Johnson Controls Frick AcuAir Installation, Operation And Maintenance Instructions
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Johnson Controls Frick AcuAir Installation, Operation And Maintenance Instructions

Hygienic air units
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AcuAir
Hygienic Air Units
This manual contains installation, operation, and maintenance
instructions. Read thoroughly before beginning installation. Failure
to follow these instructions could result in damage or incorrect
Check www.FrickCold.com for the latest version of this publication.
Form 210.100-IOM (JUL 2021)
Installation - Operation - Maintenance
File:
Replaces:
Dist:
operation of the unit.
Service Manual - Section 210
210.100-IOM (JUL 2018)
3, 3a, 3b, 3c

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  • Page 1 Form 210.100-IOM (JUL 2021) Installation - Operation - Maintenance File: Service Manual - Section 210 Replaces: 210.100-IOM (JUL 2018) Dist: 3, 3a, 3b, 3c AcuAir Hygienic Air Units This manual contains installation, operation, and maintenance instructions. Read thoroughly before beginning installation. Failure to follow these instructions could result in damage or incorrect operation of the unit.
  • Page 2 Johnson Controls-Frick's published specifications and must be performed ONLY by qualified Johnson Controls- Frick personnel. Johnson Controls-Frick is not responsible for damages or problems resulting from incorrect connec- tions to the controls or application of incorrect control signals. Failure to follow this voids the manufacturer’s war- ranty and cause serious damage to property or injury to persons.

  • Page 3: Table Of Contents

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation - Operation - Maintenance Page 3 Table of Contents General information Operation Safety ................5 Start-up ................39 Warranty ................5 Initial start-up ..............39 Pre-installation requirements ..........7 Inspection ..............39 Training and safety considerations .......
  • Page 4 210.200-IOM (JUL 21) Acuair Hygienic Air Units ® Page 4 Installation - Operation - Maintenance This page is intentionally left blank.

  • Page 5: General Information

    Page 5 Warranty General information NOTICE This manual, in combination with the appropriate controls related manuals, provides the information necessary to For Warranty Support with the Frick AcuAir unit, safely install and start up Frick AcuAir equipment. Due ® ®...
  • Page 6 210.200-IOM (JUL 21) Acuair Hygienic Air Units ® Page 6 Installation - Operation - Maintenance Figure 1: Access door latch 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...

  • Page 7: Pre-Installation Requirements

    ® on the unit. Correct safety precautions such as the use of provided by Johnson Controls-Frick, use the finest in insulating soles and gloves and a trained lookout buddy HVACR materials and corrosion protection to deliver are indispensable.
  • Page 8 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 8 Installation Figure 2: AcuAir system-to-wall spacing requirements Note: • This is a generic unit layout shown. Consult the order specific • The AcuAir hygienic unit has sections under both positive and ®...

  • Page 9: Installation

    Tarp over the roof and down the side to the base channel and secure. Receiving and inspection 3. Store on a level surface. If the unit must be raised off Frick AcuAir units are inspected and tested before ship- ® ground, supports under base channel and base channel ment, ensuring a high-quality product.

  • Page 10: Lifting And Handling

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 10 Installation See forms 210.100-SB1, 210.100-SB2, and 210.100- Figure 3: Standard lifting with four lifting points SB3 for long-term storage details and the delay of war- ranty commencement. Lifting and handling The unit ships (as specified on unit submittal) either as- sembled, as a subassembly (collection of parts), or as individual sections.

  • Page 11: Support Structure Information

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 11 Figure 5: Lifting lugs WARNING Do not lift non-base units or subassembly by attach- ing clevis hooks, pins or bolts to casing, casing hard- ware, angles, tabs or flanges. HOUSING NOTICE Save bolts when removing lifting lugs.
  • Page 12 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 12 Installation Figure 6: Generic structural steel support...
  • Page 13 AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 13 Figure 7: Generic roof curb support...

  • Page 14: Section Reconnect Ship Loose Items

    Screw gun with nut drivers • Paint brush or roller for applying Acu-Shield roof coating Assembling roof curb (optional) 1. When supplied by Johnson Controls - AcuAir , roof ® curbs ship either fully welded or in pieces. If bolted curb construction, bolt together.

  • Page 15: Performance Grade Connections

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 15 Performance Grade connections 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. Reassembling split unit, As the unit settles, the out-of-square racking caused Performance Series only...

  • Page 16: Installing And Sealing The Reconnection Attachment

    POLYURETHANE CAULKED EXTERIOR SKIN BETWEEN SECTIONS IN FIELD LINER .25-20 X .75 HEX BOLT WITH .25 FLANGED LOCKNUT (SUPPLIED BY JOHNSON CONTROLS) INTERNAL RECONNECT Installing and sealing the Figure 11: Multi-section reconnect sealing of AcuAir performance series units reconnection attachment 1.

  • Page 17: Insulating The Base Reconnect Seam Of An Acuair Performance Series Unit

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 17 Insulating the base reconnect seam NOTICE of an AcuAir Performance Series unit Inject the foam into the open seam after the air unit sections have been securely reconnected. When two AcuAir unit sections are drawn together the ®...
  • Page 18 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 18 Installation CAUTION Do not use silicone caulking on field reconnects or on shipping split covers. NOTICE Only use caulking shipped with unit. Figure 13: Split reassembly procedure for AcuAir performance series units only #10-16 SS TEK SCREW SHIPPING SPLIT COVER W/EPDM WASHER (TYP)

  • Page 19: Sealing The Acuair Performance Series Roof

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 19 Sealing the AcuAir Performance Note: Series roof • Do not apply when inclement weather is imminent within a 24 hr period. 1. Ensure to bolt and seal the mechanical joint between •...

  • Page 20: Food Grade Connections

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 20 Installation Food Grade connections roofs together. If bar clamps are needed, use wood for protection in between the bar clamp and unit. Installing the reconnect 5. Check to see if all bolts are secured correctly, and ap- 1.

  • Page 21: Applying The Acuair Food Grade Roof Reconnect Finish

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 21 Applying the AcuAir Food Grade box to prevent the migration of moisture. 11. Inspect all splits to see if all electrical and piping con- roof reconnect finish nections are complete and correct. 1.
  • Page 22 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 22 Installation Note: 4. Apply Acu-Shield roof coating with a good quality syn- • Do not apply roof coating when inclement weather is thetic bristle paintbrush (not provided). imminent within a 24 hr period. 5.

  • Page 23: Insulating The Base Reconnect Seam Of An Acuair Food Grade Series Unit

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 23 Insulating the base reconnect seam Follow the instructions provided by the foam manufac- turer for preparing the two part foam mixture and the of an AcuAir Food Grade Series unit injection kit.

  • Page 24: Foam Kit 15 Use Guidelines For Acuair Unit Base Reconnect Insulation

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 24 Installation Foam kit 15 use guidelines for Figure 21: Remove hoses and applicator to full length AcuAir unit base reconnect insulation Always review and follow the directions provided in your foam kit. The following instructions are a general over- view, meant to accompany the reference photos.

  • Page 25: Attaching The Acuair Fresh Air Intake Plenum

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 25 Attaching the AcuAir fresh air 1. For those unit arriving with unattached hoods, reattach the hoods starting with a hood in the bottom position intake plenum first. Use the factory attached hoods as a model and The fresh air intake plenum and hoods are shipped as an the existing screw holes to finalize locations.
  • Page 26 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 26 Installation Figure 27: Plenum leg attachment 9. 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 ®...
  • Page 27 AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 27 Figure 29: Plenum assembly positioning and alignment...

  • Page 28: Condensate Drain Trap Sizing

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 28 Installation Condensate drain trap sizing Figure 31: Condensate drain trap sizing All condensate drain connections and floor drains must be trapped at the job site location. Failure to correctly trap a drain results in flooding of the drain pan and potential water damage to the air-handling unit and other building facilities.

  • Page 29: Duct Connections

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 29 Duct connections with all state and local codes and standard industry practices. Make duct connections to the casing by screwing flanged There must be sufficient flexibility in the piping so that ducts directly to the casing with self-tapping sheet metal any vibration from the unit is not transmitted to the screws.

  • Page 30: Connecting The Weather Hood Directly To The Acuair Fresh Air Opening

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 30 Installation Connecting the weather hood Figure 35: Connection of weather hood(s) to unit directly to the AcuAir fresh air opening POLYURETHANE CAULKING 1. Apply polyurethane caulking to the flange of the hood. 2.

  • Page 31: Filter Latches

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 31 CA-04 Filter latches Figure 38: Filter latches Use with a 4 in. pleated panel filter (prefilter) installed in a standard type 8 filter frame. Use with a 12 in. DH double headered rigid filter installed in a standard type 8 filter frame.
  • Page 32 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 32 Installation Table 2: AcuAir single-filter application (non-HEPA filter) Filter holding clips to be used with 4 in. pleated panel prefilter 12 in. rigid final filter, double header filter styles style C86 or CA-04s C80 or CF83Fs Table 3: Filter, clips, and frames Description...
  • Page 33 AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 33 Figure 39: Multi-pleat filters Multi-Pleat Multi-Pleat XL8 HC XL11 HC Table 5: Final filter dimensions, non-HEPA Width x height x depth (in.) AcuAir part Number MERV 13 rigid 12 x 24 x 12 DH KOCH 110 722 002 24 x 12 x 12 DH Same as above...

  • Page 34: Hepa Filter Application

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 34 Installation NOTICE NOTICE HEPA filters must always be installed with the pleats Non-HEPA filters must be installed with the pleats oriented vertically oriented vertically whenever possible HEPA filter application Non-HEPA filters in HEPA frames Table 6: HEPA filter application dimensions Table 7: Non-HEPA filter dimensions in HEPA frame Description...

  • Page 35: Installing A 4 In. Pleated Panel (Pre)Filters

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 35 Installing a 4 in. pleated panel (pre) Installing a rigid DH double- filters headered filter These instructions are for installing 4 in. panel filters into These instructions are for installing a rigid DH double- type-8 holding frames.
  • Page 36 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 36 Installation 5. After the latches have been installed, configure the Figure 45: Pull and fasten the spring latch in hole in the frame as shown in the following Figure. header of the filter Figure 44: Frame with 4 latches CAUTION Take care to prevent contamination of the filter me-...

  • Page 37: Hepa Filters

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation Page 37 HEPA filters Figure 46: Installing HEPA filter frames AIRFLOW AIRFLOW AIRFLOW AIRFLOW FILTER RETAINER CLIPS MUST BE ATTACHED TO SIDES ONLY SEE DETAIL A FILTER CLIP INSTALLATION FLAT SEALING GASKET SEAL SURFACE HEPA FILTER HOLDING FRAME...
  • Page 38 210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 38 Installation This page is intentionally left blank.

  • Page 39: Operation Start-Up

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Operation Page 39 Blower, motor, drives Operation 1. Mechanical tightness Start-up a. Verify tightness of the fan bearing bolts. b. Verify tightness of the blower wheels to shafts. Before attempting to start up and operate any electrical cooling equipment such as an AcuAir system unit, it is ®...

  • Page 40: Gas Heat Start-Up

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 40 Operation Employ refrigerant sensing devices in the hygienic air sys- Gas heat shutdown tem. Select and locate these sensors based on the refrig- 1. Set the controls to lowest setting. erant within the system. When the refrigerant is ammonia, 2.

  • Page 41: Maintenance

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 41 Maintenance NOTICE Daily operation and routine Air units move air (and airborne contaminants) across the coil. Protect the coil from corrosion by maintenance washing and rinsing frequently. Inspect, clean, and lubricate the AcuAir unit on a periodic ®...

  • Page 42: Maintaining The Filters

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 42 Maintenance Electrical conduit sealing • Replace any damaged blades – clean operating parts. requirement • Inspect blade edge and side seal – replace as neces- sary. The AcuAir hygienic unit has the potential to operate with ®...

  • Page 43: Calibrating The Temperature Sensors

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 43 Calibrating the temperature sensors must undergo a sequence of chemical reactions. First the zinc must react with oxygen to create zinc oxide. Second, Temperature sensors that are out of calibration can affect the zinc oxide reacts in the presence of moisture to create both the correct function and efficient operation of the zinc hydroxide.

  • Page 44: Lubricating The Fan Bearing

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 44 Maintenance 3. Finally, rinse with plain water to completely remove all Lubricant for fan bearings traces of the powdery hydroxide and the cleaner. A lithium/petroleum base grease conforming to an NLGI Grade II consistency is normally used.

  • Page 45: Mounting Hardware And Adjustable Motor Base

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 45 Mounting hardware and adjustable motor CAUTION base Be sure that the grease you are adding to the motor • Inspect for loose parts. is compatible with the grease already in the motor. •...

  • Page 46: Inspecting V-Belts And Sheaves

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 46 Maintenance Table 13: Motor bearing service conditions Severity of service Ambient max. temp. Atmospheric contamination Type of bearing Standard 40°C Clean, little corrosion Deep groove ball bearing Severe 50°C Moderate dirt, corrosion Ball thrust, roller >50°C* or Extreme...

  • Page 47: Replacing Belts

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 47 Figure 54: Sheave alignment 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. Tensioning V-belts and sheaves Replacing belts Always replace belts as a matched set.

  • Page 48: Simple Tensioning Procedure

    Piezometer to an air pressure gauge. For help with setup and calibration of Piezometers and This Piezometer automatically produces a pressure differ- Transducers, contact Johnson Controls-Frick AcuAir ® ential signal whenever the fan is moving air. See Figure 56. service at 717-762-2121.

  • Page 49: Filters

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 49 3. Inspect the blower belt tension. Tension the belts in Unit exterior accordance with the included Blower Belt Tension 1. Visually inspect the unit exterior. The seams between Guidelines. Visually inspect the belts for indications of panels are factory sealed with silicon, and must be wear.

  • Page 50: Spare Parts

    210.100-IOM (JUL 2021) AcuAir Hygienic Air Units Page 50 Maintenance Spare parts It is also advisable to reorder parts before taking existing spares from inventory. This policy helps prevents down- Frick suggests that customers maintain an inventory of time due to forgotten spare parts order placement. spare parts for the AcuAir air unit.

  • Page 51: Troubleshooting

    AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Maintenance Page 51 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 and ammonia detectors, if applicable Check end switch on OA dampers, if applicable Check fuses...

  • Page 52: Acuair Factory Start-Up Assistance

    • 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 provides a basic control system review, basic troubleshooting training, and instruction regarding any AcuAir operator interface controls provided by Johnson Controls.

  • Page 53: Acuair Air Handler Prestart-Up Checklist

    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 Authorized firm Phone No.
  • Page 54 210.200-IOM (JUL 21) Acuair Hygienic Air Units ® Page 54 Installation - Operation - Maintenance Index Acu-Shield roof coating, 21 heater, 40 thermal expansion, 28 airborne contaminants, 41 HEPA, 9 tools, 14 air-leakage, 29 HEPA filters, 37 troubleshooting, 51 alignment, 46 hood, 30 hoods, 25 HVACR contractors, 7...
  • Page 55 AcuAir Hygienic Air Units 210.100-IOM (JUL 2021) Installation - Operation - Maintenance Page 55 This page is intentional left blank.
  • Page 56 Form 210.100-IOM (2021-07) Johnson Controls Supersedes: 210.100-IOM (2018-07) 100 Cumberland Valley Avenue Subject to change without notice Waynesboro, PA 17268-1206 USA Published in USA • 07/21 • PDF Phone: 717-762-2121 • FAX: 717-762-8624 www.johnsoncontrols.com/Frick © 2021 Johnson Controls - All Rights Reserved...

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