Johnson Controls Frick AcuAir - User Manual

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.

Johnson Controls Frick AcuAir Specifications

General

Brand	Johnson Controls
Model	Frick AcuAir
Category	Air Compressor
Language	English

Summary

General Safety Guidelines

General Safety Guidelines

Safety guidelines for operating and service personnel.

Safety Symbols Explained

Symbols alerting readers to potential hazards and their meanings.

Document Changeability

Information subject to change without notice; verification required.

General Information

Safety Responsibilities

User responsibility for qualified personnel and adherence to safety procedures.

Warranty Information

Warranty Support Contact

Contact Frick Service for warranty support.

Pre-Installation Requirements

Training and Safety Considerations

Importance of experienced personnel and understanding the manual.

Site Layout Considerations

Locating the unit to minimize exhaust air recirculation and ensure airflow.

Field Piping Design Considerations

Requirements for supported and anchored field piping, not supported by the unit itself.

Installation

Receiving and Inspection

Inspecting units for damage and verifying all parts are present.

Storage Guidelines

Guidelines for short-term and long-term storage to maintain unit integrity.

Lifting and Handling Procedures

Procedures for safely lifting and handling AcuAir® unit sections.

Support Structure Information

Anchoring AcuAir® systems to suitable support structures like concrete or steel.

Loose Items Information

List of loose items shipped with the unit for reassembly.

Required Installation Tools

Required tools for completing the AcuAir® system installation.

Assembling Roof Curb

Steps for assembling a roof curb, ensuring it is level and properly sealed.

Installing Roof Curb

Procedures for installing a roof curb, ensuring a level and sealed connection.

Split Unit Reassembly

Instructions for reassembling split units to ensure proper performance.

Removable Lifting Lugs

Guidance on using and repositioning lifting lugs for unit sections.

Electrical Wiring and Piping

Installer's responsibility for reconnecting internal and external electrical/piping splits.

Performance Grade Connections

Reassembling Performance Series Split Units

Detailed steps for reassembling split units of the Performance Series.

Reconnection Attachment Installation and Sealing

Procedures for installing and sealing the unit's reconnection attachment.

Base Reconnect Seam Insulation (Performance Series)

Filling the base reconnect seam cavity with foam insulation.

Sealing the Performance Series Roof

Sealing the mechanical joint and applying Acu-Shield roof coating.

Food Grade Connections

Food Grade Reconnect Installation

Steps for installing the reconnect for food grade units, including bolting and sealing.

Applying Food Grade Roof Reconnect Finish

Applying roof reconnect finish after caulking is dry and surface is ready.

Base Reconnect Seam Insulation (Food Grade Series)

Injecting foam into the base reconnect seam of Food Grade units.

Foam Kit 15 Guidelines

Guidelines for using Foam Kit 15 for AcuAir unit base reconnect insulation.

Attaching Fresh Air Intake Plenum

Fresh Air Intake Plenum Attachment

Procedures for attaching the fresh air intake plenum and hoods to the unit.

Condensate Drain Trap Sizing

Condensate Drain Trap Sizing

Guidelines for designing and sizing condensate drain traps.

Drain Pan Construction

Details on AcuAir® recessed hygienic drain pans, materials, and depth.

Field Piping Requirements

General requirements for field piping, including thermal expansion and support.

Duct Connections

Duct Connections

Methods for making duct connections to the unit casing and collar openings.

Connecting Weather Hood to Fresh Air Opening

Connecting Weather Hood to Fresh Air Opening

Procedures for attaching weather hoods to the fresh air opening with caulking and screws.

Field Penetrations for Piping and Electrical Connections

Guidelines for making field penetrations for piping and electrical connections.

Filter Latches

Filter Latches

Information on filter latches and their usage with different filter types.

HEPA Filter Application

HEPA Filter Application

How HEPA filters are installed in hygienic air units for particle control.

Non-HEPA Filters in HEPA Frames

Installation of Non-HEPA filters within HEPA filter frames.

Installing 4-Inch Pleated Panel Filters

Installing Spring Latches for Panel Filters

Steps for installing spring latches for 4 in. pleated panel filters.

Installing Latches for Panel Filters

Procedures for installing latches for panel filters.

Installing Rigid DH Double-Headered Filter

Installing Spring Latches for DH Filters

Steps for installing spring latches for rigid DH double-headered filters.

Installing Latches for DH Filters

Procedures for installing latches for DH double-headered filters.

HEPA Filters

Installing HEPA Filter Frames

Procedures for installing HEPA filter frames and ensuring proper seal.

Operation

Unit Start-Up Overview

Initial steps and knowledge required before starting the unit.

Initial System Start-Up

Verifying the entire system before placing it online for the first time.

Pre-Start-Up Inspection

Verifying unit condition, conduit openings, drive assembly, and fan guards before operation.

Blower, Motor, and Drives Maintenance

Checking mechanical tightness, belt tension, and motor mounting.

New Belt Run-In Procedure

Procedure for running in new belts to ensure proper seating and extend life.

Filter Installation

Installing prefilters and final filters into their respective holding frames.

Cooling Coil Procedures

Procedures for handling cooling coils, evacuation, and support.

Gas Heat Start-Up

Step-by-step procedure for starting the gas heat system.

Gas Heat Shutdown

Steps for safely shutting down the gas heat system.

24-Hour Run-In

Services to perform after 24 hours of operation under load.

Start-Up After Prolonged Shutdown

Essential checks before restarting the unit after extended downtime.

Maintenance

Daily Operation and Routine Maintenance

Importance of inspecting, cleaning, and lubricating the unit regularly.

Maintaining the Coils

Visual inspection and cleaning of cooling and heating coils for optimal performance.

Maintaining the Dampers

General maintenance for dampers, including cleaning and lubrication.

Periodic Damper Inspections

Regular checks of automatic dampers to ensure proper function and control.

Damper Inspection Checklist

Minimum items to include in scheduled damper inspections.

Maintaining the Filters

Inspecting and replacing filters based on appearance or pressure drop.

Finish and Sealing

Inspecting and repairing unit sealing, using food grade caulk.

Electrical Conduit Sealing

Importance of sealing conduit openings to prevent moisture and damage.

Sources of Water or Ice

How water can enter electrical conduits and form ice.

Remedy for Water and Ice Collection

Sealing electrical conduit openings to prevent moisture migration.

Calibrating Temperature Sensors

Annual check of temperature sensor calibration using ice bath or infrared scanner.

Unit Cleaning and Sanitation

Procedures for frequent and thorough cleaning of the hygienic unit.

White Rust and Wet Storage Stain

Understanding and addressing white rust on galvanized steel surfaces.

Lubricating Fan Bearings

How to maintain lubricating ability and maximize fan bearing life.

Lubrication Interval and Quantity

Using tables to determine correct lubrication intervals and amounts.

Fan Segment-Fan Motor Maintenance

Keeping the fan motor clean, dry, and properly lubricated.

Mounting Hardware and Motor Base

Inspecting mounting hardware and the adjustable motor base.

Motor Condition (Visual)

Visually inspecting the motor for leaks, damage, dirt, and debris.

Motor Electrical Checks

Inspecting electrical terminations, fittings, clamps, and operating amperage.

Motor Bearing Lubrication

Using high-grade grease and following guidance for motor bearing lubrication.

Inspecting V-Belts and Sheaves

Inspecting V-belts and sheaves for wear and damage before installation.

Sheave Alignment Inspection

Verifying sheave alignment to prevent premature belt failure and bearing overload.

Replacing Belts

Steps for replacing belts, ensuring they are used as a matched set.

Tensioning V-Belts and Sheaves

Adjusting belt tension for optimal performance and longevity.

Simple Belt Tensioning Procedure

A procedure for tensioning belts using span length and deflection.

Monthly Service Inspection

Thorough monthly inspection of unit components.

Filter Inspection

Inspecting and replacing prefilters, intermediate, and final filters.

Unit Exterior Inspection

Inspecting unit exterior seams and repainting scratches.

Maintenance Intervals Schedule

Scheduled maintenance requirements for keeping units performing to specification.

Piezometer Operation and Maintenance

Operating the Piezometer

How the Piezometer operates to produce a pressure differential signal.

Maintaining the Piezometer

Keeping pressure pickup holes clear and checking tubing for wear.

Spare Parts

Spare Parts Recommendations

Maintaining an inventory of spare parts for immediate replacement.

Troubleshooting

Troubleshooting Symptoms and Corrections

Common symptoms and their probable causes and corrections.

AcuAir Factory Start-Up Assistance

Coordination Responsibilities for Factory Start-Up

Roles of parties involved in coordinating project start-up.

Factory Start-Up Assistance Support

Services provided by factory technicians, including testing and calibration.

Factory Start-Up Assistance Exclusions

Services NOT included in factory start-up assistance.

AcuAir Air Handler Prestart-Up Checklist

Prestart-Up Checklist: General Unit Inspection

Checklist items for general unit inspection before operation.

Prestart-Up Checklist: Fan Inspection

Checklist items for inspecting fans, sheaves, belts, and bearings.

Prestart-Up Checklist: Burners

Checklist items for verifying gas supply, pressure, and flue.