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CRITICAL ENVIRONMENT TERMINAL UNIT MODELS: SSLFHFD-FP, SSLFHFD-FP-MA, SSLFHFD-FP-MEA, SSLF, SSLFHFD, FRD, FRD-HEPA, HRDP, HRDP-HEPA, SSHEMI, SSHEMI-HEPA, SSEPD-N, SSEPD-T, SSEPD-TC INSTALLATION AND SERVICE MANUAL

A-J Manufacturing Co. * PO BOX 270320 * 3601 East 18th Street * Kansas City, MO 64127 Phone 816-231-5522 * FAX 816-231-8437 * Toll Free 800-247-5746

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MODELS AVAILABLE WITH FAN OPTION:

SSLFHFD-FP*

SSLFHFD-FP-MA*

SSLFHFD-FP-MEA*

MODELS AVAILABLE WITH LIGHTED OPTION:

SSLF

SSLFHFD

SSLFHFD-MA*

SSLFHFD-MEA*

FRD

FRD-HEPA

HRDP

HRDP-HEPA

SSEPD-**

NOTE: The lighted option is NOT available on the standard fan filter unit (SSLFHFD-FP).

* -- Can be 120, 208/240, or 277

** -- Can be N, T, or TC


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Critical operation conditions of the Fan Filter Unit

• DO NOT TOUCH the HEPA filter media. Damage to filter media may void the filter warranty. The screen is to protect against accidental contact with the filter. Never place objects on the filter. Always transport or lift the filter by its frame.

• Prior to powering the unit, verify that it is wired to the correct power supply. The rating plate label located on the electrical box cover shows the electrical data.

• For replacement parts refer to the model number and serial number on the rating plate label located on the electrical box.

Replacement Part numbers FPH-RP11 FPH 48 x 24 HEPA filter FPH-RP12 FPH 16 x 16 x 3/8 expanded aluminum pre-filter FPH-RP13 FPH 24 x 24 HEPA filter FPH-RP14 FPH 14 x 14 x 3/8 expanded aluminum pre-filter FPH-RP16 FPH 36 x 24 HEPA filter FPH-RP21 FPH Programmable variable speed motor (120, 208/240VAC) FPH-RP21 FPH Programmable variable speed motor (277VAC) FPH-RP31 FPH Control circuit board FPH-RP32 FPH 0-10VDC control circuit board FPH-RP33 FPH Network control circuit board FPH-RP34 FPH Fan verification kit FPH-RP35 FPH LED filter indicator Kit FPH-RP36 FPH 120/24VAC transformer FPH-RP37 FPH 208/240/24VAC transformer FPH-RP38 FPH 277/24VAC transformer FPH-RP39 FPH Network power control circuit board FPH-RP50 FPH LAMP 4’ T5HO White FPH-RP51 FPH Lamp 4’ T5HO Green FPH-RP52 FPH LAMP 2’ T5HO White FPH-RP53 FPH Lamp 2’ T5HO Green FPH-RP54 FPH Light Ballast FPH-RP55 FPH Light Ballast - Dimmable


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WARNING – TO REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, OR INJURY TO PERSONS, ALLOW ONLY QUALIFIED TECHNICIANS TO INTALL AND SERVICE THE UNIT. ALL

PERSONS SHOULD OBSERVE THE FOLLOWING:

a) Use this unit only in a manner intended by the manufacturer. If you have questions, contact the manufacturer.

b) Before servicing or cleaning unit, switch power off at the service panel and lock the service in accordance with OSHA (LOTO) practices and procedures to prevent power from being accidentally switched on avoiding accidental electric shock and injury. When the service disconnecting means cannot be locked, securely fasten a prominent warning device, such as a tag, to the service panel.

• Installation work and electrical wiring must be completed by qualified personnel in accordance with

all applicable codes and standards, to include fire-rated constructions. • When cutting or drilling into walls and ceilings, be careful not to damage electrical wiring and other

hidden utilities. • If this unit is to be installed within close proximity to water, mark the unit in accordance with

applicable codes and standards. • This unit is to be used only as intended by the manufacturer. If you have any questions regarding the

use, installation, or operation of this unit, contact the manufacturer:

AJ Manufacturing Co., Inc. PO Box 270320

3601 East 18th Street Kansas City, MO 64127

Tel: 816-231-5522


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TABLE OF CONTENTS

1 INSTALLATION……………………………………………………………………………………….……… 6

2 CLEANING THE FFU PRE-FILTER………………………………….………………………………….7

3 REMOVAL AND REPLACEMENT OF THE GEL SEAL HEPA/ULPA FILTER…..……… 8

4 REMOVAL AND INSTALLATION OF THE MOTOR (SSLFHFD-FP)…………………..…10

5 REMOVAL AND INSTALLATION OF THE MOTOR (SSLFHFD-FP-MA/MEA)………11

6 ON/OFF SWITCH – AIRFLOW ADJUSTMENT………………………………………….………14

7 NETWORKED UNITS ………………………..…………………………………………………..………16

8 LIGHTED OPTION …………………………………………………………………………………….…..16

9 INFRARED REMOTE CONTROL OPTION…………………………………………………………16

10 REMOVAL AND REPLACEMENT OF THE FLOURSCENT LAMPS……………………...17

11 REMOVAL AND REPLACEMENT OF THE FLOURSCENT BALLAST…………………...18

12 TESTING………………………………………………………………………………………………..………20

13 TROUBLE SHOOTING……………………………………………………………………….….………..20

14 SSLFHFD-FP WIRING DIAGRAM …………………………………………………………………..21

15 SSLFHFD-FP-MA/MEA WIRING DIAGRAM …………………………………………………..22

16 SSLFHFD-FP (NETWORK) WIRING DIAGRAM …………….………………………………..23

17 SSLFHFD-FP-MA/MEA (NETWORK) WIRING DIAGRAM …….………………………..24

18 LIGHTED OPTION WIRING DIAGRAM ……………………………….………………………..25

19 WARRANTY…………………………………………………………………………………………………..26


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Installation The terminal unit is fully assembled from the factory with the exception of the HEPA filter and lamps (as applicable) which is shipped in a separate box. Step 1 -- Carefully remove the unit from the shipping carton and inspect for damage that may have

occurred during shipping. If shipping damage is found, do not install. Call the manufacturer to report damage.

Step 2 -- Wipe down unit to remove shipping dust and debris. Step 3 -- Raise unit into ceiling and lower onto gasketed opening. Gasket should be a closed-cell material

approved for the environmental conditions. It is recommended (required for fan option unit) to further support the unit from above using the tabs welded to the plenum.

Step 4 -- A qualified technician should connect the unit to the appropriate power supply per applicable

codes and standards. Refer to the wiring diagrams included in these instructions. SSLFHFD-FP-120 --- 120VAC SUPPLY SSLFHFD-FP208/240 --- Duel rated 208 or 240VAC SUPPLY SSLFHFD-FP277 --- 277VAC SUPPLY Step 5 -- Blow out / clean entire duct system leading to unit to remove construction debris. This is

especially important for motor accessible units as they do not have a pre-filter. Wash pre-filter if applicable per “Cleaning the Fan Filter Unit Pre-filter” on page 7.

Step 6 -- Install the HEPA filter per the “Removal and Replacement of the HEPA Filter with Gel Seal”

section on page 8.


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Cleaning the Fan Filter Unit Pre-filter (when applicable)

WARNING! Disconnect the unit from the electrical power source before attempting to service the unit.

Note: For maximum performance, wash pre-filter every three to six months at a minimum. Step 1 -- Turn the unit off with the rocker switch located on the unit. Step 2 -- Disconnect the unit at the power source or at the service panel in accordance with OSHA (LOTO)

practices and procedures. Step 3 -- Using a driver, remove the screw holding the hinged door. This allows access to the pre-filter.

Slide the pre-filter out of the motor enclosure. This step is not applicable if unit is non-ducted. Step 4 -- Wash the filter with hot water and a mild detergent and rinse thoroughly. Do not use a caustic

solution to clean the filter. Blow dry or let air dry and slide the filter back into the motor enclosure. Filter should be completely dry before reinstalling into unit.

Step 5 -- Using the screwdriver, re-secure the cover with the screw.


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Removal and Replacement of the HEPA Filter with Gel Seal (when applicable)


WARNING! The HEPA filter may be protected by an expanded metal screen. The screen prevents accidental contact with

the filter media. It is not meant to allow handling of the filter by the media. Handle the filter ONLY by the frame.

NOTE: The manufacturer recommends two people to remove and install the HEPA filter in the unit. Step 1 -- Using a flat screwdriver, release the face frame by rotating the four (4) fasteners a quarter-turn

counter clock-wise. Unhook the safety cables from the filter clips. Set the frame aside. Step 2 -- Turn the unit off with the switch located on the unit. Step 3 -- Disconnect the unit at the power source or at the service panel in accordance with OSHA (LOTO)

practices and procedures. Step 4 -- Using a 7/16” nut-driver, evenly loosen the nuts holding the filter retaining clips by working your

way around the unit loosening the nuts a little at a time. To make installing the new filter easier, loosen the nuts until flush with the end of the threaded stud. USE TWO PEOPLE TO SUPPORT THE FILTER and rotate the filter clips toward the offset hole until clip is clear of the filter.

Step 5 -- Allow gravity to pull the filter away from the unit. If installing a new filter discard the filter in an

appropriate manor. Step 6 -- Unpack the new filter and inspect for shipping damage. If damage is found, do not install in

unit; call the manufacturer for replacement arrangements. Step 7 -- Using two people, raise the filter into place in between the threaded posts assuring the seal

edge is approximately in the center of the gel channel. Step 8 -- While supporting the filter by its frame, rotate the filter clips so that the clips are supporting the

frame and are at 90° to the frame. Evenly tighten the nuts by working your way around the unit tightening the nuts a little at a time. Stop tightening when the aluminum filter frame contacts the stainless steel housing frame. DO NOT OVER TIGHTEN. Wait at least 30 minutes before performing any challenge testing to allow the gel to fully adhere to the unit.


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Step 9 -- Inspect all gaskets and seals for integrity. Reconnect power and turn unit power on. Step 10 -- Raise the face frame back into place, reattach the safety chains, and secure quarter-turn

fasteners.

Replacement of HEPA Filter with Gel Seal

Figure 1


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Removal and Installation of the Variable Speed Motor (SSLFHFD-FP)


Step 1 -- Turn the unit off with the rocker switch located on the back of the unit. Step 2 -- Disconnect the unit at the power source or at the service panel in accordance with OSHA (LOTO)

practices and procedures. Step 3 -- Remove the HEPA filter and the pre-filter and set aside. See sections 2 and 3 for instructions. Step 4 -- Use the 1/8” drill bit and drill to remove the six (6) rivets located around the motor housing

cover. Set cover aside. Clean out metal shavings and rivet parts from the unit. NOTE: If duct is attached to cover, be careful not to damage duct. Disconnect duct if necessary.

Step 5 -- Disconnect the 6-pin power cable and the 4-pin data cable from the motor. Step 6 -- Using the 7/16” nut driver, remove the six nuts holding the motor. Step 7 -- Lift the motor/fan/ring assembly out of the unit. Step 8 -- Use a 5/32” hex driver to loosen set screw and slide fan off the motor shaft. Step 9 -- Use a driver to loosen the motor mount harness and slide off the motor. Step 10 -- Reverse above steps to reassemble the motor/fan/ring assembly into the unit. Motor mount

should be 1” from shaft end of the motor (even with vent openings) and fan collar should be even with the end of the motor shaft. Either rivets or sheet metal screws can used to secure the motor housing cover.


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Removal of Variable Speed Motor (SSLFHFD-FP)

Figure 2


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Removal and Installation of the Variable Speed Motor (SSLFHFD-FP-MA/MEA)


Step 1 -- Using a flat screwdriver, release the face frame by rotating the four (4) fasteners a quarter-turn

counter clock-wise. Unhook the safety cables from the filter clips. Set the frame aside. Step 2 -- Turn the unit off with the switch located on the frame of the unit. Step 3 -- Disconnect the unit at the power source or at the service panel in accordance with OSHA (LOTO)

practices and procedures. Step 4 -- Remove the HEPA filter and the pre-filter and set aside. See sections 2 and 3 for instructions. Step 5 -- Turn the unit off with the rocker switch located inside the unit. Step 6 -- Using a flat screwdriver, release the mid panel by rotating the three (3) fasteners a quarter-turn

counter clock-wise. Step 7 -- Use a 5/32” hex driver to loosen set screw and slide fan off the motor shaft. Step 8 -- Disconnect the 6-pin power cable and the 4-pin data cable from the motor. Step 9 -- Using the 7/16” nut driver, remove the six (6) nuts holding the motor. Step 10 -- Lower the motor /ring assembly out of the unit. Step 11 -- Use a driver to loosen the motor mount harness and slide off the motor. Step 12 -- Reverse above steps to reassemble the motor/fan/ring assembly into the unit. Motor mount

should be 1” from shaft end of the motor (even with vent openings) and fan collar should be even with the end of the motor shaft.


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Removal of Variable Speed Motor (SSLFHFD-FP-MA/MEA)

Figure 3


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ON/OFF Switch – Airflow Adjustment The Fan Filter Unit is equipped with a two position, illuminated rocker main power switch located on the side of the electrical box on the top of the unit as installed (SSLFHFD-FP) or on the mid-panel support bracket inside the unit (SSLFHFD-FP-MA/MEA). Also located on the electrical box is a digital display of the current airflow with an airflow adjustment knob (non-networked units).

Shut-off Switches (SSLFHFD-FP-MA/MEA)

Figure 4


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Digital Airflow Control (non-networked units) The FFU includes a Digital Airflow Control unit to adjust the airflow in the range of 250 CFM to 700 CFM. The adjustment is made by turning the recessed knob located to the lower left of the display. To increase the airflow, adjust the knob clockwise with a small flat screw driver. Turning it counter-clockwise lowers the desired airflow. The digital display alternates between the selected flow input (%) and the current airflow (CFM).

Electrical Box Figure 5


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Networked Units

A wide variety of controls and networking options can be specified for the fan filter units ranging from a simple wall mount control for an individual unit to a complete network of up to 400 units and a 12” touch screen interface. The network can be connected to a building’s existing BMS network for added flexibility. Please see included literature for the specific control system ordered.

Infrared Remote Control Option The Infrared Remote Control provides a means to remotely adjust the airflow of the Fan Powered HEPA Unit. A handheld remote control sends modulated infrared signals to an infrared sensor on the unit. A flow index lamp flashes out the unit’s current airflow. A red status lamp indicates the motor is powered and turning. OPERATION Using the remote, you can turn the motor on and off, adjust the airflow input from 1-100, and read the current settings. Point the remote at the unit (red lamp if the motor is on). Operate the on/off button or any of the four ↑/↓ buttons. The green lamp near the target lights, indicating you are in an adjustment session. Continue to operate the on/off button or any of the four ↑/↓ buttons to achieve the desired settings. Press the Enter button to save your new settings and exit the adjustment session. Press the Clear button to discard your new settings and exit the adjustment session. If you enter an adjustment session and do not make any adjustments for 15 minutes, the adjustment session automatically clears. Using the remote to read the current settings Point the remote at the unit and press the Clear button. A green lamp begins to flash indicating the signal was received. The flash sequence indicates the current flow index. The sequence occurs in two sets. The tens (1st) set uses long flashes to indicate the tens digit. The ones (2nd) set uses short flashes to indicate the ‘ones’ digit. An extra long flash in the tens set or the units set indicates the value of the corresponding digit is zero. − A flow index of 24 flashes two longs, then 4 shorts. − A flow index of 89 flashes 8 longs, then 9 shorts. − A flow index of 30 flashes 3 longs, then an extra long. − A flow index of 04 flashes an extra long, then 4 shorts. − A flow index of 100 flashes 10 longs, then an extra long. Using the remote to turn the motor on or off Point the remote at the unit and press the on/off button. If you press Enter while the motor is off, the motor stays off, even through a power on/off cycle. Adjust the airflow input using the ↑/↓ buttons. The ↑/↓ button pair on the left adjusts the index ↑/↓ x10. The ↑/↓button pair on the right adjusts the flow index ↑/↓ x1. Using the ↑/↓ x10 pair, you can quickly move the input up and down. Using the ↑/↓ x1 pair, you can precisely set the index to achieve the desired flow. During an


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adjustment session, the green lamp blinks each time you make a valid entry. If the flow input is already 100, and you try to increase the flow index, the green lamp does not blink, and the increase does not occur. If the airflow input is at 91 and you press the ↑ x10 button, the green lamp does not blink and the increase does not occur because your entry would take the input above 100. When the airflow input is greater than 90, use the ↑ x1 button to increase the input. The ↓ x1 and ↓ x10 keys respond in a like manner when you try to set the airflow input below 1. (Zero is not a valid flow index).

See the below chart for airflow corresponding to the airflow input.

AIRFLOW INPUT (%) AIRFLOW (CFM) 20 235 30 335 40 420 50 490 60 550 70 600 80 640 90 680

100 732

Lighted Option

Select products have a lighted option that adds two (2) T5HO fluorescent lamps to the diffuser.

Removal and Installation of the Fluorescent Lamps

WARNING! Disconnect the unit from the electrical power source before attempting to service the unit in accordance with

OSHA (LOTO) practices and procedures.

Step 1 -- Using a flat screw driver, release the face frame by rotating the four (4) fasteners a quarter-turn counter clock-wise. Unhook the safety cables from the filter clips. Set the frame aside.

Step 2 -- Holding both ends, rotate the lamps 90° and allow to drop out of the lamp holders. Step 3 – If replacing lamps, discard responsibly per local codes and regulations.


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Step 4 – Holding both ends, slide the pins of the lamp into the lamp holders and rotate 90° until locked in place. Step 5 – Replace face frame by reversing step 1.

Removal and Installation of the Fluorescent Lamp Ballast

WARNING! Disconnect the unit from the electrical power source before attempting to service the unit in accordance with

OSHA (LOTO) practices and procedures.

Step 1 -- Using a flat screwdriver, release the face frame by rotating the four (4) fasteners a quarter-turn counter clock-wise. Unhook the safety cables from the filter clips. Set the frame aside.

Step 2 – If applicable, remove the HEPA filter per “Removal and Replacement of the HEPA Filter with Gel Seal” on page X. Step 3 – If applicable, use a flat screw driver to release the mid panel by rotating the three (3) fasteners a quarter-turn counter clock-wise. Step 3 – Remove the two screws holding the ballast cover in place. Set screws and cover aside. Step 4 – Using a flat screwdriver, depress the release button and remove all wires from the ballast. Step 5 – Remove the two screws holding the ballast in place. Discard responsibly per local codes and

regulations. Step 6 – Install new ballast with existing screws. Step 7 – Install wires into new ballast per wiring diagram on ballast and in these instructions. Step 8 – Reinstall ballast cover, HEPA filter (if applicable), and face frame by reversing steps 1-3. Step 9 – Reconnect power.


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Ballast Removal

Figure 6


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Testing

Each fan filter unit is thoroughly tested at the factory before shipment. However, many codes and standards require testing for by-pass leakage after installation. The manufacture encourages that the customer contact an independent, certified testing organization with technicians that are trained and experienced in performance evaluation and maintenance of clean air equipment. The manufacturing recommends at least 30 minutes elapse after HEPA/ULPA filter installation before performing any type of challenge leak testing. The unit should be sealed to the ceiling and the room should have a positive pressure held during testing and normal operation.

Trouble Shooting (SSLFHFD-FP-*) Low Airflow

• If optional HEPA red LED light is on, replace the HEPA filter. • Inspect the pre-filter. Clean or replace as necessary. • Adjust the digital speed control for higher blower output. • Check the power supply for proper voltage, amperage, and distribution frequency • Replace HEPA filter if airflow remains low.

High Airflow

• Adjust digital speed control for lower output. Non-Laminar Airflow and/or Excessive Contamination

• Insure that upstream airstream is clear of large obstructions. • Ensure that no other air moving devices are operating in such a way to disrupt the room’s airflow

pattern. • Check airflow and if not desired airflow see above. • Conduct smoke or photometer test on HEPA filter and gel seal. If fail seal or replace the HEPA filter as

necessary.


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WARRANTY LIMITED WARRANTY AJ Manufacturing Co. Inc. warrants to Buyer, or any person receiving products originating from our factory, that the goods at time of shipment will be free from defects of material and workmanship for normal use and service. This warranty does not extend to goods subjected to misuse, neglect, accident, or improper installation, or to maintenance of products which have been altered or repaired by anyone except Seller, Buyer, or any persons receiving such a product during the duration of the warranty and shall contact AJ Manufacturing as soon as any defect becomes known. AJ’s sole obligation under the foregoing warranty shall be limited to: at its option, repair or replace defective goods provided, however that if AJ is unable to correct a defective component part or product after a reasonable number of attempts, the Buyer shall be entitled to elect a refund at original Buyer’s purchase. CHARGES ACCRUED AGAINST SELLER’S ACCOUNT WITHOUT PRIOR APPROVAL OF SELLER WILL NOT BE PAID BY SELLER. If after notifying AJ of defect, Buyer returns goods to AJ for repair and AJ determines that it has not breached the foregoing warranty, the Buyer will be assessed AJ regular reconditioning charges. AJ SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES ARISING FROM DEFECTIVE EQUIPMENT. THIS EXPRESS WARRANY IS IN LIEU OF AND EXCLDES ALL OTHER WARRANTIES, GUARANTEES, OR REPRESENTATIONS, EXPRESSED OR IMPLIED, BY OPERATION OF LAW OR OTHERWISE.


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