Johnson Controls Frick AcuAir Installation Operation & Maintenance

Johnson Controls Frick AcuAir Installation Operation & Maintenance

Hygienic air units
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Installation - Operation - Maintenance
AcuAir
Hygienic Air Units
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
OPERATION OF THE UNIT.
Please check www.jci.com/frick for the latest version of this publication.
Form 210.100-IOM (MAR 2014)
INSTALLATION - OPERATION - MAINTENANCE
File:
SERVICE MANUAL - Section 210
Replaces:
210.100-IOM (OCT 2013)
Dist:
3, 3a, 3b, 3c
®

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Summary of Contents for Johnson Controls Frick AcuAir

  • Page 1 Form 210.100-IOM (MAR 2014) INSTALLATION - OPERATION - MAINTENANCE File: SERVICE MANUAL - Section 210 Replaces: 210.100-IOM (OCT 2013) Dist: 3, 3a, 3b, 3c Installation - Operation - Maintenance AcuAir ® Hygienic Air Units THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP, AND MAINTENANCE INSTRUCTIONS.
  • Page 2 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.
  • Page 3: Table Of Contents

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION - OPERATION - MAINTENANCE Page 3 TABLE OF CONTENTS ACuAiR.SiNglE.FilTER.APPliCATioN.(NoN.hEPA)..32 INTRODUCTION hEPA.FilTER.APPliCATioN..........33 SAFETY................4 iNSTAllATioN.oF.2”.PlEATEd.PANEl.(PRE)FilTERS..34 WARRANTY............... 4 Installation of Spring Latches ........34 PREINSTALLATION REqUIREmENTS iNSTAllATioN.oF.4”.PlEATEd.PANEl.(PRE)FilTERS..34 Installation of Spring Latches ........
  • Page 4: Introduction

    Please read the complete manual Never open an access door while air unit is in operation. prior to installing, operating, or servicing the equipment. WARRANTY NOTICE For Warranty Support with the Frick AcuAir unit, contact Frick Service at 717-762-2121.
  • Page 5 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION - OPERATION - MAINTENANCE 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 LATCH SIDE VIEW...
  • Page 6: Preinstallation Requirements

    ® and gloves and a trained “lookout buddy” are indispensable. provided by Johnson Controls-Frick, utilize the finest in HVACR Ice formation in cold weather can present slip and fall hazards. materials and corrosion protection to deliver dependable,...
  • Page 7 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 7 WALL, OBJECT OR OBSTRUCTION COOLING COIL SEE NOTE 1 SEE NOTE 4 CONNECTIONS COIL PULL SEE NOTE 5 AREA AMMONIA DETECTOR FLOOR DRAIN 27" CONN. TYPICAL SUPPLY PLAN VIEW RETURN AIR RIGHT HAND LOW SIDE...
  • Page 8: Installation

    If unit must be stored more than 1 week outdoors, To prepare for safely lifting the air unit, estimate the Johnson Controls-Frick recommends the following guidelines: approximate center of gravity. Internal placement of components may cause the weight to be unevenly distributed, 1.
  • Page 9 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 9 SPREADER BARS MUST BE WIDER THAN THE UNIT WIDTH TO PREVENT DAMAGE TO THE HOUSING Figure 3 – Recommended Lifting With Four Lifting Points SPREADER BARS MUST BE WIDER THAN THE UNIT WIDTH TO PREVENT DAMAGE TO THE HOUSING.
  • Page 10: Support.structure.information

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 10 INSTALLATION WARNING Do not lift non-base units or subassembly by attaching clevis hooks, pins or bolts to casing, casing hardware, HOUSING angles, tabs or flanges. NOTICE Save bolts when removing lifting lugs. Bolts will be used BASE SKIN for assembly of split units.
  • Page 11: Section.reconnect.ship.loose.items

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 11 NOTES: 1. SEE UNIT INSTALLATION DIMENSION DRAWING FOR UNIT WIDTH, LENGTH AND WEIGHT. 2. ALTERNATE METHODS OF SUPPORT TO INCLUDE SUPPORT AT ALL SECTION SPLITS. * SUPPORT DESIGNED AND SUPPLIED BY OTHERS. DRAWING FOR REFERENCE ONLY.
  • Page 12: General.split.unit.reassembly

    Page 12 INSTALLATION Roof Curb Assembly (Optional) GENERAL SPLIT UNIT REASSEMBLY 1. When supplied by Johnson Controls - AcuAir , roof Units which are shipped in sections, must be installed on a ® curbs ship either fully welded or in pieces. If bolted curb proper foundation and carefully assembled to provide the construction, bolt together.
  • Page 13: Performance.grade.connections

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 13 PERFORMANCE GRADE CONNECTIONS REASSEMBLY PROCEDURE FOR SPLIT UNIT on the blind side and bolts installed from accessible side. All bolt holes require a bolt. PERFORMANCE SERIES ONLY 7. If bolt holes do not align, it may be due to racking during 1.
  • Page 14: Acuair.performance.series.unit

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 14 INSTALLATION FIELD SEAL BEFORE EXTERIOR SKIN RECONNECTING SECTIONS WITH POLYURETHANE CAULK GASKET INSTALLED IN FIELD .25-20 X .75 HEX BOLT LINER WITH .25 FLANGED LOCKNUT INTERNAL RECONNECT (SUPPLIED BY JCI) Figure 10 –...
  • Page 15 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 15 INSULATION OF THE BASE RECONNECT SEAM NOTICE OF AN ACUAIR PERFORMANCE SERIES UNIT iNjECT.ThE.FoAm.iNTo.ThE.oPEN.SEAm.AFTER.ThE. When two AcuAir unit sections are drawn together the base AiR.uNiT.SECTioNS.hAVE.bEEN.SECuRElY. channels of the two sections form an uninsulated cavity that RECoNNECTEd.
  • Page 16 210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 16 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 SHIPPING SPLIT COVER W/EPDM WASHER (TYP) CAULK CAULK ALONG SCREW SHIPPING SPLIT...
  • Page 17: Acuair.performance.series.roof.sealant

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 17 ACUAIR PERFORMANCE SERIES 4. Do not apply to wet, ice, or snow covered surfaces. ROOF SEALANT PROCEDURE 5. Before applying, clean surface with wire brush or solvent (See Figure 14) wipe (not provided).
  • Page 18: Food.grade.and.sanitary.connections

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 18 INSTALLATION FOOD GRADE AND SANITARY CONNECTIONS RECONNECT INSTALLATION PROCEDURE 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 1.
  • Page 19: Acuair Food Grade Or Sanitary Series Roof Reconnect Finish

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 19 ACUAIR FOOD GRADE OR SANITARY SERIES 11. Reconnect all electrical conduit and wiring at the reconnect junction boxes. Use electrical conduit sealing putty to seal all ROOF RECONNECT FINISH conduit openings into and out of the junction box to prevent the 1.
  • Page 20 210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 20 INSTALLATION 3. Do not apply roof coating when inclement weather is 7. One quart applied at 45 mils is equal to a 3 inch wide x imminent within a 24 hour period. 33 foot long section.
  • Page 21: Insulation.of.the.base.reconnect.seam.of.an

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 21 INSULATION OF THE BASE RECONNECT SEAM Follow the instructions provided by the foam manufacturer for preparing the two part foam mixture and the injection kit. OF AN ACUAIR FOOD GRADE OR Take special note of the 30 second inactivity limit after which SANITARY SERIES UNIT the injection nozzle may become permanently clogged.
  • Page 22: Foam.kit.15.Use.guidelines

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 22 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.
  • Page 23: Acuair.fresh.air.intake.plenum

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 23 ACUAIR FRESH AIR INTAkE PLENUM 1. The fresh air intake plenum and hoods will be shipped as an assembly on smaller cfm units. The plenums will arrive with one set of hoods unmounted for larger cfm units. 2.
  • Page 24: Fan.hold-Down./.Spring.isolator.setup.(Opt)

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 24 INSTALLATION FAN HOLD-DOWN / SPRING ISOLATOR SETUP Place tubes on studs and place shoulder washer (shoulder up) on studs. Place one (1) nut on each stud and tighten it on (OPTIONAL) shoulder washer.
  • Page 25: Condensate.drain.trap.sizing

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 25 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.
  • Page 26: Duct.connections

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 26 INSTALLATION 3. Refrigerant Piping – When a cooling coil is supplied, all DUCT CONNECTIONS refrigeration piping must be installed in accordance with all (See Figures 30 and 31) state and local codes and standard industry practices. Make duct connections to the casing by screwing flanged ducts directly to the casing with self-tapping sheet metal screws.
  • Page 27: Fresh.air.opening

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 27 WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR FRESH AIR OPENING POLYURETHANE CAULKING (See Figures 32 and 33) 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.
  • Page 28: Horizontal And Vertical Tube Steam Heat Coil With Integral Face And Bypass Dampers

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 28 INSTALLATION HORIZONTAL AND VERTICAL TUBE STEAM HEAT COIL WITH INTEGRAL FACE AND BYPASS DAMPERS Figure 34 – Integral Face and Bypass Coil (Horizontal; Tubes, Steam Shown) The Vertical Tube Integral Face and Bypass (VIFB) or the Integral Face and Bypass (IFB) operates with full steam pressure or water flow at all times when the air is at or below 35°F.
  • Page 29: Shipping Bolts (Vifb Only)

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 29 Shipping Bolts (VIFB Only) FIELD PENETRATIONS FOR PIPING AND ELECTRICAL CONNECTIONS Headers, whether return steam condensate or hot water supply and return, are securely bolted to lower mounting brackets to WARNING prevent damage to header and tubes during shipment and piping of the coils.
  • Page 30 210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 30 INSTALLATION 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.
  • Page 31: Filter.latches

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 31 FILTER INSTALLATION TABLE OF CONTENTS ACuAiR.mATRix:..AAF.FilTERS.ANd.AAF.FRAmES./.lATChES..................32 iNSTAllATioN.oF.2”.PlEATEd.PANEl.FilTERS........................ 34 iNSTAllATioN.oF.4”.PlEATEd.PANEl.FilTERS........................ 34 iNSTAllATioN.oF.Sh.SiNglE.hEAdEREd.Rigid.FilTERS....................35 iNSTAllATioN.oF.A.dh.doublE.hEAdEREd.Rigid.FilTER....................35 iNSTAllATioN.oF.hEPA.FilTERS............................39 FILTER LATCHES Use with a 2" pleated panel filter (prefilter) or with a single header (SH) rigid filter (final Filter), either one installed in a standard type 8 filter frame.
  • Page 32: Acuair.single.filter.application.(Non.hepa)

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 32 INSTALLATION ACUAIR SINGLE FILTER APPLICATION (NON HEPA FILTER) 4" Pleated 12" Rigid Final Filter Holding Clips to be used 2" Pleated Panel 12" Rigid Final Filter - Panel Filter - Double with Filter Styles Prefilter Single Header Style...
  • Page 33: Hepa.filter.application

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 33 HEPA FILTER APPLICATION Filter and Frame Description AAF Part Number JCI Part Number AcuAir HEPA Filter Frames Filter Frame Is Designated: Height X Width 24" X 24"-14 ga. Galvanized AAF 312-400-003 JCI 026-35789-001 24"...
  • Page 34: Installation.of.2".Pleated.panel.(Pre)Filters

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 34 INSTALLATION INSTALLATION OF 6. The filter should now be securely installed into the frame (see Figure 39). 2” PLEATED PANEL (PRE)FILTERS CAUTION Care should be taken to prevent contamination of the filter media prior to placement in the filter racks.
  • Page 35: Installation.of.sh.single.headered.filters

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 35 4. Insert the filter into the frame making sure that the pleats 3. The latch installation should now be complete. The latch are vertical. should now be “trapped” within the three (3) knockouts, but should be able to freely rotate.
  • Page 36: Installation Of Spring Latches

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 36 INSTALLATION Installation of Spring Latches 5 Insert the rigid DH filter into the frame. While holding the filter in the frame, grasp the loop on the end of the latch and 1.
  • Page 37: Hepa.filters

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION Page 37 HEPA FILTERS 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 GASKET GASKET SEAL DETAIL A...
  • Page 38: Start-Up

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 38 OPERATION c. Verify tightness of blower, motor, and sheave. Start-up d. Verify tightness of all motor mounting bolts. Before attempting to start up and operate any electrical 2. Belt Tension cooling equipment such as an AcuAir system unit, it is ®...
  • Page 39: Filters

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® OPERATION Page 39 its function in the system (relative to air velocity and static 7. Close the door on the front of the gas manifold. pressure requirements). 8. Open the manual gas valve external to the furnace. 5.
  • Page 40: Start-Up.after.prolonged.shutdown

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 40 OPERATION 24-Hour Run-In After 24 hours of operation under load, the following services should be performed: 1. Examine the unit for any unusual noise or vibration. 2. Readjust fan belt tension if required. START-UP AFTER PROLONGED SHUTDOWN It is imperative that maintenance personnel conduct a thorough start-up before running the unit after a prolonged...
  • Page 41: Daily.operation.and.routine.maintenance

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® MAINTENANCE Page 41 then follow his recommendations. Establish and follow a mAINTENANCE regular testing and treatment schedule. DAILY OPERATION AND ROUTINE MAINTENANCE Further need for cleaning or repair of an AcuAir system coil ®...
  • Page 42: Electrical.conduit.sealing.requirement

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 42 MAINTENANCE Finish and Sealing Remedy AcuAir units utilize a food grade caulk for air and water sealing ® In order to eliminate the collection of condensed water on the interior and exterior. The sealing on the units should inside electrical conduit, panels and instrumentation it is very be inspected and repaired as necessary.
  • Page 43: Fan.bearing.lubrication

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® MAINTENANCE Page 43 FAN BEARING LUBRICATION FAN SEGMENT-FAN MOTOR Standard fan configurations ship with fan bearings factory Keep the motor clean, dry and properly lubricated at all times. lubricated (ready for start-up). The fan should be turned off Blow dust and dirt out of windings periodically using low- and locked out to prevent accidental start-up of the fan during pressure (50 psig) air.
  • Page 44: Lubrication

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 44 MAINTENANCE Lubrication CAUTION Motor Bearing Lubricant - Bearing grease will lose its To avoid damage to motor bearings, grease must be kept lubricating ability over time. The lubricating ability of grease free of dirt.
  • Page 45: Inspecting.v-Belts.and.sheaves

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® MAINTENANCE Page 45 INSPECTING V-BELTS AND SHEAVES of contact. Ordinarily, a misalignment of more than one-half of one degree (one-eighth inch in one foot) will adversely affect Before a new set of V-belts are installed, inspect the condition belt life.
  • Page 46: Simple Tensioning Procedure

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 46 MAINTENANCE ALIGNMENT USING STRAIGHTEDGE (A) Straightedge touching sheaves at points indicated by arrows. ALIGNMENT USING STRING (B) Cord tied to shaft Cord touching sheaves at points indicated by arrows. Figure 54 – Sheave Alignment 4.
  • Page 47: Instructions.for.piezometer

    In the unlikely event that one of the brass fittings which is sweated to the Piezometer breaks loose from the Piezometer, Johnson Controls-Frick recommends that the unit undergo a simply remove that fitting and replace it with a straight thorough monthly inspection. The inspection should include, coupling fitting of similar construction.
  • Page 48: Recommended.maintenance.intervals

    SPARE PARTS RECOMMENDATIONS It is also advisable to reorder parts prior to taking existing spares from inventory. This policy helps prevents downtime Johnson Controls-Frick recommends that customers ® due to “forgotten” spare parts order placement. maintain an inventory of spare parts for the AcuAir air unit.
  • Page 49: Troubleshooting

    ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® MAINTENANCE Page 49 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...
  • Page 50: 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 will provide a basic control system review, basic troubleshooting training, and instruction regarding any AcuAir operator interface controls provided by Johnson Controls.
  • Page 51: 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.
  • Page 52: Start-Up

    210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 52 INSTALLATION - OPERATION - MAINTENANCE START-UP PERFORM THE FOLLOWING STEPS IN ORDER: Refer to safety standards Ensure all door latches are secured before starting.   1. Energize power to the unit disconnect switch. 6.
  • Page 53 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION - OPERATION - MAINTENANCE Page 53 Index Filter Latches, 31 Filter Section, 8 Actuators, 38 final filters, 39 Acu-Shield Roof Coating, 19 flanged ducts, 26 airborne contaminants, 41 flexible connector, 29 air-leakage, 26 foam kit, 22 Alignment, 45...
  • Page 54 210.100-IOM (MAR 14) ACUAIR HYGIENIC AIR UNITS ® Page 54 INSTALLATION - OPERATION - MAINTENANCE neoprene gasket, 12 Periodic Inspections, 41 Pieziometer, 47 plenum, 23 prefilters, 39 pressure gauge, 39 PRESTART-UP, 51 Recommended Maintenance Intervals, 48 reconnect seam, 15 reducing bushing, 29 Refrigerant Piping, 26 return piping, 28 roof curbs, 12...
  • Page 55 ACUAIR HYGIENIC AIR UNITS 210.100-IOM (MAR 14) ® INSTALLATION - OPERATION - MAINTENANCE Page 55...
  • Page 56 Form.210.100-iom.(2014-03) johNSoN.CoNTRolS Supersedes: 210.100-IOM (2013-10) 100 CV Avenue Subject to change without notice Waynesboro, PA 17268-1206 USA Published in USA • 03/14 • GUI 50 Phone: 717-762-2121 • FAX: 717-762-8624 www.jci.com/frick © 2014 Johnson Controls Inc. - ALL RIGHTS RESERVED...

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