Johnson Controls Frick AcuAir Installation, Operation And Maintenance Instructions Download

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AcuAir

Hygienic Air Units

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

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.

Check www.FrickCold.com for the latest version of this publication.

Summary of Contents for Frick AcuAir

Page 1: ...laces 210 100 IOM JUL 2018 Dist 3 3a 3b 3c 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 Check www FrickCold com for the latest version of this publication ...

Page 2: ... This document is intended for use by owner authorized operating and service personnel It is expected that this individual possesses independent training that enables them to perform their assigned tasks correctly and safely It is essential that before performing any task on this equipment this individual must read and understand this document and any referenced materials This individual must also...

Page 3: ...Installing a 4 in pleated panel pre filters 35 Installing spring latches 35 Installing latches 35 Installing a rigid DH double headered filter 35 HEPA filters 37 Operation Start up 39 Initial start up 39 Inspection 39 Blower motor drives 39 New belt run in 39 Filters 39 Cooling coils 39 Gas heat start up 40 Gas heat shutdown 40 24 hr run in 40 Start up after prolonged shutdown 40 Maintenance Daily...

Page 4: ...210 200 IOM JUL 21 Page 4 Acuair Hygienic Air Units Installation Operation Maintenance This page is intentionally left blank ...

Page 5: ... Automatic control sequences CAUTION Users and installers of this equipment must be aware of all relevant safety procedures and information such as AMCA publication 410 90 Safety Practices CAUTION Never open an access door while air unit is in opera tion Warranty NOTICE For Warranty Support with the Frick AcuAir unit contact Frick Service at 717 762 2121 CAUTION A fan even though locked out electr...

Page 6: ...ation Maintenance Figure 1 Access door latch 1 25 1 50 LATCH FRONT VIEW LATCH SIDE VIEW DANGER WITH LOCK BOLT OR SCREW PRIOR TO OPERATION SECURE THIS ACCESS OR PROPERTY DAMAGE CAN CAUSE PERSONAL INJURY CONTACT WITH MOVING PARTS DISCONNECT AND LOCKOUT POWER BEFORE SERVICE ...

Page 7: ...ied and corrected before testing or placing the system back in operation Wet surface precautions Poorly maintained and wet ted 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 Correct safety precautions such as the use of insulating soles and gloves and a trained lookout...

Page 8: ...om any electrical enclosure to an ob ject is 48 in The installation of the AcuAir unit must be in ac cordance with the codes of the authorities having jurisdiction The AcuAir hygienic unit has sections under both positive and negative pressure with respect to ambient during normal op eration When piping the individual drain pan outlets to a com mon drain line AcuAir suggests individual p traps The...

Page 9: ...a level surface If the unit must be raised off ground supports under base channel and base channel cross supports at maximum interval of 5 ft 4 Rotate fan wheels by hand 90 every month Lightly lubricate bearings every 2 months 5 A 200 W light bulb needs to burn continually in each sec tion to prevent water condensation inside the unit 6 Inspect and ventilate each section every 2 weeks to prevent t...

Page 10: ...vy To prepare for safely lifting the air unit estimate the ap proximate center of gravity Internal placement of com ponents 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 dam age to the cabinet and protruding components during a lift The lugs are...

Page 11: ...t of the unit as provided on the order related document plus any operat ing 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 Frick suggests designing the structure for at least 110 of the ope...

Page 12: ...l unit split supports on units 150 or wider as represented below in Fig 7 Roof Curb Support 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 L egs to support the frame above the finished roof Number of legs and design by others ...

Page 13: ...00 IOM JUL 2021 Page 13 AcuAir Hygienic Air Units Installation ALTERNATE METHOD OF INTERMEDIATE SUPPORT LOCATED AT UNIT SPLIT S WHEN REQUIRED Required on units 150 or wider Figure 7 Generic roof curb support ...

Page 14: ...e 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 ac cordance with the local codes General split unit reassembly Units that are shipped in sections must be installed on an appropriate foundation and...

Page 15: ...te side As the unit settles the out of square racking caused during transit realigns 7 After the sections are drawn together and the recon nect flanges are aligned and attached apply two paral lel 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 washe...

Page 16: ... 4 Installing and sealing the reconnection attachment 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 4 Install the reconnection flange hardware starting from the middle of the bottom angle working around to the...

Page 17: ... the injection kit Take special note of the 30 s inactivity limit after which the injection nozzle may become permanently clogged Inject foam into the cavity at a rate of 3 bd ft to 4 bd ft for each linear foot of seam This means a 15 bd ft can of expanding foam fills between 4 ft to 5 ft linear of AcuAir reconnect seam INTERNAL RECONNECT AcuAir Performance Series Only 25 MINIMUM DIA PARALLEL CONT...

Page 18: ... 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 Figure 13 Split reassembly procedure for AcuAir performance series units only CAUTION Do not use silicone caulking on field reconnects or on shipping split covers NOTICE Only use caulking shipped with unit NOTICE Shipping split covers ship with the air handler installed to one s...

Page 19: ...rature is between 45 F and 108 F Below 45 F extra steps are necessary to keep the polyurethane caulking Acu Shield and metal reconnect surfaces heated for correct application during installation Contact Product Service for further direction Note Do not apply when inclement weather is imminent within a 24 hr period Do not apply to wet ice or snow covered surfaces 3 Before applying clean surface wit...

Page 20: ... 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 realigns 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 clam...

Page 21: ... 11 Inspect all splits to see if all electrical and piping con nections are complete and correct NOTICE Do not remove temporary roof supports and diagonal shipping supports until the split sections are com pletely reassembled Applying the AcuAir Food Grade roof reconnect finish 1 The mechanical joint between the unit sections must be bolted and sealed with polyurethane caulking before applying the...

Page 22: ...s imminent within a 24 hr period Do not apply to wet ice or snow covered surfaces 3 Before applying clean surface with wire brush or sol vent wipe which are not provided 4 Apply Acu Shield roof coating with a good quality syn thetic bristle paintbrush not provided 5 One quart applied at 45 ml is equal to a 3 in wide x 33 ft long section 6 Cure time varies with temperature and humidity Under normal...

Page 23: ...CAULK TYP JOINT OF TWO SECTIONS WITH FLAT SURFACES Inject Foam Prior to Installing Cover CAULK BASE SKIN BASE CHANNEL INTERNAL WALL FINISH BEAD OF CAULK C L SPLIT SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT Inject Foam Prior to Installing Cover SPLIT COVER Follow the instructions provided by the foam manufac turer for preparing the two part foam mixture and the injection kit Take special note of th...

Page 24: ... Ensure gun safety is on the roller must be locked to ward end of applicator 4 Pull yellow tab to remove black plastic valve lock Discard See Figure 22 5 Activate valves by pulling black strap up and insert strap into slit which are marked in yellow on back of box Hoses partially fill with chemicals 6 Hold unit upside down move roller to On position towards the hoses and dispense foam Adjust rolle...

Page 25: ...plenum into position mount the two brackets using the cap screws provided 3 Before 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 4 The plenum and hood assembly can be lifted using the lifting lugs provided on the top if the plenum 5 On the blank wall of the plenum is an acces...

Page 26: ...he unit 10 Replace the access panel ensuring that all screws are in place 11 When a set of detached hoods is shipped separately one hood requires a 1 in hole in the side for mount ing the fresh air temperature sensor Locate the hood nearest the sensor and electrical flex conduit Drill a 1 in hole and insert the sensor conduit probe and secure the j box to hold the assembly in position See the fol ...

Page 27: ...IS 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 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 CLAR...

Page 28: ...ified otherwise Figure 31 Condensate drain trap sizing Figure 32 Drain pan detail SLOPE RECESSED HYGIENIC OUTLET SLOPE MPT SLOPE AIRFLOW ACUAIR UNIT HOUSING REFRIGERANT CONNECTION STUB DRAIN DRAIN PAN HAT CHANNEL COIL SUPPORT COIL SUPPORTS Field piping requirements 1 General Every effort must be made in field piping to keep the stresses to a minimum on the coil connec tions a Allow for thermal exp...

Page 29: ...nsibility to pro vide 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 wa ter or brine can collect and freeze Pitch all piping away from the unit coil Install the p...

Page 30: ...ly seal any screw piping or electrical holes with appropriate sealant Self tapping screws are not weather tight Figure 35 Connection of weather hood s to unit Figure 36 Weather hood installation POLYURETHANE CAULKING SHEET METAL SCREWS HOODS Field penetrations for piping and electrical connections WARNING Use only metal cutting hole saws and or blades to make penetrations through panels Never use ...

Page 31: ...lled in a standard type 8 filter frame Use with a 4 in pleated panel pre filter in a smooth notch free style filter rack NOTICE When filters are supplied by others usually so are the filter clips Used to attach HEPA filters to holding frame HEPA Arm Filter Clip JCI P N 391 008 101 Galv JCI P N 391 008 100 Stainless L 12 Knock On Clip CF83Fs 4 Knock On Clip CA 04s C80 CA 04 Use with a 12 in rigid D...

Page 32: ...5 004 12 in SS knock on clip KOCH 122 708 012 Type 8 filter frames notchless style frames require the knock on clips above 12 in X 24 in 16 gauge galvanized KOCH 122 608 1224 12 in X 24 in 18 gauge stainless steel KOCH 122 618 1224 12 in X 24 in 18 gauge SS notchless KOCH 310 123 107 24 in X 24 in 16 gauge galvanized KOCH 122 608 2424 24 in X 24 in 18 gauge stainless steel KOCH 122 618 2424 24 in ...

Page 33: ...as above 24 x 24 x 12 DH KOCH 110 720 001 MERV 16 extended surface MiniPleat 12 x 24 x 12 DH KOCH 111 691 103DH 24 x 12 x 12 DH KOCH 111 691 103KDH 24 x 24 x 12 DH KOCH 111 691 101DH Table 5 Final filter dimensions non HEPA Multi Pleat XL8 HC Multi Pleat XL11 HC Double Header Rigid Filter DuraMAX 4V MiniPleat Note Unless specified otherwise filter dimensions are designated in width x height x dept...

Page 34: ... KOCH H64A 4X1 23 375 X 11 375 X 11 5 KOCH H79A 4X1 11 375 X 23 375 X 11 5 KOCH H60A 4X1 Width x height x depth in AcuAir part number MERV 13 Rigid with gasket downstream DS 24 X 24 X 12 DH KOCH 110 722 030K 12 X 24 X 12 DH KOCH 110 722 031K MERV 14 Rigid with gasket downstream DS 24 X 24 X 12 DH KOCH 110 720 030K 12 X 24 X 12 DH KOCH 110 720 031K NOTICE Non HEPA filters must be installed with the...

Page 35: ...ockouts but can freely rotate Repeat the installation process with the remaining latches 4 Rotate all of the latches outward and insert the SH filter into the frame Insert the bulk of the filter through the frame protruding out the backside Ensure only the header of the filter is contacting the flange of the frame 5 After the filter has been placed into the frame grasp the circular end of the latc...

Page 36: ...of the latch and pull it until it stretches over the header and rests into the pre drilled hole in the header of the filter see Figure 45 Repeat this with the remaining latches 7 Ensure the filter is securely installed into the frame Figure 45 Pull and fasten the spring latch in hole in the header of the filter CAUTION Take care to prevent contamination of the filter me dia before placement in the...

Page 37: ...s 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 before installing them in the AcuAir unit filter frames they become subjected to unnecessary contamination wand possibly long term hygienic compromise 2 In order for HEPA filtratio...

Page 38: ...210 100 IOM JUL 2021 Page 38 AcuAir Hygienic Air Units Installation This page is intentionally left blank ...

Page 39: ...list See Prestart up check form Blower motor drives 1 Mechanical tightness a Verify tightness of the fan bearing bolts b Verify tightness of the blower wheels to shafts c Verify tightness of the 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 hr of operation and again after 100 hr of o...

Page 40: ...g and burner firing Figure 47 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 Figure 48 AcuAir gas burner wrapper 24 hr run in After 24 hr of operation under load perform the following services 1 Exami...

Page 41: ...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 NOTICE Air units move air and airborne contaminants across the...

Page 42: ...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 make a thorough inspection of all conduit openings and any compromised openings resealed Perform follow up inspections as indicated on the suggested in Maintenance intervals Sources of water or ice Water may enter the inside of the electrical conduit and do...

Page 43: ...in layer of impermeable zinc carbonate The carbonate layer is what forms the long lasting passive coating that drastically slows down any fur ther reaction of the zinc and provides corrosion protection of the underlying steel When correctly formed the zinc carbonate layer is identified by a dull gray appearance If the zinc coating of new galvanized material is prevented from thoroughly drying and ...

Page 44: ...p with fan bearings factory lubricated ready for start up Turn off and lock out the fan to prevent accidental start up of the fan during lubri cation 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 Correct lubrication of bearings helps to assure maximum bearing life Generally lubricate bearings e...

Page 45: ...ation Motor bearing lubricant Bearing grease loses its lubri cating 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 You can help maintain lubricating ability if you implement the following guidance in your maintenance program Use a high grade ball...

Page 46: ... can substantially short en 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 mo tor failure and or shaft failure Verify sheave adjustment by placing a straight edge across the sheave faces so that it touches all four points of contact Ordinarily a...

Page 47: ... 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 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 does not slip during ...

Page 48: ...y event that the pneumatic tubing on the piezometer is damaged simply remove the damaged sec tion 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...

Page 49: ...nce requirements for keeping air handling units per forming to specification Scheduled the maintenance using the information in Table 14 Before performing any maintenance or inspection make certain that all power has been disconnected locked out and tagged correctly Table 14 Maintenance intervals Type of service Start up Weekly Monthly Every 3 months Every 12 months Inspect general condition of th...

Page 50: ...1160G02 QH6D flashcard V12 01 control panel Yes 649A1149G03 QH6D flashcard V3 20 SIP panel Yes 639B0115H03 DC power supply 24 VDC Yes 639B0115H02 DC power supply 12 VDC Yes 639B0115H01 DC power supply 5 VDC Yes Thermostats and sensors 111Q0280889 Supply fan airflow switch 1910 00 0 07 to 0 15 Yes 649A0998H04 Unit pressure preset 6 in Yes 639A0403H02 Room humidity and temperature sensor Yes 640A003...

Page 51: ...eam valve Direct fired burner doesn t light Check setpoint for heat Check OA lockout setpoint Ensure lockout is above OA temperature 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 temperature limit burner door switch Check to make sure outside air dampers are open and return damper...

Page 52: ...can work with you to determine the best available date that a factory technician can be at the job site Factory start up assistance includes the following support 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 Tes...

Page 53: ...ace Outdoor unit mounted within roof slope limitations where applicable Air hoods installed correctly 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 correctly Verify that all ductwork is complete and available for full airflow Unit...

Page 54: ... 43 gas manifold 40 gas shutoff valve 40 general maintenance 41 grease 44 grease fittings 45 grease relief plug 45 guards 7 H heater 40 HEPA 9 HEPA filters 37 hood 30 hoods 25 HVACR contractors 7 I inspection 39 inspection checklist 41 installer 14 intake hoods 25 J jack 15 L latches 35 lubrication 44 lubrication intervals 45 M mechanical tightness 39 motor bearing lubricant 45 motor bearings 40 N...

Page 55: ...210 100 IOM JUL 2021 Page 55 AcuAir Hygienic Air Units Installation Operation Maintenance This page is intentional left blank ...

Page 56: ...ge Page 14 Updated image callout Page 20 Removed Sanitary from heading Page 21 Removed Sanitary from heading Page 22 Updated image callout Page 23 Removed Sanitary from heading Page 26 Removed section Fan hold down spring isolator setup optional This was on page 25 in previous revision Page 28 Updated Figure 32 Page 30 Removed section Materials required and figure This was on page 29 in previous r...

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