DRAIN CONN. TYP. S3 R1 S1 W P1 P2 AMMONIA DETECTOR P-CONE GAUGE SEE NOTE 2 FILTER PRESSURE GAUGE (TYP. 2) GAS TRAIN & CONTROLS WEATHER HOODS SEE NOTE 3 L FINAL FILTERS COIL OUTLET CONN. (Typ.2) S2 H R2 S4 LIQUID INLET CONN. (Typ.2) Y *Generic unit layout shown. Please consult the order specific unit layout drawing before beginning site engineering. Figure 2 - AcuAir System-to-Wall Spacing Requirements 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 exhaust fans. 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. See page 26 for help designing the drain piping. 2. The minimum distance from an access door, in the open position, to an object is the door width, i.e. 24", plus 8". 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. 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. 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 (JUL 2018) Page 8 ACUAIR® HYGIENIC AIR UNITS INSTALLATION INSTALLATION RECEIVING & 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 & 17) Split Reconnect Hardware (Nuts, bolts, polyurethane caulking) Extra Fan Belts (If Ordered) Installation and Start-Up Manual Lifting Lugs Filters & 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.) 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. A 200-watt 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 prevent 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 WARNING 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 space maintained between 35°F and 40°F - such as a refrigerator. Following these procedures does not extend warranty on any chemical sensor cell. NOTICE Gas detector electrochemical sensor cells are a degrading component irrespective of active service. Warranty on these sensor cells is strictly based on that extended by the manufacturer and is irrespective of when the air unit is placed into active service. Long Term Storage Long-term storage is considered to be any period beyond six (6) months from date of shipment. (See Form 210.100-SB Long Term Storage) If long-term storage of the AcuAir unit is anticipated, contact your Johnson Control-Frick sales representative at the time of order entry for proper instructions and requirements for long-term storage. A delayed start up warranty for up to 1 year is available for a cost premium and documentation of storage and maintenance compliance. Delayed Start up Warranty must be purchased prior to units shipping from the factory. See forms 210.100-SB1, 210.100-SB2, and 210.100-SB3 for long term storage details and the delay of warranty commencement. ACUAIR® HYGIENIC AIR UNITS INSTALLATION 210.100-IOM (JUL 2018) Page 9 Lifting & Handling The unit will ship (as specified on unit submittal) either assembled, as a subassembly (collection of parts), or as individual sections. WARNING SPREADER BARS MUST BE WIDER THAN THE UNIT WIDTH TO PREVENT DAMAGE TO THE HOUSING When lifting individual AcuAir sections, weight may not be evenly distributed causing the section to be unbalanced 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 cabinet and protruding components during a lift. The lugs are positioned at the face of the sections to facilitate lifting the sections at the factory for securing on truck trailers. Lifting lugs can be relocated to sides of the individual sections to facilitate placement on site supports. Use all lifting lugs provided. Adjust the tension in each line for proper load distribution, (See Figures 3 and 4 for recommended lifting). WARNING When lifting; use all lifting lugs to avoid damage and/or personal injury. Lifting lugs are shown in Figure 5. 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 210.100-IOM (JUL 2018) Page 10 ACUAIR® HYGIENIC AIR UNITS INSTALLATION WARNING HOUSING 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. BASE SKIN LIFTING LUG PERIMETER CHANNEL LD07923A Figure 5 – Lifting Lugs 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. CAUTION If you do not rig or lift the unit carefully, you could damage the unit, hurt yourself or others. USE CAUTION! SUPPORT 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 document, plus 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 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 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 ½” 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 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. ACUAIR® HYGIENIC AIR UNITS INSTALLATION 210.100-IOM (JUL 2018) 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 ABOVE THE FINISHED ROOF. NUMBER OF LEGS AND DESIGN BY OTHERS. LOCATE AT CENTER OF UNIT WIDTH FOR SUPPORT OF AIR HANDLERS 150” OR WIDER (Optional lateral unit split supports on units 150" or wider as represented below in Fig. 7 - Roof Curb Support. Figure 6 - Generic Structural Steel Support ALTERNATE METHOD OF INTERMEDIATE SUPPORT LOCATED AT UNIT SPLIT(S) WHEN REQUIRED (Required on units 150" or wider) Figure 7 - Generic Roof Curb Support SECTION RECONNECT SHIP LOOSE ITEMS • • • • • AcuShield Roof Coating Joint Sealing Caulk Seal Gasket Tape 1/4" Bolts and Nuts Electrical Conduit Sealing Putty INSTALLATION TOOLS To complete the installation of an AcuAir® system, the following tools are required: • • • • • • • • • • Drift Pins 8-Foot Straight Edge Level 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 (JUL 2018) Page 12 ACUAIR® HYGIENIC AIR UNITS INSTALLATION GENERAL SPLIT UNIT REASSEMBLY Roof Curb Assembly (Optional) 1. When supplied by Johnson Controls - AcuAir , roof curbs ship either fully welded or in pieces. If bolted curb construction, bolt together. Units which are shipped in sections, must be installed on a proper foundation and carefully assembled to provide the required unit performance. 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). • 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- MATCH MATCH ters on the base channel (A-A, B-B, for example) to indicate which sections are → ← to match up for reassembly. ® 3. The installer is responsible to secure the roof curb to the building structural support in accordance with local 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 codes. A 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 for continuity. SPLIT MIDSPAN Figure 8 – Roof Curb Detail A ACUAIR® HYGIENIC AIR UNITS INSTALLATION 210.100-IOM (JUL 2018) Page 13 PERFORMANCE GRADE CONNECTIONS REASSEMBLY PROCEDURE FOR SPLIT UNIT PERFORMANCE SERIES ONLY 1. Position sections on level surface. 2. Apply polyurethane caulk in two parallel continuous beads on both faces as indicated in Figures 9, 10 and 11. 3. 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. 4. Install the reconnect flange attachment hardware starting from the middle of the bottom 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. 7. Once the 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. 8. Install the shipping split covers as shown 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. 9. Once the shipping cover is in place and the caulk has had time to set, apply the roof coating as shown in Figure 14. 10. INSPECT all splits to see if polyurethane caulk was applied and split was bolted properly. 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 see if all electrical and piping connections are complete and correct. 5. 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 on the blind side and bolts installed from accessible side. All bolt holes require a bolt. NOTICE Temporary roof supports and diagonal (shipping) supports should not be removed until the split sections are completely reassembled. See Page 18 for Food Grade and Sanitary Connections! 6. 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. .25 MINIMUM DIA. PARALLEL CONTINUOUS BEADS OF POLYURETHANE CAULKING REQ’D (BOTH FACES OF SPLIT) PRIOR TO REASSEMBLING INTERNAL RECONNECT (AcuAir Performance Series Only) HOUSING RECONNECT, HOUSING, AND HARDWARE NOT SHOWN THIS SIDE FOR CLARITY .75 HEX BOLT (USE FROM LIFTING LUG) .75 HEX NUT (USE FROM LIFTING LUG) .75 SPLIT WASHER .75 FLAT WASHER .75 FLAT WASHER Figure 9 – Base Assembly Attachment - Relates to AcuAir Performance Series Unit Only 210.100-IOM (JUL 2018) Page 14 ACUAIR® HYGIENIC AIR UNITS INSTALLATION APPLY POLYURETHANE CAULK TO SURFACE AFTER REASSEMBLING SECTIONS POLYURETHANE CAULKED BETWEEN SECTIONS IN FIELD LINER INTERNAL RECONNECT EXTERIOR SKIN .25-20 X .75 HEX BOLT WITH .25 FLANGED LOCKNUT (SUPPLIED BY JOHNSON CONTROLS) Figure 10 – Cross Section Of Split Wall Assembly - AcuAir Performance Series Only RECONNECTION ATTACHMENT AND SEALING PROCEDURE (See Figure 11) .25” MIN DIA CONTINUOUS POLYURETHANE CAULK SEE NOTE 1 1. Apply a generous amount of polyurethane caulking to the two faces of the housing and split plate as shown. 2. Pull sections together from the base split plate until they meet. 3. Clamp off bottom leg of reconnect until no gaps are visible. INTERNAL RECONNECT FLANGE 4. Install reconnection flange hardware starting from the middle of the bottom 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. 5. Once unit sections have been joined, contractor to seal the exterior and interior reconnect seam with polyurethane caulk. HARDWARE START POINT SEE NOTE 4 Figure 11 – Multi-Section Reconnect Sealing of AcuAir Performance Series Units ACUAIR® HYGIENIC AIR UNITS INSTALLATION INSULATION OF THE BASE RECONNECT SEAM OF AN 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. On the Performance Series air units this insulation must be injected from underneath the unit after the sections have been securely joined. 210.100-IOM (JUL 2018) Page 15 NOTICE INJECT THE FOAM INTO THE OPEN SEAM AFTER THE AIR UNIT SECTIONS HAVE BEEN SECURELY RECONNECTED. NOTICE IF FOAM DISPENSING HAS STOPPED FOR MORE THAN 30 SECONDS, REPLACE THE NOZZLE WITH THE EXTRA PROVIDED. Follow the instructions in the section "FOAM KIT 15 USE GUIDELINES" on 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. PARALLEL CONTINUOUS BEADS OF POLYURETHANE CAULKING REQ’D (BOTH FACES OF SPLIT) PRIOR TO REASSEMBLING INTERNAL RECONNECT (AcuAir Performance Series Only) HOUSING RECONNECT, HOUSING, AND HARDWARE NOT SHOWN THIS SIDE FOR CLARITY Foam Injected From Underneath Figure 12 – Foam Injection Underneath Base Assembly Attachment - Relates to AcuAir Performance Series Unit Only 210.100-IOM (JUL 2018) Page 16 ACUAIR® HYGIENIC AIR UNITS INSTALLATION NOTICE CAUTION Only use caulking shipped with unit. Do not use silicone caulking on field reconnects or on shipping split covers. #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 reconnect. Remove cover and install across the split as shown on Detail A & B. SHIPPING SPLIT COVER CAULK SHIPPING SPLIT COVER CAULK CAULK SHIPPING SPLIT DETAIL A Acceptable Polyurethane Caulking: Manus-bond, Gray, P/N 013-02966-001 Manus-bond, Champagne, P/N 013-03317-220 Bostik, Gray, P/N 013-03318-170 Bostik, Champagne, P/N 013-03319-170 DETAIL B CAULK SHIPPING SPLIT COVER Figure 13 – Split Reassembly Procedure For AcuAir Performance Series Units Only ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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. 210.100-IOM (JUL 2018) 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. 3. Do not apply when inclement weather is imminent within a 24 hour period. ACU-SHIELD ROOF COATING * CAULKING (PROVIDED) 3" MIN ROOF HOUSING SPLIT * Provided with ship loose items in fan section (see table in Section, "Receiving & Inspection"). Figure 14 – Outdoor Split Roof Sealant Procedure - AcuAir Performance Series Only 210.100-IOM (JUL 2018) Page 18 ACUAIR® HYGIENIC AIR UNITS INSTALLATION FOOD GRADE AND SANITARY CONNECTIONS RECONNECT INSTALLATION PROCEDURE ASSEMBLY HINT 1. Position sections on level surface. 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. 2. Apply polyurethane caulk in two parallel continuous beads on both faces as indicated in Figures 15, 16 and 17. 3. 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 6. Apply two continuous .25” dia. beads of caulk on either side of the floor section split. Reference either the lower left or the lower right views of Figure 15. It may be advantageous to locate the first AcuAir unit section in its final position and attach it to the support structure before pulling the next section into position against it. 7. Center the split cover over the floor split and two parallel beads of caulk. Attach the split cover using #12 TEK screws. It may be necessary to predrill holes through the base flange for the TEK screws. 4. The factory installed unit reconnect flanges will be joined using ¼” bolts and nuts shipped loose in a container in the blower section of the unit. All bolt holes require a bolt. 8. Seal the edges of the split cover with beads of caulk as shown in Figure 15. 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. 9. Inspect all splits to see if polyurethane caulk was applied and split was bolted properly. 10. 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) 11. Inspect all splits to see if all electrical and piping connections are complete and correct. 5. Check to see if all bolts are secured properly, and apply polyurethane caulk to all exterior seams per Figures 18. Interior Finish Caulking to be: DOW RTV-732 Food Grade Caulk CAULK SPLIT COVER BASE CHANNEL CAULK EDGE OF COVER AFTER ANCHORING BASE SKIN 1.5 X 1.5 X UNIT I.D. – 0.5 SPLIT COVER #12–24 x 1.25 TEK SCREW W/EPDM WASHER 3" x UNIT I.D. SPLIT COVER .25" DIA CONTINUOUS BEAD OF CAULK CAULK BASE SKIN BASE CHANNEL INTERNAL WALL #12–24 x 1.25 TEK SCREW W/EPDM WASHER CAULK BASE SKIN FINISH BEAD OF CAULK BASE CHANNEL CL SPLIT TYP JOINT OF TWO SECTIONS WITH FLAT SURFACES Figure 15 – Base Split Reassembly Procedure CL SPLIT SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT ACUAIR® HYGIENIC AIR UNITS INSTALLATION NOTICE Temporary roof supports and diagonal (shipping) supports should not be removed until the split sections are completely reassembled. 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. HCS NC GR5 .25 X .75 WITH FLANGE LOCKNUT NC .25-20 210.100-IOM (JUL 2018) Page 19 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. 3. Do not apply roof coating when inclement weather is imminent within a 24 hour period. 4. Do not apply to wet, ice, or snow covered surfaces. 5. Before applying, clean surface with wire brush or solvent wipe (not provided). SPLIT REATTACHMENT ANGLE POLYURETHANE FOAM INSULATION EXTERIOR SKIN Interior Finish Caulking to be: DOW RTV-732 Food Grade Caulk CONTINUOUS FINISHING BEAD OF CAULK ALONG INNER SEAM INTERIOR WALL PANEL Figure 16 – Cross Section Of Split Wall Assembly EXTERNAL RECONNECT POLYURETHANE CAULK .25 DIA CONTINUOUS BEAD OF CAULK BASE RECONNECT FLANGE Figure 17 – Multi-Section Reconnect Sealing On AcuAir Food Grade and Sanitary Series Units 210.100-IOM (JUL 2018) Page 20 ACUAIR® HYGIENIC AIR UNITS INSTALLATION 6. Apply Acu-Shield Roof Coating with a good quality synthetic bristle 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. CAUTION CAULK SHIPPING SPLIT DO NOT use silicone caulking on field reconnects or on shipping split covers. CAULK ALONG RECONNECT HOLE LOCATION NOTICE Only use caulking shipped with unit. SHIPPING SPLIT COVER CAULK SHIPPING SPLIT DETAIL A CAULK NOTICE SHIPPING SPLIT COVER Shipping split attachment angles come attached to each side of split. Reattach with provided hardware. CAULK Acceptable Polyurethane Caulking: Manus-bond, Gray, P/N 013-02966-001 Manus-bond, Champagne, P/N 013-03317-220 Bostik, Gray, P/N 013-03318-170 Bostik, Champagne, P/N 013-03319-170 DETAIL B SHIPPING SPLIT COVER Figure 18 – Split Reassembly Procedure For AcuAir Food Grade and Sanitary Series Units Only CAULK ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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. 210.100-IOM (JUL 2018) 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. Foam should be injected into the cavity at a rate of 3-4 brdft 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. 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. 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 NOTICE Inject the foam into this open seam after the sections are joined and before the seam cover is installed. If foam dispensing has stopped for more than 30 seconds, replace the nozzle with the extra provided. CAULK SPLIT COVER BASE CHANNEL CAULK EDGE OF COVER AFTER ANCHORING BASE SKIN Inject Foam Prior to Installing Cover Inject Foam Prior to Installing Cover INTERNAL WALL SPLIT COVER .25" DIA CONTINUOUS BEAD OF CAULK CAULK BASE SKIN BASE CHANNEL SPLIT COVER CAULK BASE SKIN FINISH BEAD OF CAULK BASE CHANNEL CL SPLIT TYP JOINT OF TWO SECTIONS WITH FLAT SURFACES Figure 19 – Insulation of the Base Reconnect Seam CL SPLIT SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT 210.100-IOM (JUL 2018) Page 22 ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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 strap 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 21 – Remove Hoses and Applicator to Full Length Figure 22 – Pull Yellow Tab to Remove the Valve Lock Figure 20 – Opening the Foam Kit Box ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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. 210.100-IOM (JUL 2018) Page 23 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. The AcuAir unit is provided with plenum alignment tabs and attachment clips to assist with correctly positioning the plenum assembly and holding it in position as it is secured to the air unit. (See Figure 27). The Alignment tabs are installed in the factory. The attachment brackets are shipped loose along with cap screws to mount the brackets and bolts for securing the plenum in the brackets. In preparation for lifting the plenum into position, mount the two brackets using the cap screws provided. 5. Prior to placing the hood in the mounting position, apply a continuous 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. Figure 23 - Fresh Air Intake Plenum Ready for Shipping 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 26. Site Applied Caulk to Seal the Plenum to the AcuAir Unit Figure 24 - Detached Intake Hoods Ready for Shipping 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) Factory Drilled Tapper Screw Holes Fresh Air Plenum Caulking Figure 26 - Applying Caulk to Plenum 9. Using a crane, lift the plenum with mounted hoods into position for attaching to the AcuAir unit. The four alignment tabs are intended to guide the hood into position horizontally. Figure 25 - Fresh Air Intake Plenum and Hoods Preassembled in the Factory 10. Position the two inner legs under the plenum into the two attachment brackets and insert the four bolts through the brackets and legs. This will secure the plenum in position vertically. The two outer legs must rest securely on the additional site support. 210.100-IOM (JUL 2018) Page 24 O/A OPENING ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE THIS SIDE IS OPEN AND ATTACHED TO UNIT HOUSING WALL. HOLES ARE PRE-DRILLED IN THE OA BOX SUPPORTS TO ATTACH TO THE UNIT HOUSING. SCREWS ARE PROVIDED IN THE UNIT SHIP LOOSE PARTS TO ATTACH THE HOODS AND THE OA BOX TO THE UNIT. O/A HOOD ALIGNMENT GUIDES (12 GA. GALV.) THIS SIDE WILL HAVE SOLID COVERS. AN ACCESS PANEL IS IN ONE COVER TO ALLOW ENTRY INTO OA BOX TO AID IN ATTACHMENT TO THE UNIT HOUSING. SLOPING ROOF PANELS HAVE BEEN REMOVED FOR CLARITY ATTACH REMAINING HOODS TO THIS SIDE IF NECESSARY *THIS ASSEMBLY MAY BE MIRRORED DEPENDING ON UNIT HANDING WEATHER HOODS WILL ARRIVE ATTACHED TO ONE SIDE OF THE OA BOX. IF SHIPPING SIZE ALLOWS, OA BOX WILL BE FULLY ASSEMBLED. IF NOT COMPLETELY ASSEMBLED, THE SHIPPED LOOSE HOODS WILL HAVE BEEN TEST FITTED AND SOME SCREW HOLES WILL REMAIN AS A GUIDE. Figure 27 – Plenum Assembly Positioning and Alignment Figure 28 - Plenum Leg Attachment 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 required. The plenum assembly must be securely screwed to the unit. 12. Replace the access panel, ensuring that all screws are in place. 13. When a set of detached hoods is shipped separately, one hood will require a 1” hole in the side for mounting the fresh air temperature sensor. Locate the hood nearest the sensor and electrical flex conduit. Drill a 1” hole and insert the sensor conduit probe and secure the j-box to hold the assembly in position. (Figure 29) Figure 29 - Fresh Air Temperature Sensor Mounting 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. ACUAIR® HYGIENIC AIR UNITS INSTALLATION FAN HOLD-DOWN / SPRING ISOLATOR SETUP (OPTIONAL) If fans are supplied with internal spring isolation, they will be bolted down (See Figure 30) for unit shipping. After the unit is in place, assembled and leveled, the fan mounts can be disassembled by removing two (2) nuts and one (1) washer from each side. Remove tubes from wire and discard wire. 210.100-IOM (JUL 2018) Page 25 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. Place remaining nuts on studs and tighten to lower nut to lock in place. WIRE NUTS SHOULDER WASHER TUBE STUD TUBE STUD NUTS NUTS SHOULDER WASHER STUD SHOULDER WASHER TUBE ½" SHIPPING POSITION SIDE VIEW EXPANDED ASSEMBLY VIEW OPERATING POSITION SIDE VIEW P-STYLE PLUG FAN REMOVE JAM NUT SHIPPED POSITION 0.38 ± 0.13 OPERATING POSITION SHIPPING POSITION OPERATING POSITION (SIDE VIEW) (SIDE VIEW) BUY-OUT ISOLATORS 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 fan base support angle until the desired level is achieved. Figure 30 – Spring Isolator Setup 3. Repeat step two until all isolators are set at the proper elevation and the fan base is level. 210.100-IOM (JUL 2018) Page 26 ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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 31 as well as the total static pressure (TSP) associated with the main fan and motor as indicated on the applicable AcuAir data drawing. For AcuAir drain and system piping information and recommendations, refer to AcuAir white paper, 210.200-WP6. 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. Figure 31 – Condensate Drain Trap Sizing COIL SUPPORTS AIRFLOW ACUAIR UNIT HOUSING SLOPE SLOPE REFRIGERANT CONNECTION SLOPE HAT CHANNEL COIL SUPPORT MPT RECESSED HYGIENIC OUTLET STUB DRAIN DRAIN PAN Figure 32 – Drain Pan Detail FIELD PIPING REQUIREMENTS 1. General – Every effort must be made in field piping to keep the stresses 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. 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 at 150 PSI, with a maximum operating pressure of 50 PSI. ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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 within the refrigeration system to prevent internal pressures from becoming higher than the tested operating pressure. CAUTION 210.100-IOM (JUL 2018) Page 27 DUCT CONNECTIONS (See Figures 33 and 34) 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 Halocarbon refrigeration coils may not have been fully evacuated or totally dried at the factory. It is the customer’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 Brine 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 brine can collect and freeze. All piping should be pitched away from the unit coil. The piping should be installed in a manner which will allow the coil to be filled with a solution to prevent freezing, if necessary. Figure 34 – Connection of Duct DUCT SHEET METAL SCREW Figure 33 – Detail of Duct Connection 210.100-IOM (JUL 2018) Page 28 ACUAIR® HYGIENIC AIR UNITS INSTALLATION WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR FRESH AIR OPENING (See Figures 35 and 36) POLYURETHANE 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, repeat this procedure for each of the hoods. 4. Carefully, remove excess polyurethane caulking from around the flange of the hood. 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 weather tight. HOODS SHEET METAL SCREWS Figure 35 – Connection of Weather Hood(s) to Unit Figure 36 – Weather Hood Installation FIELD PENETRATIONS FOR PIPING AND ELECTRICAL CONNECTIONS NOTICE WARNING 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. Electrical conduits must be sealed internally to prevent airflow and moisture condensation. Tools Required • Drill motor. • Pilot starter bit. • Hole saws-approximately 2½”, 3¼” & 4½” diameter for holes. • Power cords as required. ACUAIR® HYGIENIC AIR UNITS INSTALLATION Material Required • Neoprene grommet, 2½”, 3¼”, 4½” or 5½" 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 013-03317040 for outdoor units with champagne paint. • X-acto® knife. • Clean up supplies. Procedure See Figure 37 - Penetration Details. 1. Make sure any components; bulkheads or other obstructions are disconnected from panel inside and out. 2. Layout location and dimensions of hole opening to be cut. Do this on both sides of double wall panels. WATER & STEAM COILS NOMINAL ESCUTCHEON PIPE DIMENSIONS SIZE O.D. I.D. 0.50 3.0 0.550 0.75 3.0 0.815 1.00 3.0 0.815 1.50 6.0 1.400 2.00 6.0 1.875 2.50 6.0 2.375 3.00 6.0 3.000 4.00 7.0 4.000 210.100-IOM (JUL 2018) Page 29 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. Select 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. 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. DX/REFRIGERANT COILS ESCUTCHEON CONNECTION DIMENSIONS SIZE O.D. I.D. 0.500 3.0 0.175 0.625 3.0 0.550 0.875 3.0 0.550 1.125 3.0 0.815 1.375 3.0 1.000 1.625 6.0 1.315 2.125 6.0 1.875 2.625 6.0 2.375 3.125 6.0 2.875 ESCUTCHEON O.D. I.D. 3.0 0.175 3.0 0.550 3.0 0.815 3.0 1.000 6.0 1.315 6.0 — 6.0 1.400 6.0 1.875 6.0 2.375 6.0 2.875 6.0 3.000 7.0 4.000 JCI PART NO. 028 14910 001 028 14910 002 028 14910 003 028 14910 004 028 14910 005 028 14910 006 028 14910 007 028 14910 008 028 14910 009 028 14910 010 028 14910 011 028 14910 012 PART Caulking Gray Champagne Champagne Touch-up Spray Paint THICKNESS 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 PART NUMBER 013-03317-050 013-03317-040 044-03504-000 WARNING Use only metal cutting hole saws and/or blades to make penetrations through panels. Never use a cutting torch due to foam insulation. Figure 37 – Penetration Details 210.100-IOM (JUL 2018) Page 30 ACUAIR® HYGIENIC AIR UNITS INSTALLATION FILTER INSTALLATION TABLE OF CONTENTS ACUAIR MATRIX: KOCH FILTERS AND KOCH FRAMES / LATCHES ................................................................................... 30 INSTALLATION OF 4” PLEATED PANEL FILTERS................................................................................................................ 34 INSTALLATION OF SH SINGLE HEADERED RIGID FILTERS................................................................................................. 34 INSTALLATION OF A DH DOUBLE HEADERED RIGID FILTER.............................................................................................. 34 INSTALLATION OF HEPA FILTERS......................................................................................................................................36 CA-02 CA-02 CA-02 CA-02 FILTER LATCHES CA-04 Use with a single header (SH) rigid filter (final filter), installed in a standard type 8 filter frame. CA-04 CA-04 CA-04 Use with a 4" pleated panel filter (Prefilter) installed in a standard type 8 filter frame. C80 C80 C80 C80 Use with a 12" DH Double Headered Rigid Filter installed in a standard type 8 filter frame. L L L CA-04s 4” Knock On Clip Use with a 4" pleated panel (pre)filter in a smooth (notch free) style filter rack. 4" Knock On Clip CA-04s 4” Knock On Clip CA-04s 4” Knock On Clip CA-04s 12” Knock On Clip CF83Fs Use with a 12" rigid DH (final)filter in a smooth (notch free) style filter rack. 12" Knock on Clip C83F 12” Knock On Clip CF83Fs 12” Knock On Clip CF83Fs HEPA Arm Filter Clip HEPA Arm Filter Clip HEPA Arm Filter Clip Used to attach HEPA Filters to Holding Frame. JCI P/N - 391-008-101 Galv JCI P/N Stainless JCI- 391-008-100 P/N - 391-008-101 Galv Figure 38 – Filter Latches JCI P/N - 391-008-100 Stainless JCI P/N - 391-008-101 Galv JCI P/N - 391-008-100 Stainless NOTICE Typically when filters are supplied by others, so are the filter clips. ACUAIR® HYGIENIC AIR UNITS INSTALLATION 210.100-IOM (JUL 2018) Page 31 ACUAIR SINGLE FILTER APPLICATION (NON-HEPA FILTER) Filter Holding Clips to be used with Filter Styles 4" Pleated Panel Prefilter C70 or CA-02s C86 or CA-04s C80 or CF83Fs ✔ 12" Rigid Final Filter Single Header Style 12" Rigid Final Filter Double Header Style ✔ ✔ Filter, Clip, & Frame Description Koch Part Number Koch Model AcuAir Part Number Filter Holding Clips C70 Stainless Steel 122-712-001 C-70 KOCH 122 712 001 C86 Galvanized 122-713-003 C-86 KOCH 122 713 003 C86 Stainless Steel 122-712-003 C-86 KOCH 122 712 003 C80 Galvanized 122-713-002 C-80 KOCH 122 713 002 C80 Stainless Steel 122-712-002 C-80 KOCH 122 712 002 Filter Holding Clips to be used with the Smooth Filter Frames which require Knock-On Clips 2" SS Knock-on Clip* 122-705-002 CA-02s KOCH 122 705 002 4" SS knock-on Clip* 122-705-004 CA-04s KOCH 122 705 004 12" SS knock-on Clip** 122-708-012 CF83Fs KOCH 122 708 012 Type 8 Filter Frames (Notchless style frames require the knock-on clips above) 12" X 24"-16 ga. Galvanized 122-608-1224 KOCH 122 608 1224 12" X 24"-18 ga. Stainless Steel 122-618-1224 KOCH 122 618 1224 12" X 24"-18 ga. SS Notchless 310-123-107 KOCH 310 123 107 24" X 24"-16 ga. Galvanized 122-608-2424 KOCH 122 608 2424 24" X 24"-18 ga. Stainless Steel 122-618-2424 KOCH 122 618 2424 24" X 24"-18 ga. SS Notchless 310-123-106 KOCH 310 123 106 NOTICE NOTICE Typically when filters are supplied by others, so are the filter clips. Filter Pleats Must Be Installed Vertically When Possible Width x Height x Depth† 12" X 24" X 4" 24" X 24" X 4" 12" X 24" X 4" 24" X 24" X 4" Koch Part Number Koch Model MERV 8, MP XL8 High Capacity 102-701-023 MP XL8-HC 102-701-031 MP XL8-HC XL8-HC Filters are AcuAir Standard Supply for Prefilters MERV 11, MP XL11 High Capacity 120-500-023 MP XL11-HC 120-500-031 MP XL11-HC Alternate Disposable Pleated Panel Filter * Clip part is stainless steel, not latch wire ** Total SS Construction; Product description must follow p/n for entry. † Unless specified otherwise, filter dimensions are designated in width x height x depth. AcuAir Part Number KOCH 102 701 023 KOCH 102 701 031 KOCH 102 500 023 KOCH 102 500 031 210.100-IOM (JUL 2018) Page 32 ACUAIR® HYGIENIC AIR UNITS INSTALLATION Multi-Pleat XL8 HC Multi-Pleat XL11 HC ACUAIR SINGLE FILTER APPLICATION (NON-HEPA FILTER) cont. Width x Height x Depth† Koch Part Number Koch Model AcuAir Part Number Rigid‡ 12" X 24" X 12" DH 24" X 12" X 12" DH 24" X 24" X 12" DH 12" X 24" X 12" DH 24" X 12" X 12" DH 24" X 24" X 12" DH 12" X 24" X 12" DH 24" X 12" X 12" DH 24" X 24" X 12" DH MERV 13 110-722-002 Multi-Cell SBM 85 Same as above 110-722-001 Multi-Cell SBM 85 MERV 14 Rigid‡ 110-720-002 Multi-Cell SMB 95 Same as above 110-720-001 Multi-Cell SMB 95 MERV 16 4V Extended Surface MiniPleat Filter‡ 111-691-103DH DuraMAX 4V MERV 16 111-691-103KDH DuraMAX 4V MERV 16 111-691-101DH DuraMAX 4V MERV 16 † Unless specified otherwise, filter dimensions are designated in width x height x depth. ‡ DH = Double Header Double Header Rigid Filter DuraMAX 4V MiniPleat KOCH 110 722 002 Same as above KOCH 110 722 001 KOCH 110 720 002 Same as above KOCH 110 720 001 KOCH 111 691 103DH KOCH 111 691 103KDH KOCH 111 691 101DH ACUAIR® HYGIENIC AIR UNITS INSTALLATION 210.100-IOM (JUL 2018) Page 33 NOTICE NOTICE HEPA Filters must always be installed with the pleats oriented vertically Non-HEPA Filters must be installed with the pleats oriented vertically whenever possible HEPA FILTER APPLICATION Description - H x W Koch Part Number 24" X 24"-14 ga. Galvanized 12" X 24"-14 ga. Galvanized 24" X 24"-14 ga. Stainless Steel 12" X 24"-14 ga. Stainless Steel NOTE! H x W x D 23.375" X 23.375" X 11.5" 23.375" X 11.375" X 11.5" 11.375" X 23.375" X 11.5" NOTE! H x W x D 23.375" X 23.375" X 11.5" 23.375" X 11.375" X 11.5" 11.375" X 23.375" X 11.5" Koch Model AcuAir HEPA Filter Frames 122-508-2424 Galv. HEPA Frame 122-508-1224 Galv. HEPA Frame 122-518-2424 304 SS HEPA Frame 122-518-1224 304 SS HEPA Frame 99.97% BioMAX HC HEPA (MERV 17), Galvanized H64A2X1 BioMAX HC H79A2X1 BioMAX HC H60A2X1 BioMAX HC 99.99% BioMAX HC HEPA (MERV 18), Galvanized H64A4X1 H79A4X1 H60A4X1 BioMAX HC BioMAX HC BioMAX HC AcuAir Part Number KOCH 122 508 2424 KOCH 122 508 1224 KOCH 122 518 2424 KOCH 122 518 1224 KOCH H64A 2X1 KOCH H79A 2X1 KOCH H60A 2X1 KOCH H64A 4X1 KOCH H79A 4X1 KOCH H60A 4X1 NON-HEPA FILTERS IN HEPA FRAMES Width x Height x Depth† 24" X 24" X 12" DH 12" X 24" X 12" DH 24" X 24" X 12" DH 12" X 24" X 12" DH Koch Part Number Koch Model MERV 13 Rigid with Gasket Downstream (DS) 110-722-030K Multi-Cell SBM 85 110-722-031K Multi-Cell SBM 85 MERV 14 Rigid with Gasket Downstream (DS) 110-720-030K Multi-Cell SBM 95 110-720-031K Multi-Cell SBM 95 † Unless specified otherwise, filter dimensions are designated in width x height x depth. ‡ SH = Single Header, DH = Double Header High Capacity BioMax HC Multi-Cell SBM 85 or 95 AcuAir Part Number KOCH 110 722 030K KOCH 110 722 031K KOCH 110 720 030K KOCH 110 720 031K 210.100-IOM (JUL 2018) Page 34 ACUAIR® HYGIENIC AIR UNITS INSTALLATION 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 30. • A single latch should be installed at each of the four (4) corners of the frame. 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. 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. • 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. Repeat the installation process with the remaining latches. Installation of Spring Latches 1. Insert the straight end of the latch between the two (2) knockouts furthest from the corner. 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. 2. Using a moderate amount of pressure, force the latch over the third knockout. Push the end of the latch towards the filter, until the latch catches beneath the knockout on the frame. Repeat the installation process with the remaining latches. Repeat for 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. 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. Repeat for the remaining latches. 6. The filter should now be securely installed into the frame. INSTALLATION OF SH SINGLE HEADERED FILTERS These instructions are for installing single-header rigid filters into type 8 holding frames. CAUTION Figure 39 – Fully installed SH (single header) filter 6. The filter should now be securely installed into the frame (see Figure 39). INSTALLATION OF A RIGID DH DOUBLE-HEADERED FILTER 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 the installation of a Rigid DH DoubleHeadered filter (nominal 12” deep double header) into a type 8 holding frame. • Latches needed for these applications are four (4) clips as indicated in the table on page 30. • The latches needed for this application are four (4) clips as indicated in the table on page 30. • A single latch should be installed at each of the four (4) corners of the frame. • Two latches should be attached on each side 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. • 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 40 for the sets of knockouts that should be used for the latches. ACUAIR® HYGIENIC AIR UNITS INSTALLATION DO NOT USE! 210.100-IOM (JUL 2018) Page 35 USE THESE! Figure 40 – Correct Use of Knockouts Installation of Spring Latches 1. Insert the straight end of the latch between the 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. Figure 42 – Frame with 4 latches installed. NOTICE The frame contains 2 latches per side, none on the top or bottom. 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 predrilled hole in the header of the filter (see Figure 43). Repeat this with the remaining latches. 6. The filter should now be securely installed into the frame. Figure 41 – Correct latch/knockout configuration. 4. Repeat the latch installation with the remaining latches. Note the orientation of the latch to the knockouts in Figure 41. After the latches have been installed, the frame should be configured like that shown in Figure 42. Figure 43 – Spring latch should be pulled and fastened in hole in the header of the filter. CAUTION 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. CAUTION Pleated filters must be installed with the pleats running vertical whenever possible. 210.100-IOM (JUL 2018) Page 36 ACUAIR® HYGIENIC AIR UNITS INSTALLATION HEPA FILTERS TOP AIRFLOW AIRFLOW AIRFLOW AIRFLOW FILTER RETAINER CLIPS MUST BE ATTACHED TO SIDES ONLY SEE DETAIL A HAT FILTER CLIP INSTALLATION FLAT SEALING SURFACE GASKET GASKET SEAL HEPA FILTER HOLDING FRAME GASKET SEAL DETAIL A FILTER CLIPS INSTALLED Figure 44 – Installation of HEPA Filter Frames 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. 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. For ultimate success, the HEPA filters must be handled properly, installed correctly and the final installation verified. 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. 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. 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 can be repaired in the field. ACUAIR® HYGIENIC AIR UNITS OPERATION START-UP 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. NOTICE 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 verify 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 Maintenance 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 measures 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. 210.100-IOM (JUL 2018) Page 37 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 instructions: 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 retensioning and will help extend the life of the belts. 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 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. 210.100-IOM (JUL 2018) Page 38 ACUAIR® HYGIENIC AIR UNITS OPERATION 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. 2. Turn off the electrical power to the furnace. 3. Set the temperature to the lowest possible setting. 4. Set the burner controls to the OFF position. 5.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. 7. Close the door on the front of the gas manifold. Figure 46 - AcuAir Gas Burner Wrapper 8. Open the manual gas valve external to the furnace. 24-Hour Run-In 9. Turn on the electrical power supply to the furnace. After 24 hours of operation under load, the following services should be performed: 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. 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. Figure 45 - AcuAir Direct Fired Gas Burner GAS HEAT SHUTDOWN 1. Set the controls to lowest setting. 2. Turn off the electrical power supply to the furnace. 3. Set the burner controls to the OFF position. 4. Close the manual gas shutoff valve external to the furnace. 6. Verify the voltage and current of all three 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. ACUAIR® HYGIENIC AIR UNITS MAINTENANCE 210.100-IOM (JUL 2018) Page 39 MAINTENANCE NOTICE DAILY OPERATION AND ROUTINE MAINTENANCE Air units move air (and airborne contaminants) across the coil. Protect the coil from corrosion by washing and rinsing frequently. The AcuAir unit should be inspected, cleaned, and lubricated on a periodic basis. The required services and recommended frequency for the various components 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 during each shift. Any notations should be entered as they occur (or as internal policy dictates). It is essential that the maintenance manager examine all notations (from the previous 24 hours) on a daily basis. As weather and safety allow, a visual check of the AcuAir 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 conducted of the equipment on site. In particular, filtration performance is important for satisfactory and problem-free AcuAir hygienic system operation. 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, 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 AcuAir® 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 remove accumulated frost and ice 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 crushing or rupturing coil tubes and piping. CAUTION The Recommended Maintenance Intervals schedule included in the later part of this IOM section should be used to develop the site specific hygienic air unit inspection log and maintenance schedule. NEVER take shortcuts to clear ice from a coil by applying an open flame to melt ice or frost. COIL 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 cleaned and lubricated as indicated in the Recommended Maintenance Interval schedule in this manual. An AcuAir air unit's operational readiness is dependent on the condition of the fin-coil heat exchanger(s). Coils that are dirty, blocked from airflow, or physically damaged may affect overall heat transfer capability of the AcuAir system to a significant degree. Regular visual inspections should be made of both the inlet and leaving sides of the cooling coil(s) as well as the refrigerant pipe connections. These inspections should occur at least as frequently as indicated in the maintenance schedule in this IOM. Remove any airborne debris that may have collected on the face of the fin coils. If site conditions require coil cleaning measures following each of the recommended routine inspections it may be necessary to increase the frequency of the inspections. A typical refrigerated food processing facility has stainless steel food contact surfaces and clean work spaces. Evaporators trap airborne contaminants and corrosive elements in the coils. Dirty coils are also unsanitary. They must be cleaned regularly with simple, gentle, wash and rinse procedures. Refrigerant could leak into the process airstream and come in contact with food products and personnel. As such, proper maintenance of refrigerant coils is essential to prevent corrosion and leaks that result in product loss and to ensure the safety of plant personnel. 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. DAMPER MAINTENANCE A light molybdenum oil in aerosol cans is preferable since the jet nozzle permits pinpointing the stream of lubricant where required. It usually contains an evaporating solvent and dries to a non-oily 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 AcuAir 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. 210.100-IOM (JUL 2018) Page 40 ACUAIR® HYGIENIC AIR UNITS MAINTENANCE • 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 damaged. (Reference the Recommended Maintenance Intervals chart) The process air stream static pressure drop across the filters will indicate the need to change the filters when compared to the manufacturer supplied “Final” pressure drop data. Generally these will be 1” w.g. for Koch Multi-Pleat XL8 prefilters and 1.5” w.g. for Koch 12” Multi-Cell final filters. 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. 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 moisture migrating into unsealed conduits that are open to the inside the AcuAir enclosure. Moisture that migrates into an electrical conduit 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. 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 moisture and the potential for water collection and damage. NOTICE The example in Figure 47 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. It is important that food grade sealant be used when repairing or replacing unit caulking. TEMPERATURE SENSOR CALIBRATION 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. Plug Vertically Down Conduit Openings At All Door Switches Plug All Gas Wrapper Panel Conduit Openings Figure 47 – Required Putty Locations Plug All Conduit Wall Penetrations (Many) Temperature sensors that are out of calibration can affect both the proper function and efficient operation of the hygienic air unit. As part of the routine maintenance program, temperature sensor calibration should be checked annually. Two calibration methods are: 1. Ice Bath – Cool a cup of water to 32°F using excess ice and agitating the water for several minutes. Immerse the tip of the temperature sensor into the 32°F water while the AcuAir controller channel is calibrated to 32°F. Plug All Junction Box Conduit Openings Typical (2) Boxes Plug All Control Panel Conduit Openings Plug All Smoke Detector Enclosure Electrical Conduit Openings Plug All Starter / VFD Panel Conduit Openings ACUAIR® HYGIENIC AIR UNITS MAINTENANCE 2. Infrared Temperature Scanner – Focus the scanner on the tip of the temperature sensor. Use the temperature reading on the infrared scanner to calibrate the AcuAir controller input channel. Submerge Tip in Ice Bath or Focus Infrared Scanner Here Figure 48 – Temperature Sensor UNIT CLEANING AND SANITATION The AcuAir hygienic unit requires frequent and thorough cleaning. Your chemical supplier should be consulted when picking the proper cleaning chemicals. CAUTION DISCONNECT ALL ELECTRICAL POWER BEFORE CLEANING THE UNIT. Before cleaning, any capped drain pipes should be uncapped, and motors 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. 210.100-IOM (JUL 2018) Page 41 If the zinc coating of new galvanized material is prevented from thoroughly drying and receiving exposure to CO2 the passive carbonate layer is not formed. If the Zinc hydroxide to carbonate reaction does not take place, excessive zinc hydroxide accumulates as a layer of soft, white, fluffy product of corrosion. Instead of being dense and protective, this powdery substance is porous and non-protective of the substrate material. When the zinc oxide-hydroxide reaction is allowed to progress, it can rapidly degenerate the substrate layer of zinc. This buildup of zinc hydroxide is known as white rust. It is created by small localized corrosion cells and will appear as stain patterns in contrast to the uniform dull-gray zinc carbonate layer mentioned previously. Addressing A Light Coating Of White Rust Also Known As Wet Storage Stain Occasionally AcuAir units may arrive on site with patches of visible zinc hydroxide deposits. In other cases white patches of the deposit may become visible shortly after arrival. In either case, because the AcuAir products are built and are shipped very shortly thereafter, these hydroxide zones are quite young and any deterioration of the underlying zinc is insignificant. In most cases the zinc hydroxide is so light it will erode over time and the desirable zinc carbonate layer will form naturally with the rain and drying cycles. However, in a few instances and for cosmetic reasons it may be necessary to intervene and expedite the passivation process. Light coatings of zinc hydroxide can be removed using readily available cleaning products. A study presented by the American Galvanizers Association (AGA) suggests the following five cleaning products to successfully handle the task. Available at any local grocery store: • Lime Juice • White Vinegar Commercial Cleaners tested: WHITE RUST AND WET STORAGE STAIN OF GALVANIZED STEEL • Picklex 10G (best solution according to the test – only available direct from the manufacturer) Many AcuAir rooftop units are purchased with simple mill galvanized exterior finish. Galvanizing is the result of applying a coating of zinc to sheet metal. The zinc coating is intended to provide long lasting protection of the underlying steel. • Navel Jelly Rust Dissolver (not recommended for heavy wet storage stain) Raw zinc, by nature, is reactive and tends to corrode quite readily when exposed to moisture. To develop the long lasting protective quality for which it is applied, the zinc must undergo a sequence of chemical reactions. First the zinc must react with oxygen to create zinc oxide. Second, the zinc oxide reacts in the presence of moisture to create zinc hydroxide. Finally, the zinc hydroxide reacts with CO2 within dry air to create a thin layer of impermeable zinc carbonate. The carbonate layer is what forms the long lasting passive coating that drastically slows down any further reaction of the zinc and provides corrosion protection of the underlying steel. When properly formed, the zinc carbonate layer is identified by a dull-gray appearance. • CLR Cleaning White Rust 1. Use a nylon bristle brush to apply one of the cleaners to the affected area. 2. Thoroughly scrub the surface using the nylon bristle brush, applying water as necessary. 3. Finally, rinse with plain water to completely remove all traces of the powdery hydroxide as well as the cleaner. 4. Allow the cleaned surface to dry completely. The drying process facilitates the formation of the passive zinc carbonate boundary layer that will mature over time with the naturally occurring rain and dry cycles. 210.100-IOM (JUL 2018) Page 42 ACUAIR® HYGIENIC AIR UNITS MAINTENANCE FAN BEARING LUBRICATION FAN SEGMENT-FAN MOTOR 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. Keep the motor clean, dry and properly lubricated at all times. Blow dust and dirt out of windings periodically using lowpressure (50 psig) air. (Figure 49) 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 & 3. Observation of the condition of the grease expelled from the bearings at the time of relubrication is the best guide as to whether lubrication intervals and the amount of grease added should be altered. Always lubricate bearings prior to extended shutdown or storage and rotate shaft monthly. ODP Figure 49 – ODP (Open Drip Proof) TEFC (Totally Enclosed Fan Cooled) Mounting Hardware and Adjustable Motor Base • Inspect for loose parts. • Inspect for damage. Recommended Lubricant for Fan Bearings Motor Condition (Visual) A Lithium / Petroleum base grease conforming to an NLGI Grade II 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. • Inspect for leaky bearing seals. Proper Interval and Quantity - See Tables 1, 2 & 3 TEFC • Inspect for damage. • Inspect for dirt, dust & 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 – FAN BEARING – LUBRICATION INTERVALS - BALL BEARING PILLOW BLOCKS Relubrication schedule (months) SPEED (RPM) 500 1000 1500 2000 2500 3000 3500 SHAFT DIA. 6 6 5 3 3 2 2 1/2" thru 1ZZ\zn" 6 5 4 2 2 1 1 1ZB\zn" thru 2M\zn" 5 4 3 2 1 1 1 2ZZ\zn" thru 2ZB\zn" 4 3 2 1 1 1 3M\zn" thru 3ZB\zn" 4000 4500 2 1 1 1 TABLE 2 – FAN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER BEARING SOLID PILLOW BLOCKS Relubrication schedule (months) SPEED (RPM) 500 1000 1500 2000 2500 3000 3500 4000 4500 SHAFT DIA 6 4 4 2 1 1 1 1 1/2 1C\zn" thru 1M\zn" 4 2 1½ 1 1/2 1/2 1/2 1/2 1/2 1ZZ\zn" thru 2C\zn" 3 1½ 1 1/2 1/2 1/2 1/2 2M\zn" thru 3M\zn" 2½ 1 1/2 1/4 3ZB\zn" thru 4ZB\zn" TABLE 3 – FAN BEARING – LUBRICATION INTERVALS - SPHERICAL ROLLER BEARING-SPLIT PILLOW BLOCKS Relubrication schedule (months) SPEED (RPM) 500 750 1000 15000 2000 2500 3000 3500 4000 SHAFT DIA 6 4½ 4 4 3½ 2½ 2½ 1 1 1M\zn" thru 1ZB\zn" 5 4½ 4 2½ 2½ 1½ 1/2 1/4 1/4 2C\zn" thru 2ZZ\zn" 4½ 4 3½ 2½ 1½ 1 1/2 2ZB\zn" thru 3ZB\zn" 4 4 2½ 1 1/2 4M\zn" thru 4ZB\zn" 4 2½ 1½ 1 5M\zn" thru 5ZB\zn" Grease to be added at each interval 0.50 oz 0.75 oz 2.00 oz 4.00 oz 7.00 oz ACUAIR® HYGIENIC AIR UNITS MAINTENANCE Lubrication Motor Bearing Lubricant - Bearing grease will lose its lubricating ability over time. The lubricating ability of grease depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates and the severity of the operating conditions. Good results can be obtained if the following recommendations are used in your maintenance program: • A high-grade ball or roller bearing grease should be used. Recommended grease for standard service conditions is Polyrex EM (Exxon Mobil). – Maximum operating temperature for standard motors = 110°C. 210.100-IOM (JUL 2018) Page 43 CAUTION To avoid damage to motor bearings, grease must be kept free of dirt. For an extremely dirty environment, contact your distributor or an authorized Service Center for additional information. – With Grease Relief Plug 1. Clean all grease fittings. 2. Remove grease relief plug. 3. Add only the recommended amount of grease. 4. Reinstall grease relief plug – Shutdown temperature in case of a malfunction = 115°C. • Proper Lubrication Intervals – Recommended lubrication intervals are shown in Table 4. It is important to realize 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 50) CAUTION 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 50 – Grease Fittings TABLE 4 – MOTOR BEARING – LUBRICATION INTERVALS NEMA / (IEC) FRAME SIZE UP TO 210 INCL (132) OVER 210 TO 280 INCL. (180) OVER 280 TO 360 INCL. (180) OVER 360 TO 5,800 INCL. (180) * ** 10,000 ** 6,000 2,700 hr Rated speed - rpm 3,600 1,800 5,500 hr 12,000 hr 3,600 hr 9,500 hr *2,200 hr 7,400 hr *2,200 hr 3,500 hr 1,200 18,000 hr 15,000 hr 12,000 hr 7,400 hr 900 22,000 hr 18,000 hr 15,000 hr 10,500 hr Lubrication intervals are for ball bearings For roller bearings, divide 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 STANDARD 40°C CLEAN, LITTLE CORROSION SEVERE 50°C MODERATE DIRT, CORROSION >50°C* OR EXTREME SEVERE DIRT, ABRASIVE DUST CLASS H INSULATION LOW TEMPERATURE <-30°C** CORROSION * TYPE OF BEARING DEEP GROOVE BALL BEARING BALL THRUST, ROLLER ALL BEARINGS Special high temperature grease is recommended. NOTE that high temperature grease may not 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 STANDARD 1.0 SEVERE 0.5 EXTREME 0.1 LOW TEMPERATURE 1.0 210.100-IOM (JUL 2018) Page 44 ACUAIR® HYGIENIC AIR UNITS MAINTENANCE 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 51) Inspect and clean sheaves; replace worn or damaged sheavesWorn sheave grooves are one of the principal causes of premature belt failure. • Clean dirty, dusty, 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 of contact. Ordinarily, a misalignment of more than one-half of one degree (one-eighth inch in one foot) 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 52 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 52 (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 52 (B) shows how the string should touch four points when the drive is properly aligned. DISHING BELTS SHOULD RIDE LIKE THIS LOW RIDING BELTS INDICATE WORN GROOVES Belt Replacement Always replace 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. Figure 51 – Sheave Inspection Inspect Sheave Alignment NOTICE An incorrectly aligned sheave can substantially shorten belt life or overload blower and motor bearings, shortening 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 CAUTION Never place the belts on the sheaves by using a screwdriver to pry the belt over the rim of the sheave. TENSIONING V-BELTS AND 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. ACUAIR® HYGIENIC AIR UNITS MAINTENANCE 210.100-IOM (JUL 2018) Page 45 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 52 – Sheave Alignment 4. Inspect tension after: • The first 24 hours of operation. • One week of operation. K SPAN New belt tension will drop rapidly during the first few hours of operation. 5. Overtensioning shortens belt and bearing life. FORCE 6. Keep belts free from foreign material, which may cause slip. 7. Make V-drive inspection on a periodic basis. Tension belt 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. At the 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 19/16 inches. See Figure 53. Figure 53 - Simple Tensioning Procedure BELT DEFLECTION 1/64" PER INCH OF SPAN 210.100-IOM (JUL 2018) Page 46 ACUAIR® HYGIENIC AIR UNITS MAINTENANCE OPERATING AND MAINTENANCE INSTRUCTIONS FOR PIEZOMETER CAUTION CONNECT TO HIGH PRESSURE SIDE CONNECT TO LOW PRESSURE SIDE 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. The ring on the exterior side of the blower inlet cone as well as the upstream static pressure port are fitted with a 0.25 union brass tee. The 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 54) Maintenance of the Piezometer Basic Piezometer maintenance requires keeping the five tiny pressure pickup holes, in the inlet panel face and the throat of the inlet cone, free from blockage or debris buildup. Annually check the tubing and fittings attached outside the Piezometer for wear or damage. In addition, it may become necessary to back-flush each line gently with compressed air. This will help to blowout debris from inside 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. There are four pickup holes on the throat of the inlet cone and one on the upstream face. Elimination of one of the throat holes will not adversely affect the performance of most Piezometer. However, obstructing the upstream face hole will completely nullify its performance. Figure 54 – Plenum Fan Tap Location And Connection NOTICE For help with setup and calibration of Piezometers and Transducers, contact Johnson Controls-Frick AcuAir service at 717-762-2121. RECOMMENDED MONTHLY SERVICE Along with daily logs and weekly inspections, Johnson Controls-Frick recommends that the unit undergo a thorough monthly inspection. The monthly inspection should include but not limited to the following areas as indicated in the Recommended Maintenance Interval schedule below: 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 indications of wear. Replace the belts if there is evidence of cracking, fraying, or uneven wear. ACUAIR® HYGIENIC AIR UNITS MAINTENANCE 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. 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 immediately. 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 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 resealed 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. 210.100-IOM (JUL 2018) Page 47 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 Inspect general condition of the unit Clean debris from inside the unit Check condition of and pressure drop across the prefilters Check condition of and pressure drop across the final filters Check the condensation and washdown drains Inspect heat transfer components (Cooling and heating coils, and burner surfaces) Inspect all dampers and lubricate damper bearings Inspect and adjust damper linkage(s) Check and adjust fan belt tension Check gas burner operation and safeties Check the AHU for unusual noises or vibrations Check fan bearing locking collars Check motor electrical voltages and currents Check all temperature sensor calibrations Lubricate fan shaft bearings Lubricate motor base adjusting screws Lubricate the fan motors Check all fans for rotation without obstruction Check fans for proper direction of rotation Check the main fan Piezometer(s) Inspect protective finish Check unit access door seals Check & clean the smoke detector air filter & detector board Check the ammonia detector chemical sensor cell Check all interior wall and panel seam caulking Check the sealing 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. START-UP WEEKLY MONTHLY ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ EVERY 3 MONTHS EVERY 12 MONTHS ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔ 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. 210.100-IOM (JUL 2018) Page 48 ACUAIR® HYGIENIC AIR UNITS MAINTENANCE TROUBLESHOOTING Symptom Probable causes and Corrections Motor 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 overloads Check power to coil on starter Check power from starter to motor Motor starts but quits shortly after. Check Check Check Check Cooling doesn’t come on 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 Steam valve doesn’t modulate Check setpoint for heat Check OA lockout setpoint (lockout should be above OA Temp) Check output for steam valve Direct-fired burner doesn’t light 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 and gap pilot assembly (3/16" gap) Check gas supply Indirect-fired burner doesn’t light 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 Exhaust fan doesn’t start 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 Check power to and from starter Check damper end switch ( if applicable ) fan belts tubes to airflow switch to be clean power through air flow switch rotation of fan ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 210.100-IOM (JUL 2018) Page 49 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 narrow 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 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 review 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. 210.100-IOM (JUL 2018) Page 50 ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE ACUAIR AIR HANDLER PRESTART-UP CHECKLIST Name of Installing Contractor_______________________________ Qualified Technician’s Name:_______________________________ Frick Sales Order #________________________________________ Job Name________________________________________________ Job Site Location_________________________________________ Job Site Contact and Phone #______________________________ Unit Tag #__________________________________________ Unit Model #_______________________________________ Unit Serial #________________________________________ 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 within roof slope limitations where applicable. Air hoods installed properly. Package Installed According to 090.400-SB (Proper Installation of Electronic Equipment) Terminal screws and wiring connections secure in control, electric and Air Modulator panels. All shipping splits sealed and secured properly. Verify that all ductwork is complete and available for full 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, VIFB, 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 Remote Panel is mounted and wired. Verify all plastic spacers have been removed between door and door frame. Unit control panel is accessible. (Catwalk, ladder, etc.) 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. All field piping connections complete. 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. Belt tension adjusted properly per drive package label on fan. Verified fan base isolators and thrust restraints for proper adjustment. NOTE: Do not remove functional bolts from seismic isolators. Verified fan alignment with unit discharge. Adjust with isolation. Fan bearings properly lubricated. Sheaves properly aligned and tight on shaft. Burners Gas Supply is provided up to unit. Flue is installed, if needed. Gas supply pressure is correct. Gas line is purged. PRV installed, if required? I 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 Please FAX to Johnson Controls - Frick Service: 717-762-8624 Authorized Firm Phone # ACUAIR® HYGIENIC AIR UNITS INSTALLATION - OPERATION - MAINTENANCE 210.100-IOM (JUL 2018) Page 51 Index A H T Acu-Shield Roof Coating, 19 airborne contaminants, 39 air-leakage, 27 Alignment, 44 heater, 38 HEPA, 8 HEPA FILTERS, 30, 36 hood, 28 hoods, 23 HVACR contractors, 6 thermal expansion, 26 tools, 11 Troubleshooting, 48, 52 B Base Reconnect Seam, 21 belt run-in, 37 Belt Tension, 37 blower bearings, 46 bolt holes, 13 brass fittings, 46 burner, 38 C cage nuts, 13 cleaning products, 41 coil connections, 26 condensate drain, 26 Cooling Coils, 37 Cure time, 20 I Inspection, 37 Inspection Checklist, 39 installer, 12 Intake Hoods, 23 zinc, 41 zinc hydroxide, 41 zinc oxide, 41 L latches, 35 Lifting & Handling, 8 lubrication, 42 LUBRICATION INTERVALS, 43 Mechanical Tightness, 37 Motor Bearing Lubricant, 43 motor bearings, 38 fan belt tension, 38 fan covers, 6 Fans, 6 FAN SECTION, 8 fan shaft, 38 field piping, 6, 26 Filter LATCHES, 30 FILTER SECTION, 8 final filters, 37 flanged ducts, 27 foam kit, 22 foundation, 6 frame, 35 fresh air intake plenum, 23 frost blockages, 6 G Galvanizing, 41 gas manifold, 38 gas shutoff valve, 38 General Maintenance, 39 grease, 42, 43, 46 grease fittings, 43 Grease Relief Plug, 43 guards, 6 Wet Storage Stain, 41 white rust, 41 Z M F W jack, 13 damper bearings, 47 Drain pan, 26 drain trapping, 12 duct connections, 27 extended shutdowns, 6 V-belts, 44 vibration, 27 Vibration, 6 J D E V N neoprene gasket, 12 P Periodic Inspections, 39 prefilters, 37, 47 pressure gauge, 37 PRESTART-UP, 50 R Recommended Maintenance Intervals, 47 reconnect seam, 15 Refrigerant Piping, 27 roof curbs, 12 run-in procedure, 37 S Sensing devices, 37 shaft retainers, 6 Sheave Alignment, 44 sheaves, 44 SH filter, 34 Shipping Bolts, 28 shutdown, 38 silicone caulking, 16, 20 Split Reassembly Procedure, 16 Split seams, 13 spring isolation, 25 start-up, 37 steam coil, 26 July 2018 Form Revisions p.7 – Updated Figure 2 with newest unit drawing p.12 – Added "split midspan" callout to Figure 8 p.16 – Updated polyurethane caulking options p.20 – Updated polyurethane caulking options p.26 – Revised Hat Channel terminology p.29 – Removed Tube Steam Heat Coil section p.30 – Updated filter latch/clip images and descriptions p.31 – Removed specifications and references to 2" filters – Removed references to standard capacity filters – Updates to filter part numbers p.32 – Removed references to single headered filters p.34 – Removed 2" pleated panel installation section p.37 – Removed control dampers section - Various text terminology, formatting and figure number changes throughout Form 210.100-IOM (2018-07) Supersedes: 210.100-IOM (2017-07) Subject to change without notice Published in USA • 09/18 • PDF JOHNSON CONTROLS 100 Cumberland Valley Avenue Waynesboro, PA 17268-1206 USA Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick © 2018 Johnson Controls Int'l PLC - ALL RIGHTS RESERVED APPENDIX Form 210.100-SB1 (MAR 2016) SERVICE BULLETIN File: Replaces: Dist: Revised: SERVICE MANUAL - Section 210 NOTHING 3, 3a, 3b, 3c May 2017 (Logo) Long Term Storage Requirements NOTICE Failure to comply with these requirements will render any written or implied Johnson Controls warranty null and void. I. PURPOSE The purpose of Long-Term Storage Requirements is to ensure that equipment manufactured by Johnson Controls does not sustain any damage or degradation due to being in a dormant state for extended periods of time. The proper implementation and adherence to the Long-Term Storage Requirements will ensure that when the equipment is started and operated it will be in the intended condition. This will benefit the customer by providing equipment with the maximum service life. II. DEFINITION OF LONG TERM STORAGE III. CUSTOMER RESPONSIBILITIES In general, all equipment manufactured by Johnson Controls that meets any, some, or all of the conditions below shall be prepared for Long-Term Storage. It is the Customer’s responsibility to ensure that the necessary procedures described have been completed. It will be the responsibility of the Customer to submit completed log sheets showing the condition of the unit and noting any discrepancies. The logs shall be sent to the Johnson Controls AcuAir Service Department in Waynesboro, PA. A. Equipment not “started” within six (6) months of leaving the Johnson Controls factory. B. Equipment being stored within five (5) miles of a body of salt water (time independent). C. Equipment being shipped on a body of salt water (time independent). “Start-up” is defined as useful operation or Testing, Charge and/or Adjustment (TCA). Condition A is based upon the unit being stored indoors in a vibration-free, non-corrosive environment. Special provisions may be necessary for environmental conditions outside these parameters. Please contact Johnson Controls for further instructions if storage is subject to non-standard environmental changes/conditions even for periods less than six (6) months. Failure to adhere to the Long-Term Storage Requirements as outlined can and will render any written or implied Johnson Controls warranty null and void. Form 210.100-SB1 (2016-03) Supersedes: NOTHING Subject to change without notice Published in USA • 05/17 • PDF © 2017 Johnson Controls International PLC - ALL RIGHTS RESERVED If after four (4) months from shipment, the equipment has not been started and/or in the event that Start-up is delayed, the Customer shall notify the Johnson Controls AcuAir Service Department as soon as possible. In the event there is an unplanned delayed Start-up, the Customer shall notify the Johnson Controls AcuAir Service Department in writing with as much information on the new schedule and the site and equipment conditions. Every effort shall be made by all parties to make this determination and notification as soon as possible. Any delay in the process will hinder Johnson Controls’ ability to provide Warranty Services to the customer in a cost effective way. The Customer shall be responsible for the cost of any LongTerm Storage actions that Johnson Controls determines are necessary to provide for the proper life of the equipment and subsequent ability to provide any written or implied Warranty Services. JOHNSON CONTROLS 100 Cumberland Valley Avenue Waynesboro, PA 17268 USA Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick Form 210.100-SB2 (MAR 2016) SERVICE BULLETIN File: Replaces: Dist: Revised: SERVICE MANUAL - Section 210 NOTHING 3, 3a, 3b, 3c May 2017 (Logo) Long Term Storage Requirements Field Preparation of Air Handling Units Upon completion of the long-term storage period, the standard AcuAir warranty commences. 12 MONTHS PARTS ONLY (Not to exceed 18 months from ship date.) NOTICE Failure to comply with these requirements will render any written or implied Johnson Controls warranty null and void. I. SUPPLEMENTARY DOCUMENTATION The following documentation is required to FULLY COMPLY with the Long-Term Storage requirements. A. Long-Term Storage Requirements – GENERAL (Refer to Form 210.100-SB) B. Long-Term Storage Requirements – PERIODIC CHECKLIST AND LOGS - AIR HANDLING UNITS (Refer to Form 210.100-SB3). II. FIELD PREPARATION FOR LONG TERM STORAGE General 1. Remove and dispose of shipping materials. 2. Perform a visual inspection of the equipment. Outdoor Units Outdoor units are not fully wrapped. Exposed openings are covered for protection from weather, road dirt, etc. during inland transit. A thorough inspection, both inside and out, should be done at the time of delivery. Visible damage should be noted on the signed and dated bill of lading with a request that the carrier inspect the damage within 72 hours of notification. Concealed damage must be reported within 15 days of delivery with a request that the carrier inspect the damage within 72 hours of notification. Any concealed damaged reported after 15 days will compromise a claim settlement. Inspection requests may be done by telephone or in person, but should be confirmed in writing. If assistance is needed with the claim process, contact your JCI Sales person. 3. Touch up any paint that has worn or chipped off using paint supplied in ship loose items. Prepare the surface as required using a wire brush. 4. Verify that all ship loose items are present. Note any missing items on the Periodic Checklist and Log Sheet (210.100-SB3). 5. Locate unit(s) so that passing traffic will not damage shafts, coil connections, damper linkages or unit panels. 6. Refrigerant coils must be evacuated and pre-charged with 5 psi holding charge of nitrogen. DO NOT damage or disturb these coils and connections. 7. Water coils must have all inlet and outlet connections capped or closed tight to prevent foreign materials and liquids from gaining entrance during the storage period. 210.100-SB2 (MAR 2016) Page 2 LONG TERM STORAGE FIELD PREPARATION OF AIR HANDLING UNITS AcuAir Applied Details: Protection Supplies: 1. Main gas burner panel – Install Corrosion Inhibitor (C.I.) Frick BPC Part # 026-37705-000 Corrosion Inhibitor (C.I.) (Good for up to 5 cu ft protection) 2. Exhaust fan motor(s) – Coat electrical connections with Cortec anti corrosion spray. Wrap motor(s) and Install C.I. 3. Unit Split – Protect electrical pig tail ends with Cortec anticorrosion spray and plastic wrap. Seal electrical junction box conduit openings. Frick BPC Part # 026-37706-000 Corrosion Inhibitor (C.I.) (Good for up to 11 cu ft protection) Frick BPC Part # 026-37707-007 Anti-corrosion Spray (For blower and motor shafts and sheaves) 4. Main blower – Coat electrical connections with Cortec anti corrosion spray. Wrap motor(s) and Install C.I. Frick BPC Part # 026-37707-000 Cortec Anti-corrosion Spray (For electrical connections) 5. Disconnect belts. (Store belts in a dry place) Desiccant packet – Generally available. Size for internal panel volume. Replace quarterly or as needed. 6. Spray shafts with anti-corrosion spray. 7. Grease bearings on blower shaft. 8. Main 3-phase electrical panel – Assure all conduit openings through the panel enclosure are completely sealed. Install desiccant packet sized for panel. Install C.I. Follow-up Periodic Documentation: Form 210.100-SB3 details monthly, quarterly and annual checks and procedures that must be documented to prove compliance and forwarded regularly to the Johnson Controls AcuAir Service Department. 9. AcuAir Quantum or A-B Control panel – Assure all conduit openings through the panel enclosure are completely sealed. Install desiccant packet sized for panel. Install C.I. 10. Ammonia detector – Remove chemical cell. Bag and place in the refrigerator. 11. Smoke Detector(s) – Install C.I. and desiccant pack. 12. Cooling Coils (3) – Check for and document internal nitrogen pressure charge. Form 210.100-SB2 (2016-03) Supersedes: NOTHING Subject to change without notice Published in USA • 05/17 • PDF © 2017 Johnson Controls International PLC - ALL RIGHTS RESERVED JOHNSON CONTROLS 100 Cumberland Valley Avenue Waynesboro, PA 17268 USA Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick Form 210.100-SB3 (MAR 2016) SERVICE BULLETIN File: Replaces: Dist: Revised: SERVICE MANUAL - Section 210 NOTHING 3, 3a, 3b, 3c May 2017 (Logo) Long Term Storage Periodic Checklist And Logs — Air Handling Units NOTICE Failure to comply with these requirements will render any written or implied Johnson Controls warranty null and void. I. SUPPLEMENTARY DOCUMENTATION The following documentation is required to FULLY COMPLY with the Long-Term Storage requirements. A. Long-Term Storage Requirements – GENERAL (Refer to Form 210.100-SB) B. Long-Term Storage Requirements – FIELD PREPARATION OF AIR HANDLING UNITS (Refer to Form 210.100-SB2). II. CHECKS 1.0 Monthly Checks 2.0 Quarterly Checks 1.1 Visually inspect Air Handler for damage. 2.1 Complete Assembly - The unit should be checked quarterly to see that no damage has occurred to the protective covering. Any apparent damage to the covering or units should be noted in the comments section of the quarterly log sheet (See page 2). 1.1.1 Motors, Drives - The motors and sheaves should be inspected externally for evidence of damage to the protective covering. An inspection is necessary only if it is apparent that the control protection has been disturbed. If this is found, the motor should be re-protected by wrapping and tightly sealing the control with plastic and inserting a desiccant to absorb moisture. 1.2 Refrigerant Coils - Check holding charge pressure monthly to be sure that the pressure has not dropped. If pressure has dropped, the unit should be inspected for signs of visible damage which may have caused loss of pressure. If pressure drops more than 2 psi, the unit should be pressure tested to locate the leak; the leak should be repaired and the unit recharged with nitrogen to 5 psig pressure. Note this in the comments section of the monthly log sheet (See page 2). 1.3 Rotate fan shaft several revolutions by hand every month. 2.2 Grease bearings every three months. The greasing procedure is explained in the product service manual. 3.0 Semi Annual Checks 3.1 None 4.0 Annual Checks 4.1 Unwrap all electrical cabinets and install new Vapor Emitters. (Frick BPC Part # 026-37705-000 OR 026-37706-000 Corrosion Inhibitor). Reseal. 4.2 Re-spray all exposed shafts and sheaves with anti-corrosion spray. (Frick BPC Part # 026-37707-007 Anti-corrosion Spray). ACUAIR AIR HANDLING UNIT PERIODIC CHECKLIST AND LOGS Job Name:_______________________________________________ Date Delivered:___________________________________________ Date of Storage Prep:_____________________________________ Contract #_________________________________________ Unit Model #_______________________________________ Unit Serial #________________________________________ Condition of Unit Delivered:____________________________________________________________________________________ Explain:______________________________________________________________________________________________________ ____________________________________________________________________________________________________________ 1.0 MONTHLY Rotate Shafts 5 PSI Coil Pressure Motor Belts & Drives Protected and Dry Comments Date Initial Date 2 Initial Date 3 Initial Date 4 Initial Date 5 Initial Date 6 Initial Date 7 Initial Date 8 Initial Date 9 Initial Date 10 Initial Date 11 Initial Date 12 Initial 1 2.0 QUARTERLY 1 2 3 4 Grease Bearings Inspect Protective Covering Install New Vapor Filters Re-spray Exposed Shafts & Sheaves Comments Date Initial Date Initial Date Initial Date Initial 4.0 ANNUAL 1 Comments Date Initial Form 210.100-SB3 (2016-03) Supersedes: NOTHING Subject to change without notice Published in USA • 05/17 • PDF © 2017 Johnson Controls International PLC - ALL RIGHTS RESERVED JOHNSON CONTROLS 100 Cumberland Valley Avenue Waynesboro, PA 17268 USA Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/frick ">

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