Frick AcuAir User manual

AcuAir®
Hygienic Air Units
Form 210.100-IOM (JUL 2018)
INSTALLATION - OPERATION - MAINTENANCE
File: SERVICE MANUAL - Section 210
Replaces: 210.100-IOM (JUL 2017)
Dist: 3, 3a, 3b, 3c
THIS MANUAL CONTAINS RIGGING, ASSEMBLY, START-UP,
AND MAINTENANCE INSTRUCTIONS. READ THOROUGHLY
BEFORE BEGINNING INSTALLATION. FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN DAMAGE OR IMPROPER
OPERATION OF THE UNIT.
Please check www.johnsoncontrols.com/frick for the latest version of this publication.

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION - OPERATION - MAINTENANCE
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls policy for continuous
product improvement, the information contained in this docu-
ment is subject to change without notice. While Johnson
Controls-Frick makes no commitment to update or provide
current information automatically to the manual owner, that
information, if applicable, can be obtained by contacting the
nearest Frick Factor or the nearest Frick Sales ofce.
It is the responsibility of operating/service personnel to verify
the applicability of these documents to the equipment in
question. If there is any question in the mind of operating/
service personnel as to the applicability of these documents,
then prior to working on the equipment, they should verify
with the owner whether the equipment has been modied
and if current literature is available.
This equipment is a relatively complicated apparatus. During
installation, operation, maintenance or service, individuals may
be exposed to certain components or conditions including,
but not limited to: refrigerants, oils, materials under pressure,
rotating components, and both high and low voltage. Each
of these items has the potential, if misused or handled
improperly, to cause bodily injury or death. It is the obligation
and responsibility of operating/service personnel to identify
and recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure to comply
with any of these requirements could result in serious damage
to the equipment and the property in which it is situated, as
well as severe personal injury or death to themselves and
people at the site.
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
This document is intended for use by owner-authorized
operating/service personnel. It is expected that this indi-
vidual possesses independent training that will enable them to
perform their assigned tasks properly and safely. It is essential
that, prior to performing any task on this equipment, this
individual shall have read and understood this document and
any referenced materials. This individual shall also be familiar
with and comply with all applicable governmental standards
and regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:
CAUTION CAUTION identies a hazard which
could lead to damage to the ma-
chine, damage to other equipment
and/or environmental pollution. Usually an instruction will
be given, together with a brief explanation.
DANGER DANGER indicates an imminently
hazardous situation which, if not
avoided, will result in death or seri-
ous injury.
NOTICE NOTICE (or ASSEMBLY HINT) is used
to highlight additional information
which may be helpful to you.
WARNING
WARNING indicates a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.
NOTE: For Product Warranty Support, call 717-762-2121
WARNING
External wiring, unless specied as an optional connection in the manufacturer’s product line, is NOT to be connected
inside the micro panel cabinet. Devices such as relays, switches, transducers and controls may NOT be installed inside
the micro panel. NO external wiring is allowed to be run through the micro panel. All wiring must be in accordance
with Johnson Controls-Frick's published specications and must be performed ONLY by qualied Johnson Controls-Frick
personnel. Johnson Controls-Frick will not be responsible for damages/problems resulting from improper connections to
the controls or application of improper control signals. Failure to follow this will void the manufacturer’s warranty and
cause serious damage to property or injury to persons.

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION - OPERATION - MAINTENANCE
TABLE OF CONTENTS
INTRODUCTION
SAFETY ............................................................................4
WARRANTY......................................................................4
PREINSTALLATION REQUIREMENTS
TRAINING & SAFETY CONSIDERATIONS ........................... 6
PRELIMINARY SITE LAYOUT CONSIDERATIONS ................ 6
PRELIMINARY FIELD PIPING DESIGN CONSIDERATIONS .... 6
INSTALLATION
RECEIVING & INSPECTION ................................................ 8
STORAGE.......................................................................... 8
SUPPORT STRUCTURE INFORMATION ............................ 10
SECTION RECONNECT SHIP LOOSE ITEMS ..................... 11
INSTALLATION TOOLS .................................................... 11
GENERAL SPLIT UNIT REASSEMBLY ................................ 12
REMOVABLE LIFTING LUGS............................................. 12
ELECTRICAL WIRING/PIPING ........................................... 12
Roof Curb Assembly (Optional).......................................12
Roof Curb Installation .....................................................12
PERFORMANCE GRADE CONNECTIONS .......................... 13
REASSEMBLY PROCEDURE FOR SPLIT UNIT
PERFORMANCE SERIES ONLY...................................... 13
RECONNECTION ATTACHMENT AND SEALING
PROCEDURE................................................................ 14
INSULATION OF THE BASE RECONNECT SEAM OF AN
ACUAIR PERFORMANCE SERIES UNIT ......................... 15
ACUAIR PERFORMANCE SERIES
ROOF SEALANT PROCEDURE .......................................17
FOOD GRADE AND SANITARY CONNECTIONS ................ 18
RECONNECT INSTALLATION PROCEDURE ....................... 18
ACUAIR FOOD GRADE OR SANITARY SERIES
ROOF RECONNECT FINISH ........................................ 19
INSULATION OF THE BASE RECONNECT SEAM OF AN
ACUAIR FOOD GRADE OR SANITARY SERIES UNIT...... 21
FOAM KIT 15 USE GUIDELINES
ACUAIR UNIT BASE RECONNECT INSULATION............. 22
ACUAIR FRESH AIR INTAKE PLENUM .............................. 23
FAN HOLD-DOWN / SPRING ISOLATOR SETUP............... 25
CONDENSATE DRAIN TRAP SIZING ................................. 26
DRAIN PAN CONSTRUCTION........................................... 26
FIELD PIPING REQUIREMENTS ........................................ 26
DUCT CONNECTIONS.......................................................27
WEATHER HOOD CONNECTION DIRECT TO THE ACUAIR
FRESH AIR OPENING ................................................... 28
FILTER INSTALLATION TABLE OF CONTENTS................... 30
FILTER LATCHES.............................................................. 30
ACUAIR SINGLE FILTER APPLICATION (NON-HEPA)......... 31
HEPA FILTER APPLICATION ............................................. 33
NON-HEPA FILTERS IN HEPA FRAMES ............................ 33
Installation of 4” Pleated Panel (Pre)Filters.................... 34
Installation of SH Single Headered Filters...................... 34
Installation of a RIGID DH Double-Headered lter ......... 34
HEPA FILTERS ................................................................. 36
START-UP
INITIAL START-UP ...........................................................37
Blower, Motor, Drives .....................................................37
NEW BELT RUN-IN ..........................................................37
Filters .............................................................................37
Cooling Coils...................................................................37
START-UP AFTER PROLONGED SHUTDOWN.................... 38
MAINTENANCE
DAILY OPERATION AND ROUTINE MAINTENANCE........... 39
COIL MAINTENANCE....................................................... 39
DAMPER MAINTENANCE ................................................ 39
FILTER MAINTENANCE ....................................................40
ELECTRICAL CONDUIT SEALING REQUIREMENT..............40
Sources of Water or Ice................................................. 40
Remedy ......................................................................... 40
TEMPERATURE SENSOR CALIBRATION ...........................40
Two calibration methods are: ........................................ 40
UNIT CLEANING AND SANITATION.................................. 41
WHITE RUST AND WET STORAGE STAIN OF
GALVANIZED STEEL..................................................... 41
FAN BEARING LUBRICATION ........................................... 42
Recommended Lubricant for Fan Bearings .................... 42
Proper Interval and Quantity - See Tables 1, 2 & 3........ 42
FAN SEGMENT-FAN MOTOR ........................................... 42
Mounting Hardware and Adjustable Motor Base............ 42
Motor Condition (Visual)................................................ 42
Electrical Checks............................................................ 42
Lubrication..................................................................... 43
INSPECTING V-BELTS AND SHEAVES..............................44
TENSIONING V-BELTS AND SHEAVES .............................44
OPERATING AND MAINTENANCE INSTRUCTIONS FOR
PIEZOMETER ............................................................... 46
RECOMMENDED MONTHLY SERVICE .............................. 46
MAINTENANCE INTERVALS............................................. 47
RECOMMENDED MAINTENANCE INTERVALS .................. 47
SPARE PARTS RECOMMENDATIONS ............................... 47
TROUBLESHOOTING
ACUAIR FACTORY START-UP ASSISTANCE ..................... 49
ACUAIR AIR HANDLER PRESTART-UP CHECKLIST........... 50
PRESTART-UP (For Site Records).................................... 50
APPENDIX

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION - OPERATION - MAINTENANCE
INTRODUCTION
This manual, in combination with the appropriate controls
related manuals, provides the information necessary to safely
install and start up Frick AcuAir®equipment. Due to the custom
nature of the AcuAir®products there may be areas beyond the
scope of this manual. If there are any questions about a special
application lacking the required information, please contact
the installing contractor or your local Frick Sales Ofce.
SAFETY
The customer is responsible for providing qualied and trained
personnel to install and operate the equipment. Consult all
local building, occupational safety, electrical, gas, and other
codes applicable to the installation.
A variety of optional safety features are available from the
manufacturer; it is the responsibility of the owner to determine
if the unit is equipped with all of the safety devices required
for the particular application.
Safety considerations include:
1.The accessibility of the equipment to non-service personnel.
2.The provision of electrical lockout switches.
3.Maintenance procedures.
4.Automatic control sequences.
CAUTION
Users and installers of this equipment should be aware
of all recommended safety procedures and information
such as AMCA publication 410-90-Safety Practices.
CAUTION
Never open an access door while air unit is in operation.
WARRANTY
NOTICE
For Warranty Support with the Frick AcuAir unit, contact
Frick Service at 717-762-2121.
CAUTION
A fan, even though locked out electrically, can rotate in
a seemingly insignicant air ow. During maintenance
the impeller should be secured to restrict rotation. Verify
that the restrictive device is removed before putting the
fan back into service.
CAUTION
Equipment wired to automatic control devices may start
without warning, resulting in personal injury or property
damage. In many instances, a unit will have multiple elec-
trical connection points. To prevent unforeseen startup,
prior to beginning work on a hygienic air unit, always
lock out all power supplies.
CAUTION
Always replace any protective covers removed for ser-
vicing.
CAUTION
Always replace bolts or locks on latches of access doors
that provide access to areas with moving parts. This
mechanical protection from moving parts is required by
UL 1995 (See Figure 1).
CAUTION
A number of additional safety issues are discussed
throughout the manual. Please read the complete manual
prior to installing, operating, or servicing the equipment.

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION - OPERATION - MAINTENANCE
Figure 1 – Access Door Latch
1.25
1.50
LATCH FRONT VIEW LATCH SIDE VIEW
DANGER
WITH LOCK, BOLT OR SCREW
PRIOR TO OPERATION SECURE THIS ACCESS
OR PROPERTY DAMAGE
CAN CAUSE PERSONAL INJURY
CONTACT WITH MOVING PARTS
DISCONNECT AND LOCKOUT POWER BEFORE SERVICE

PREINSTALLATION REQUIREMENTS
TRAINING & SAFETY CONSIDERATIONS
The AcuAir®precision-engineered hygienic air systems
provided by Johnson Controls-Frick, utilize the nest in HVACR
materials and corrosion protection to deliver dependable,
consistent, and accurate control of temperature and humidity
in process rooms. This manual provides the information
needed for safe installation, operation, and maintenance.
Close attention to the instructions and guidelines provided
will ensure the longest possible system life and dependable,
consistent performance.
CAUTION
Before installing, operating, or maintaining the system,
it is recommended that only experienced HVACR
contractors, operators, and maintenance technicians
be used (in conjunction with formal training on the
AcuAir®system’s design and features). Reading and
understanding of this manual should serve as the
minimum application-specic training requirement.
AcuAir®system installation, operation, and maintenance
involves heavy rotating machinery operating at high speed and
high voltage. Normal operations and maintenance procedures
may require working at elevations, enclosed space entry, or
use of hand and power tools. Taking these considerations into
account along with the hygienic nature of AcuAir®applications,
it is clear that safety should always be the top priority.
We recommend that every AcuAir®system user analyze and
develop an installation-specic safety regime that takes
into account such variables as specic site/system features,
personnel qualications, hazard identication, etc.
The following elements of operational safety are recommended
for inclusion in every client’s AcuAir®system safety plan/
requirements:
NOTICE
Congure all power switches and controls to provide an
open, safe circuit before and during maintenance pro-
cedures, until the system is cleared by management for
normal on-line operations. For extended shutdowns, it
is recommended that a qualied 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®system.
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 the doors open.
Enclosed space inspections – Inspections of coils, lters, 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
investigated, identied, and corrected before testing or placing
the system back in operation.
Wet Surface Precautions – Poorly maintained and wetted
machinery requires care to avoid electrical shocks from
inadequate or loose eld wiring and connections. All personnel
must lock out and tag machinery before working on the unit.
Proper safety precautions such as the use of insulating soles
and gloves and a trained “lookout buddy” are indispensable.
Ice formation in cold weather can present slip and fall hazards.
Icing safety procedures should be mandatory when the daily
ambient temperature falls below 40°F.
AcuAir®systems typically serve in a continuous-duty capacity
and must be properly sited, installed, and connected in the
eld (by others) to appropriately sized and installed wiring for
electrical power and controls, air ducting, refrigerant lines, and
fuel piping. The engineering plans, piping layouts, etc. for all
peripheral “eld” work should be detailed in accordance with
local and governing codes and the best industry 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.
PRELIMINARY SITE LAYOUT CONSIDERATIONS
All AcuAir®systems must be located to minimize the effect
of exhaust air recirculation. Prevailing winds, other structures
or even other air handling units can cause exhausted air to
be drawn back into the AcuAir®unit. Short cycling air in this
manner can create an excess cooling load, condensation
load or in cold climates, frost blockages. It is the owner’s
responsibility to properly locate each system and consult with
a qualied engineer before laying out structural or foundation
supports and installing the AcuAir®system.
Sufcient access must always be available to allow adequate
airow 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 orice is at or above the elevation of
nearby walls, structures, and equipment.
For other minimum spacing requirements see the generic
layout in Figure 2 for examples showing an AcuAir®system
installed next to a wall.
PRELIMINARY FIELD PIPING DESIGN
CONSIDERATIONS
CAUTION
All AcuAir® systems require strongly supported and
properly anchored eld piping. NO eld piping 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 eld piping. A qualied cooling system
design engineer should provide nal eld-piping plans
and specications.
Before nalizing piping installation plans, it is recommended
that related plans for system and plant expansion be discussed
with your refrigeration system designer.
210.100-IOM (JUL 2018)
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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION

Figure 2 - AcuAir System-to-Wall Spacing Requirements
NOTES:
1. The minimum distance from the exhaust fan housing to
any sensitive object in the discharge air stream is 2 fan
diameters. Any closer and the object may be damaged.
The minimum recommended distance from the exhaust
fan housing to an airow obstruction (such as a wall) is
4 fan diameters for a single fan and 6 fan diameters for
two exhaust fans.
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 object is 48". The installation of the AcuAir unit must
be in accordance with the codes of the authorities having
jurisdiction.
4. The AcuAir hygienic unit will have sections under both
positive and negative pressure with respect to ambient
during normal operation. When piping the individual
drain pan outlets to a common drain line AcuAir
recommends individual p-traps. The piping design should
take into account the pressure inside the specic section
and the elevation required to create the necessary trap.
See page 26 for help designing the drain piping.
5. Consult the refrigeration contractor as to how much
space is required for the coil piping. A minimum walk
space of 30" should be left between the nal eld piping
to any object.
6. As with any large equipment placement consideration of
maintenance, service and part/component replacement
should be allowed when designing space for the unit.
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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
FLOOR DRAIN
CONN. TYP.
FLAT
PREFILTERS
FINAL FILTERS
LIQUID INLET CONN. (Typ.2)
COIL OUTLET CONN. (Typ.2)
WEATHER
HOODS
SMOKE
DETECTOR
AMMONIA
DETECTOR
WS1
S3
P-CONE
GAUGE GAS TRAIN & CONTROLS
R1
P1
P2
R2
S2
L
S4
H
Y
FILTER PRESSURE
GAUGE (TYP. 2)
*Generic unit layout shown. Please consult the order specic unit layout drawing before beginning site engineering.
SEE NOTE 4
SEE NOTE 1
SEE NOTE 3
SEE NOTE 2

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
INSTALLATION
RECEIVING & INSPECTION
Frick®AcuAir®units are inspected and tested prior to
shipment, ensuring a high quality product. Upon receipt of
the unit(s), inspect for any damage that may have occurred
during shipment.
Upon delivery, compare items on the bill of lading with the
items on the shipment to verify all parts have been received.
Any shortage, breakage or damage noticed at time of delivery
should be indicated on the carrier’s freight bill and signed by
the driver or carrier’s representative. Damage, noticed after
delivery, should be reported to the carrier at once. Request
their inspection of the shipment and ll out a concealed damage
inspection report.
Located on the inside of fan section access door is a
handwritten list of eld install items shipped with the unit.
Items typically shipped loose include:
FAN SECTION
Acu-Shield Roof Coating (see Figure 14) (optional)
Thermal Break Gasketing (see Figures 9, 11, 15 & 17)
Split Reconnect Hardware (Nuts, bolts, polyurethane
caulking)
Extra Fan Belts (If Ordered)
Installation and Start-Up Manual
Lifting Lugs
Filters & Filter Clips (Typically Shipped Separately)
FILTER SECTION
HEPA Filter Latches ship loose and/or attached to HEPA
lter frames
NOTICE
Shortage of eld installed items must be reported within
ten (10) days after receipt of order.
STORAGE
Short term storage is considered six (6) months or less from
date of shipment. Storage maintenance during this time period
is usually limited to the following:
Indoor Storage
1. Store units in dry, indoor protected area on a rm at
surface to prevent unit distortion.
2. Protect units from excessive vibration and accidental impact.
3. Do not store other equipment on top of or inside unit.
Outdoor Storage
Whenever possible, unit should be stored indoors or under
cover. If unit must be stored more than 1 week outdoors,
Johnson Controls-Frick recommends the following guidelines:
1. Cover all oor openings and secure all doors.
2. Tarp unit to protect unit from dust, rain, snow and rodents.
(Tarp over the roof and down the side to the base channel
and secure.)
3. Store on level surface. If unit must be raised off ground,
supports under base channel and base channel cross supports
at maximum interval of 5 feet.
4. Fan wheels should be rotated by hand 90° every month.
Lightly lubricate bearings every two (2) months.
5. A 200-watt light bulb needs to burn continually in each section
to prevent water condensation inside unit.
6. Inspect and ventilate each section every 2 weeks to pre-
vent them from getting musty and to ensure that unexpected
problems are addressed immediately. Special care may be
required for electrical or electronic components.
Storage of Units with Ammonia Sensors
WARNING
Ammonia detection electrochemical sensors are subject
to degradation when stored in warm or humid conditions.
Special storage measures recommended.
Chemical cell gas sensors (Ammonia Detectors) inside AcuAir
hygienic units are sensitive to storage temperatures and
humidity. The electrochemical sensor begins to degrade
immediately upon manufacture. The degradation process is
worsened in the presence of warm to hot temperatures as
well as high humidity. For this reason gas detector sensor
cell warranty is strictly based on time lapse from the date it
is purchased from the manufacturer and irrespective of the
date the AcuAir unit is placed into active duty. For optimal
sensor life involving storage:
• Remove the electrochemical sensor cell
• Place the cell in a zip-lock style storage bag
• Store the bag with the cell in a space maintained between
35°F and 40°F - such as a refrigerator.
Following these procedures does not extend warranty on
any chemical sensor cell.
NOTICE
Gas detector electrochemical sensor cells are a degrad-
ing component irrespective of active service. Warranty
on these sensor cells is strictly based on that extended
by the manufacturer and is irrespective of when the air
unit is placed into active service.
Long Term Storage
Long-term storage is considered to be any period beyond
six (6) months from date of shipment. (See Form 210.100-SB
Long Term Storage) If long-term storage of the AcuAir unit
is anticipated, contact your Johnson Control-Frick sales
representative at the time of order entry for proper instruc-
tions and requirements for long-term storage.
A delayed start up warranty for up to 1 year is available for
a cost premium and documentation of storage and main-
tenance compliance. Delayed Start up Warranty must be
purchased prior to units shipping from the factory.
See forms 210.100-SB1, 210.100-SB2, and 210.100-SB3
for long term storage details and the delay of warranty
commencement.

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Page 9
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 3 – Recommended Lifting With Four Lifting Points
Figure 4 – Recommended Lifting With Multiple Points
SPREADER BARS
MUST BE WIDER
THAN THE UNIT WIDTH
TO PREVENT DAMAGE
TO THE HOUSING
RIGGING INSTRUCTIONS:
FOR LIFTING AIR HANDLERS WITH LIFTING LUGS, USE SPREADER BARS AND CABLES AS
INDICATED. DO NOT USE A FORKLIFT. ALL LIFTING LUGS MUST BE USED TO AVOID DAMAGE.
SPREADER BARS MUST BE
WIDER THAN THE UNIT
WIDTH TO PREVENT
DAMAGE TO THE HOUSING.
Lifting & Handling
The unit will ship (as specified on unit submittal) either
assembled, as a subassembly (collection of parts), or as
individual sections.
WARNING
When lifting individual AcuAir sections, weight may not
be evenly distributed causing the section to be unbal-
anced or top heavy.
To prepare for safely lifting the air unit, estimate the
approximate center of gravity. Internal placement of
components may cause the weight to be unevenly distributed,
with more weight in the coil and fan areas.
Removable lifting lugs are provided to rig the unit/sections into
place. Spreader bars are required to prevent damage to the
cabinet and protruding components during a lift. The lugs are
positioned at the face of the sections to facilitate lifting the
sections at the factory for securing on truck trailers. Lifting lugs
can be relocated to sides of the individual sections to facilitate
placement on site supports. Use all lifting lugs provided. Adjust
the tension in each line for proper load distribution, (See
Figures 3 and 4 for recommended lifting).
WARNING
When lifting; use all lifting lugs to avoid damage and/or
personal injury. Lifting lugs are shown in Figure 5.

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Page 10
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 5 – Lifting Lugs
WARNING
Do not lift non-base units or subassembly by attaching
clevis hooks, pins or bolts to casing, casing hardware,
angles, tabs or anges.
LD07923A
HOUSING
BASE SKIN
LIFTING LUG
PERIMETER
CHANNEL
Do not lift non-base units or subassemblies by attaching clevis,
hooks, pins, bolts, etc. to casing, casing hardware, angles, tabs
or anges. See CAUTION !Lift the air unit only in an upright
position. Never lift or move a unit on its side or upside-down.
CAUTION
If you do not rig or lift the unit carefully, you could
damage the unit, hurt yourself or others. USE CAUTION!
SUPPORT STRUCTURE INFORMATION
AcuAir®systems may be shipped in two or more sections.
These sections must be anchored to a suitable support
structure - concrete pads, concrete piers, or structural steel,
capable of supporting the total system operating weight plus a
signicant safety margin as determined by a qualied structural
engineer. The weight the support structure must support and
the anchoring requirements will vary with live loads (expected
snow/ice buildup) seismic, and wind loading. See Figures 6
and 7 for AcuAir unit support methods.
If the support structure is in the form of two or more parallel
steel beams, the beams should be sized in accordance with
standard engineering practices. The structure must be capable
of supporting the shipping weight of the unit as provided on
the order related document, plus any operating-duty-related
loads such as: water or refrigerant within the cooling and
heating coils; possible frost on the cooling coils; any applicable
ooded refrigerant surge vessel and associated piping; snow
loads that could accumulate on the roof; horizontal wind
loads; etc.
It is recommended that the structure be designed for at least
110% of the operating weight of the system distributed as
a uniform load over the longitudinal beams, allowing for a
maximum deection of 1/360 of the length, not to exceed 1/2".
The support structure, whether concrete pads, concrete piers,
or structural steel, on which the units are to be located should
be rigid and level (shim if required).
Shims should be placed at intervals no greater than 5 feet apart
and should not be used to compensate for signicant surface
slope. The sum total of any individual stack of shims should
not exceed ½” and are to be used to compensate for surface
irregularities only. On units more than 150 inches wide the
foundation shall support not only the perimeter base channel,
but also the midpoint of each unit split. (Reference Figure 6)
Consult factory if housekeeping pad is not continuous.
The AcuAir unit must be secured to the Support structure. It
is the installer’s responsibility to be sure the unit is secured
in accordance with applicable codes.
NOTICE
Shims may be used between the AcuAir unit and the
supporting structure. When shims are used they should
be spaced no more than 5 feet apart. Shim stacks should
not exceed 1/2 inch in height.
ASSEMBLY HINT
Units must typically be SLID into nal position. Applying
grease to the support surface may make this easier.
NOTICE
Save bolts when removing lifting lugs. Bolts will be used
for assembly of split units.

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ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 6 - Generic Structural Steel Support
ALTERNATE METHOD OF
INTERMEDIATE SUPPORT
LOCATED AT UNIT SPLIT(S)
WHEN REQUIRED
(Required on units 150" or wider)
Figure 7 - Generic Roof Curb Support
LOCATE AT CENTER OF UNIT WIDTH FOR
SUPPORT OF AIR HANDLERS 150” OR WIDER
(Optional lateral unit split supports on units 150" or wider
as represented below in Fig. 7 - Roof Curb Support.
NOTES:
1. SEE UNIT INSTALLATION DIMENSION DRAWING FOR UNIT WIDTH,
LENGTH AND WEIGHT.
2. ALTERNATE METHODS OF SUPPORT TO INCLUDE
SUPPORT AT ALL SECTION SPLITS.
* SUPPORT DESIGNED AND SUPPLIED BY OTHERS.
DRAWING FOR REFERENCE ONLY.
** LEGS TO SUPPORT THE FRAME ABOVE
THE FINISHED ROOF. NUMBER OF
LEGS AND DESIGN BY OTHERS.
SECTION RECONNECT SHIP LOOSE ITEMS
• AcuShield Roof Coating
• Joint Sealing Caulk
• Seal Gasket Tape
• 1/4" Bolts and Nuts
• Electrical Conduit Sealing Putty
INSTALLATION TOOLS
To complete the installation of an AcuAir®system, the
following tools are required:
• Drift Pins
• 8-Foot Straight Edge
• Level
• Assorted Open-End Wrenches
• Socket Set
• Caulk Gun
• Tape Measure
• Chain Falls
• Screw Gun with Nut Drivers
• Paint Brush or Roller for Applying AcuShield Roof Coating

210.100-IOM (JUL 2018)
Page 12
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Roof Curb Assembly (Optional)
1. When supplied by Johnson Controls - AcuAir®, roof
curbs ship either fully welded or in pieces. If bolted curb
construction, bolt together.
2. Curb must be level (shim if required). Shims (at fractions
of inch) should be placed at intervals no greater than 5 feet
apart. Shims are not intended to compensate for roof pitch.
Individual stacks if shims should not exceed 1/2" in height. On
large units with splits, remember to shim at the split’s midspan
(see Figure 8).
3. The installer is responsible to secure the roof curb to the
building structural support in accordance with local codes.
4. Seal all roof curb joints and seams with a suitable sealer/
polyurethane caulk to prevent water leakage.
Roof Curb Installation
1. Verify that the curb is level and secured to the roof.
2. Verify that there is adequate height between the base of
the unit and the roof to allow for drain trapping.
3. Install a 1/8" thick neoprene gasket on the top of the curb
to provide a seal between the unit and the roof curb. If the
unit or unit sections must be slid into place, a polyurethane
sealant may be used in lieu of the gasket.
4. Lift the unit in place.
5. The installer is responsible to secure installation in
accordance with the local codes.
Figure 8 – Roof Curb Detail
SPLIT
MIDSPAN
GENERAL SPLIT UNIT REASSEMBLY
Units which are shipped in sections, must be installed on a
proper foundation and carefully assembled to provide the
required unit performance.
• AcuAir units are assembled in one piece in our factory and
split prior to shipping.
• AcuAir units must be level for reassembly.
• All bolts, nuts, washers, split covers and polyurethane
caulking (if required) can be found in supply fan section.
• All splits are identied with welded let-
ters on the base channel (A-A, B-B, for
example) to indicate which sections are
to match up for reassembly.
REMOVABLE LIFTING LUGS
You will be provided with removable lifting lugs along either
the width or length of the various sections of the unit. (Lifting
lugs may be repositioned prior to lifting). Once the sections
have been placed as close as possible to each other, remove
any lifting lugs in the reconnect split. A hand-actuated winch or
a come-along can be used to bring the unit sections together
for nal bolting. Attach the hand winch or come-along to each
side of the base using the lifting lugs relocated to the alternate
side locations and draw the sections together.
ELECTRICAL WIRING/PIPING
It is the installer’s responsibility to reconnect all internal and
external electrical or piping splits. All wires are colored and/
or numbered to designate which wires should be joined at
each split. Before turning on power, check all electrical circuits
for continuity.
MATCH
A
→
MATCH
A
←

210.100-IOM (JUL 2018)
Page 13
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
REASSEMBLY PROCEDURE FOR SPLIT UNIT
PERFORMANCE SERIES ONLY
1. Position sections on level surface.
2. Apply polyurethane caulk in two parallel continuous beads
on both faces as indicated in Figures 9, 10 and 11.
3. Attach hand winches to either side of the base via relocated
lifting lugs and pull the sections together. Bolt base per Figure 9.
ASSEMBLY HINT
It may be advantageous to locate the rst section in
it's nal position and attach it to the support structure
before pulling the next section into position.
4. Install the reconnect ange attachment hardware starting
from the middle of the bottom angle working around to the
middle of the top angle, making use of a drift pin to align the
holes. Bar clamps may be needed to align the roofs together.
If bar clamps are needed, use wood for protection in between
the bar clamp and unit.
5. Split seams that have internal access to both sides of
split will be reattached with bolts and nuts. Split seams with
internal access to only one side of split will have cage nuts
on the blind side and bolts installed from accessible side. All
bolt holes require a bolt.
6. If bolt holes do not align, it may be due to racking during
transit to job site. Use jack to lift one side until holes on the
wall of the opposite side align. Bolt this wall together and
then remove jack from opposite side. As the unit settles, the
out-of-square racking caused during transit should realign.
7.
Once the sections are drawn together and the reconnect anges
are aligned and attached, apply two parallel beads of caulk along
either side of the reconnect seam on the exterior of the AcuAir unit
as shown in
Figure 13.
8. Install the shipping split covers as shown in Figure 13 using
the #10 TEK screws and washers provided. Apply a ne bead
of caulk to either edge of the split cover and allow time to dry.
9. Once the shipping cover is in place and the caulk has had
time to set, apply the roof coating as shown in Figure 14.
10. INSPECT all splits to see if polyurethane caulk was applied
and split was bolted properly.
11. Reconnect all electrical conduit and wiring at the
reconnect junction boxes. Use electrical conduit sealing putty
to seal all conduit openings into and out of the junction box to
prevent the migration of moisture. (reference the information
on page 42)
12. INSPECT all splits to see if all electrical and piping
connections are complete and correct.
NOTICE
Temporary roof supports and diagonal (shipping) sup-
ports should not be removed until the split sections are
completely reassembled. See Page 18 for Food Grade and
Sanitary Connections!
INTERNAL RECONNECT
(AcuAir Performance Series Only)
.75 FLATWASHER
.75 HEX BOLT
(USE FROM LIFTING LUG) .75 HEX NUT
(USE FROM LIFTING LUG)
.75 SPLIT WASHER
.75 FLAT WASHER
.25 MINIMUM DIA. PARALLEL CONTINUOUS BEADS OF
POLYURETHANE CAULKING REQ’D (BOTH FACES OF SPLIT)
PRIOR TO REASSEMBLING
RECONNECT, HOUSING, AND
HARDWARE NOT SHOWN THIS SIDE
FOR CLARITY
HOUSING
Figure 9 – Base Assembly Attachment - Relates to AcuAir Performance Series Unit Only
PERFORMANCE GRADE CONNECTIONS

210.100-IOM (JUL 2018)
Page 14
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 10 – Cross Section Of Split Wall Assembly - AcuAir Performance Series Only
EXTERIOR SKIN
APPLY POLYURETHANE CAULK TO SURFACE
AFTER REASSEMBLING SECTIONS
LINER
INTERNAL RECONNECT
.25-20 X .75 HEX BOLT WITH .25 FLANGED LOCKNUT
(SUPPLIED BY JOHNSON CONTROLS)
POLYURETHANE CAULKED
BETWEEN SECTIONS IN FIELD
Figure 11 – Multi-Section Reconnect Sealing of AcuAir
Performance Series Units
INTERNAL
RECONNECT
FLANGE
.25” MIN DIA CONTINUOUS
POLYURETHANE CAULK
SEE NOTE 1
HARDWARE
START POINT
SEE NOTE 4
RECONNECTION ATTACHMENT AND SEALING
PROCEDURE
(See Figure 11)
1. Apply a generous amount of polyurethane caulking to the
two faces of the housing and split plate as shown.
2. Pull sections together from the base split plate until they
meet.
3. Clamp off bottom leg of reconnect until no gaps are visible.
4. Install reconnection ange hardware starting from the
middle of the bottom angle working around to the middle
of the top angle, making use of a drift pin to align the holes.
Bar clamps may be needed to align the roofs together. If bar
clamps are needed use wood for protection in between the
bar clamp and unit.
5. Once unit sections have been joined, contractor to seal
the exterior and interior reconnect seam with polyurethane
caulk.

210.100-IOM (JUL 2018)
Page 15
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
INSULATION OF THE BASE RECONNECT SEAM
OF AN ACUAIR PERFORMANCE SERIES UNIT
When two AcuAir unit sections are drawn together the base
channels of the two sections form an uninsulated cavity that
under certain conditions could produce condensation. AcuAir
provides a ship loose foam insulation kit to ll this cavity as
part of the reconnect procedure.
On the Performance Series air units this insulation must be
injected from underneath the unit after the sections have
been securely joined.
Follow the instructions in the section "FOAM KIT 15 USE
GUIDELINES" on page 21 for preparing the two part foam
mixture and the injection kit. Take special note of the 30
second inactivity limit after which the injection nozzle may
become permanently clogged.
Foam should be injected into the cavity at a rate of 3 - 4
bd-ft per linear foot of seam. This will mean a 15 bd-ft can
of expanding foam will ll between 4 - 5 linear ft of AcuAir
reconnect seam.
INTERNAL RECONNECT
(AcuAir Performance Series Only)
.25 MINIMUM DIA. PARALLEL CONTINUOUS BEADS OF
POLYURETHANE CAULKING REQ’D (BOTH FACES OF SPLIT)
PRIOR TO REASSEMBLING
RECONNECT, HOUSING, AND
HARDWARE NOT SHOWN THIS SIDE
FOR CLARITY
HOUSING
Foam Injected
From Underneath
Figure 12 – Foam Injection Underneath Base Assembly Attachment - Relates to AcuAir Performance Series Unit Only
NOTICE
INJECT THE FOAM INTO THE OPEN SEAM AFTER THE
AIR UNIT SECTIONS HAVE BEEN SECURELY
RECONNECTED.
NOTICE
IF FOAM DISPENSING HAS STOPPED FOR MORE THAN
30 SECONDS, REPLACE THE NOZZLE WITH THE
EXTRA PROVIDED.

210.100-IOM (JUL 2018)
Page 16
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
CAULK
CAULK
CAULK
CAULK
CAULK ALONG SCREW
HOLE LOCATION
#10-16 SS TEK SCREW
W/EPDM WASHER (TYP)
CAULK
SHIPPING SPLIT COVER
SHIPPING
SPLIT COVER
SHIPPING SPLIT
SHIPPING SPLIT
SHIPPING SPLIT COVER
SHIPPING SPLIT COVER
DETAIL B
DETAIL A
Acceptable Polyurethane Caulking:
Manus-bond, Gray, P/N 013-02966-001
Manus-bond, Champagne, P/N 013-03317-220
Bostik, Gray, P/N 013-03318-170
Bostik, Champagne, P/N 013-03319-170
Figure 13 – Split Reassembly Procedure For AcuAir Performance Series Units Only
CAUTION
Do not use silicone caulking on eld reconnects or on
shipping split covers.
NOTICE
Only use caulking shipped with unit.
NOTICE
Shipping split covers ship with the air
handler installed to one side of the re-
connect. Remove cover and install across
the split as shown on Detail A & B.

210.100-IOM (JUL 2018)
Page 17
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 14 – Outdoor Split Roof Sealant Procedure - AcuAir Performance Series Only
ACU-SHIELD ROOF COATING *
* Provided with ship loose items in fan section (see table in Section, "Receiving & Inspection").
CAULKING (PROVIDED)
ROOF
HOUSING SPLIT
3" MIN
ACUAIR PERFORMANCE SERIES
ROOF SEALANT PROCEDURE
(See Figure 14)
1. The mechanical joint between sections must be bolted and
sealed with polyurethane caulking.
2. Acu-Shield Roof Coating can be applied after polyurethane
caulking is dry and when surface temperature is between 45°F
and 108°F. Below 45°F, extra steps must be taken to keep
the polyurethane caulking, Acu-Shield, and metal reconnect
surfaces heated for proper application during installation.
Contact Product Service for further direction.
3. Do not apply when inclement weather is imminent within
a 24 hour period.
4. Do not apply to wet, ice, or snow covered surfaces.
5. Before applying, clean surface with wire brush or solvent
wipe (not provided).
6. Apply Acu-Shield Roof Coating with 3 inch wide roller or
3 inch wide paintbrush (not provided).
7. One quart applied at 45 mils is equal to a 3 inch wide X
33 foot long section.
8. Cure time will vary with temperature and humidity. Under
normal conditions, a rubber coating can be expected within
a 24 hour period.

210.100-IOM (JUL 2018)
Page 18
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
FOOD GRADE AND SANITARY CONNECTIONS
BASE CHANNEL
SPLIT COVER
BASE SKIN
CAULK EDGE OF COVER
AFTER ANCHORING
CAULK
Interior Finish Caulking
to be: DOW RTV-732
Food Grade Caulk
BASE
CHANNEL
3" x UNIT I.D.
SPLIT COVER
#12–24 x 1.25
TEK SCREW
W/EPDMWASHER
CAULK
BASE SKIN
C
L
SPLIT
.25" DIA CONTINUOUS
BEAD OF CAULK
TYP JOINT OF TWO SECTIONS WITH FLAT SURFACES
#12–24 x 1.25 TEK SCREW
W/EPDMWASHER
CAULK
BASE SKIN
BASE
CHANNEL
INTERNALWALL
FINISH BEAD
OF CAULK
C
L
SPLIT
1.5 X 1.5 X UNIT I.D.–0.5
SPLIT COVER
SIDE VIEW WHEN INTERNAL WALL IS AT A SPLIT
Figure 15 – Base Split Reassembly Procedure
RECONNECT INSTALLATION PROCEDURE
1. Position sections on level surface.
2. Apply polyurethane caulk in two parallel continuous beads
on both faces as indicated in Figures 15, 16 and 17.
3. Attach hand winches to either side of the base via relocated
lifting lugs and pull the sections together. Bolt the base anges
per Figure 15.
ASSEMBLY HINT
It may be advantageous to locate the rst AcuAir unit
section in its nal position and attach it to the support
structure before pulling the next section into position
against it.
4. The factory installed unit reconnect anges will be joined
using ¼” bolts and nuts shipped loose in a container in the
blower section of the unit. All bolt holes require a bolt.
If bolt holes do not align, it may be due to racking during
transit to job site. Use a jack to lift one side until holes on
the wall of the opposite side align. Bolt this wall together and
then remove jack from opposite side. As the unit settles, the
out-of-square racking caused during transit should realign.
Continue assembly with bolting other side, base, and roof,
making use of a drift pin to align the holes. Bar clamps may be
needed to align the roofs together. If bar clamps are needed,
use wood for protection in between the bar clamp and unit.
5. Check to see if all bolts are secured properly, and apply
polyurethane caulk to all exterior seams per Figures 18.
ASSEMBLY HINT
It is recommended that the base ange bolts be only
loosely tted prior to tting all 1/4" reconnect external
ange bolts. Once all of the 1/4" ange bolts are in place,
tighten the base ange bolts and nish tightening all of
the reconnect ange bolts. This sequence will help make
alignment of the reconnect ange holes a bit easier.
6. Apply two continuous .25” dia. beads of caulk on either
side of the oor section split. Reference either the lower left
or the lower right views of Figure 15.
7. Center the split cover over the oor split and two parallel
beads of caulk. Attach the split cover using #12 TEK screws.
It may be necessary to predrill holes through the base ange
for the TEK screws.
8. Seal the edges of the split cover with beads of caulk as
shown in Figure 15.
9. Inspect all splits to see if polyurethane caulk was applied
and split was bolted properly.
10. Reconnect all electrical conduit and wiring at the reconnect
junction boxes. Use electrical conduit sealing putty to seal all
conduit openings into and out of the junction box to prevent the
migration of moisture. (reference the information on page 42)
11. Inspect all splits to see if all electrical and piping
connections are complete and correct.

210.100-IOM (JUL 2018)
Page 19
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
Figure 17 – Multi-Section Reconnect Sealing On AcuAir Food Grade and Sanitary Series Units
POLYURETHANE
CAULK
BASE RECONNECT FLANGE
.25 DIA
CONTINUOUS
BEAD OF CAULK
EXTERNAL RECONNECT
EXTERIOR SKIN
HCS NC GR5 .25 X .75
WITH FLANGE LOCKNUT NC .25-20
SPLIT REATTACHMENT ANGLE
Interior Finish
Caulking to be:
DOW RTV-732
Food Grade Caulk
INTERIOR WALL PANEL
POLYURETHANE FOAM
INSULATION
CONTINUOUS FINISHING BEAD
OF CAULK ALONG INNER SEAM
Figure 16 – Cross Section Of Split Wall Assembly
NOTICE
Temporary roof supports and diagonal (shipping) supports
should not be removed until the split sections are
completely reassembled.
ACUAIR FOOD GRADE OR SANITARY SERIES
ROOF RECONNECT FINISH
1. The mechanical joint between the unit sections must be
bolted and sealed with polyurethane caulking prior to applying
the roof coating.
2. Acu-Shield Roof Coating can be applied to the roof
reconnect after any exposed polyurethane caulking is dry and
when surface temperature is between 45°F and 108°F. Below
45°F, extra steps must be taken to keep the polyurethane
caulking, Acu-Shield, and metal reconnect surfaces heated
for proper application during installation. Contact Product
Service for further direction.
3. Do not apply roof coating when inclement weather is
imminent within a 24 hour period.
4. Do not apply to wet, ice, or snow covered surfaces.
5. Before applying, clean surface with wire brush or solvent
wipe (not provided).

210.100-IOM (JUL 2018)
Page 20
ACUAIR®HYGIENIC AIR UNITS
INSTALLATION
CAULK
SHIPPING
SPLIT
CAULK
SHIPPING SPLIT COVER
CAULK
CAULK
SHIPPING
SPLIT COVER
SHIPPING SPLIT COVER
CAULK ALONG RECONNECT
HOLE LOCATION
CAULK
SHIPPING SPLIT
DETAIL A
DETAIL B
Acceptable Polyurethane Caulking:
Manus-bond, Gray, P/N 013-02966-001
Manus-bond, Champagne, P/N 013-03317-220
Bostik, Gray, P/N 013-03318-170
Bostik, Champagne, P/N 013-03319-170
Figure 18 – Split Reassembly Procedure For AcuAir Food Grade and Sanitary Series Units Only
6. Apply Acu-Shield Roof Coating with a good quality
synthetic bristle paintbrush (not provided).
7. One quart applied at 45 mils is equal to a 3 inch wide x
33 foot long section.
8. Cure time will vary with temperature and humidity. Under
normal conditions, a rubber coating can be expected within
a 24 hour period.
CAUTION
DO NOT use silicone caulking on eld recon-
nects or on shipping split covers.
NOTICE
Only use caulking shipped with unit.
NOTICE
Shipping split attachment angles
come attached to each side of split.
Reattach with provided hardware.