S210-100 IOM/MAY2003

File: SERVICE MANUAL - Section 70

Replaces: S210-100 IOM/AUG 2000
Dist: 3, 3a, 3b, 3c

Installation - Operation - Maintenance

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Hygienic Air Handling 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.
S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 2 INSTALLATION, OPERATION, AND MAINTENANCE

Contents
Pre-Installation Requirements ...................................................................................................................... 3
Training & Safety Considerations ............................................................................................................ 3
Identification and Inspection of Shipment ............................................................................................... 3
Transit Damage Claims ........................................................................................................................... 3
Preliminary Siting/Layout Considerations ............................................................................................... 4
Preliminary Field Piping Design Considerations .................................................................................... 4
Installation Procedures ................................................................................................................................. 5
Installation Tools ...................................................................................................................................... 5
Foundation Information ............................................................................................................................ 5
Erecting the ACUair® SYSTEM ............................................................................................................... 6
Duct Work ................................................................................................................................................. 6
Electrical Wiring ....................................................................................................................................... 8
Drain Pan Piping ...................................................................................................................................... 8
Piping Requirements ............................................................................................................................... 8
Inlet Hood and Filter Assembly ................................................................................................................ 9
Start-up & Operation .................................................................................................................................... 10
Initial Start-up (for new ACUair® SYSTEM Units) ................................................................................. 10
Inspection ....................................................................................................................................... 10
Blower, Motor, Drives ...................................................................................................................... 10
Filters .............................................................................................................................................. 10
24-Hour Run In ............................................................................................................................... 10
Daily Operation ...................................................................................................................................... 10
Start-up After Prolonged Shutdown ....................................................................................................... 11
Recommended Maintenance Intervals ................................................................................................. 11
Spare Parts Recommendations ............................................................................................................ 11
ACUair® Maintenance ................................................................................................................................. 11
Maintenance Intervals ........................................................................................................................... 11
Recommended Spare Parts .................................................................................................................. 12
Filters ...................................................................................................................................................... 12
Lubrication ............................................................................................................................................. 13
Standard Motors ............................................................................................................................. 13
Special Motors ................................................................................................................................ 13
Fan Bearings ................................................................................................................................... 13
Blower Bearing Lubrication Guidelines ................................................................................................ 13
Drive Train .............................................................................................................................................. 13
Sheave Inspection .......................................................................................................................... 13
Sheave Alignment .......................................................................................................................... 13
Belt Replacement and Tensioning ......................................................................................................... 14
Blower Belt Tension Guidelines ...................................................................................................... 14
New Belt Run-in ..................................................................................................................................... 15
Coil Maintenance ................................................................................................................................... 15
Control Dampers Installation, Operation, and Maintenance Instructions ............................................ 15
Coil Assembly ........................................................................................................................................ 16
Finish and Sealing ................................................................................................................................. 16
Unit Cleaning and Sanitation ................................................................................................................ 16
Initial Start-up ......................................................................................................................................... 16
Monthly Service ..................................................................................................................................... 16
Troubleshooting ........................................................................................................................................... 18
ACUair® WARRANTY AGREEMENT .......................................................................................................... 19

SAFETY PRECAUTION DEFINITIONS

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
Indicates a potentially hazardous situation or practice which, if not avoided, will result in death or
serious injury.

Indicates a potentially hazardous situation or practice which, if not avoided, will result in damage to
equipment and/or minor injury.

NOTE: Indicates an operating procedure, practice, etc., or portion thereof which is essential to highlight.
 ACUair® HYGIENIC AIR HANDLING UNITS
INSTALLATION
Preinstallation Requirements
TRAINING & SAFETY CONSIDERATIONS
The ACUair® precision-engineered hygienic air handling
systems provided by YORK Refrigeration Systems utilizes
the finest in HVACR materials and corrosion protection to
deliver dependable, consistent, and accurate control of tem-
perature and humidity in process room air steams. This
manual provides the information needed for safe installa-
tion, operation, and maintenance. Close attention to the
instructions and guidelines provided will ensure the long-
est possible system life and dependable, consistent
performance.
Before installing, operating, or
maintaining the system, it is recom-
mended that only experienced
HVACR contractors, operators, and maintenance labor
be used (in conjunction with formal training on the
ACUair® system’s design and features). Reading and un-
derstanding of this manual should serve as the mini-
mum 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 pro-
cedures may require working at elevations, enclosed space
entry, or use of hand and power tools. Taking these consid-
erations into account along with the hygienic nature of
ACUair® applications, it is clear that safety should always
be the top priority.
Frick recommends that every ACUair® system user ana-
®
lyze 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 recom-
mended for inclusion in every client’s ACUair® system safety
plan/requirements:
NOTE: Configure all power switches and controls to pro-
vide 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® sys-
tem. 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
manway/door off/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 in-
vestigated (and apparent discrepancies corrected) before
testing or placing the system back in operation.
Wet Surface Precautions – Poorly maintained/wetted ma-
chinery requires care to avoid electrical shocks from inad-
equate/loose field wiring/connections. All personnel must
S210-100 IOM
Page 3
lock out and tag machinery before working on the unit.
Proper safety precautions such as the use of insulating
soles/gloves and a trained “lookout buddy” are indispens-
able. Ice formation in cold weather can present fall/slip haz-
ards. Icing safety procedures should be mandatory when
the daily ambient temperature falls below 40°F.
ACUair® systems typically serve in a continuous-duty ca-
pacity and must be properly sited, installed, and connected
in the field (by others) to appropriately sized and installed
wiring for electrical power/controls, air ducting, refrigerant
lines, and fuel piping. The engineering plans, piping lay-
outs, etc. for all peripheral “field” work should be detailed in
accordance with local/governing codes and the best indus-
try 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.
IDENTIFICATION AND INSPECTION OF
SHIPMENT
Upon arrival of the ACUair® shipment, the system should
not be signed for until it is carefully checked against the bill
of lading to ensure that all shipping crates and cartons have
been received. Any items that appear to be missing should
be noted on the shipping papers. Damage claim protocol
generally requires that receiving personnel immediately
notify an appropriate transportation company representa-
tive for inspection and reporting form execution. Frick / ®
ACUair® should also be notified of any claims made.
The following system components should be inspected:
• Blower Sheaves, Belts, Bearings/Supports, Shafts, And
Fan-Wheel
• Coil(s), Gas Train, Control Panels, Sensors, And Air Lou-
vers/Actuators
• Filters And Other Parts Shipped Loose Inside The System
Parts shipped loose include filters and any other miscella-
neous items that need to be installed in the field (by others).
These items will likely be shipped in sealed box(es) that is/
are secured inside the ACUair® system. Open each of the
operating “manway” access doors to locate all of the “loose
item” packages.
All ACUair® systems are identified by a nameplate perma-
nently attached to the system. Figure 1 - ID Plate Informa-
tion shows a copy of the ID plate as supplied with the system.
TRANSIT DAMAGE CLAIMS
The unit should be carefully inspected for shipping dam-
age. The ACUair® system owner’s authorized agent who
signs for the shipment is responsible for making damage
claims (per ICC requirement). Request immediate inspec-
tion and form execution by the agent of the carrier.
Contact the Frick /ACUair® parts and warranty department
®
to report damage claims. Prompt/timely reporting and ad-
equate documentation will likely help significantly in the
reporting process.
NOTE: When inquiring about the system or ordering re-
pair parts, provide the MODEL and SERIAL NUMBERS
from the data plates. See Figure 1 - ID Plate Information.
S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 4 INSTALLATION

Sufficient space 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 or structures/equipment.

For other minimum spacing requirements see Figure 2 for

examples showing ACUair® system(s) installed next to
single/multiple walls.

PRELIMINARY FIELD PIPING

Figure 1 - ID Plate Information
PRELIMINARY SITING/
LAYOUT CONSIDERATIONS
All ACUair® systems must be located to minimize the effect
of exhaust air recirculation. Recirculated exhaust air can
significantly derate an ACUair® System’s capacity. It is the
DESIGN CONSIDERATIONS
All ACUair ® systems require
strongly supported and properly
anchored field piping. NO field pip-
ing 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 sys-
tem design engineer should provide final field-piping
plans and specifications.
Before finalizing piping installation plans, it is recommended
that related plans for system/plant expansion be discussed
with your field piping/system designer and Frick /ACUair®
®

owner’s responsibility to properly locate each system and/ sales representative. Incorporating appropriate pipe open-
or consult with a qualified engineer before laying out struc- ings/sizes now (for existing and future needs) allows for
tural/foundation supports and installing the ACUair® system. easier installation in the future.

NOTES:
1. THE MINIMUM DISTANCE FROM THE
EXHAUST FAN HOUSING TO ANY OBJECT
IS ONE FAN WHEEL DIAMETER. IF THE
OBJECT IS ANY CLOSER THE FAN BLAST
COULD DAMAGE THE OBJECT.
2. THE MINIMUM DISTANCE FROM AN
ACCESS DOOR, IN THE OPEN POSITION,
TO AN OBJECT IS THE DOOR WIDTH, I.E.
24", PLUS 8").
3. THE MINIMUM DISTANCE FROM ANY
ELECTRICAL ENCLOSURE TO AN OB-
JECT IS 48". ACUair FEELS IT WOULD BE
ADVISABLE TO CHECK WITH STATE AND
LOCAL ELECTRICAL CODES.
4. A MINIMUM OF 36" IS NECESSARY TO
ALLOW FOR PROPER TRAPPING OF
DRAIN PIPES ON EITHER SIDE OF THE
UNIT.
5. IT IS ACUair's ADVICE TO CONSULT
THE PIPING 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.
6. AS WITH ANY LARGE EQUIPMENT
PLACEMENT CONSIDERATION OF MAIN-
TENANCE, SERVICE AND PART/COMPO-
NENT REPLACEMENT SHOULD BE AL-
LOWED WHEN DESIGNING SPACE FOR
THE UNIT.

Figure 2 - ACUair System-to-Wall Spacing Requirements

 ACUair® HYGIENIC AIR HANDLING UNITS
INSTALLATION
Installation Procedures
NOTE: The following instructions are not intended to re-
place the service of a mechanic, skilled and experienced
in the installation or repair of ventilation and air condi-
tioning equipment. It is only to acquaint a skilled service
person with ACUair® HVAC equipment.
Installation of an Frick /ACUair® system involves construct-
®
ing heavy foundations and/or structural steel supports as
well as erecting and anchoring the system. Frick /ACUair®
® •
strongly recommends that a qualified, bonded, and insured
mechanical general contractor be used to perform this heavy
structural work.
To facilitate crane use, it is advisable to clear and secure
the designated access area a day in advance to ensure
smooth/safe operations the day of the lift.
Some units have an unbalanced
load – extreme care should be
taken during initial handling to pro-
vide for a balanced load. Once the ACUair® system sec-
tions are set and secured in position, the ACUair® SYSTEM
must be secured with permanent anchors to an appropri-
ate foundation.
During construction, survey the project site periodically to
ensure that no unattended ACUair® SYSTEM components
or contractor materials/tools remain unsecured. Electrical
must be made safe against unauthorized site visitors, van-
dalism, or weather.
Figure 3 - Support Method
S210-100 IOM
Page 5
INSTALLATION TOOLS
To complete the installation of an ACUair® air handling sys-
tem, the following tools are required:
• Drift pins
• 8-foot straight edge
• Level
• Assorted open-end wrenches
• Socket set
Belt tension gage
• Caulk Gun
• Tape measure
FOUNDATION INFORMATION
ACUair systems are shipped in two or more sections. These
®
sections must be anchored to suitable “footings” - 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. Support “footing”
and anchoring requirements will vary with live loads (expected
snow/ice buildup) seismic, and wind loading.
See Figures 3 and 4 for ACUair® unit support methods.
If the support “footings” are in the form of two steel beams,
each should be sized in accordance with standard engi-
neering practices. Structural design should account for 55%
of the operating weight of the system as a uniform load on
the beam, allowing for a maximum deflection of 1/360 of the
length, not to exceed 1/2 inch.
Structural beams need to be shimmed level before final
anchoring. NOTE: Shims between the beams and the sys-
tem should not be used, as this will not provide adequate
support.
S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 6 INSTALLATION

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.

Figure 4 - Support Method Alternative

ERECTING THE ACUair SYSTEM ® the section split should be caulked and then the U-channel
As mentioned above, the first ACUair® section is hoisted
into place. Following this procedure, the remaining sec-
tions are hoisted into position, located, and bolted together.
Note: lifting-cable length is critical as shown in the rig-
ging of two sections in Figure 5 Assembly and Place-
ment Instructions.
ERECTION NOTES:
• For Extended Lifts, Use All Lifting Points and Safety Slings.
For Final Placement, Use All Lifting points.
• Use Spreaders and Blocking To Protect the Flanges of
the Casing and Prevent Caving In Sides.
•· All safety precautions should be vigilantly enforced while
crane is on site. Only properly trained members of the
crane’s crew should handle hook cables, slings, spread-
ers, etc.
Care should be taken to avoid handling or shock due to
dropping of the ACUair® unit. NEVER push or pull the unit.
For lifting, slings must be provided with the spreader bars
to prevent damaging the housing of the unit. All rigging
materials are to be provided by others. The unit must be
lifted by all four lifting lugs on each section.
If the unit is to be handled other than
with the lifting lugs, it must be done
only using the perimeter base of the
unit. Extreme caution must be used so as not to damage
the underside of the air-handling unit.
Some units have an unbalanced
load. Extreme care should be taken
on initial handling of the unit to make
sure the load is properly balanced.
Once the sections have been bolted together, both the interior
and exterior seams of the section splits should be completely
caulked water and airtight. The unit is supplied with a U-chan-
nel, which goes across the top of the section split. The top of
placed on top of the caulk and section split. The U-channel is
then self drilled to the upright flanges of the section split. Caulk
the ends of the upright section and the U-channel.
Unit Section Splits
Some units are shipped in two or more sections, and have
a section split which must be properly prepared and sealed
to maintain the integrity of the unit casing. Prior to installa-
tion, one of the section splits must have the factory supplied
gasketing installed on the face of the section split.
The unit sections must be pulled tightly together before
final installation. Using the lifting lugs, with a chain or cable
puller, is an excellent way to slide the sections together.
NOTE: Do not use the bolting flanges on the interior of
the unit to draw the unit sections together. Once the unit
sections have been pulled together, bolt the internal sec-
tion split flanges together using the factory supplied bolts,
washers, and nuts.
Access for Service
ACUair® units have access doors on the units. The mini-
mum of one door width, 18-24 inches, must be available on
the service door side of the unit for maintenance and ser-
vicing. Ideally, a space the width of the unit should be avail-
able, on one side of the unit, for possible heating and cool-
ing coil removal.
In addition, most ACUair® units have an electrical control
panel located on the same side as the doors. By code, this
door must open at least 90°.
DUCT WORK
All duct work for the ACUair® units must be made and in-
stalled in accordance with all State and local codes and
acceptable industry standards. In all applications of the
ACUair® units, the duct work must be a type that is clean-
able. The duct work should be taped and sealed so that it is
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
INSTALLATION Page 7

Figure 5 - Assembly and Placement Instructions

Figure 6 - Connecting Unit Sections

S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 8 INSTALLATION
completely water and air tight. The duct work must be insu-
lated on the exterior of the unit. If the duct work is located on
the roof, the insulation must be totally weatherproofed. The
top of the duct work should also be pitched, for water runoff,
if the unit is located on the roof.
If the duct work is located inside of the controlled area, it
must be of a double wall construction. The exterior of the
insulation must be covered with a washable, non-
deteriorating type material.
All duct work must be of a cleanable type design. Duct work
must be complete with access and inspection ports in stra-
tegic locations. All interior components within the duct, such
as dampers and turning
ELECTRICAL WIRING
All field wiring on the ACUair® unit must be in accordance
with National Electric Code and State and local codes. The
control panel is located on the exterior of the ACUair® unit.
Before wiring the unit, make certain
that the electrical characteristics
stamped on the unit motor, control
transformer and that shown on the wiring diagram agree
with the available power source.
A terminal strip is provided for simplified control wire hookup.
Refer to the unit wiring diagram for proper control wiring. It
is essential that all controls are wired in accordance with
the wiring diagram and it is mandatory that all safety con-
trols are wired and operational. The manufacturer’s war-
ranty is revoked when modifications are made in the wiring
control system without factory approval.
Figure 7 - Duct Attachment
When units are shipped in two or more sections, some of
the factory wiring is disconnected for shipping purposes. All
wiring is of a cable design and all leads are marked with the
terminal connection. Once the unit sections have been
pulled together, the lead should be fed into the control panel
and reconnected to the pertinent terminal. The entrance
into the control panel should then be sealed watertight us-
ing appropriate conduit seals and packing material.
All conduit connections should be brought in to the side or
bottom of the control cabinet, NEVER THE TOP, due to po-
tential leaking.
DRAIN PAN PIPING
If the unit is equipped with a cooling coil, the cooling coil
drain pan should be completely trapped with a minimum of
a four inch water seal. The drain pans in the other sections
are primarily used for cleaning and sanitizing purposes.
Therefore, under normal circumstances, they can be sim-
ply capped and opened only during the cleaning cycle. If all
of the drains are to be piped, each must have its own sepa-
rate trap.
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.
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
INSTALLATION Page 9

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 for a
maximum operating pressure of 150 PSI. It is recommended
that the steam pressure be reduced to 15-50 PSI or lower
for maximum steam coil life and optimum control operation.
3. Refrigerant Piping – When cooling coil is supplied, all
refrigeration piping must be installed in accordance with all
state and local codes and standard industry practices.
Please refer to the manufacturers refrigerant piping dia-
gram for specific information.
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 checked and secured to prevent
wear or vibration at all operating conditions.
4. Evaporator Coils – The evaporator coils are tested for
150 PSI operating pressure. It is the contractor’s and/or
customer’s responsibility to provide controls and reliefs on
the system to prevent refrigeration pressures from becom-
ing higher than the tested operating pressure.
Halocarbon refrigeration coils have
not been evacuated or totally dried
at the factory. It is the customer’s/
contractor’s responsibility to provide adequate evacua-
tion of the evaporator coil and ensure that the coil is dry
and water free before start-up of the system.
5. Water or Glycol Coils – It is essential that the piping for
the system be done so that all lines can be drained and so
that there are no traps or pockets on the system where
water or glycol can collect and possibly freeze. All piping
should be pitched away from the unit coil plus the piping
should be made so that the coil can be filled with antifreeze
solution during freezing weather.
INLET HOOD AND FILTER ASSEMBLY
The outside air inlet hoods for some of the units are shipped
separately for field mounting.
ACUair® units can have two different varieties of inlet hoods.
Refer to the unit specific drawing to determine which type is
supplied.
The hood is assembled as shown in Figure 8.

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Figure 8 - Optional Hood Assembly

S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 10 OPERATION
Start-up & Operation
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 handler) is an engineered
heat transfer device that provides some or all of the listed
functions: cooling, dehumidification, pressurization, filtra-
tion, heating, exhaust, and condensation control. Each unit
is engineered and designed for the specific application.
Safeties and controls vary with each ACUair® SYSTEM in-
stallation and may be interfaced with ancillary equipment
or system controls. All operators should be thoroughly
trained in an integrated cooling system’s sequence of op-
erations and safeties.
INITIAL START-UP
(FOR NEW ACUair SYSTEM UNITS)
® On units equipped with final filters, a final filter pressure
After installation of the ACUair® SYSTEM unit, controls, and
necessary ancillary/auxiliary equipment, the entire cooling
system should be prepared before placing the ACUair® SYS-
TEM unit on-line for the first time. Specifically, the following
prestart measures must be completed satisfactorily to en-
sure readiness of the ACUair® SYSTEM.
NOTE: Do not attempt any inspection or maintenance
unless the electrical supply has been completely dis-
connected and locked out.
Inspection
Do not start the unit until the following inspections prove
operational readiness. Avoid accidents or equipment fail-
ure by rectifying any unsatisfactory condition.
• Inspect general condition of unit, e.g., structural integrity,
anchors/supports, etc.
• Confirm drive assembly condition and alignment of mo-
tor, bearings/collars, and fan/shaft.
• Confirm proper belt condition and tension. (See Mainte-
nance Section)
• Check fans and guards for obstructions.
• Check fan(s) for correct rotation and electrical hookup.
• Understand and prepare for first 24 hour operation mea-
sures 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. Check tightness of fan bearing bolts.
b. Check tightness of blower wheels to shafts.
c. Check tightness of blower, motor, and sheave.
d. Check tightness of all motor mounting bolts.
2. Belt Tension
a. Adjust belt tension if slipping is evident.
b. Check belt tension after 50 hours of operation and
again after 100 hours of operation.
ACUair® SYSTEM fan motors are available for variable fre-
quency drive. A high-quality, pulse-width-modulating drive
with proper precautions against voltage spikes allows the
motor to be run as low as 20HZ. This will provide part load
capacity by reducing unit airflow.
Filters
The filters for the ACUair® unit are shipped in their original
cartons. The unit includes the necessary filter frames and
filter clips. The filter clips are shipped tie wrapped to the
frames. 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 filter sec-
tions have been installed, the final filter section and the
supply air duct work should be cleaned and sanitized.
gauge is shipped mounted. The high-pressure tube is con-
nected to the gauge at the factory. The open port on the
gauge should then be piped to the pilot tube that needs to
be field installed in the ductwork downstream of the final
filters using the tubing supplied.
24-Hour Run In
After 24 hours of operation under load, the following ser-
vices should be performed:
1. Check unit for any unusual noise or vibration.
2. Readjust fan belt tension if required.
DAILY OPERATION
The unit should be inspected, cleaned, and lubricated on a
periodic basis. The required services and recommended
frequency for each 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 “rough” log should be made once each shift.
Any notations should be entered as they occur (or internal
policy dictates). It is essential that the maintenance man-
ager examine notations (from the previous 24 hours) on a
daily basis.
As safety/weather dictates, a visual check of the ACUair®
unit should be made once each shift (daily at a minimum) to
check operating conditions. Unusual leaks, noise, vibra-
tion, part damage/failures, or vandalism should be logged
immediately. Corrective action should be initiated immedi-
ately as operations permit - or ensuing service scheduled.
Associated equipment should also be part of the daily op-
erational checks for the ACUair® SYSTEM unit. In particular,
filtration performance is important to satisfactory and prob-
lem-free ACUair® SYSTEM unit operation.
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
OPERATION, MAINTENANCE Page 11

START-UP AFTER PROLONGED SHUTDOWN
Since the ACUair® SYSTEM is exposed to freezing condi-
tions and other natural stresses, it is mandatory that main-
tenance personnel conduct a thorough start-up before run-
ning the unit after a prolonged shutdown.
At minimum, the following checks must be preformed:
6. Check the voltage and current of all three legs of the fan mo-
tors. 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 check for proper rotation as indi-
cated by sticker on unit.

1. Clean any debris from guards, fans, eliminators, heat

transfer coils, and filters.
2. Turn the fan(s) by hand to ensure rotation without ob-
struction.
3. Check 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 bear-
ings. 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.
ACUair® Maintenance
MAINTENANCE INTERVALS
Maintenance of the ACUair® SYSTEM is relatively easy if suf-
ficient consideration is given to the minimum maintenance
requirements for keeping air handling units performing to speci-
fication. 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

EVERY 3 EVERY 12
TYPE OF SERVICE START-UP WEEKLY MONTHLY MONTHS MONTHS
Inspect General Condition of Unit X X
Clean debris from unit X X X
Check condition of prefilters X X X
Check pressure drop of final filters X X X
Check drains X X
Inspect heat transfer section X X
Lubricate damper bearings X X
Check and adjust fan belt tension X X
Check burner operation/safties X X
Check unit for unusual noise or vibration X X
Check fan bearing locking collars X X
Check motor voltage current X X
Lubricate fan shaft bearings X X
Lubricate motor base adjusting screws X X
Lubricate the fan motors X X
Check fan for rotation without obstruction X X
Check fan for proper rotation X X
Inspect protective finish X X X
Inspect/adjust damper linkage X X

SPARE PARTS RECOMMENDATIONS
ACUair® recommends that customers maintain the follow-
ing spare parts “in stock” for the ACUair® SYSTEM air han-
dling unit. By maintaining this inventory of spare parts,
change-out requirements can be immediately satisfied dur-
ing preventative maintenance inspections.
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 each part is
listed in the following Recommended Spare Parts List.
S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 12 MAINTENANCE

RECOMMENDED SPARE PARTS* - CURRENT DESIGN

DESCRIPTION FRICK P/N IMECO P/N QTY
QUANTUM™ CONTROL:
Switch Differential Pressure 111Q0280889 0016600453 1
Output Module 240 VAC 111Q0281061 0016600454 1
Input Module 90-140 VAC 333Q0000116 0016600455 1
Relay 120 VAC DPDT 333Q0000194 0016036314 1
Base For DPDT Relay 333Q0000195 0016036315 1
DC Power Supply 640B0060H01 0016600456 1
DC Power Supply 640B0064H01 0016600457 1
Switch Differential Pressure (Unit High Pressure) 649A0998H02 0016600458 1
Fuse, 2A (M-O-A Switch Module) 333Q0001738 0016038016 4
DIRECT-FIRED BURNER:
Flame Relay (for > 2.5 MBTUH burner) — 0088729 1
Flame Relay (for < 2.5 MBTUH burner) — 0088730 1
Purge Card — 0088731 1
UV Flame Amplifier — 0088732 1
Flame Rod Amplifier — 0016040725 1
UV Scanner — 0088733 1
UNIT:
Direct-Fired Burner Air flow Switch 642A0015H01 0016032305 1
Temperature Sensor 640A0035H01 0016022326 2
Smoke Detector (standard on direct-fired units, optional on all others) — 0016037501 1
Humidity Sensor (when ordered as an option) — 0016037402 1
Ammonia Sensor (when ordered as an option) — 0016037507 1
Actuator (return/outside air) — 0016022701 1
Actuator (exhaust fan) — 0016022704 1
Prefilters 24 x 24 x 2" — 0016016600 See Below
Prefilters 24 x 12 x 2" — 0016016700 See Below
Final Filters 24 x 24 x 12" — 0016017009 See Below
Final Filters 12 x 24 x 12" — 0016017012 See Below
NOTE: Fan Belts, Fan Bearings, Fan Bushings, Damper Motors, and Fuses are application specific. Refer to the Spare Parts
List supplied by model & s/n, or contact YORK Refrigeration, Dixon, IL.

FILTERS
MODEL and QUANTITY
TYPE SIZE (in) IMECO P/N AA-10 AA-15 AA-20 AA-30 AA-40 AA-50 AA-60 AA-70
Prefilters 24 x 24 x 2 0016016600 4 6 8 12 15 20 28 28
24 x 12 x 2 0016016700 — — — — 3 — — —
Final Filters 24 x 24 x 12 0016017009 4 6 8 12 15 20 28 28
12 x 24 x 12 0016017012 — — — — 3 — — —
NOTE: These lists are based on one unit. When stocking for more than one unit, the quantity should be adjusted to meet
your individual requirements.
FILTER REPLACEMENT SCHEDULE
Filters
The prefilters, intermediate filters (if applicable), and the Dust Collector Inter-
Filters and mediate Final
final filters (if applicable) are shipped in their original car-
Date 30% Prefilters Filters Filters
tons. The filter frames are factory installed in the unit, and
January X X
the correct filter clips are attached to the filter frames. After February
the unit is completely installed, the filters should be installed March X
in their respective frames. After installation, the final filter April
section and the supply air duct work should be cleaned and May X
sanitized. June X
July X X X
On units that have the final filters mounted directly in the August X
discharge opening, some field mounting of the final filter September X
gauge is required. After the unit and the duct work is com- October
pletely installed, the factory supplied pilot tube should be November X
December
mounted in the supply ductwork and piped to the gauge.

The Filter Replacement Schedule is provided as a guide- spected at regular intervals. The filters should be replaced if
line for filter replacement. The filters should be visually in- they appear excessively dirty or if they appear to be dam-
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
MAINTENANCE Page 13

aged in any way. The prefilters should be changed if they DRIVE TRAIN
become wet. Failure to follow a filter maintenance schedule
with the factory-specified filters can lead to higher operat- Belt tension should be checked every month as described in
ing costs, reduced system performance, and contaminated Belt Tensioning and Replacement section. The sheaves
air entering the space. should be tight on the shafts and should be aligned properly
to minimize belt wear. The belts should be checked for wear
Filters should be ordered from the Baltimore Parts Cen- along the edges, as any irregularity will cause vibration.
ter. Phone:800-336-7264; Fax: 800-976-1613; E-mail:
baltimore.parts@york.com. Sheave Inspection
Check the sheaves for proper alignment, excessive corro-
LUBRICATION
sion, and wear or damage. Also, check the belt for exces-
Standard Motors sive heat. If the belt is too hot to touch, then the sheaves
may be damaged or need aligning.
Standard ACUair® fan motors are specifically designed for
this application to be maintenance free and no greasing is If the sheaves have excessive corrosion or are worn or
required. Standard motors are furnished with vent connec- damaged, they should be replaced. Check for sharp edges
tions to prevent condensation. Please make sure the vents from wear or pitting of the grooves from corrosion. Either
are not obstructed. Replacement motors are available from condition will promote belt wear and increase turnover.
ACUair ®. Part numbers can be found on the motor Groove gauges are also available to make it easy to see if
nameplate. the grooves are worn. If more than 1/32” of wear can be
seen, the sheave should be replaced.
Special Motors
Sheaves for the motor and fans are designed for this spe-
On occasion, special motors (i.e. two-speed, Chem Duty,
cialized application and are available from ACUair® (do not
etc.) may be specified. These motors must be maintained
substitute).
per the motor supplier’s recommendations and may require
external lubrication lines and special grease. NOTE: The Alignment of sheaves is extremely important for proper belt
grease for special motor bearings and the fan bearings installation. The sheaves are aligned at the factory, but should
may not be compatible. Please check the lubrication la- be rechecked when new belts are installed. Use a straight
bel on the unit. edge to check alignment. Misalignment will show up as a
gap between the outside face and the straight edge. Two
Fan Bearings
conditions for misalignment exist, angular and parallel.
BLOWER BEARING LUBRICATION GUIDELINES
To check both parallel and angular alignment, refer to Fig-
Recommended Lubrication Schedule (in Months)
ure 9 and follow these instructions:
Bearing Bore Diameter in Inches
1. While placing a straight edge across the top of both
11/8" - 15/8" - 2" - 211/16" - 37/16 -
motor and fan sheaves, check for four points of contact.
Fan RPM ½" - 1" 1½" 15/16" 2½" 33/16" 315/16"
To 500 6 6 6 6 5 4
500 - 1,000 6 6 6 5 4 3
1,000 - 1,500 5 5 5 4 3 2
1,500 - 2,000 5 4 4 3 2 1
2,000 - 2,500 4 4 3 2 1 -
2,500 - 3,000 4 3 2 1 2 -
3,000 - 3,500 3 2 2 2 - -
3,500 - 4,000 3 2 1 - - -
4,000 - 4,500 2 1 1 - - -
4,500 - 5,000 2 1 - - - -
If unusual environmental conditions exist - temperatures
below 32°F or above 200°F, moisture or contaminants -
more frequent lubrication is required.
Add grease slowly with a handgun until a slight bead of
grease forms at the seal. Be careful not to unseat the seal
by overlubricating.

A high quality lithium based grease conforming to NLGI

Grade 2 consistency, such as those listed below, should be
used:

Mobil 532 Texaco Multifak #2

Mobilux #2 Texaco Premium RB
B Shell Alvania #2 Unirex N2

Figure 9 - Sheave Alignment

S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 14 MAINTENANCE

2. If a four-point contact is achieved, skip to the belt
tensioning section.
3. To adjust for parallel misalignment, adjust the motor or
fan shaft sheave.
BELT REPLACEMENT AND TENSIONING
Replacement
When it is necessary to replace the belt, follow these steps:
1. Lock out and tag the starter.
2. After the power has been turned off and the motor guard
removed, loosen the motor mount adjustment nuts.
3. Move the motor until there is enough slack in the belt so
it can be removed without prying.
4. Remove the old belts and inspect for unusual wear. Ex-
cessive wear may indicate problems with alignment or
sheave damage.
5. Use replacement belts from the factory to ensure a proper
belt equivalent.
6. Inspect other drive components such as bearings and
sheaves for alignment, wear, lubrication, etc.
7. Clean the sheaves of debris before installing the new
belt.
8. Install the new belt, align the drive, and tension the belt
according to the procedures outlined here.
Tensioning
Proper belt tension is very important to ensure maximum belt
life. If too little tension is applied, the belt will slip. Too much
tension can reduce belt and bearing life. It is not recom-
mended that belt dressing be used when belt slippage oc-
curs as this will damage the belt and cause premature fail-
ure.
1. Decrease the center distance between the sheaves (by
turning the tensioning nut counter clockwise) so the sheaves
are somewhat loose.
2. Apply tension to the belt by turning the tensioning nut
clockwise.
3. Operate the drive a few minutes to seat the belt in the
sheave grooves. Observe the operation of the drive during
start-up. A slight bowing of the slack side of the drive indi-
cates proper tension. If the slack side remains taut during
the peak load, the drive is to tight. Excessive bowing or
slippage indicates insufficient tension. If the belt squeals as
the motor comes on, it is not tight enough. The drive should
be stopped and the belt tightened.
4. NOTE: Do not overtighten the drive. If the above pro-
cedure still results in the belt squealing, but the belt is
still taut on the slack side, a more precise method of
testing the belt tension must be used. In this case, use a
belt-tensioning gage available from V-belt drive manu-
facturers or from ACUair®.
All belt tension measuring devices should include operating
instructions. These are spring-loaded devices that use a hook
to place tension on a stationary belt. Tension readings are
observed at a point where the belt deflects a predetermined
distance. Tension is usually applied at the belt span’s midpoint
as measured between the tangent of belt contact for both
sheaves. Reference Blower Belt Tensioning Guidelines table.

BLOWER BELT TENSION GUIDELINES

DIAMETER OF STANDARD WRAPPED S-TX RAW EDGE
SMALL SHEAVE CONSTRUCTION MOLDED COG CONSTRUCTION
BELT INITIAL RE- INITIAL RE-
SECTION FROM (in) TO (in.) TENSION (lb) TENSION (lb) TENSION (lb) TENSION (lb)
2.50 2.80 40 30 50 40
2.80 3.65 50 40 60 50
3V/3VX
3.65 5.00 60 50 70 55
5.00 — 70 55 100 75
5.50 6.30 110 85 140 110
6.30 9.00 140 110 160 120
5V/5VX
9.00 14.00 160 120 180 140
14.00 — 170 130 190 150
2.50 3.20 40 30 60 50
3.20 4.00 50 40 70 55
A/AX/4L
4.00 5.20 60 50 80 60
5.20 — 70 55 90 70
3.60 5.00 60 50 90 70
5.00 6.40 80 60 100 80
B/BX/5L
6.40 8.00 90 70 110 85
8.00 — 100 80 120 90
5.50 8.00 140 110 180 140
8.00 10.50 160 120 190 145
C/CX
10.50 14.00 180 140 200 150
14.00 — 200 150 220 170
 ACUair® HYGIENIC AIR HANDLING UNITS
MAINTENANCE
NEW BELT RUN-IN
During initial startup of new belts, a belt run-in procedure is
recommended. During start-up, follow these instructions:
During start-up, look and listen for unusual noise or vibration.
1. After shutting down and locking out the starter, check
the bearings and motor. If they feel hot, the belt tension may
be too tight.
2. 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.
3. After running the drive, check the tension of the belts.
Re-tension to the recommended values.
This run-in procedure will reduce the future need for re-
tensioning and will help extend the life of the belts.
COIL MAINTENANCE
Examine your environment. If structure, equipment, or other
elements of your facility show rust or corrosive effects, your
coils are not likely to be impervious to the same effects of
the environment. Consider this when formulating your main-
tenance program.
Do not allow ice buildup. If a coil remains partially frosted
after a defrost, it is unlikely to ever completely clean itself 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 breaking coil tubes and piping.
NEVER take shortcuts to clear ice
from a coil by applying an open
flame to melt ice or frost.
The water used to wash the coils should be analyzed prior
to use to determine its suitability. It should not contain dis-
solved chemicals or organisms. Contact a specialist to test
the water, then follow his recommendations. Establish and
follow a regular testing and treatment schedule.
All refrigeration coils must be evacuated to remove mois-
ture 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 par-
ticles of metals (i.e. copper) embedded in the compounds
can cause corrosion due to contact of dissimilar metals.
Double check the compatibility of your construction materi-
als with the coil material of construction.
Further, isolate aluminum coils from steel piping via
gasketed flanges and sleeved bolts.
Sensing devices, which detect the presence of ammonia,
should be employed in your system.
S210-100 IOM
Page 15
Ammonia refrigeration could share the air stream with food
products and personnel. As such, proper maintenance of
coils, to prevent corrosion and leaks, is essential to prevent
product loss and to ensure the safety of plant personnel.
A typical refrigerated food processing facility sparkles with
stainless steel food contact surfaces and clean work spaces.
However, evaporators that are suspended overhead, trap-
ping airborne contaminants and corrosive elements in the
coils, are usually not so sparkly. Dirty coils are unsanitary.
They must be cleaned regularly with simple, gentle, wash
and rinse procedures.
For all coils, chlorine-based cleansing solutions, acidic
cleansing solutions and highly alkaline cleansing solutions
are hazardous to the coil's health. Use a mildly alkaline
cleanser. Consult with your chemical supplier and read the
Material Safety Data Sheet for your cleansing solution.
NOTE: Air units move air (and airborne contaminants)
across the coil. Protect the coil from corrosion by wash-
ing and rinsing frequently.
CONTROL DAMPERS
INSTALLATION, OPERATION, AND
MAINTENANCE INSTRUCTIONS
1. Location – Field openings for dampers must be prop-
erly sized. Do not force a factory damper into undersized
field ductwork or attempt to fill an oversized opening. This
will bend the frames causing air leakage. Dampers must
also be installed plumb and square. Twisted and distorted
frames develop stresses causing linkage to bind and corre-
lating improper blade operation. All control damper seams
must be caulked air and watertight.
2. Obstructions – Configuration of damper frames per-
mits the use of screws, rivets, or welding to attach damper(s)
to ducts or housings. Fastener ends must not protrude in
any way, which can interfere with blade movement. Cor-
rectly mounted dampers allow free and smooth operation
from completely closed to fully open.
3. Multiple Assemblies – Where dampers consist of more
than one panel, sections are mounted together to form larger
dampers. Matching frame members must be tightly welded
or bolted together in the field. Multiple sections require ad-
ditional structural support (provided on site by others) to
insure complete rigidity. Horizontally mounted dampers may
sag unless supported adequately. Blade motion is transmit-
ted between adjacent panels by common blade shaft cou-
plings and jackshafts. It is important that all shafts are accu-
rately aligned, otherwise blade edges will bind and prevent
a good seal.
4. Actuators – Operation of dampers may be manual us-
ing locking quadrant handles, chain operators or other de-
vices. For automatic operation, electric or pneumatic actua-
tors can be connected to dampers either internally or exter-
nally. Dampers constructed with multiple panels require in-
dividual actuators or jackshafts. Actuators or multiple ac-
tuators should be of adequate torque capacity to effectively
open and close the damper according to its type, size, loca-
tion, and its function in the system (relative to air velocity
and static pressure requirements).
S210-100 IOM ACUair® HYGIENIC AIR HANDLING UNITS
Page 16 MAINTENANCE
5. Lubrication – Before initial operation, all moving parts
of dampers should be first cleaned and then thoroughly
lubricated. Dampers furnished with stainless steel side seals
should also have the seals lubricated generously. Damp-
ers should then be manually operated several times until
linkages and blades operate freely.
6. General Maintenance – Dampers require proper main-
tenance in order to function correctly. Blade shafts, linkages,
stainless steel side seals (if applicable) and other moving
parts should be periodically cleaned and lubricated. A light
molybdenum oil in aerosol cans is preferable since the jet
nozzle permits pinpointing the stream of lubricant where re-
quired. It usually contains an evaporating solvent and dries
to a nonoily film, which will not attract dirt. For dampers lo-
cated in difficult or impossible to reach locations, field access
panels/doors are required as installed by others.
NOTE: In food plant applications a USDA approved sili-
con lubricant should be used!
7. Periodic Inspections – All automatic dampers should
be checked and serviced on a regular schedule. The rec-
ommended 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.
8. Inspection Checklist – At a minimum, include the fol-
lowing items in scheduled inspections:
• Observe damper motors and actuators through an oper-
ating cycle to check for defects and binding. Check mount-
ing bolts for integrity.
• Adjust actuator linkages so those dampers open and close
fully for given stroke.
• Check tightness of closed blades – readjust linkage for
any blades that may not close fully.
• Replace any damaged blades – clean operating parts.
• Check blade edge and side seal – replace as necessary.
• Check pins, straps, bushings, etc., for wear and replace
as required.
• Lubricate all moving part contact points and side seals.
• Check caulked joints between the damper frames and
the main structure – repair if the possibility of air or water
leakage exists.
COIL ASSEMBLY
An ACUair® air handling unit's operational readiness is de-
pendent on the condition of the coil. Coils that are dirty,
blocked from airflow, or physically damaged may affect over-
all heat transfer capability of the ACUair® SYSTEM to a
significant degree.
Periodically conduct a visual inspection of the coil section
and refrigerant line connections. Remove any airborne de-
bris that may have collected on the face of the coils
themselves.
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.
Finish and Sealing
ACUair® units utilize silicon for air and water sealing on the
interior and exterior. The sealing on the units should be
inspected and repaired as nessacary.
The repairs need to be done using USDA approved silicon.
UNIT CLEANING AND SANITATION
The unit should be thoroughly cleaned at regular intervals.
Your chemical supplier should be consulted when picking
the proper cleaning chemicals.
DISCONNECT ALL ELECTRICAL
POWER BEFORE CLEANING THE UNIT.
Before cleaning, any capped drain pipes should be un-
capped, 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.
INITIAL START-UP
1. Blower Alignment – Shipping and installation may
cause misalignment of the blower, motor and belts. Be-
fore starting the unit, rotate the blower by hand to make
certain that all components rotate freely. Start the motor,
and let it run for one hour. Shut down the motor and dis-
connect the electrical power. Touch all of the blower bear-
ings. The bearings should be slightly warmer than the air
passing through the unit, and each bearing should be
approximately the same temperature as the other bear-
ings. If any of the bearings is noticeably hotter than other
bearings, or if they are too hot to touch, the blower and
motor may be out of alignment.
2. Mechanical Tightness
a. Check tightness of fan bearing bolts.
b. Check tightness of blower, motor, and pulleys.
c. Check tightness of all motor mounting bolts.
3. Belt Tension – The blower belts are factory set to the
proper tension, but they may loosen during shipping and
installation. Check the belt tension after one hour, 50 hours,
and 100 hours of operation. Adjust tension if necessary.
MONTHLY SERVICE
It is recommended that the unit undergo a thorough monthly in-
spection. The inspection should include the following areas:
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 tempera-
ture. 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 Zerk fitting.
The bearings should be greased in accordance with
the included Blower Bearing Lubrication Guidelines.
b. Check the tightness of the blower bearing bolts, the
blower, motor, and pulleys, and the motor mounting
bolts.
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
MAINTENANCE Page 17

c. Check the blower belt tension. The belts should be

tensioned in accordance with the included Blower Belt
Tension Guidelines. Visually inspect the belts for indi-
cations of wear. Replace the belts if there is evidence
of cracking, fraying, or uneven wear.
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 imme-
diately. If the intermediate filter media, or final filter
media appears damaged, the filters should be changed
immediately. The filter maintenance schedule included
with this manual should be used as a guide for normal
filter replacement.
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.
b. Check 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.
S210-100 IOM
Page 18 INSTALLATION, OPERATION, AND MAINTENANCE
Symptom
Motor doesn’t start
Motor starts but quits shortly after.
Cooling doesn’t come on
Steam valve doesn’t modulate
Direct-fired burner doesn’t light
Check and gap pilot assembly (3/16" gap)
Indirect-fired burner doesn’t light
Exhaust fan doesn’t start
ACUair® HYGIENIC AIR HANDLING UNITS
Troubleshooting
Probable causes and Corrections
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 over loads
Check power to coil on starter
Check power from starter to motor
Check fan belts
Check tubes to airflow switch to be clean
Check power through air flow switch
Check rotation of fan
Check MOA module to see if in AUTO (green light if on/red light if
fuse is blown)
Check set point for cooling
Check OA lockout setpoint (lockout should be below OA Temp)
Check power to valve
Check setpoint for heat
Check OA lockout setpoint (lockout should be above OA Temp)
Check output for steam valve
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 gas supply
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
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 )
 ACUair® HYGIENIC AIR HANDLING UNITS S210-100 IOM
INSTALLATION, OPERATION, AND MAINTENANCE Page 19
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Preengineered for Lower Cost
Distributed System with Remote Control
Single-Cable Network
Easy to Expand or Upgrade

System integration is what we do…

Q-NET™ ... supports open-protocols for SCADA systems
(i.e. Allen Bradley DF1 and Modbus ASCII)
Q-NET™ ... connects for local or remote access
Q-NET™ ... can be applied to both new and existing systems
Q-NET™ means precise control 24 hours a day, seven days a week
Q-NET™ distributed architecture means faster, easier, economical installations
Q-NET™ delivers increased operating efficiency and lowers energy costs

Now available on Frick’s ACUair® hygienic air handlers, condensers,

screw compressors, evaporators, and refrigerant vessels, too.

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YORK Refrigeration Systems

1590 Dutch Road, Dixon Illinois 61021
Phone: 815-288-3859 • Fax: 815-288-1409 • www.frickcold.com

© 2003 YORK Refrigeration Systems