USER MANUAL FOR ALL WEATHER AIR AIRSTATIONS

INFORMATION

This manual covers the proper use of AWA Airstations. However, for the use of air compressor equipment inside, please refer to their manufacturer's manuals.

For diagnosing the compressor or dryer, please refer to the compressor manual or contact your authorized ALL WEATHER AIR dealer.

For any questions or technical assistance, please contact ALL WEATHER AIR at 1 833 292-0200 or one of our local offices in Canada and the United States by email at info@allweatherair.com.

SECTION 1: INTRODUCTION AND GLOSSARY

SECTION 2: SAFETY AND PRECAUTIONS

MAKE SURE TO READ AND FOLLOW ALL SAFETY RECOMMENDATIONS REGARDING THE EQUIPMENT INCLUDED OR ADDED TO YOUR AWA AIRSTATION.

Contact ALL WEATHER AIR for any questions.

Danger! High voltage. Risk of lethal electric shock. Reserved for qualified professionals. Follow warnings and marked areas. ⚡ [High Voltage]

Never remove protective devices. Do not modify the AWA Airstation and its equipment.

Wear appropriate personal protective equipment, such as eye protection, hearing protection, safety boots, and safety gloves when working inside the AWA Airstation.

Warning: Pressurized machinery. Reserved for trained operators. Risk of serious injury if not adhered to. ⚠️ [Pressurized Machinery]

Warning: Pressurized piping. Stay clear. Only trained personnel should intervene. Use appropriate locking devices. Avoid direct contact. Risk of serious injury. ⚠️ [Pressurized Piping]

Be informed that noise levels inside the station are higher.

Before any manipulation, ensure pneumatic isolation and depressurization of the equipment requiring intervention.

Follow proper site lockout/tagout procedures when servicing the AWA Airstation.

Figure 1 shows a lockout/tagout device attached to a panel, with text 'Schneider LOCKOUT TAGOUT DANGER DO NOT OPERATE'.

Be cautious of hot surfaces, sharp edges, and moving parts.

Specific Warnings:

• Do not use anti-icing systems with AWA Airstations.
• Condensate drainage from compressors, dryers, wet tanks, and filters may contain oil or other contaminants.
• Adhere to all local regulations for proper handling and disposal of contaminants.

Never remove a piece of piping or other elements under pressure. The system may still be pressurized.

Only open the electrical panel when absolutely necessary; if so, use appropriate protective equipment. Ensure all personnel are outside the AWA Airstation before closing and locking the enclosure doors. Failure to comply with any of these instructions may cause serious damage, injuries, or even death.

In the event of a major collision with the AWA Airstation:

1. Immediately cut off power from outside the station.
2. Inspect and correct any damage to the piping network.
3. Check and correct any damage to the electrical network.
4. Inspect all equipment for potential damage.
5. Keep in mind the potential risk of injury and electrocution.

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SECTION 3: OPERATING PRINCIPLE

The Airstation is designed to create optimal operating conditions for a compressed air system. It protects your equipment from the weather conditions, filters the air, distributes electricity to all its devices, and connects the equipments to a single compressed air outlet.

TEMPERATURE CONTROL

The louvers are sized to allow sufficient fresh air intake from the outside, exhaust hot air from the compressor to the outside, and recover heat inside the enclosure. Air circulation is ensured by the compressor's fan(s).

It is important to note that the louvers operate only when the compressor(s) is/are running. An interlock auxiliary contact is factory-installed in the compressor's electrical panel.

Control of all louvers is provided by a single dedicated thermostat, with a single signal sent to all louver actuators.

Types of louvers:

• Wall-mounted fresh air intake louvers;
• Wall-mounted hot air exhaust louvers (connected to the ventilation duct);
• Hot air recovery louvers (on the ventilation duct).

When the Compressor(s) is/are not running, the louvers are in their initial position. This means that the wall-mounted intake and exhaust louvers are fully closed (NC), and the heat recovery louvers on the ventilation duct are fully open (NO).

When the Compressor(s) is/are running and the temperature inside the station is below the thermostat setpoint, the recovery louvers are open, and the wall-mounted louvers are closed.

Notes: The degree of closure and opening of the louvers depends on the level of difference between the ambient temperature and the setpoint temperature to be reached. The greater the difference, the more open the recovery louvers are and the more closed the wall-mounted louvers are.

When the Compressor(s) is/are running and the ambient temperature is above the setpoint, the recovery louvers close, and the wall-mounted louvers open.

Notes: The degree of closure and opening of the louvers depends on the level of difference between the ambient temperature and the setpoint temperature to be reached. The greater the difference, the more closed the recovery louvers are and the more open the wall-mounted louvers are.

The system is modulating and is directly proportional to the temperature difference between the ambient temperature and the temperature set on the thermostat.

Figure 2 shows a control unit labeled A350PS-1C.

Some AWA Airstations are equipped with one or more extraction fans, controlled by a dedicated thermostat.

Figure 3 shows a control unit labeled A421, and an associated ventilation grille.

Auxiliary Heating Units

Some AWA Airstations are equipped with one or more auxiliary heating units to maintain the indoor temperature above freezing point when the compressor(s) is/are not running. The auxiliary heating unit(s) is/are controlled by a dedicated thermostat.

Figure 4 shows a thermostat unit.

This same heating system is interlocked with the compressor(s) to prevent them from running unnecessarily at the same time.

Electrical System

In most AWA Airstations, a custom-designed main electrical panel is installed. This panel powers and protects the equipment and accessories inside the station: lights, thermostat, louvers, fan, automatic drain, and heating unit.

The station requires a single voltage input to the main panel. This panel transforms and distributes specific secondary voltages to the various electrical devices.

The electrical system has been designed to prevent the risk of electrocution during the proper use of the station. Each equipment and appliance is individually grounded. Leakage current is thus evacuated in case of insulation failure.

The main electrical panel of an AWA Airstation contains several disconnect switches. The number of switches varies depending on the different configurations.

Single Compressor System:

• One isolating switch for accessories;
• One isolating switch for compressor.
• For models with a dryer on an independent circuit, the panel will be equipped with an additional switch.

Multiple Compressor System:

• One main switch.
• One switch for accessories.
• One switch for each compressor.
• For models with a dryer on an independent circuit, the panel will be equipped with an additional switch.

The accessory switch primarily powers the heating unit, lighting, ventilation system, service outlet, as well as some low-consumption devices such as nitrogen generators, desiccant or refrigerated dryers.

Wiring Diagrams:

Each Airstation have their own electrical schematic provided.

Piping System

Compressed Air

The piping network at the compressor outlet distributes compressed air to various devices according to the user's needs.

Isolation valves are strategically positioned to isolate the equipment from each other.

Generally, the system has a single air outlet, but there may be multiple outlets depending on the user's requirements.

Condensate

Purge valves on equipped devices are connected to the piping network for condensate drainage.

Some AWA Airstations include oil/water separators in their piping networks.

Condensate or water filtered by the separators is then directed to the condensate discharge point.

WARNING: Condensate drainage from compressors, dryers, and filters may contain oil or other contaminants.

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SECTION 4: RECEPTION AND HANDLING OF THE AWA AIRSTATION

UPON RECEIPT, INSPECT THE AWA AIRSTATION FOR EXTERNAL AND INTERNAL DAMAGES. IN CASE OF DAMAGE, INFORM THE FREIGHT CARRIER IMMEDIATELY TO FILE A CLAIM.

Handling by Forklift

Only models with fork holes can be lifted by forklift. (See Figure 5)

Otherwise, refer to the crane handling section.

AWA Airstations must be handled by qualified personnel only.

Never move AWA Airstations without a spotter present.

Only use a forklift truck with a minimum lifting capacity equal to the nominal weight of the AWA Airstation.

The weight of the air station varies depending on the model; refer to the drawings provided with your AWA Airstation to determine its specific weight.

CAUTION: The center of gravity of most AWA Airstations is approximately 48 inches. (See Figure 6)

Figures 5 and 6 show AWA Airstations being handled by forklifts.

Handling by Crane

Ensure that the area where lifting is being performed is clear and safe.

AWA Airstations should only be handled by professional crane operators.

Never move an AWA Airstation without a signaler present.

It is essential to use all available lifting points on an AWA Airstation.

Use spreader bars to avoid damage to the structure of the Airstation.

Refer to the provided drawings for the position of the center of gravity, nominal weight, and lifting points.

Figures 7 and 8 illustrate four-point and six-point crane lifts of AWA Airstations, showing lifting points.

SECTION 5: INSTALLATION

LOCATION

Prepare the ground by ensuring that the AWA Airstation is level and stable, thus ensuring safety and optimal operation.

Ensure that the foundation can support the total weight of the AWA Airstation stably and evenly.

Place the air station in a clean and well-ventilated area.

Position the station in a location with sufficient airflow to maintain a stable operating temperature. Adequate ventilation is crucial to avoid excessive ambient temperature increase.

Do not confine the AWA Airstation. Ensure it is in an easily accessible location for maintenance, with a minimum of 48 inches of space on each side.

Figure 9 shows an AWA Airstation with a 48-inch clearance indicated.

For sites exposed to risks such as extreme weather events like tornadoes, hurricanes, earthquakes, excessive water or snow accumulation, modifications may be necessary. Please discuss this with your representative or contact All Weather Air to address these eventualities.

It is highly recommended to keep one side of the Airstation accessible to forklifts.

LAYOUT

Standard AWA Airstations are designed to operate in temperatures ranging from -40°F to 104°F (-40°C to 40°C). However, these data may vary; please refer to the manufacturer's specifications of the equipment installed inside the AWA Airstation.

Operating conditions below or above these require additional modifications to the AWA Airstations. Please consult the manufacturer for further information.

For models exceeding 24 feet in length, it is strongly recommended that the AWA Airstation rest on a concrete slab.

Figure 10 shows an AWA Airstation installed on a concrete slab.

It is also recommended that the AWA Airstation be anchored with foundation bolts to prevent any movement.

Figure 11 shows foundation bolts securing an AWA Airstation.

GENERAL

If the AWA Airstation is equipped with swan necks on the shutters, please unfold them following these steps:

1. Remove the transport shackles,
2. Unfold the structure,
3. Secure the ends with the provided bolts.

ELECTRICAL

The electrical installation and connection of the AWA Airstation must be carried out according to local regulations by a qualified electrician. Connect from your installations to the main panel of the station.

The selection of the appropriate cable must be made in advance by a master electrician based on the total electrical consumption. Refer to the provided electrical drawings for more details. Connect the AWA Airstation's grounding lug to a rod in the ground, or any other grounding device. (See Figure 12)

Figure 12 shows a grounding lug connected to a grounding rod.

The electrical wiring of the equipment inside the station is factory-installed. Only a single connection is required to power all the AWA Airstation's circuits.

Figure 13 shows electrical wiring connections inside the AWA Airstation.

COMPRESSED AIR PIPING

Connect your installation to the compressed air outlet as indicated on the General Arrangement Drawing. If the Airstation does not have an isolation valve, it is advisable to add one to isolate the Airstation from the service line.

Figure 14 illustrates the compressed air piping connection to the Airstation.

Warning! Avoid transmitting loads by supporting the piping between the Airstation and your installation.

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SECTION 6: SYSTEM STARTUP

Warning! When the system is energized, the compressors may be in automatic mode and start at any time.

Warning! Piping connections and electrical connections may have loosened during transport.

Before starting up the AWA Airstation, please read and follow the instructions contained in this manual. Contact your AWA authorized distributor to schedule your startup.

PRELIMINARY INSPECTION

A certified technician will perform the initial startup. To do so, they will need to:

1. Check the torque of all electrical connections in the main panel.
2. Ensure that all pneumatic connections are securely fastened. Every hose should be connected in the right place.
3. Ensure that the piping is securely fastened and supported.
4. Verify that all actuators of the louvers are in place and correctly fixed to the transmission shaft. (See Figure 15)
5. Measure the electrical voltage at the input of the main panel. It should match the voltage indicated on the electrical diagrams (green sheets) and on the manufacturer's nameplate.

Figure 15 shows a close-up of a louver actuator mechanism.

PREPARATION FOR STATION STARTUP:

1. Power up the AWA Airstation using the designated power supply.
2. Measure the electrical voltage (voltage) at the AWA Airstation's input.

PREPARATION FOR STARTUP OF PRESSURIZED EQUIPMENT:

To activate and maintain the manufacturer's warranty for the equipment contained in the AWA Airstation, please contact your authorized AWA dealer. A certified technician will perform the initial startup.

Refer to the manuals for equipment such as compressors, air dryers, nitrogen generators, etc., for proper startup and operation.

STARTUP PROCEDURE

Before proceeding with startup, make sure you have read and understood section 2 on the operating principle.

Follow the steps below to proceed with startup.

1. Activate the accessory switch.

Figure 16 shows an accessory switch in the 'ON' position.

2. Activate the compressor switch(es).

Figure 17 shows a compressor switch in the 'ON' position.

3. Activate the dryer switch(es), if your AWA Airstation contains one.

Figure 18 shows a dryer switch in the 'ON' position.

4. Activate all circuit breakers located inside the main panel of the AWA Airstation.

Figure 19 shows circuit breakers inside the main panel.

INSPECTION AFTER POWERING ON THE DEVICES AND ACCESSORIES

Once all elements are energized, ensure that:

• The thermostat(s) is/are turned on.
• The heating unit(s) is/are functional by adjusting the thermostat to a high temperature. The heating unit(s) should start to reach this temperature.

Note: The heating unit(s) is/are interlocked with the compressor(s) and only operate(s) when the compressor(s) is/are not running. When the compressor(s) is/are running, the heating unit(s) cannot operate.

• All automatic purgers are turned on.
• The lights turn on when the switch is set to ON.
• All devices are turned on.

Note: In cold and/or humid weather, it is advisable to operate the heating unit for a few hours before starting the compressor(s). This allows the oils to warm up and reduces the humidity inside.

EQUIPMENT START-UP

The initial commissioning should be carried out by a certified technician for warranty reasons.

Refer to the manufacturer's manual to start up the equipment.

INSPECTIONS DURING OPERATION

Perform inspections and adjustments to ensure the proper functioning and reliability of the AWA Airstation.

Check for possible leaks in the piping network:

• Verify the proper operation of the louvers by adjusting the thermostat to the highest degree. The wall louvers will be completely closed and the recovery dampers will be fully open. Repeat the opposite exercise by adjusting the thermostat to the minimum temperature. The wall louvers will open completely, and the recovery louvers will close (see operating principle section 2).
• Manually check the purgers by pressing the test button of each one.
• Ensure that the amperage at the entrance of the main panel does not exceed that indicated on the provided drawings and the station nameplate.

Please ensure their proper functioning if your unit is equipped with the following options:

• Emergency Stop Button: When the compressor(s) is/are running and you press the button, the compressor(s) should stop.
• External Operation Indicator Light: When the compressor(s) is/are energized, the indicator light should illuminate. When the compressor(s) is/are running, the operational indicator light should be on. Both lights should be illuminated simultaneously.
• Heating Cable: In cold weather, ensure that the heating cable(s) become warm.
• Exterior Lighting Fixture with Photovoltaic Cell: The light should turn on when it is dark if the exterior lighting fixture is equipped with a photovoltaic cell.
• Exhaust Fan: Make sure it runs when the "ON" set point is reached and it stops when the "OFF" set point.

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SECTION 7: OPERATION

This section helps you understand how to operate your AWA Airstation properly. It is important to read carefully this section to avoid malfunctions or damage.

Notes: Repeat the initial startup procedure (Section 5) when the AWA Airstation has been moved or when disconnecting from the three-phase power source.

DURING OPERATION

• Ensure proper operation of the louvers for adequate ventilation.
• Ensure that the ventilation and heating system control functions properly.
• Scrutinize for any potential damage, leaks, or abnormal noises.

TEMPERATURE CONTROL

The AWA Airstation can be equipped with several thermostats:

• The thermostat shown in Figure 20 controls the louvers. Its role is to maintain an appropriate ambient temperature during compressor operation. Set it to 68°F / 20°C to maintain optimal operating temperature inside.

Figure 20 shows a wall-mounted thermostat controlling dampers.

• The thermostats shown in Figures 21 and 22 are used to control the heating unit. Set the heating unit thermostat between 50°F and 59°F (10°C and 15°C). It is important to set it 9°F (5°C) below the thermostat that controls the extraction fan if the station has one.

Figure 21 shows a wall-mounted thermostat for heating control.

Figure 22 shows another type of wall-mounted thermostat for heating control.

• Some AWA Airstations may have a third thermostat that controls the extraction fan and its dedicated louver. Follow its instruction manual for configuration. Set both thermostats in the same way; the thermostat controlling the heating unit(s) should be set 5°F to 9°F (3°C to 5°C) below the PENN A421 cutoff point.

Figure 23 shows a wall-mounted thermostat controlling fans and extraction louvers.

PIPING

Compressed Air

The system automatically supplies compressed air based on the user's equipment demand.

Some AWA Airstations with an air dryer may have a bypass network. It allows manually isolating the dryer for maintenance or repair without interrupting compressed air production.

Note: During bypass, air quality is compromised. During normal operation, ensure that the bypass valve is closed.

Bypass Procedure:

1. Open the bypass valve (A).
2. Close the inlet (B) and outlet (C) valves.

Figure 25 is a diagram illustrating the compressed air bypass system with valves A, B, and C.

CONDENSATE

Equipment automatically drains condensate into the designated piping network. They are directed through the piping network to a single outlet point.

SYSTEM SHUTDOWN/STANDBY

To shut down the system, it is recommended to follow these steps:

• Do not disconnect the AWA Airstation's electrical power.
• Stop the compressed air equipment.
• Ensure the heating unit is functioning.
• Confirm that all wall louvers are properly closed.

WARNING, IN WINTER: For compressors or dryers cooled by water, watch out for equipment freezing risks. If the equipment freezes, refer to the troubleshooting section.

In case of a power outage preventing the heating unit(s) from operating, purge all wet tank drains and condensate piping.

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SECTION 8: MAINTENANCE

Maintenance for the AWA Airstation is minimal but essential to minimize the risk of component failure leading to equipment damage and/or production downtime.

Follow the recommended maintenance schedule on the following page.

GENERAL

• During winter operation, ensure there are no door obstructions or snow accumulation on the roof of the AWA Airstation.

PIPING

• Weekly Inspect the condensate drains for proper operation.
• Inspect piping networks to locate any air or liquid leaks.

ELECTRICAL SYSTEM

• Visually inspect all electrical components, including the main panel, for any damage.

VENTILATION SYSTEM

• Clean filters with water at the prescribed frequency in the schedule. *Pay attention, some units are equipped with throw-away filters, don't try to wash them.
• Ensure that louvers operate correctly and are free of debris for adequate ventilation.

COMPRESSOR(S) AND DRYER(S)

For preventive maintenance of compressors and dryers inside the AWA Airstation, refer to the equipment manual.

For more information, visit www.allweatherair.com.

MAINTENANCE - CALENDAR

EVERY WEEK:

• Inspect condensate drains for proper operation.

EVERY 3 MONTHS:

• Check for possible air leaks in the piping network.
• Ensure proper operation of louvers: actuators and absence of debris.
• Clean louver filters with water.** (Adjust frequency based on your environment) **Ensure they are completely dry before reinstalling.

EVERY 6 MONTHS:

• Especially before the winter season, verify the proper operation of the heating system.
• Check the proper operation of the extraction fan if your station is equipped with one.

EVERY YEAR:

• Perform a visual inspection of the electrical system.
• After powering off the station, tighten all electrical connectors.

GENERAL STRUCTURE INSPECTION:

EXTERIOR EXAMINATION:

• Carefully inspect the exterior of the AWA Airstation, paying particular attention to joints and attachment points.
• Check the condition of seals around doors, louvers, and other openings.
• Look for cracks in the sealant.

INTERIOR INSPECTION:

• If possible, examine the interior of the AWA Airstation for any signs of moisture or leakage.
• Check seals on louvers and doors from the inside for any potential water infiltration.
• If the AWA Airstation has accessible spaces, also check internal parts of walls or panels for any signs of corrosion or moisture.

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SECTION 9: TROUBLESHOOTING GUIDE

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SECTION 10: LONG-TERM STORAGE AND WARRANTY

LONG-TERM STORAGE

Each equipment inside the AWA Airstation is accompanied by its own manuals, and long-term storage procedures must comply with the manufacturer's specifications for each product.

Maintaining the louvers, heaters, ventilation fans (if equipped) powered on, helps regulate humidity levels inside the AWA Airstation, which prevents equipment degradation due to oxidation.

To ensure maximum protection and preservation of your AWA Airstation and the equipment it contains, please follow this procedure:

ELECTRICAL SUPPLY AVAILABLE:

• Power the Airstation electrically to activate all auxiliary equipments
• Set the accessory disconnect switch to the "ON" position.
• Set the thermostat setpoint of the heating device to 150°F (10°C)
• Ensure all wall louvers are properly closed.
• Purge the entire condensate system: drains, water/oil separators, wet tank, prefilters, etc.
• If your unit has one, set the thermostat setpoint of the exhaust fan 9°F (5°C) above the setpoint of the heating unit.

If your AWA Airstation does not have an exhaust fan, to allow proper air exchange, connect wire A to wire 46 as shown on Figures 26 and 27.

Then adjust the thermostat setpoint controlling the actuators to 59°F (15°C).

*Caution: You will need to set back the wires in the relay or dry contact (Figure 26) when you re-operate the Airstation.

*NOTE: If you cannot power your Airstation with its designed voltage you can add any other electrical heating device.

Figures 26 and 27 show wiring diagrams for connecting wires A to 46 for air exchange in the absence of an exhaust fan.

ELECTRICAL SUPPLY NOT AVAILABLE:

• Set all electrical disconnect switches to the "OFF" position.
• Ensure all wall louvers are properly closed.
• Purge the entire condensate system: drains, water/oil separators, wet tank, prefilters, etc.
• Install activated clay desiccant bags. (Highly recommended) OR periodically open access doors to allow air exchange.

WARRANTY

The AWA Airstation comes with a standard warranty covering labor as well as defects in components and accessories. However, the equipment and appliances are subject to the respective warranties of their manufacturers.

The warranty period is one year and begins at commissioning or 90 days after receipt of the AWA Airstation.

Warranty Conditions:

• Thorough initial inspection upon receipt is essential.
• Failure to commission under the supervision of a certified technician results in the end of the warranty.
• Any interruption, standby, or storage not following the procedures described in the user manual will terminate the warranty.

Warranty Exclusions:

• Any damage resulting from transportation, such as disconnections, loosening, or damage to piping and/or electrical networks, or any other damage.
• The warranty is valid only for the original customer who purchased the air compression cabinet from AWA Airstation or an authorized dealer.
• The warranty does not cover damage resulting from misuse, improper maintenance, unauthorized modifications, accidents, natural disasters, or any other external cause.

To claim this warranty, the customer must provide valid proof of purchase, as well as all relevant information about the alleged defect.

Customer Remedies:

In the event of a defect covered by the warranty, ALL WEATHER AIR undertakes to repair or replace, at its discretion, the defective components of the air compression cabinet at no cost to the customer.

Covered by our warranty are the following points:

• Electrical System: We warrant the absence of manufacturing defects for all electrical components of the cabinet throughout the warranty period. This includes control panels, electrical wiring, and any other component of the electrical system integrated into the system.
• Piping: We warrant the absence of manufacturing defects and leaks for the AWA Airstation piping, which has been factory tested. This includes main lines, fittings, valves, and any other piping component included in the system.

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SECTION 11: SPARE PARTS

SPARE PARTS FOR THE AWA AIRSTATION

BELIMOS SERVO-MOTORS

Image shows a Belimos servo-motor actuator. Actuators installed on the transmission shafts of the louvers.

THERMOSTATS

Images show various thermostats, including models for Belimo and general heating control. Thermostats for controlling the louvers and the exhaust fan.

LOUVERS

Images show inlet and outlet air louvers. Louver

FILTERS AND FRAMES

Image shows a washable filter for air intake louvers. Washable filters for air intake louvers.

Continued on the next page.

FAN

Diagrams show components of a wall-mounted hot air exhaust fan: motor, protective grille, enclosure, fan blade, protection kit. Wall-mounted hot air exhaust fan (on certain AWA Airstations only)

HEATER

Image shows a forced air ceiling heater unit. Heating unit

THERMOSTAT

Image shows a thermostat controlling the heating unit. Thermostat controlling the heating unit.

LIGHTS

Image shows an interior LED ceiling light. Ceiling lights for interior lighting.

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SECTION 12: DIMENSIONS AND WEIGHTS

The dimensions may vary depending on the standard or custom version of the AWA Airstation.

The weight depends on the compressor model(s) and accessories installed in the package.

Please contact ALL WEATHER AIR for information on the package weight.

AWA
ALL WEATHER AIR
1 833 292-0200
info@allweatherair.com