HUNTAIR FANWALL Technology Retrofit Operating and safety instructions

9
OPERATION AND MAINTENANCE DATA
PROJECT: BDMC Women’s & Infant Services
1B Antepartum Unit
LOCATION: Mesa, AZ
CONTRACTOR: Comfort Systems USA SW
SUBMITTED BY: Climatec, Inc.
2851 W. Kathleen Rd.
Phoenix, AZ. 85053
602-944-3330
MANUFACTURER: Huntair
PRODUCT: Fanwall Technology Retrofit
Air Handling Unit
FWT
TAGS: AHU – 1
DATE: 8/25/11

INSTALLATION/MAINTENANCE
GUIDE
FANWALL Technology®Retrofit
Improper installation, adjustment, alteration service or maintenance
can cause property damage, injury or death. Read the installation,
operating and maintenance instructions thoroughly before installing
or servicing this equipment.
FOR YOUR SAFETY

TABLE OF CONTENTS
GENERALDESCRIPTION............................................................................................................ 1
INSTALLATIONCODES/PRECAUTIONS ................................................................................. 1
INSTALLATION
SHIPLOOSEITEMS/INSTALLATIONTOOLREQUIREMENT ..................................... 2
FANWALLASSEMBLY
ELECTRICALCONNECTIONS......................................................................................... 3
DEMOLITION .................................................................................................... 4
FANWALLASSEMBLYANDINSTALLATION ................................................................ 5,6
WIRING ............................................................................................................................ 7
CAULKING ....................................................................................................................... 8
FAN/CONEALIGNMENT............................................................................................... 9,10,11
OPTIONAL
VFDPOLY TUBINGINSTALLATION.............................................................................. 12
MAINTENANCE ............................................................................................................................ 13,14
START-UP .................................................................................................................................... 15
TROUBLESHOOTING .................................................................................................................. 16
START-UPINSPECTIONREPORT............................................................................................. 17
WARRANTY .................................................................................................................................. 18
PAGE
© Copyright 2011, HUNTAIR, Inc.
ALL RIGHT RESERVED. NO PART OF THIS BOOK MAY BE REPRODUCED,
STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY FORM BY AN
ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING MEANS OR
OTHERWISE WITHOUT THE WRITTEN PERMISSION OF HUNTAIR, INC.
COPYRIGHT 2011.
Themanufacturer reservestheright tomodify thematerials and specificationsresulting froma continuingprogramof
productimprovement orthe availabilityof newmaterials.

GENERAL DESCRIPTION
1
INSTALLATION CODES
Electricalcharacteristicsareshownontheunitratingplate.
The unit shall be carefully installed in accordance with the
standards of the National Fire Protection Association (Na-
tionalElectrical Code).
Authorities having jurisdiction should be consulted
beforeinstallations are made to verifylocalcodes and
installationprocedures.
INSTALLATION PRECAUTIONS
1. The services of qualified field service personnel are
mandatoryforsafeandproperinstallationofthisequip-
ment.
2. Air volumes and external static pressures that do not
coincide with those listed on the rating plate will ad-
versely affect the performance of the unit. Please
consult the factory if either of these values change.
3. Thefollowingclearancesfromcombustiblematerialsare
to be maintained: Top - 6", control side - 48", opposite
controls - 6", bottom - 0". If roof curb is provided by
others, it must be at least 4" high and constructed from
non-combustiblematerial.
4. This unit is designed for installation on a level surface.
5. Do not locate the supply inlet opening within 10' of any
exhaustdischargepointorwithin24"ofanyobstruction.
INSTALLATION CODES / PRECAUTIONS
Follow all safety codes. Wear safety glasses and work
gloves.
WARNING
Before installing or servicing system, always turn off
main power to system. There may be more than one
disconnect switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury
or death.
CAUTION: Beforeproceeding,makesureallelectrical
service to unit is locked in “Off” position.
GENERALDESCRIPTION
HuntairFanwallTechnology®isafan-arrayapproachtoair
handlerdesignthatthatusesseveralsmallerfanstoreplace
onelargerfan,providingdesignflexibility,reducingmainte-
nance costs, and increasing energy savings.
Safety Considerations
Installing and servicing air conditioning equipment can be
hazardous due to system pressure and electrical compo-
nents. Onlytrainedandqualifiedservicepersonnelshould
install or service air conditioning equipment.
Untrainedpersonnelcanperformbasicmaintenance,such
as cleaning and replacing filters. All other operations
should be performed by trained service personnel. When
working on air conditioning equipment, observe precau-
tions in literature and on tags and labels attached to unit.

22
Common Ship Loose Item
5/16-18WHIZBolts —
5/16-18FlangeNuts—
1/4-20 x 3/4 Self Tapping Tek Screws —
#10-32 x 3/8 Type F Pan Phillips Self Tapping Screws —
#12-24x 1-1/2UnslottedHWTselfTapping TekScrew—
In-lineOrificeRestrictor—
1/4 Inch Flat Washer —
3M540PolyurethaneCaulking—
Or Sikaflex 1a Caulking —
Touchuppaint—
Optional Red and Blue Poly Tubing for VFD Controls —
FANWALLInstallationTools
1/2 inch End Wrenches
1/2 or 3/8 inch Socket set
ImpactDriver
NutDriverBit Set
Note:
Verifiy ship loose pieces with the ship loose packing slip to ensure that all ship loose items are
present and accounted for. Some items on the packing list may not be depicted on this page.

ElectricalConnections
Allelectricalwiringandconnectionsincludingelectricalgrounding
mustbemadeinaccordancewiththelatesteditionoftheNational
ElectricCode(ortheeditionyourauthorityhavingjurisdictionhas
adopted). There may also be local ordinances that apply.
a. TheFWTnameplateandthedrawingsinthesubmittalpackage
statethelinevoltageandminimumamperagerequirementsfor
this unit. A separate line voltage power supply should be run
directly from the building distribution panel to the electrical
panelprovidedonthesideoftheFWTunit. Thequantityofwires
and the connection terminals are identified on the wiring
diagramin the submittalpackage. Allexternal wiring mustbe
within approved conduit and have a minimum temperature
ratingof90°C.
b. IMPORTANT: Ifanyoftheoriginalwiresuppliedwiththeunit
must be replaced, it must be replaced with type THHN 90°C
wireoritsequivalent,exceptformiscellaneous120voltcontrol
wiring that must be type SJO 90°C.
c. Refer to the submittal package for other control interface
connections.
INSTALLATION
3
General Maintenance
HUNTAIR’sFANWALLTECHNOLOGY®payscarefulattention
given to balance in the design and construction of the units.
Each unit uses standardized precision parts, and is individually
spin-balancedat the factory to eliminate vibration. Forthis
reason,whenever maintenance workisdoneonthemotor or if
thefan is removedfrom themotor shaft, rebalancingthe fan is
required.

4
FANWALL ASSEMBLY
FANWALLAssembly
DANGER! Risk of Electric Shock
Alwaysdisconnectpowerto the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
Verifyfactoryfurnishedcomponentsarecompleteagainst
enclosed packing list. Each FANWALL retrofit cube is
numberedandmustbelocatedinthearrayperthesubmittal
drawing. Cellnumberingalwaysbeginsintheupperlefttop
cell,runsleft to right,then begins at theleft end oftherow
beneath that. Fan cells are banded to a skid and shrink
wrappedforshipment. Cellsusedontheperimeterofafan
array have insulation retaining panels, interior cells have
just insulation.
CELLIDENTIFICATION
Priorto demolition of existing fan:
Verify that FANWALL cube dimensions are correct and
assembled array will fit inside existing air handling unit.
InternaldimensionsofairhandlerwereprovidedtoHUNTAIR
by others.
1. Disconnect power to the existing fan at the main
disconnectcontrol panel.
2. Make note of all wire locations for reinstallation later.
3. Disconnectexistingfanmotorpowercablefromtermi-
nallocatedinmotorJ-BoxandconduitfittingfromJ-Box
asshown in thedemolition drawings.
4. Remove existing fan/motor assembly and clean the
areathoroughly.
FANARRAYNUMBERINGSAMPLE
Individualcomponentssuch as theelectricalchase and
motor removal rail, etc. are shipped on a separate skid.
REMOVEEXHISTINGFAN
EXHAUSTINGFAN
REMOVED
LOCATE & MARK
FANCELLS WITHFANCELLS WITH
FANCELLS WITHFANCELLS WITH
FANCELLS WITH
INSULATIONRETAININGINSULATIONRETAINING
INSULATIONRETAININGINSULATIONRETAINING
INSULATIONRETAINING
PANELSONSHIPPINGSKIDPANELSONSHIPPINGSKID
PANELSONSHIPPINGSKIDPANELSONSHIPPINGSKID
PANELSONSHIPPINGSKID

FANWALL ASSEMBLY
5
FANWALLAssembly
5. Makesure that floor on airhandler is level and rigid.
6. Determinetheoffset for theassembled array (from in-
sidepanels) on both sides ofunit so that the fan array
is centered in the air tunnel and mark accordingly.
7. Align the first fan cell frame needed at the bottom row,
furthest from the access door. Make sure to maintain
the correct distance from the unit side panel. Hoist the
next fan cell on top of the first fan cell and secure with
5/16-18WHIZboltsand5/16-18 flangenuts.
8. Repeat this process until the proper number of fan
cellper column has been obtained and thenumber of
columns has been reached. SEE FIGURE 1.
9. Onceyouhavereachedthecorrectnumberofcolumns,
slide the second column into place next to the first
column as tight as possible. Make sure that the cell
side insulation sheets have been installed in both the
firstand second fan columns. Bolt together using the
5/16-18WHIZ bolts and 5/16-18 flange nuts.
10. Repeat process until all fan columns are in place.
SEE FIGURE 2.
FIGURE1
FIGURE2
Insulation

5
6
11. Fill the void space with the specidied insulation be-
tween the top of the assembled FANWALLarray and
the unit roof.
12.Securetheside and topblank-offs to thecellframes on
boththeinletanddischargesideoftheFANWALLusing
the5/16-18 WHIZ bolts and 5/16-18 flange nuts. The
blank-offs have one flange with a matching hole pat-
tern with the fan cells.
13. Secure the blank-offs to the roof and side panels using
the1/4-20 x3/4"selftappingtekscrews on10inchcen-
ters.
14. Once all the insulation and blank-offs have been in-
stalled. Secure the FANWALL to the base by using
the #12-24 x 1-1/2" unslotted HWT self tapping tek
screws and 1/4 inch flat washer.
FANWALLAssembly
FANWALL ASSEMBLY
Insulation
Blank-offs

FANWALL ASSEMBLY
7
FANWALLElectricalInstallation
DANGER! Risk of Electric Shock
Alwaysdisconnectpowerto the fan control panel
before maintenance. Follow all lockout and tag
out procedures.
1. Verify fanwall assembly install is complete.
2. Install electrical chase on the discharge side
usingdrivescrews. Seeseprateinstallationdesign
drawings.
3. AttachFMC (flexible metalconduit) from motor j-box
(Pecker head) to electrical chase using FMC con-
nectors.
4. Sizewire (per NECcode) andpull from motor(s) to
enclosure/j-box.
5. Wireinternalmotorconnection.
A. Crimponringterminals.
B. Boltterminalstogetherforwhatevervoltageyouare
using(seemotornameplate).
C. First layer wrap with Friction tape (3M Varnished
Cambric).
D. Secondlayerwithrubbersplicingtape (3M 130C).
E. Thirdlayerusevinyltape(3MSuper33).
Note: 3 wraps on all taped layers.
6. Hi-potwires.
7. Connect wires to Enclosure / j-box.
ELECTRICALCHASE
MOTOR J-BOX
FLEXIBLEMETAL
CONDUIT (FMC)
FMCCONNECTOR
8. Install electrical chase cover with #10-32 x 3/8 type
Fselftappingscrewsprovided.
9. Re-assemble air handling unit walls, doors, safety
devices etc. that removed during retrofit per
manufacturer'srecommendations.
10. Prior to connection to main power check fan wheel/
cone alignment per instructions starting on page 8.
11. Perform VFD startup as specified by VFD manufac-
turer.
12. Verifythatthefansarerotatinginthecorrectdirection
asindicatedbythefanrotationstickerandoperatingat
requiredCFM at design static pressure.
Note: If fans are rotating in the opposite direction of
the fan rotation sticker. DO NOT correct rotation
by switching Line or Load wiring of the drive
units. Change rotation by switching wires on the
Load side of the MSP.
ELECTRICALCHASECOVER
FMC TO ELECTRICAL
ENCLOSURE
FMC MOTOR J-BOX
TOELECTRICAL CHASE
Flexible Metal Conduit
to motor J-Box
Ring Terminals
All electrical work must be preformed by a
licenced electrician. All grounds are pulled
continuously thru fanwall chase without splic-
ing to accommodate for box fill calculations.
ELECTRICAL NOTE