AAF Flanders SAAF RU500V User manual
THE WORLD LEADER IN CLEAN AIR SOLUTIONS
INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS
SAAF™
Air Purification Systems
Recirculation Unit and Pressurization and Recirculation Unit
Table of Contents
1.0 Introduction
1.1 About this Document
1.2 Packaging and Shipping,
Receiving and Inspection,
Handling and Storage
1.3 Product Descriptions
1.4 Product Model Designations
1.5 Product Drawings
1.6 Assembly – General Comments
1.7 Related System Equipment
2.0 Principles of Operation
2.1 General
2.2 Recirculation System
2.3 Pressurization System
3.0 Installation Instructions
3.1 Space Requirements
3.2 Foundations, Supports,
and Anchoring
3.3 Typical RU Housing Details
3.4 General Filter System
Installation Procedure
3.5 Preparation for Filter Installation
3.6 PrelterInstallation
3.7 Gas-Phase Chemical
Filter Installation
3.8 AfterlterInstallation
3.9 High-EciencyFilterInstallation
3.10 Latch RU Doors
3.11 Pressure Gauge
3.12 F a n s
4.0 Start-up Instructions
5.0 Maintenance
5 .1 P re l te r
5.2 Afterlter
5.3 High-EciencyFinalFilters
5.4 Gas-Phase Filter Monitoring
5.5 Removal and Replacement of
Particulate and Gas-Phase
Chemical Filters
5.6 Disposal of Used Filters
5.7 Gas-Phase Chemical Filter
Cassette Face Sealing Gaskets
5.8 AfterlterandHigh-Eciency
Particulate Filter Sealing
Gaskets
5.9 Access Door Sealing Gaskets
5.10 General System Maintenance
6.0 Troubleshooting
6.1 High Pressure Drop Reading
Across the Filter System
6.2 Visible Discharge of Particulate
6.3 Odors and Smells
6.4 Vibration
7.0 Spare Parts List
8.0 Equipment Characteristics,
Dimensions, Operating Weights,
and Shipping Weights
9.0 Technical Guidelines
9.1 Fan Selection and Sizing
1.0 Introduction
1.1 About this Document
This document contains the
information necessary to properly
receive, assemble, install, operate,
and maintain the AAF Flanders
Recirculation Unit (RU) and
Pressurization and Recirculation
Unit(PRU)ltersystemsandlters.
The purchaser, installer, and operator
oftheltersystemMUSTreadand
comply with this document in its
entirety prior to installation of the
equipment and its operation. Failure to
comply with the requirements of this
manual may void the product warranty.
CAUTION: These instructions
arespecictotheAAFFlanders
Recirculation Unit and Pressurization
andRecirculationUnitlter
systemsandlters.Allancillary
tasks including, but not limited to,
electrical and mechanical work,
equipment handling, and safety
procedures must be performed in
accordance with industry-accepted
practice and all relevant local, state,
and federal government codes,
laws, and policies.
NOTE: The AAF Flanders
Recirculation Unit and
Pressurization and Recirculation
Unitltersystemsandltersare
similar in most respects. For ease of
reading, this manual will refer only
to the Recirculation Unit. Unless
specicallystatedotherwise,all
references to the Recirculation
Unit will apply equally to the
Pressurization and Recirculation
Unit. A detailed description of both
systems can be found in section
2.0, Principles of Operation.
1.2 Packaging and Shipping, Receiving and Inspection,
Handling and Storage
1.2.1 Packaging and Shipping: Unlessotherwisedened
in the purchase order and agreed by AAF Flanders, the RU
lterhousingandltersarepackagedfordomestictransit
and shipped FOB the AAF Flanders factory. The method of
shipmentwillbeasspeciedinthecustomer’spurchase
order to AAF Flanders.
1.2.2 Receiving and Inspection: Obtain a copy of the
purchase order, the product drawing that was submitted by
AAF Flanders in association with the order, and a copy of
the bill of lading, along with any other shipping papers.
Upon receipt of the equipment, or any part thereof, these
documents shall be used to ensure that the correct product
has been received.
For maximum protection, complete the following steps upon
receiptoftheRUandlters:
• Inspect the shipment and all associated documentation.
Notify the carrier immediately if there is any visible damage
to the packaging or the equipment, or a discrepancy in the
shippingpapers.Ifnecessary,leanimmediateclaimwith
the carrier against such damage or discrepancy.
•Conrmthattheequipmentreceivedagreeswiththe
contents of the shipping papers.
•Conrmthattheshippingdocumentsagreewiththe
purchase order. Refer to the product drawing submitted
for the order as necessary.
• If it is determined that any equipment ordered on the
purchase order has not been delivered and is not accounted
for in the shipping papers, contact AAF Flanders
immediately by calling 1-800-477-1214. Reference the
AAF Flanders control number, which will be listed on the
shipping papers.
Eachshipmentmayinclude:
• One or more individually packaged RUs.
• Packagedparticulatelters.
• Packagedgas-phasechemicalltercassettes.
NotethattheRUandtheparticulateandgas-phaseltersmay
shipfromdierentlocationsandbereceivedatdierenttimes.
1.2.3 Handling and Storage: Following receipt, inspection,
and acceptance of the equipment, and prior to installation, the
RUandtheparticulateandgas-phaseltersshouldbehandled
with great care. The RU may ship mounted vertically or
horizontally on a pallet for protection during shipping and
handling. It is recommended that it remains on its pallet until
ithasbeenmovedtoitsnalinstallationlocation.Only
personnel experienced in rigging and handling equipment
should be employed for this task. In most cases, the RU may
be moved using a forklift. A suggestion for rigging horizontally
shipped equipment is shown in Figure 1. Rig the housing using
straps or a sling. Fasten the strapping under the skid on which
the RU ships. To prevent damage to the exterior surface of
the RU, use spreader bars at all times. Position the spreader
bars to keep the cables from rubbing against any part of the
housing. Before hoisting, make sure that the load is properly
balanced.
2
! WARNING: The housing top (when shipped vertically) or the
top-side (when shipped horizontally) will not support the
weight of the unit. Any attempt to support the housing from
these surfaces may result in serious equipment damage and
severe personal injury. Do not walk on the top or the top-side
of the unit, or use these surfaces for storage of materials.
The components shall be retained and stored in their protective
packaging until immediately prior to installation. Care should be
taken to ensure that the packages are not dropped or subjected
to any impact loads.
At all times the equipment should be protected from exposure
to weather. The equipment should be stored in a clean, dry,
temperature-controlled environment. All items should be stored
on pallets so that they are elevated above grade. Recirculation
Units(RU)shouldnotbestacked.Particulateandgas-phaselters
should not be stacked more than three (3) cartons high to prevent
crushing.Onlyparticulateltersshouldbestackedonparticulate
lters,andgas-phaseltersongas-phaselters.Thegas-phase
ltersshipinsideacartonenclosedintransparentprotective
plastic.Undernocircumstancesshouldtheltersberemoved
from this plastic protection until immediately prior to installation.
Filter products should not be stored in areas where they may
become contaminated by chemicals, either acids or alkalis, in
liquid, vapor, or gaseous form.
1.3 Product Descriptions
1.3.1 Recirculation Unit (RU): Each RU will be received
individually mounted on a shipping pallet and wrapped in
plastic for protection during shipping. Refer to the product
drawings submitted on the order for details. The RU is typically
supplied in one style, the Heavy Duty (HD) model. This refers to
thestyleofSAAFCassettegas-phasechemicallterthatcan
be accommodated in the unit (see 1.3.2 for details).
Spreader bar
Straps or sling
Shipping skid
Figure 1
RU
3
Typical Recirculation Unit. Recirculation Unit Model RU2000V with tracking to accommodate
four (4) SAAF™HD cassettes.
12″high x 24″wide x 12″deep SAAF™HD cassette ships in two halves.
1.3.2 Gas-Phase Chemical Filter Cassettes: Gas-Phase
ltercassettesareshippedincartonsandplasticbags.The
cartonshowntotherightcontainsasingle6″highx24″wide
x18″deepMediumDuty(MD)cassette,whichissuppliedas
two(2)6″highx12″widex18″deephalf-cassettes.AnHD
cassettecartonwillcontainasingle12″highx24″widex12″
deepcassettewhichissuppliedastwo(2)12″widex12″deep
half-cassettes.
Thegas-phasechemicalltercassettetypicallysuppliedwith
theRUisasfollows:
1.3.3 Particulate Filters
Prelters and Afterlters – Particulatepreltersand
afterlterswilltypicallybeAAFFlandersPerfectPleat®pleated
lters.DependingonthesizeoftheRUordered,24″highx24″
widex2″deepfullsizeltersor12″highx24″widex2″deep
halfsizeltersmaybesupplied.PerfectPleat2″deepltersare
packaged 12 to a carton.
High-Eciency Filters – High-eciencylterswilltypically
be AAF Flanders VariCel®M-Pakpleatedlters.Dependingon
thesizeoftheRUordered,24″highx24″widex6″deepfull
sizeltersor12″highx24″widex6″deephalfsizeltersmay
besupplied.M-Pakltersarepackagedtwotoacarton.
Note: Optional or
speciallterarrangementsmaybe
supplied, depending on the requirements of the project.
Check the purchase order and AAF Flanders submittal
drawing(s) for details.
4
1.4 Product Model Designations
TheproductmodelsaredesignatedasshowninTable1:
Thefullproductdescriptionisdenedbelow:
RU* – 500V – 2P – HD– F – HD – 2P – 6F
Supports a 6″ deep particulate nal lter
Supports a 2″ deep particulate afterlter
Second gas-phase chemical lter bank, supports HD cassettes
Fan
First gas-phase chemical lter bank, supports HD cassettes
Supports a 2″ deep particulate prelter
Nominally rated to deliver 500 CFM in a vertical airow orientation
Recirculation Unit (RU)
* Substitute PRU for RU when the unit is a
Pressurization and Recirculation Unit.
** In the case of the PRU, the nominal delivered airow
is a combination of pressurization and recirculation
airow controlled via an in-built damper
1.5 Product Drawings
DetailsofsomestandardRUltersystemsareshownonthe
followingAAFFlandersdrawings:
Model AAF Flanders Drawing Number
RU500V 114D-3025889
RU1000V 114D-3025855
RU2000V 114D-3025897
Copies of the appropriate drawings will have been supplied as
part of the AAF Flanders submittals in response to the purchase
order. Obtain and review the drawing(s) before proceeding with
theinstallationoftheltersystem.TheRUltersystemdrawings
includethefollowingdetails:
• Overallltersystemdimensions
• Shipping weights
• Operating weights
• Sizes and quantities of the particulate and gas-phase
ltersrequired
• Details of the gas-phase chemical media supplied
• Detailsoftheparticulatelterssupplied
• Systemdesignairow
• Pressurelossesacrosstheltersystematnominalairow
design velocities
• Product details
1.6 Assembly – General Comments
As indicated previously, the individual components that will
comprisetheltersystemwillshipseparatelyandwillberequired
to be installed on site. The RU is a self-contained product and,
consequently, a minimum amount of assembly is required. Refer
to section 3.0, Installation Instructions, of this manual for further
detailed instructions. Consult with an experienced installer to
obtain an accurate estimate of the time, personnel, and
equipment resources and tools that will be required to complete
theassemblyandinstallationoftheltersystem.Siteassembly
will be limited to moving and lifting individual components,
screwing components together, and caulking. The RU weights
and dimensions can be found on the product submittal drawings.
Thegas-phasechemicallterswilltypicallyhaveamaximum
weightofapproximately40pounds(20kg).Particulatelterswill
typicallyweighlessthanthegas-phaselters.
Completion of the following preparations and provision of the
followingitemswillbetheresponsibilityoftheinstallerorothers:
• Site preparation
• Connecting screws and hardware for attaching inlet and outlet
ducts, if required
• Provisions for anchoring and supporting the RU, including
anchor bolts, angles, straps, hangers and cradles, etc.
• Caulk, as required
• Inlet and outlet ducts, or other sheet metal parts, as required
These items will not be supplied by AAF Flanders unless noted
specicallyintheAAFFlandersquotationandintheaccepted
customer purchase order.
Table 1: Typical Model Numbers
Recirculation Unit (RU) Pressurization & Nominal Delivered Full Product Description
RecirculationUnit(PRU) Airow(CFM)**
RU500V PRU500V 500 RU*-500V-2P-HD-F-HD-2P-6F
RU1000V PRU1000V 1000 RU*-1000V-2P-HD-F-HD-2P-6F
RU2000V PRU2000V 2000 RU*-2000V-2P-HD-F-HD-2P-6F
RU4000V PRU4000V 4000 RU*-4000V-2P-HD-F-HD-2P-6F
5
NO WELDING WILL BE REQUIRED.
Ingeneral,assemblyoftheltersystemwillconsistofthe
following:
• Preparation of the installation location
• Transportation of all components to the installation location
• Unpacking the RU
• Installing the RU
• Installing inlet and outlet ducts, if required
• Unpackingandpreparationofthegas-phasechemicallter
cassettes
• Installinggas-phasechemicalltercassettes
• Unpackingparticulatelters
• Installingparticulatelters
• Cleaning the site
• Start-upandcommissioningoftheltersystem
1.7 Related System Equipment
Ventilation systems will often include other equipment, including
butnotlimitedto:
• Fan(s), if not supplied as part of the RU
• Dampers
• Weather louvers
• Air tempering equipment
• Analog instrumentation
• Electronic instrumentation and controls
Neithertheinterfaceoftheseitemswiththeltersystemsupplied
by AAF Flanders, nor the installation, operation, and maintenance
of these items, is covered in this manual. Whether these items are
supplied by AAF Flanders or by others, consult the documenta-
tionspecictotheseproductsforappropriateinstructions.
2.0 Principles of Operation
2.1 General
An understanding of the design and operating principle of the RU
withgas-phasechemicalltersisusefulforeectiveinstallation,
operation, and maintenance. Typically, the RU and PRU systems
are intended to remove gaseous contaminants from intake and/or
recirculated ventilation air. Examples of such contaminants may
be nuisance odors and smells that may cause domestic and
neighborhood discomfort and reduce workplace productivity, or
harmful gases that may cause damage to health, plant, and prod-
uct in industrial applications. The heart of the system is the AAF
Flanders SAAF Cassette. This is a high-impact plastic frame that
supports various types of dry, granular, chemical media between
perforatedscreensthatallowairtomovethroughthelter.The
SAAF Cassette is designed to support the chemical media in a
V-bankcongurationofmediabedsthatmaximizesthemedia
exposed to the air stream, reduces the air stream velocity through
themediabed,maximizesenergyeciency,andmaximizesthe
removal of contaminants and the life of the product. The method
of contaminant removal is through a combination of the physical
property of adsorption and the chemical process of oxidation.
AAFFlandersoersavarietyofimpregnatedandun-impregnated
dry granular media to handle a wide range of contamination
problems.FormoreinformationonAAFFlanders’gas-phaseair
cleaning products, contact your AAF Flanders representative.
The AAF Flanders RU is one of the various framing and support
systems designed to support the SAAF Cassette in the air
stream, allowing easy installation, operation, and maintenance
of the system.
2.2 Recirculation System
Therecirculationsystemisintendedtodrawairfromadened
space, clean the air, and then return the cleaned air to the space.
The system is supplied when contaminants are generated within
thespaceorinltratefromoutsidethespace.Itisnormally
provided to protect personnel, equipment (particularly electronic
equipment), or product. A typical schematic of the recirculation
system operation is shown in Figure 2.
2.3 Pressurization System
The pressurization system is intended to pressurize a space by
drawing air from outside the space, cleaning the air, and then
discharging the cleaned air to the space. The system is supplied
when contaminants are generated from outside the space. All
leakage will be from the higher pressure space within the room
to the lower pressure surrounding environment. This prevents
outside contaminants from entering the space. An optional
arrangement allows some in-room recirculation to take place.
This system is normally provided to protect personnel, equipment
(particularly electronic equipment), or product. A typical
schematic of the pressurization system operation is shown
in Figure 3.
RU
Filter
System
Fan
Outlet
Inlet
Contaminated
Air
Recirculated
Air
Clean Air
Enclosed Room
Figure 2 - Recirculation System Using the Recirculation Unit (RU)
PRU
Filter
System
Fan
Outlet
Clean Air
*Pressurized Space
Air Leakage at
Windows, Doors and
Other Penetrations
will be Outwards
from the Room
Enclosed Room
Optional Inlet Damper and Dampered
In-room Inlet may be Supplied to
Allow some Recirculation of Air
Inlet Air
from Outside
of the Room
Duct
Figure 3 - Pressurized System Using the Recirculation & Pressurization Unit (PRU)
Figure 2 - Recirculation System Using the PRU
Figure 3 - Pressurization System Using the PRU
6
3.0 Installation Instructions
Consult the product drawing(s) submitted on this order before
proceeding.
3.1 Space Requirements
A minimum of 36” clear space must be available at the access
side of the Recirculation Unit to perform routine maintenance.
Additional space may be required for inlet and outlet ductwork.
3.2 Foundations, Supports, and Anchoring
The foundation and/or supports must be designed to be
adequatetosupporttheltersystemoperatingweight,andany
seismic,liveorotherloads(ifany),withasucientfactor
of safety as determined to comply with the requirements of all
applicable governing codes, standards, and laws. Ensure that
the foundation or support surface is level and smooth before
proceeding.Theltersystemisdesignedforoperationinindoor
locations.Theequipmentisnotspecicallydesignedtoresist
and operate under unusual dynamic loading situations, such as
earthquake conditions. If the equipment is required to function
in such circumstances, special precautions may be required to
ensure that the equipment will remain intact, anchored, and
functioning.Ifthissituationapplies,consultwithaqualied
professional engineer before installing the equipment.
3.3 Typical RU Housing Details
Fan section access panel
Safety grille
Fan
Typical fan section with access panel removed.
Outlet air grille
Door hinge
Door latch
Final lter track
2″ After-lter track
Second stage HD
cassette positioning
and support track,
sealing face
Typical insulated
double wall panel
Fan section
2″ Prelter track
Hollow core gasket
Final lter track
2″ After-lter track
Extruded
aluminum track
2″ After-lter and nal lter track. The nal
lter track shown is designed to accept a
typical 1″ nominal header-style lter.
Galvanized steel
(or similar) formed track
First stage HD
cassette positioning
and support track,
sealing face
2″ Prelter track
Insulated double
wall access doors
Filter side-seal gaskets
Track support
Inlet air grille
Pressure gauges
Fan control
A typical Recirculation Unit Model RU500 is shown.
7
Hollow core face sealing gasket
Plastic strips provide low
friction cassette bearing surface
Track support hardware
Track support beam
Extruded aluminum track
Cassette support track, sealing face.
The RU is uniquely designed to accommodate and securely
sealAAFFlanders’gas-phasechemicalltercassettes.Each
housingincorporatesAAFFlanders’patent-pendingltersealing
system to ensure that the contaminated air passes through the
lteranddoesnotbypassaroundthelters.Typicaldetailsof
the tracks are shown in these illustrations. In some instances,
dependingontheequipmentsuppliedandtheltersrequired,
minortrackdetailsmaydierfromthoseshown.
Track connection detail at support beam. This detail shows AAF Flanders’
“quick release” track installation method. Accurately located support post
holes ensure high tolerance track spacing. Note that the track connection is
completely isolated from the lter sealing surface and cannot interfere with
lter installation.
3.4 General Filter System Installation Procedure
3.4.1InstallingtheRU:KeepingtheRUonitsshippingpallet,
moveittoitsnalinstallationlocation.Removetherestraints
that secure the RU to its pallet and remove any wrapping or
packaging material.
! WARNING: The housing top will not support the weight
of the unit. Any attempt to support the housing from the
top may result in serious equipment damage and severe
personal injury. Do not walk on the top of the unit or use
the top for storage of materials.
3.4.2 Locating, Mounting, and Supporting the RU: Locate
theRUinitsnalinstallationlocation.Thesupportsurfaceunder
the base of the frame should be level, smooth, clean and dry.
Thelocationshouldnotbesubjecttostandingwaterorooding.
The circumference of the housing base should be fully supported.
Adjust the supports so that the base is level in all directions.
Anchoring the Housing: Depending on the project
requirements, it may not be necessary to anchor the
housing. However, if it should be necessary, a suggestion
for anchoring the standard housing is provided in Figure 4.
Aluminum frame
Figure 4
Figure 5
Angle support clip,
by others
Anchor bolt,
by others
In all cases, the foundation and supporting structure should
bedesignedforeachspecicinstallationbyaqualied
professional engineer.
Provision of anchoring hardware or any other supporting
component will be the responsibility of the installer or others.
These items will not be supplied by AAF Flanders unless noted
specicallyintheAAFFlandersquotationandintheaccepted
customer purchase order.
3.4.3 Connection of Inlet and Outlet Ducts: Inlet and outlet
ducts, when required, should be connected to the inlet and
outlet faces of the housing as shown in Figure 5.
Inlet or outlet
duct wall, by others
Connecting hardware,
by others
13⁄16″
[30 mm]
Duct Connection
Duct Connection Alternate Method
! WARNING: The housing is not designed to support the
weight of inlet and outlet ducts. All ducts should be
supported independently of the housing. Any attempt to
support the ducts from the housing may result in serious
equipment damage and severe personal injury.
8
3.4.4 Sealing the Inlet and Outlet Duct Connections
Provide continuous gaskets, or caulk generously, between
theangesoftheconnectingductsandthehousingto
prevent air leaks.
Provision of the inlet and outlet ducts, the connecting hardware,
and the gaskets or caulk will be the responsibility of the installer
or others. These items will not be supplied by AAF Flanders
unlessnotedspecicallyintheAAFFlandersquotationandin
the accepted customer purchase order. Any caulk used should
bealong-life,exible,nondryingcaulkingmaterial.Thecaulk
supplier should ensure that the caulk meets the customer
specicationsfortheapplicationinwhichitisbeingused.
CAUTION: Many installations prohibit the use of certain
caulking materials, such as Silicone. The use of materials
containing VOCs should also be avoided, as they may
haveanegativeeectonthelifeofthegas-phaselters.
3.5 Preparation for Filter Installation
Inordertomaximizethelifeofthegas-phasechemicalltersand
theparticulatelters,itisrecommendedthatlterinstallationbe
thenalinstallationtaskbeforestart-upandcommissioningofthe
system.Inpreparationforlterinstallation,itisrecommendedthat
thefollowingbecompleted:
• Completely clean the system to remove all construction debris
and dirt, sweep and vacuum to remove visible dirt.
• Damp wipe all surfaces to remove dust.
• Finalize and complete all caulking in the system.
• Finalize and complete all painting in the system.
It is recommended that all cleaning materials and paints used
in the system be free of solvents. If this is unavoidable, it is
recommendedthatsucienttimebeallowedforcompletedrying
tooccurandfortheVOCstodispersebeforeinstallingthelters.
This process can be accelerated by “blowing down” the system,
i.e.,operatingthefanwithoutthelterstoventilatethesystem.
Itisrecommendedthatablanket-styleconstructionlterbe
installed at the inlet to the system to prevent construction dust
from being drawn into the system. Consult with your AAF
Flanders representative to obtain an appropriate product. Also,
before “blowing down” the system, check that it is safe to operate
the fan without the pressure load of the gas-phase chemical
lters.ConsulttheAAFFlanderssubmittaldrawingforpressure
information.
3.6 Prelter Installation
Preltersareusedtopreventthebuild-upoflintanddustonthe
faceofthegas-phasechemicallters.Ifpreltersarenotinstalled,
theeectiveoperatinglifeofthegas-phaseandhigh-eciency
nalltersmaybereduced.Installthepreltersasshowninthe
sequence shown below. The standard RU is designed to accept
2″deeppreltersonly.Forbestresults,AAFFlandersrecom-
mends the use of the MERV 8-rated PerfectPleat. The tracks are
spacedandsizedtoaccept24″x24″x2″and/or24″x12″x2″
nominalASHRAEstylelters.
Place the prelter into the prelter track.
Step 1: Insert the prelter into the track
Step 2: Slide the prelter in as far as it will go
Step 3: The installed prelter
Repeat the process of prelter installation until all prelters have been installed.
9
3.7 Gas-Phase Chemical Filter Installation
Thefollowinginstructionsarespecictotheinstallationofthe
HDgas-phasechemicalltercassettesintoanRUhousing.
Typically,twostagesofgas-phaseltrationwillbesuppliedinany
RU,alowerlterbankandanupperlterbank.Theinstructions
forinstallingthegas-phaselterswillbeidenticalforbothbanks.
3.7.1 Preparing the Cassette for Installation: Remove the
cassette from its carton and plastic bag. You will notice that
each half-cassette is accompanied by a plastic bag containing
loosegaskets(seeright).Thesearesuppliedspecicallyfor
use when the cassette is to be installed into the RU. These
gaskets are critical for the sealing of the gas-phase cartridges
topreventbypassofcontaminatedairaroundthelters.
Type HD half-cassette with buttery and side gaskets.
Step 2: Locate the gasket on the leaving air side of the half-cassette along the
edge of the cassette side plate. A gasket location guide has been formed into
the side plate. The gasket should be located to the outside of this line.
Step 3: Firmly press the gasket into position so that it adheres to the side plate.
Step 4: Repeat to install the second side gasket on the other side of the
half-cassette.
Step 1: Remove the paper strip on the back of the yellow “buttery-style” face
gasket to expose the adhesive.
Buttery-style Face Gaskets
Step 1: Remove the paper strip on the back of the black gasket to expose
the adhesive.
Side Gaskets
First, completely remove any dust that may have settled on
the outer surface of the plastic cassette during shipping and
handling. If not removed, such dust may interfere with the
adhesion between the gaskets and the plastic cassette. Install
the gaskets onto the half-cassettes. The following pictures
showtheinstallationofgasketsontoaTypeHDhalf-cassette:
10
Step 2: Locate the gasket on the edge of the leaving
air side face of the half-cassette as shown and rmly
press the gasket into position so that it adheres to
the face of the half-cassette.
Step 1: Bring the HD half-cassette to the RU and prepare to install it. Turn the half-cassette so that the yellow buttery gasket will be on the bottom and pointing
into the enclosure.
Step 3: Repeat to install the second buttery gasket
on the other side of the leaving air side face of the
half-cassette.
Step 4: The Type HD half cassette is now ready for
installation into the RU.
3.7.2 Handling of the Cassette: The AAF Flanders SAAF
Cassetteisdesignedtobesturdyandtosupportasignicant
weight of chemical media. However, it should not be handled
roughly. The cassette should always be lifted with two hands,
one beneath each side panel as shown in the following installa-
tion pictures. The cassette should never be lifted, supported,
carried, or pulled by a single side panel.
3.7.3 Installation of the Cassettes in the RU: Install the
cassettes as shown in the sequence below starting with the
bottom cassette(s). Slide each half-cassette into the RU tracks
andpushitrmlyintotheenclosureuntilthesidegasketonthe
rsthalf-cassetteisrmlycompressedagainsttheenclosure
wall surface on the opposite side from the access door. The
plasticedgeofthenalcassetteinsertedshouldbeevenwith
the outer edge of the extruded aluminum track. Repeat this
processuntilthetracksateachlevelhavebeenlled.
11
Step 2: Address the left and right hand side support and sealing tracks at a
slight angle as shown. Engage the black hollow core gaskets in the tracks with
the yellow buttery gaskets on the half-cassette, see detail below. Also, begin to
align the left and right hand side notches in the half-cassette with the horizontal
cassette locator bars which form part of the track.
Step 3: Rotate the cassette slightly upwards so that the vertical locator bars are
inserted into the slots in the half-cassette, while maintaining the compression
between the hollow core and buttery gaskets. Maintaining a steady and even
force on the side of the cassette, push it into the housing to engage the notches
on the outer side of the half-cassette and continue to insert the half-cassette
until it is fully installed.
Detail - Step 2 Detail - Step 3
Cassette locator bar
Buttery gasket and
hollow core gasket
Notch
12
Step 5: Repeat the process until all gas-phase lter tracks are lled with cassettes.
Step 4: Repeat the process of gas-phase cassette installation and sealing
until the track is lled with sealed cassettes as shown. The outside face of the
cassette should be even with the edge of the track.
3.8 Afterlter Installation
Itisrecommendedthatatemporaryafterlterbeinstalledinthe
system to collect an initial plume of dust that might be blown from
thegas-phasechemicallters.Theinstallationoftheafterlters
isexactlythesameprocessasdescribedforthepreltersin
Section3.6.Seebelow:
Step 1: Insert the afterlter into the track.
Step 2: The installed afterlter.
13
Repeattheprocessofafterlterinstallationuntilalltracksare
lledwithafterlters.
3.9 High-Eciency Final Filter Installation
Ahigh-eciencynallterbankensuresthatthelteredairmeets
thehighestlevelsofparticulatecleanliness.Installthenallteras
shownhere.ThestandardRUisdesignedtoaccepta6″-deep,
singleheadernallteronly.Forbestresults,AAFFlanders
recommends the use of one of its line of single header M-Pak
high-eciencylters.Thetracksarespacedandsizedtoaccept
24″x24″x6″and/or24″x12″x6″nominalASHRAEstylelters.
Repeattheprocessofhigh-eciencylterinstallationuntilall
tracksarelledwithhigh-eciencylters.
3.10 Latch RU Doors
Now close and latch the RU doors as shown.
Step 1: Insert the high-eciency M-Pak lter into the track.
Step 2: The installed high-eciency M-Pak lter.
14
3.11 Pressure Gauge
Pressuregaugesareinstalledacrosstheltersystemtoindicate
whentheparticulatelters(beingtheprelterandhigh-eciency
lters)needtobereplaced.Thepressuregaugewillregisterthe
pressuredierentialacrosseachlterbank.Astheparticulate
lterloadswithdirt,theresistancetotheairow,andconsequently,
thepressureacrossthelter,willincrease.Thepressureacross
thegas-phasechemicallter(s)willremainconstant,sincethese
lterscollectgasmoleculesandnotparticulate.Pressuregauges
acrossthegas-phaselterbanksarenotsuppliedaspartofthe
standard product. The pressure gauges are normally part of the
housingandwillbesuppliedintheinstallationshownbelow:
3.12 Fans
The standard RU is supplied with an internally-mounted fan.
See the AAF Flanders submittal drawing and wiring diagram for
information and details.
CAUTION: All electrical work must be carried out in
accordance with all appropriate governing electrical codes
and standards.
! WARNING: All electrical work has the potential to cause
shock, injury, and even death. Disconnect all power
wheneverworkingonthesystem.Onlyqualiedelectrical
personnel should work on the fan and control system.
3.12.1 Provideanappropriatepowersupplyasspeciedinthe
submittal information.
CAUTION: Use of the incorrect line voltage may result in
irreparable damage to electrical components.
Recirculation Unit (RU) with wall mounted gauges
3.12.2 Access to the Fan: Access to the fan section is
obtained by removing the center panel, as shown in the
following sequence.
Step 1: Remove screws holding the fan access panel in place.
Step 2: Remove the panel.
15
3.12.3 Installation: In order for the fan to be operated, some or
allofthefollowinginstallationstepsmayberequired:
3.12.3.1 On the standard product, the fan will be fully wired
internally, and the controls required to operate it will be
installed. Under some circumstances, the installer may need
to provide, install, and wire a properly sized motor starter.
See the AAF Flanders wiring diagram supplied on the order
for details. In all cases, an appropriate disconnect switch
with fuses/circuit breakers should be provided. These
components are normally supplied and installed by others.
CAUTION: An electrical disconnect should be incorporated
into the power wiring and mounted adjacent to the
equipment, so that power can be cut when required
during start-up and maintenance. Normally, the disconnect
switch will be supplied and installed by others.
3.12.3.2: Installation of Power Wiring to the Fan Motor:
See the AAF Flanders wiring diagram supplied on the order
for details.
3.12.3.3: Provision, installation, and wiring of any special
controls and interconnecting wiring to associated
equipment,suchasdampers,airowmonitors,chemical
sensors, etc.
For guidelines on fan selection, see paragraph 9.1
4.0 Start-up Instructions
Check the rotation of the fan wheel to ensure that the fan motor is
wired correctly. The centrifugal fans typically supplied with the RU
feature fan wheels with backward curved blades. It is critical that
the blades rotate in the direction shown.
Ifthefanwheelrotatesinthewrongdirection,theairowwill
be severely restricted and the system will not provide the
properairow.
Direction of rotation
Typical RU fan wheel
Fan wheel
Fan blade
Step 3: Mark the tubes that are connected to the pressure gauges to ensure
that they are returned to the correct locations later, and disconnect the tubes
from the gauges.
Step 4: Remove the safety grille to access the fan and motor.
Fast but limited access to the fan can be obtained from above the fan, as shown,
with the lters removed.
Secondary
Fan Access
Whenthefansystemisstartedup,theairowvolumecanbe
controlled by varying the fan speed, using a variable speed
control or by increasing the static pressure using dampers, if
these have been supplied. The HD cassettes are nominally rated
to operate at a face velocity of 250 feet per minute. Note that
some systems may be supplied with single speed fans. Review
the product drawing and wiring diagram for details.
Immediatelyonstart-up,examinetheltersystemforany
apparent air leaks or other anomalies. Air leaks may be detected
bynoiseorbyuseofasyntheticsmokepungdeviceatthe
externaljointsandseamsoftheltersysteminstallation.
Correct or repair any discrepancies as necessary. Repeat this
examination after 24 hours of operation and again after one
week of operation.
Monitorthepressuredropacrosstheltersystemtoensurethat
theltersareoperatingwithinthepressurerangeexpectedandto
ensure that the pressure drop is not too high. Consult the AAF
Flandersdrawingfortheexpectedcleanlterpressuredierentials.
5.0 Maintenance
5.1 Prelter
Record the pressure drop weekly to obtain the status of the
particulatelter.Anormalparticulateltercanbeexpectedto
lastforbetweentwoandthreemonthsbeforereachingitsnal
recommended pressure drop (see the AAF Flanders drawings for
details). However, under heavier or lighter dust loading conditions,
thismayvary.Atanairowvelocityof250feetperminute,the
2″deepAAFFlandersPerfectPleatltercanbeexpectedto
haveaninitialpressuredropintherangeof0.11″watergauge.
Therecommendednalpressuredropis1.0″watergauge.
Thismeansthatwhenapressuredropincreaseof0.89″water
gaugehasbeenrecorded,itistimetochangetheprelter.
5.2 Afterlter
Installanafterlterinthesystemtocollectanyinitialplumeofdust
thatmightbeblownfromthegas-phasechemicallters.Thislter
can eventually be removed from the system to reduce the energy
required to operate the system. Monitor the pressure drop across
thislter.Whenthepressureceasestoincrease,itissafeto
removethislterfromthesystem.Thisshouldtypicallybeno
longerthanafter40hoursofoperation.Ifafterltersstillhave
signicantliferemainingatthetimeofremoval(basedonthe
pressure drop reading), they should be retained for re-use as
afterltersfollowingthechange-outofthechemicallters,orbe
usedasreplacementsfortheprelters.
5.3 High-Eciency Final Filters
Recordthepressuredropweeklytoobtainthestatusofthelter.
Anormalhigh-eciencyltercanbeexpectedtolastforone
yearormorebeforereachingitsnalrecommendedpressure
drop (see the AAF Flanders drawings for details). However, under
heavier or lighter dust loading conditions, this may vary. At an
airowvelocityof250feetperminute,the6″deepAAFFlanders
VariCelM-Pakltercanbeexpectedtohaveaninitialpressure
dropintherangeof0.23″watergauge.Therecommendednal
pressuredropis1.5″watergauge.Thismeansthatwhena
pressuredropincreaseof1.27″watergaugehasbeenrecorded,
itistimetochangethehigh-eciencylter.
5.4 Gas-Phase Filter Monitoring
Adiscussionofsophisticatedgas-phaseltermonitoringis
beyond the scope of this manual. At its most simple, when the
lterisusedtoremovenuisanceodors,thetimetochangeout
the gas-phase chemical media cassette is when the odor begins
16
toberegularlydetectedonthecleansideoftheltersystem.
In more stringent applications where the system is supplied to
protect health and/or high value plant and product, active
real-time electronic and passive coupon corrosion monitoring
systems are available to determine the performance of the
system. The remaining life of the media in the SAAF Cassette
can be determined by taking a sample of media and returning
it to AAF Flanders for analysis. Consult with your AAF Flanders
representative regarding active and passive monitoring systems
and media sampling for remaining life analysis.
5.5 Removal and Replacement of Particulate and Gas-Phase
Chemical Filters
Removaloflterswillbethereverseoftheinstallationprocess
described earlier in this manual. Filter replacement will be carried
out exactly the same as at initial installation.
5.6 Disposal of Used Filters
Usedchemicalltersandparticulateltersshouldbepackaged
and disposed of in full accordance with all required and
applicable laws and regulations. Consult with local environmental
control authorities, such as local, state, and federal EPA & OSHA
authorities, for direction. Material Safety Data Sheets (MSDS) are
available on all products supplied by AAF Flanders. Contact your
AAF Flanders representative for further information.
5.7 Gas-Phase Chemical Filter Cassette Face
Sealing Gaskets
The proper maintenance of the hollow core gaskets located in
the track on the entering air, or sealing, face of each cassette
is critical to the performance of the system. Check the gaskets
carefullywheneverthegas-phasechemicalltersarereplaced.
If gaskets are worn, frayed, or damaged in any way, they should
be replaced. Check the seal between the gas-phase chemical
ltercassetteandthehollowcoregasketontheairenteringface
of the gas-phase cassettes whenever new SAAF Cassettes are
installed.
5.8 Afterlter and High-Eciency Particulate Filter
Sealing Gaskets
The proper maintenance of the hollow core gaskets located
intheafterlterandhigh-eciencyparticulateltertracksis
critical to the performance of the system. Check the gaskets
carefullywhenevertheafterltersandhigh-eciencyparticulate
ltersarereplaced.Ifgasketsareworn,frayed,ordamagedin
any way, they should be replaced. Check the seal between the
ltersandthehollowcoregasketswhenevernewparticulate
ltersareinstalled.
5.9 Access Door Sealing Gaskets
There are two types of door sealing gaskets that must be
considered, the access door perimeter sealing gasket and the
access door side sealing gasket. The proper maintenance of the
access door sealing gaskets is critical to the performance of the
system. Check the gaskets carefully whenever the gas-phase
chemicalltersarereplaced.Ifgasketsareworn,frayed,or
damaged in any way, they should be replaced. Check the seal
between the door and the housing whenever new SAAF
Cassettes are installed.
5.10 General System Maintenance
Ducts, external RU surfaces, access doors, and other system
infrastructure should be checked at least every six months.
InternalRUsurfacesshallbeexaminedwheneverltersare
replaced.Examineallcomponentsforthefollowing:
17
5.10.1 Cleanliness: Sweep and vacuum all standing dust or
dirt in the system and damp wipe all surfaces. Be mindful of
the impact of cleaning solvents on the performance and life
ofthegas-phasechemicallters,andtakeappropriate
precautions to protect the system.
5.10.2 Water: The system should be completely dry at all
times. The presence of standing water, condensation, or
dampness is detrimental to the performance and life of the
system. Determine and remove the cause for the presence
of water in the system, dry the system, and examine all
components for the presence of mold and other biological
growth. Remove all contamination, and clean and sterilize
as necessary.
5.10.3 Filter System Integrity: Ensurethatalllterframes
containtheappropriatelterelements,bothparticulateand
gas-phase, and that these elements are correctly installed.
Check for missing or improperly installed components and
reviewthelterseals.Checkforairleaksatjointsandseams,
replace gaskets and worn hardware, and seal with caulk
as necessary.
5.10.4 Duct and System Integrity: Examine the entire system
toensurethatcontaminatedaircannotleakaroundthelter
system. Check all perimeter seals and repair as necessary.
5.10.5 Corrosion: If metal components are corroded, repair
the corrosion and provide protective coatings as necessary.
Be mindful of the impact of painting on the performance and
lifeofthegas-phasechemicallters,andtakeappropriate
precautions to protect the system. Determine the source of the
corrosion and rectify.
6.0 Troubleshooting
6.1 High Pressure Drop Reading Across the Filter System
6.1.1 High Dust Loading: The most probable cause of high
pressuredropwillbehighdustloadingoftheparticulatelters.
The rate of dust loading may not always be constant and may
besignicantlyaectedbyseasonandlocation;e.g.,thetiming
of pollen blooms, production schedules, and rural versus urban
locations.
6.1.2 High Airow Volume:Highairowvolumemayresult
fromimpropercontrolofthefan.Whencleanparticulatelters
are installed in the system, the pressure drop across the
systemwilldecreaseandtheairowwillnormallyincrease.
Theairowshouldbecontrolledthroughtheuseofavariable
speed control, or if the system is ducted, modulating dampers
canalsobeusedtocontrolairow.Modulatingdampersare
designed to keep the system pressure constant.
6.1.3 Condensation: Humid air combined with cold surfaces
may result in condensation of moisture and blinding of both the
particulateandgas-phaselters.Thismoisturecanalsoresult
in mold growth and corrosion, which may also impact the
performanceoftheltersystem.Ifcondensationisarecurring
problem,dehumidicationorothertemperingoftheairmaybe
required. Additional system insulation may also be necessary.
If the source of the moisture is at the intake, weather hoods
or weather louvers to remove sensible moisture, in the form of
rain, should be considered. If the source of moisture is from
leaking ducts, repair the leaks.
6.1.4 Freezing: On air intake systems, the presence of
moistureinthelterswhencausedbyorcombinedwith
condensation, rain, snow, sleet, or ice, and when subjected
tofreezingtemperatures,cancausethelterstofreezeand
become impassible. In such cases, provide intake protection
systems to remove the cause of the problem.
6.2 Visible Discharge of Particulate
Checkformissingordamagedltersandsystemleaks.Replace
ltersandre-sealasnecessary.
Providehighereciencyltersonthedownstreamside(air
leaving side) of the system.
6.3 Odors and Smells
Checktheperformanceofthegas-phasechemicallters.Ifthe
ltersarenolongereective,replacethem.
Checkformissingordamagedltersandsystemleaks.Replace
ltersandre-sealasnecessary.
6.4 Vibration
If excessive vibration or noise occurs, check the fan to ensure
thefollowing:
• Thefanisrmlyboltedinplaceandhasnotcomeloose.
• The components of the fan are moving freely and moving
parts are not rubbing.
• The fan wheel is running smoothly and has not gone out
of balance.
• The fan wheel is clean and has not become unbalanced
from accumulated dirt.
• The fan motor is running smoothly.
• The fan and motor bearings are running smoothly and are
not overheating.
• The fan is operating within the stable portion of the fan curve.
18
7.0 Spare Parts List
It is recommended that the following spare parts be stored at
the installation site for routine maintenance purposes. The
quantities required will depend on the size of the system.
Consult with your AAF Flanders representative to determine
actual quantities required. Minimum recommended quantities are
provided in the table below.
8.0 Equipment Characteristics, Dimensions,
Operating Weights, and Shipping Weights
See the AAF Flanders submittal drawing supplied on the
specicorder.
9.0 Technical Guidelines
9.1 Fan Selection and Sizing
The following guidelines are provided to inform the user of the
criteria used by AAF Flanders to select an integral fan that is
provided with the RU.
9.1.1 Determination of Fan Selection Pressure Drop: The
followingconcernsinitialandnallterpressuredropandthe
useofpressuredropforfanselection.AAFFlanders’standard
productliteratureindicatesthestart-up,beingthecleanlteror
initial,andtherecommendednal,ordirtylter,pressure
dropsforallltersataparticularairowvelocity.Iftheairow
velocityintheactualinstallationdiersfromthatreferencedin
the literature, then the start-up (initial) pressure drop will also
dier.Forinstance,anAAFFlandersPerfectPleatorM-Pak
lteristypicallyratedat500FPMvelocity.However,whenused
withatypeHDcassette,theairowvelocitywillnormallybe
250 FPM so the initial pressure drop will be lower. Similarly,
thenalpressuredropreferencedintheliteratureisa
“recommended”valueonly,andtheltermaybechanged
out at a lower pressure drop, if required.
AAF Flanders Part Number Description Recommended Spares
Refertotheoriginalcustomerpurchase SAAFcassettegas-phasechemicallters Onefullreplacementsetofeachtype
order and the AAF Flanders submittal drawing included in the system
Refertotheoriginalcustomerpurchase Particulatelters Onefullreplacementsetofeachtype
order and the AAF Flanders submittal drawing included in the system
2500932 Extruded plastic strips which provide 20% of the number supplied
low friction cassette bearing surface with the equipment
2500924 Hollow core track gasket One full replacement set or a roll of 50 feet
2500981 Access door perimeter gasket One full replacement set or a roll of 50 feet
2500999 Access door side seal gasket One full replacement set
Refer to the original customer purchase Fan One replacement fan
order and the AAF Flanders submittal drawing
Toorderreplacementpartscall:1-800-477-1214.
AtypicalpressuredropproleforanRUmightbeasshownin
Table3below:
Table3:NominalPressureDrop(ΔP)@250FPMNominal
AirowVelocity
PressureComponent InitialΔP(in.w.g.) FinalΔP(in.w.g.),
Recommended
or Actual
External pressure 0.10 0.10
loss from inlet and
outlet ducts
2″PerfectPleat®0.11 1.0
HD Cassette with 0.73 0.73
SAAFOxidant™
HD Cassette with 0.73 0.73
SAAFOxidant™
After-lter 0 0
M-Paklter 0.23 1.5
TOTALS 1.90 4.06
19
9.1.2 Issues to be Considered when Selecting the Fan:
There are a number of issues to be considered when
determiningthefandesignandselectioncriteria:
1. If the fan is selected for the maximum pressure drop
shown (4.06 in. w.g.), then it will have been selected for an
operatingpointthatwillrarelyoccur.Thismaybeinecient
in terms of energy usage (motor HP), physical fan size, and
product cost.
2. If the fan is selected for the maximum pressure drop
shown (4.06 in. w.g.), then it will deliver far more than the
requiredairowatthelowerstart-uppressuredrop(1.90
in.w.g).Unlesstheairowiscontrolledbyusingbalancing
dampers or a variable speed drive, this may result in
discomfort from high discharge velocities, high noise levels,
highenergyuse,andinecientlterperformance.
3. Conversely, if the fan is selected for the minimum
pressure drop shown (1.90 in. w.g.), then it will deliver far
lessthantherequiredairowatthehighernalpressure
drop (4.06 in. w.g). This may result in inadequate air supply.
Alternatively,thelterscanbereplacedbeforetheyreach
theirnalrecommendedpressuredrop,whichresultsin
higherlterreplacementcosts.
Otherfactorstobeconsideredare:
4. The space available inside the cabinet. This limits the fan
style or size that can be accommodated within the cabinet.
5. The costs associated with providing non-standard fans,
or fan or motor control systems.
6. The type of fan to be selected. For instance, will a
non-overloading fan wheel be required?
7. Power available in terms of voltage, phase, and frequency.
8. Special parameters, such as special electrical,
environmental, explosion, or temperature requirements.
As is evident from this discussion, there are a number of
factors to be considered when selecting the appropriate fan.
9.1.3 AAF Flanders’ Policy Regarding the Provision of
Internally Mounted Fans: Items1&2arestandardoerings,
anditem3isanoption:
1. When the size of the cabinet allows, AAF Flanders will
supplyafancapableofgeneratingthedesignairowatthe
average pressure drop through the system. In the case of
table 3, the average pressure drop is 0.5 x (1.90 + 4.06)
= 2.98 in. w.g. An external pressure drop of 0.1 in. w.g. is
assumed. A backward inclined non-overloading fan wheel
will be supplied unless otherwise advised.
2. When the size of the cabinet limits the fan selection (nor-
mally on special smaller RU sizes), AAF Flanders will advise
the maximum performance that can be supplied by a fan
thatwilltintothespaceavailable.Anexternalpressuredrop
of 0.1 in. w.g. is assumed. A backward inclined non-over-
loading fan wheel will be supplied unless otherwise advised.
3. Whenthecustomerspeciesafanperformancethatis
dierentfromthatbasedonthedesignairowatthe
average pressure drop through the system and the size of
the cabinet is not an obstacle, AAF Flanders will select a fan
tomeetthespeciedrequirements.Thiswillnormallyoccur
when the external static pressure drop exceeds the standard
value of 0.1 in. w.g.
SeeAAFFlanders’submittaldrawingfortheorderinquestion,
for the details of the fan supplied and its performance.
PerfectPleat®and VariCel®are registered trademarks of AAF International in the
U.S. and other countries.
SAAF™Air Purification Systems
Recirculation Unit and Pressurization and Recirculation Unit
9920 Corporate Campus Drive, Suite 2200, Louisville, KY 40223-5690
888.223.2003 Fax 888.223.6500 | aafintl.com
AAF Flanders has a policy of continuous product
research and improvement and reserves the right to
change design and specifications without notice.
©2017 AAF International and its affiliated companies.
ISO Certified Firm GPF-3-107B 01/17
This manual suits for next models
7
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