Installation, Operational & Maintenance

Manual

MODULAR AIR HANDLING UNIT

Air Handling System

FASI03-2020/21A
 Content

Contents

Content ............................................................................................................................1
Safety Precautions .............................................................................................................2
Installation .......................................................................................................................3
Wiring Diagram .................................................................................................................6
Electrical Installation ..................................................................................................6
Motor Wiring Connection ..........................................................................................6
Electrical Heater Connection .....................................................................................7
Commissioning ..................................................................................................................8
Pre-Start Checklist ....................................................................................................8
Start-Up Procedure ....................................................................................................9
Servicing and Maintenance ................................................................................................ 10
Servicing Methods ................................................................................................... 10
Steam Type Humidifier: ........................................................................................... 11
High-pressure Spray Humidifier: ............................................................................... 13
Troubleshooting............................................................................................................... 17

Modular Air Handling Unit Model

FAC
FBC

© 2020 FRIMEC-INTERNATIONAL. All rights reserved.

Page 1
 Safety Precautions
Please read the following safety precautions carefully. Failure to follow safety precautions could
result in death or serious injuries.

Important:
• Installation of equipment in corrosive, combustive or explosive environment is strictly
prohibited.
• Do not use Oxygen, Acetylene, poisonous or any other gas that will cause explosion during
equipment leak test.

Warning:
• Installation and maintenance should be performed by qualified personnel who are
familiar with the product, local codes and regulations.
• The equipment must be installed according to local rules and regulations.
• Field-installed wiring must comply with local codes and regulations, and must be
carried out by qualified personnel.
• Power supply must comply with unit’s name plate specifications.
• The unit must be GROUNDED to prevent possible hazards due to insulation failure.
• Disconnect all electric power before servicing job in order to prevent any electric shock
or injuries caused by direct contact with moving parts.
• When working with live electrical components, have a qualified licensed electrician or
other individual who has been properly trained in handling live electrical components to
perform these tasks.

Caution:
• Avoid direct contact with sharp edges and coil surfaces which are potential hazards for
injuries.
• Ensure that the drainage piping is connected properly to prevent leakage of condensate
water.

Notice:
• This manual should be returned to unit’s designated place when installation is
complete.
• This manual should be read carefully before installation. Unit installation and service
should be performed by experienced technicians in accordance with manual’s
procedures to achieve normal and reliable unit operation.
• This manual does not cover all unit differences and problems that may arise during
installation. Please contact our local sales office for further information and assistance.
• Warning and Caution will appear in proper section throughout this manual, which should
be firmly conformed to ensure safety and better operation performance. We claim no
liability for unqualified installation or service.
• The manufacturer reserves the right to revise any of the specifications and designs
contained herein at any time without prior notification.

Page 2
 Installation

Caution: Don't step the feet on the top panel to avoid delamination occur during installation

General
1.Transportation
Depending on size of the units, transportation mode may be different. Units can be shipped
in full assembly if the size is small enough. Otherwise, they can be arranged to be shipped in
the form of CKD (Complete Knock Down).

2. Inspection and Acceptance

Before installation, check if all sections and components are in good condition. Inform the
dealer immediately if found any defect.

3. Placement of Unit
If unit needs to be placed outdoor, ensure the unit is free from dust, rain, snow and keep it
away from animals to protect the exterior finishing of the unit. The unit cannot be exposed to
hot sun or the insulated panels may be deformed or discolor. Do not stack units in storage.

4. Lifting of Unit
Keep the unit level while moving or lifting to avoid damage. Hoist the unit through lifting
holes provided. Ensure there is proper protection procedures adopted during lifting (for
example, to put chipboard/plywood to isolate the lifting cable and the unit) to protect the
surface of the unit.

5.Foundation
a) Leveling of the foundation will affect the installation and operation of the unit. If the
foundation is not level, the following problems could happen:
i. Difficult to install
ii. Air leakage at joints of panels and sections
iii. Condensate water discharge problem
iv. Fan installation problem
It is recommended that the difference of level to be within ±3mm.

b) The foundation can be made of concrete or welded steel. Keep the steel surface
smooth while welding. The height of foundation should not be less than 150mm. The
water drainage is required for discharge of condensation water and for maintenance
purposes.

Page 3
Ensure that the foundation able to withstand the total weight of unit. Add shock absorber under
the foundation if necessary.

6.Unit Installation
The installation must be done by certified installer. Take note of the following:
a) Strictly comply with the installation instructions provided.
b) Leave enough space for repair and maintenance.
c) Use flexible duct for section of duct connection between the unit and external air duct
to avoid vibration transmission.
d) The panels must be fitted tightly. Rubber gasket must be compressed properly to avoid
air leakage.
e) Air filter should be the last item to be installed.
f) Proper cleaning must be carried out to clean the interior of the unit to remove debris of
installation before commissioning.

7.Water Pipe Installation

1. Keep the water pipes clean and install filter at the inlet of water pump.

2. The condensate water pipes are positioned at the bottom of the unit. The U-trap needs to be
installed (refer diagram below) to ensure condensing water can be discharged freely and to
prevent in-flow of odor.

3. For Chilled Water Coil: Use torque wrench when installing the water inlet/outlet pipes.
The torque should be less than 250.8Nm (21kgf.m) to prevent heat exchanger from being
damaged. Install valves at water supply and return pipes outside the unit (except the
condensing water discharge pipes) for modulation of water volume and to isolate the unit
during maintenance. All the water pipes outside the unit should be properly insulated.

4. The standard chilled water temperature should not be lower than 5°C. Hot water temperature
should not be higher than 80°C and 60°C is the recommended hot water temperature.

5. If hot or chilled water is the media of the heat exchanger, the water inlet pipes are positioned
at the bottom and water outlet pipes are positioned at the top. If the media is steam, the air
inlets are positioned at the top and water outlet pipes are at the bottom.

6. All the water pipes must be sealed and ensure no leakage.

Water discharge pipe

H = Internal Static Pressure (mmH2O) + 20mm

Page 4
8.Vacuuming & Refrigerant Charging (For DX Coil)

1. Vacuuming is necessary to eliminate all moisture and air from the system

2. After the system piping is properly connected, vacuum the air conditioner system to at least
500 microns Hg.

3. Before charging, the vacuum must be held at 500 microns Hg for at least 15 minutes. After
charging, operate the unit for 15 minutes, ensuring that refrigerant charges is of correct
quantity by monitoring running current and suction and liquid line pressures. Suction and
discharge pipe pressures should be in the region of 75 psig and 275 psig.

Page 5
 Wiring Diagram
Electrical Installation

Caution:

• Field-installed wirings must comply with local codes and regulations. Voltage tolerance
should be kept at rated voltage ±10%.
• Electrical wiring system should be kept away from transformer system, as it will induce
strong interference with electrical wiring system.
• Check if the main power supply matches the nameplate rating before installation takes
place
• Each air-conditioning unit should be equipped with independent electric supply furnished
with circuit breaker
• Unit must be GROUNDED properly
• Field-installed wiring must be connected properly according to enclosed wiring diagram

Motor
Motor Wiring
Wiring Connection
Connection

Note: U V W N U1 V1 W1 U2 V2 W2
For unit < 11kW - DOL Starter
For unit ≥ 11kW – Star-delta

0a 0a

Diagram A : DOL Diagram B : Star-delta

Note :
Note:
1. For unit < 11kW - DOL Starter.
1. For unit < 11kW – DOL Starter
2.2.ForFor
unitUnit
≥ 11kW
≥ 11kW- Star-Delta Starter.
– Star Delta Starter
3.3.Overload, fuse and thermal protection
Overboard, fuse and thermal protection are to beto
are installed
be at
field.
installed at field

Page 6
Electrical Heater Wiring Connection
Electrical Heater Connection
Power supply equipped
with circuit breaker

R S T N
SB0 SB1 SB2 KA FR

KA
KA KM1

KM2
KM1

KA KM1 70°C 110°C SA KM2

DT

Fan

Electrical
Heater

Legends:
QF=Circuit Breaker, FU=Fuse, KA=Relay, KM1=Fan Contactor, KM2= Electrical Heater Contactor,
SB0=Panic Button, SB1=Unit Stop Button, SB2=Unit On Button, SA=Electrical Heater On/Off Button, DT=Electrical
Heater Protection Switch

Warning:
The high temperature working condition of electrical heater may cause fire or injuries if it is
not handled with care.
Please make sure the following has been checked when working with electrical heater
• The protection switch has been installed correctly.
• Electrical heater is working properly.
• Electrical heater is connected to control circuit properly.
• Make sure electrical heater is able to be cut-off if malfunction.
• Make sure electrical heater is able to be cut-off when there is no airflow. Electrical
heater should only be switched on when the unit is operating with stable volume of
airflow.
• When stopping the unit from operation, electrical heater is switched off and fan is
allowed to run for another 5 minutes so that excess heating energy is drawn off from
the unit. (Fan should run longer if heating energy is greater)

Electrical connection for other components

1. Electrical connection of other unit components should follow the wiring diagram attached with the
unit.
2. Humidifier should have interlock connection with fan blower. This is to make sure that
humidifier could only be switched on when fan blower is on. Also, the fan blower could only be
switched off when humidifier is off.
3. Damper should be switched on/off before fan blower to make sure that fan blower is
operating under normal condition.
4. Unit could be equipped with 24V water-resistant light bulb and transformer upon request.

WARNING: ALL ELECTRICAL COMPONENTS MUST BE GROUNDED PROPERLY. FAILURE

TO DO SO COULD RESULT IN SERIOUS EXPLOSION, FIRES AND INJURIES.

Page 7
 Commissioning
Pre-Start Checklist
The following should be checked before the unit is ready for operation:
1. All operating personnel read the manual carefully.
2. Unit has been installed according to manufacturer’s specifications, local codes and regulations.
3. Power supply is in accordance with the nameplate ratings.
4. Field-installed wiring is according to manufacturer’s wiring diagram.
5. Field wiring and protection device are correctly sized and installed.
6. Unit’s power supply and controls are properly connected and unit is properly grounded.
7. Unit is properly isolated from vibration (i.e. unit isolation pad, hose kits)
8. Unit is serviceable. (Sufficient clearance space has been provided)
9. Piping system is clean, properly installed and free of leakage.
10. Piping is insulated, valves are opened, and air vent is closed.
11. Water is circulating well through the system.
12. Proper mix of heat transfer fluid has been added to prevent freezing in closed system
application.
13. Condensate water drainage pipe is not blocked, free of leakage.
14. Air duct (if necessary) is correctly sized, insulated and installed.
15. Ensure no debris in drain pan, blower filters and casing.
16. Blowers are free to turn, filters are properly installed.
17. Air trapped in water circuit has been released by using air vent.
18. Air filters installed should be clean and not damaged. Install nylon filters before the pre-filter
to make sure dust or dirt from the ducting does not contaminate the filter material. Medium
and high efficiency filters (HEPA) should only be installed after the unit commissioning is
completed.
19. Check if the spring isolators beneath the fan motor base are dismantled. These isolators
are installed to reduce vibration during unit transportation and should be removed before unit
operation.
20. Check if dampers have been installed and adjusted according to design specifications.
21. Check if the electrical insulation of the motor is within specification. Insulation resistance of
motor might be affected when it is not used for long period of time. Measure the resistance
reading of motor insulation, the reading should exceed 2MΩ at 25°C.

CAUTION: MOTOR INSULATION MUST BE DISCHARGED ELECTRICALLY AFTER RESISTANCE

MEASUREMENT TO AVOID ELECTROCUTION. IF THE READING DOES NOT REACH
THE REFERENCE VALUE, THE INSULATION HAS TO BE DRIED UP.

Page 8
Start-Up Procedure
1. Apply power to the motor for a short interval to check if the motor is rotating in the correct
direction.
2. Make sure the running current of motor does not exceed the rated motor current as shown on
motor’s nameplate during commissioning to avoid motor overload and motor burnt.
3. Stop the unit immediately if any unusual vibration or noise occurs.
4. Remove belt from motor drive package and allow the motor to run unloaded to determine if
the motor shaft is possibly bent.
5. If the vibration continues after all the checks above, lower the unit speed by approximately
10% to determine if a natural frequency is causing the vibration. Unit water coil should be
filled with water when this check is carried out.
6. Shut down the equipment after 24 hours of satisfactory operation. Re-check all set screws,
bolts, shaft bearing and tighten where necessary.
7. When unit is not operating during winter, close the fresh air damper, shut off the heating
cycle to prevent damage of heat exchanger from freezing.

CAUTION: DO NOT ALLOW THE UNIT TO OPERATE UNDER EXCESSIVE VIBRATION TO AVOID PERMANENT
DAMAGE TO THE UNIT.

Page 9
 Servicing and Maintenance
Servicing Methods
The following should be examined and replaced if necessary:

1. Coils should be cleaned frequently and periodically. After 2-3 years of operation, the internal
wall of water pipes should be thoroughly cleaned and if condition permit, use soft water.

2. If the unit is not in operation during winter, all the water in the system must be released,
otherwise the coil will crack.

3. Check the condition of filter periodically (recommend to check monthly). If the unit is equipped
with Pressure Differential Gauge, filter must be cleaned or replaced if the predefined value is
reached. Recommended value for different type of filters are as following:

Filter specifications Resistance value(Pa)

G3 (Pre-filter) 100-200
G4 (Pre-filter) 150-250
F5-F6 (Secondary filter) 250-300
F7-F8 (High Efficiency 300-400
F9-F11(Sub-HEPA filter) 400-450
HEPA filter 400-600

4. The belt tension should be re-checked one week after commissioning. Subsequently, it should
be examined once every 3 months.

5. The terminals for electrical wires should be re-tightened 3 days after commissioning.

6. Bearings for fan and motor must be examined periodically (recommended 3 months once).
Abnormality of bearings can be determined through abnormal noise and vibration of fan,
excessive usage of lubrication oil or through special bearing testing devices. Once the faulty
bearings are identified, they should be replaced immediately.

7. It is recommended to check the rubber gasket, flexible ducts and connections monthly.
Immediate replacement is necessary if it is found to be leak.

Page 10
Steam Type Humidifier:

1. Humidifier should be cleaned thoroughly before installation to remove dirt and foreign
particles that could clog the electronic modulating valve.

2. Water strainer and shut-off valve should be installed before entering point of humidifier.

3. Drain valve and water fill valve should be installed at the same level after the humidifier.

4. Wiring for modulating valve should be connected properly.

5. Pressure relief valve must be installed when pressure within steam pipeline is > 0.4MPa.

6. When steam gas is supplied to humidifier, shut-off valve should be opened gradually to
build up the pressure and to prevent the electronic valve from clogged. Meanwhile, the
drain valve should be opened to drain the condensate water within.

7. Humidifier should be switched off, when it is not used for long period of time. Maintenance
should be performed based on the surrounding humidity condition.

8. The throwing distance between the nozzle of humidifier and the bending point of air
duct system, reducer and discharge opening should not be less than 1.2m. And the
distance between the nozzle and temperature controller and temperature sensing point
should not be less than 1.5m.

Page 11
 Troubleshooting guide for Steam Type Humidifier:

Fault Possible Causes Remedial Action

Steam humidifier not No steam gas in the pipeline Inspect supply steam pipe
working Valve could not be open Open main pipe valve
Manual modulating valve not open Open manual valve
Solenoid valve not open Open solenoid valve
High humidity in Valve opening too large Reduce valve opening
conditioned area Pressure of steam gas too high Reduce steam gas pressure
Low humidity in Size of the supply steam pipe is too
conditioned area Replace to bigger pipe
small
Increase pressure with pressure
Pressure of steam gas too small
limit < 0.4Mpa
Valve opening is not large enough Increase valve opening
Clogged water strainer Clean or replace water strainer
Air leakage in ducting Inspect for leakage and repair
Exhaust air from conditioned room
Reduce exhaust air volume
too large
Humidifier too small Increase quantity of humidifier
Leakage of humidifier Loose connection of steam pipe and
Tighten the connection
hose
Broken seal Replace with new seal
Steam gas supply route has been Repair or replace parts that
deterred physically affect the supply
Moisture carried-over of Supply hose is too long, defective
humidifier Enhance the piping insulation
insulation, condensation of steam
Level the supply steam pipe
Supply pipe is not leveled properly, properly
causing backflush of condensate and install a water fill valve
Excess accumulated water in piping Open drain valve to release all
during unit start-up water
Replace with bigger water fill
Water fill valve too small or defective valve
Drainage opening of water fill valve
Clean the water fill valve
blocked
Humidifying effect has reached
Reduce humidifying capacity
saturated level
Shut-off or minimize humidifying
Humidity inside unit is too high capacity
Humidifying throwing distance is too Increase the throw
short distance of humidifier
Malfunction of solenoid Incorrect wiring Rectify
valve Actuator and controller signals do not Rectify
align
Incorrect actuator On/Off position Rectify
Damage of actuator control panel Replace
Motor/Internal parts damage Replace
Corrosion Repair/ Replace
Air leakage of solenoid Blockage of steam pipe at valve
valve Clean and clear blockage
opening
Loose fixing screw of valve body Tighten screw

Page 12
High-pressure Spray Humidifier:
Basic water supply requirements:
Water type : Tap water, purified water and etc.
Supply water pressure : 0.05MPa ~ 0.3MPa
Water temperature : 4°C ~ 60°C

Troubleshooting guide for High-pressure Spray Humidifier:

Fault Possible Causes Remedial Actions

Unit ON but equipment Power supply is not connected Supply power according to
is not working (Light required specification
Power supply is not according to the
indicator is OFF) specification
Unit ON but Fuse burn Replace fuse
equipment is not Water pressure is too small or no Increase water pressure
working (Light water
indicator is ON)
Humidity reaches setting value Normal
Inappropriate sensing point of Relocate sensing point
controller
Damaged control circuit Change control board
Unit ON, equipment Water is not supplied Connect the equipment to water
running, but not Blockage of water supply Clean water piping
spraying
Clogged water strainer Clean water strainer
Damaged solenoid valve Replace solenoid valve
Low pressure Water pressure too small Increase pressure of water
Piping leakage Repair or change water piping
Pump wear off Replace pump
Nozzles malfunction Nozzles clogged Clean nozzles
or abnormal Broken nozzles Replace nozzles
Pressure gauge Broken pressure meter Replace pressure meter
Nozzles still spraying Damaged solenoid valve Replace solenoid valve
when equipment is
switched off
Note: Humidifier should be allowed to run for 5~10 minutes every two months if it is not used
for long period of time

Page 13
Electrode Type Humidifier:

1. Basic supply water requirements:

Water type : Clean tap water, soft water
Conductivity : 125 ~ 1250μ s/cm
Resistivity : 800 ~ 8000 Ω
Supply water pressure : 0.1MPa ~ 1.0MPa Supply water temperature : 1°C ~
45°C

Water softener should be used when water hardness is large. Do not use de-ionized water
and distilled water.

2. The connection of outlet point of steam gas and the nozzle should be firm and not bended.

3. Unit is firmly installed and rigid.

4. Drain pipe material should be galvanized or any other material that could withstand high
temperature.

5. Supply water pipe should be insulated to prevent water condensation. Drain pipe should
also be insulated to prevent possible injuries caused by direct contact with the pipe.

6. Supply pipe should be cleaned thoroughly before installation to remove dirt and foreign
particles that could clog the humidifier.

7. Steam container should be cleaned every 200 hours. The container should also be inspected
for its seal and electrodes. Electrodes should be replaced every 2000 hours.

8. Steam container should be cleaned as follow:

Open drain valve, release all water within, switch off the humidifier, remove the plug of
the electrodes and mark as necessary.

9. Packaged type humidifier should be cleaned as follow;

After 150 hours of usage, manually open the drain valve to release all water within, close
the drain valve. Refill water into humidifier and drain it off again. Repeat for two or three
times. Humidifier container should be replaced when electrodes have been corroded.

Page 14
Hose Connection of Electrode Type Humidifier

20% and above

5% and below Higher level of

flexible hose
connection

Lower level of flexible

hose connection

Pressure Differential Gauge

Pressure differential gauge model used in the unit is Mark II.

1. Commissioning and installation
Inspect the oil level of the pressure gauge periodically. Use the zero-knob to adjust the
reading to zero, when pressure-tube is not connecting to any pressure (only atmospheric
pressure). Use mild soap water for cleaning to avoid damage to the pressure gauge meter.

2. Meter oil charging

Rotate the zero-knob anti-clockwise until it reaches the end. Turn the knob clockwise for
three rounds. (This will enable the knob to be adjusted to the mid position of the
adjusting range) Pull off the charging hole and start charging the meter oil until it
reaches zero. Rotate the zero-knob to fine-tune the zero calibration, and close the
charging hole.

CAUTION: SERVICE AND MAINTENANCE INFORMATION FOR UNIT EQUIPMENTS SUCH

AS PRESSURE DIFFERENTIAL GAUGE, HUMIDIFIER IS ONLY FOR REFERENCE
ONLY. ACTUAL INSTALLATION GUIDE SHOULD BE REFERRED TO THE
EQUIPMENT MANUALS PROVIDED.

Page 15
Maintenance Schedule

Frequency
Maintenance Task
Weekly Monthly Quarterly Half- Yearly
yearly
General Inspection for loose connection, excessive X
noise, leaks, poor insulation
Fan Equipment Checks:
Belt Tension X
Belt Wear X
Fan Motor Bearing Mountings X
Pulley Alignment X
Motor Amps X
Fan Wheel Cleanliness X
Evaporator Coil Checks
Clean Coil X
Clean Drain X
Clean Drain Pan X
Air Filter Checks:
Inspect and Clean X
Electrical Component Checks:
General Inspection for loose connection X
Check Control Panel Operation and Outputs X
Check Volts and Amps for imbalance X
Check Overheating of motors X
Cabinet Checks:
Inspect and Clean Rust X
Tighten Loose Screws X

Page 16
 Troubleshooting
Troubleshooting Guide

Problem Probable Causes Solutions

The impellers and fan bearings are
Fasten the bearing foundation.
loose.
Something inside the impellers. Shut down unit and remove the object.
Air ducts and adjusting valves are
Fasten.
loose.
Have belts and pulley looked at by
V-belts not properly in grove of
professional and or have belts adjusted
Noise pulley or improper tension.
to recommended tension.

Foundation of blower is loose. Fasten the panel.

The soft connector is too tight. Adjust or change suitable connector.
Rotating speed of blower is too high. Select suitable blower.
Low quality of lubricant Use high quality lubricant and clean the
bearings.
The filter is too dirty. Clean the filter.
The air ducts are not well sealed. Check and eliminate the leakage.
Shortage of Object blocking the air ducts or air
Check and remove the object.
Air Volume valve is not opened.
Improper speed of blower. Adjust the speed of the blower.
Improper selection of blower. Contact supplier for suitable blower.
The blower speed is too high. Adjust the speed.
Condensing water cannot be
Water Check and remove the dirt.
discharged freely. Water flows out
Leakage of the drain pan.

Air leakage Keep the unit sealed.

The inlet water is too high. Adjust the temperature.
Low The surface of heat exchanger is Clean the heat exchanger.
Cooling
Air volume is too small. Enlarge the air volume.
Capacity
Selection is not suitable. Select again.

Air Speed is Air speed is too high. Enlarge the air supply area.
too High Improper airflow Check the design of air ducts.
Open the fresh air duct larger.
Low/Poor Low fresh air volume
Clean the air filter.
Air Quality
Enlarge the air duct's cross section.

Page 17
 Installation, Operation & Maintenance Manual
MODULAR AIR HANDLING UNIT

Air-Side Products
FASI03-00