Pace PAI Installation And Assembly Manual Download

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PAI/PAO

Indoor and Outdoor

Air Handling Units

Installation and Assembly Manual

Form PA102.20-N1 (718) │ Supersedes: PA102.20-N1 (1017)

LD22601

Summary of Contents for PAI

Page 1: ...PAI PAO Indoor and Outdoor Air Handling Units Installation and Assembly Manual Form PA102 20 N1 718 Supersedes PA102 20 N1 1017 LD22601...

Page 2: ...he on prooduct labels this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertain...

Page 3: ...current informa tion automatically to the manual or product owner Up dated manuals if applicable can be obtained by con tacting the nearest PACE sales representative It is the responsibility of riggi...

Page 4: ...Fan with Service Disconnect only M SWSI PL Fan with Motor Starter N SWSI PL Fan with VFD P SWSI PL Fan Direct Drive without Motor Controller Q SWSI PL Fan Direct Drive with Service Disconnect Only R S...

Page 5: ...20 Inspection Damage and Shortage 20 Check Doors and Latches 21 Indoor AHUs 21 Outdoor AHUs 21 Shipped Loose Parts 21 Lifting Weights 21 Moving the AHU 21 Rigging 21 Using Fork Lift in Special Circums...

Page 6: ...ilter 54 Hepa Filters 56 Koch HEPA Filter Frame 56 Welded Bevel Seal Frame 57 Visual Control Filter Clamps 57 HEPA Filter Applications 57 Filling Inertia Fan Base 60 Thrust Restraint Replacement and A...

Page 7: ...eam Control 91 Steam Traps 91 Drains and Traps 93 Condensate Drain Piping 93 Elevating AHU for Gravity Floor Drain Connections 94 Duct Connections 94 Duct Connection Guidelines 94 Flanged Duct or Slee...

Page 8: ...nd Caulk to Raceway Split 30 FIGURE 22 Typical Come A Longs 31 FIGURE 23 Electrical Connector Not Connected 31 FIGURE 24 Electrical Connectors Connected 31 FIGURE 25 Remove and Reposition Shipping Spl...

Page 9: ...E 64 Hood 45 FIGURE 65 Damper Shaft Extension Kit P N 026 33715 002 46 FIGURE 66 Corner Connector Hole Plug P N 021 19568 000 8 46 FIGURE 67 Touch Up Spray 12 Oz P N 013 03322 000 46 FIGURE 68 Shippin...

Page 10: ...nce Locked Into Place for Shipping 71 FIGURE 114 Counterbalance Unlocked for Start Up 71 FIGURE 117 Install Pipe Chase Base Rail to AHU Base Rail 72 FIGURE 115 Install Gasket Under Roof Overhang 72 FI...

Page 11: ...152 Drain Trap Showing Water Location for Draw Through Operation 93 FIGURE 153 Trap Detail for Drain Pan in Negative Environment Draw Through 93 FIGURE 154 Trap Detail for Drain Pan in Positive Envir...

Page 12: ...Damage and Shortage 20 Receiver s Responsibility 20 Shipped Loose Parts 21 Installing Ceiling Suspended AHUs 27 Installing Damper Actuator 41 Installing Multi Zone MZ Dampers 42 Installing Field Supp...

Page 13: ...nd instructions detailed in the manual WARRANTY PACE warrants AHUs in accordance with the Limited Warranty Engineered Systems Equipment procedure Refer to the Standard Limited Warranty Engineered Syst...

Page 14: ...PACE Installation Assembly Manual Issue Date 07 03 2018 14 Form PA102 20 N1 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...er the outdoor air is cool and dry enough to satisfy the internal cooling demand The outdoor and the return air dampers are operated by individual ac tuators As the outdoor air dampers are opened by t...

Page 16: ...r components are located and described as left or right hand The proper orienta tion to describe the proper hand is when airflow is at your back as shown in Figure 2 on page 16 AHU IDENTIFICATION ID I...

Page 17: ...d in a multi piece AHU is marked with a skid ID label which indicates its order of assembly in the direction of airflow as shown in Figure 4 on page 17 Segment ID Box The segment ID box indicates the...

Page 18: ...FF FLAT FILTER 2 or 4 in AF ANGLE FILTER 2 or 4 in RF HIGH EFFICIENCY FILTER Rigid Filter 12 in Bag Filter 21 in Mini Pleat Filter 4 in HF HIGH EFFICIENCY FILTER INLET SEGMENTS MB MIXING BOX FM FILTER...

Page 19: ...t be taken to cover and protect the AHUs from Dust Rain and snow Rodents Construction vehicles and personnel Condensation Ventilation required Protect all parts and porous materials from rain and othe...

Page 20: ...e trailer or rail car when received be fore unloading for any visible signs of damage Report any damage or signs of possible damage to the trans portation company immediately for its inspection After...

Page 21: ...event damage from job site dirt and various weather conditions If the AHU is covered with plastic cut the wrap in the outline of the door s and proceed to access the AHU using the information above Cl...

Page 22: ...internal components and should be handled in an upright position Care must be exercised to avoid twisting the equipment structure Prevent unnecessary jarring or rough handling Proper rigging and hand...

Page 23: ...ts properly into the se lected location use the following instructions Allow sufficient space around the AHU to remove the access panels and various parts Provide a minimum clearance equal to the widt...

Page 24: ...her to form rectangular perimeter as shown leaving bolts loose After the curb is set in place ensure proper consideration has been given to the air duct openings through the roof 4 The curb installati...

Page 25: ...pipe chase curb Mtg will be field located C Pipe chase length muinus 0 875 in D Total unit width from YORKworks minus 0 875 in WALL PANEL STANDARD RACEWAY CURB GASKET CURB REST 2 in X 4 in NAILER NOMI...

Page 26: ...l to the width of the AHU plus 6 in must be pro vided on one side of the AHU to remove the coil or fan assembly Concrete pads may not be as flat as they should be Shimming and or grouting may be neces...

Page 27: ...Structure Positioned Perpendicular to Airflow The AHUs must be supported at a minimum at the following locations Both ends At each shipping split if applicable Upstream and downstream of each cooling...

Page 28: ...as the gaskets shown in Figure 52 on page 43 through Figure 67 on page 46 Do not damage the factory installed pipe chase electrical cabinet hoods pipe stubs door handles or roof overhang when installi...

Page 29: ...led after sections are pulled together 3 If the AHU sections are going to be assembed be fore placing them on a curb be sure the they are lying on a flat surface during assembly 4 Make sure the top of...

Page 30: ...bing con nection pigtails are secured out of the path of the shipping split mating surfaces to prevent damage 10 Apply separate gasket squares P N 028 11883 010 as shown in Figure 21 on page 30 Place...

Page 31: ...or or block it before setting the next section 3 Attach the come a longs power pulls as shown in Figure 22 on page 31 to the first section Use lifting lugs on the base rail not at the shipping split o...

Page 32: ...ing the sections due to racking of one section or the other use a come a long diagonally on the inside of that section at the shipping split or across the tops of the opposite sections e If there is a...

Page 33: ...ws with the EPDM washer provided in the fastener pack 6 Completely cover each damper opening in the AHU panels by its respective hood The bottom of the hood should extend approximately 6 in below the...

Page 34: ...sket P N 028 11883 010 at Shipping Split GASKET INSTALLING INDOOR AHU Before installing the indoor AHU identify the shipped loose parts such as gaskets as shown in Figure 52 on page 43 through Figure...

Page 35: ...ded Cabinet 3 Apply the neoprene gasket to all raceway mating surfaces of one mating section On large AHUs install two gaskets side by side on intermediate raceway surfaces 4 Make sure that the sectio...

Page 36: ...lifting lugs within the shipping split shown in Fig ure 36 on page 36 Keep the bolts and nuts Figure 36 Remove Lifting Lugs in Expanded Cabinet LD14265 LIFTING LUG BASE CHANNEL WELDED CHANNEL FILLER 4...

Page 37: ...tion at the shipping split or across the tops of the opposite sections e If there is any difficulty aligning the sections due to the top and bottom not pulling together simultaneously apply shims unde...

Page 38: ...al alignment bolt the two brackets with the hardware supplied fastener pack P N 386 03419 000 as shown in Figure 44 on page 38 3 8 in Lock Nut 3 8 x 3 4 in Button Head Screw 3 8 x 3 4 in Button Head S...

Page 39: ...lift 11 Feed the electrical and control connections from the top tier to bottom tier and make sure that they will be accessible after the sections are joined If any connections will not be accessible...

Page 40: ...ns as follows a Make sure assembly surface is clean and level to allow the sections to slide freely If the surface is irregular use metal shims un der sections as necessary to align mating surfaces b...

Page 41: ...will be the dampers spring return position Note whether the damper shaft is rotated fully clockwise or counter clockwise Outside air and exhaust air dampers Position the damper blades so that they wil...

Page 42: ...ks from air entering side only 4 Apply the neoprene gasket to the mounting flang es of the damper assembly 5 Center the damper assembly over the discharge openings of the hot and cold decks 6 Attach t...

Page 43: ...s shown in Figure 51 on page 43 is pro vided for each zone per the factory order form LD116504 Figure 51 Damper Shaft Extension Kit P N 026 33715 002 The contractor should supply the actuators and mou...

Page 44: ...way Bracket Assembled P N 386 04747 000 Pipe Chase Hoods and Seam Caps Use the following parts to install the seam cap s pipe chase s and hood s as shown in Figure 62 on page 45 through Figure 64 on p...

Page 45: ...19568 000 Champagne P N 013 03317 040 For Pipe Chase Only Never use silicone caulk sealant in or on any air handling equipment LD17322 Figure 62 Roof Seam Cap Assembled Apply 2 in Gasket and Caulk Ap...

Page 46: ...e instruc tions Figure 65 Damper Shaft Extension Kit P N 026 33715 002 LD116504 LD16514 Figure 66 Corner Connector Hole Plug P N 021 19568 000 8 Figure 67 Touch Up Spray 12 Oz P N 013 03322 000 LD1165...

Page 47: ...d without filters The PACE sales office is responsible for ordering and delivering the filters in a timely manner The contractor or commission ing agent must contact PACE regarding this issue be cause...

Page 48: ...8 604 C89 P N 026 35788 605 Used with 2 in and 4 in pre filter combined with a double header DH final filter P N 026 35788 612 Used with 2 in Pre filter Combined with a DH Final Filter P N 026 35788 6...

Page 49: ...L SBM DOUBE HEADER 4 IN MULTI PLEAT XL8 AND MULTI CELL FM SINGLE HEADER SH OR MULTI SAK 4 IN MULTI PLEAT ELITE AND MULTI CELL SBM DOUBLE HEADER P N 026 35778 702 and 026 35778 604 X P N 026 35778 612...

Page 50: ...ter Installation Installing a 2 in Pleated Filter Use the following instructions to install a 2 in Multi Pleat Elite filter into a 16 g galvanized holding frame with four latches P N 026 35788 702 as...

Page 51: ...row of knockouts closest to the gas ket for nominal 1 in filters or filters with a 13 16 in single header Use the second set of knockouts for nominal 2 in filters 1 Insert the straight end of the latc...

Page 52: ...circular end of the latch and rotate it across the corner of the filter 7 Push the end of the latch towards the filter until the latch catches beneath the frame knockout 8 Repeat the process with the...

Page 53: ...4 The latch installation should be complete The latch should now be trapped within the three knockouts 5 Repeat the steps with the remaining latches Note the orientation of the latch to the knockouts...

Page 54: ...ce the latch over the third knockout 4 The latch installation should now be complete The latch should now be trapped within the three knockouts as shown in Figure 84 on page 54 LD10154 Figure 84 Corre...

Page 55: ...er placement of the pre filter LD10165 Figure 87 Position Pre Filter in Front of Final Filter 4 Grasp the end of the pre filter latch and spring it so that it fits over the edge of the pre filter as s...

Page 56: ...en perfor mance shall be certified via a DOP test on the installed system and classified as UL Class 1 when tested in accor dance with UL Standard 586 FILTER RETAINER CLIPS MUST BE ATTACHED TO SIDES O...

Page 57: ...racture causing the gasket to relax allowing leakage 2 in 2 in 2 in T Section Perimeter Section Type H Main Runner Perimeter Extrusion LD06674a Figure 92 Hepa Filter Cross Section VISUAL CONTROL FILTE...

Page 58: ...MODEL NUMBER LENGTH L 029 22081 000 Latch HEPA Single 11 1 2 in 029 22082 000 Latch HEPA Double 11 1 2 in 11 1 2 in Astrocel HCX Single Filter Clamps Perimeter Double Filter Clamps T Section Red Silv...

Page 59: ...ALLATION Issue Date 07 03 2018 3 AIRFLOW Figure 95 Installing Welded Bevel Seal Filter LD06646a Visual Control Clamp Adjust bolt Head Flush With Clamp Spring Ductwork Cell Side Media Pack Gasket Cell...

Page 60: ...ly opposite to the airflow Thrust restraints are provided for all fans when the air thrust exceeds 15 of the equipment weight when the fan discharge is rear see Figure 96 on page 60 Any other fan orie...

Page 61: ...ASHER STEEL WASHER FAN END SPRING STEEL WASHER STEEL WASHER RUBBER WASHER RUBBER WASHER STEEL CUP STEEL CUP BULKHEAD OR BULKHEAD CLIP DOUBLE NUTS FOR ADJUSTMENT DOUBLE NUTS LOCKED TOGETHER THRUST REST...

Page 62: ...are tight on both sides of bulkhead or bulkhead clip 2 Adjust third flat steel washer and second set of double nuts hand tight against thrust restraint mounting bracket on fan 3 Turn second set of do...

Page 63: ...loosen the mounting hardware on the opposite drive side of the base 4 Continue to lower both ends of the base until the belts can be removed as shown in Figure 102 on page 64 5 After the sheaves are c...

Page 64: ...r the base accord ingly and repeat Steps 6 10 13 Mark the position of the base s opposite drive side mounting hardware before lowering the base which may help determine where to secure the hardware th...

Page 65: ...ACE fac tory provides the following pre wired parts Internal wiring with a magnetic door safety switch A lockable disconnect switch with a Press to Test pilot light A latching circuit that has to be m...

Page 66: ...SECTION 3 HANDLING STORAGE AND INSTALLATION PACE Installation Assembly Manual Issue Date 07 03 2018 66 Form PA102 20 N1 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 67: ...Form PA102 20 N1 67 Installation Assembly Manual PACE SECTION 3 HANDLING STORAGE AND INSTALLATION Issue Date 07 03 2018 3 085 013 001 Figure 108 UV Control Panel Wiring 8 amps...

Page 68: ...SECTION 3 HANDLING STORAGE AND INSTALLATION PACE Installation Assembly Manual Issue Date 07 03 2018 68 Form PA102 20 N1 LD16609 Figure 109 UV Control Panel Wiring Greater Than 8 Amps...

Page 69: ...l doors are closed all the SW1 s will allow C1 to energize as long as power is available By selecting CS 1 to the on position the 24vac control power circuit will be energized As long as all doors wit...

Page 70: ...factory mounted transducer on the fan wall The positive port is left open to the fan section Wiring is not provided to the transducer unless factory packaged controls were selected The fan manufactur...

Page 71: ...LD17198 INSTALLING THE PIPE CHASE Install the pipe chase before connecting the piping Use the following instructions to install the pipe chase Tools and Materials Screw gun Complete set of mechanic s...

Page 72: ...e pipe chase curb 3 in away from the AHU 2 Tilt the top of the pipe chase toward the AHU Work it under the roof overhang Be careful not to damage the neoprene gaskets Lift the pipe chase slightly to c...

Page 73: ...mplete seal as shown in Figure 120 on page 73 Pay special attention to the top and bottom corners raceway and base rail engage ments and under the roof overhang Figure 120 Apply Caulk Between Pipe Cha...

Page 74: ...AHU NOTCH 7 Starting at the top and alternating between the AHU and pipe chase continue installing self drill ing screws until reaching the bottom as shown in Figure 124 on page 74 Use caution not to...

Page 75: ...e poten tial to create highly acidic condensation particularly during extended operation at low capacity or low firing rate conditions To insure proper drainage use the fol lowing instructions as show...

Page 76: ...5 Condensate drain and trap discharge should be pitched away from the equipment at a slope of 1 4 in per linear foot or as local code dictates 6 For outdoor or unconditioned space installations local...

Page 77: ...onform to the International Building Codes IBC National Electrical Code NEC and local codes The AHU is ETL listed Some compo nents are UL labeled Any changes in the field may affect its validity The c...

Page 78: ...t will need to be loosened After it is loose rotate the motor to access the electrical box to make the connections 2 Remove the belts 3 Rotate the motor or move it back far enough to access the electr...

Page 79: ...ure 133 Gas Burner Component Locations LD11596b MAIN POWER AND CONTROL TERMINATION PANEL INSIDE GAS BURNER PIPE CHASE BURNER CONTROL PANEL FLUE CONNECTOR ID FAN ID FAN MOTOR DRAFT DAMPER ADJUSTABLE QU...

Page 80: ...penetra tions to prevent airflow or leakage Refer to the ser vice manual for more information Use the following instructions to connect the discon nect switch 1 Hook up the power as shown in Figure 13...

Page 81: ...ll SCR Completely electronically controlled by varying signal and varying output of a controller like a VFD for electric heat with 0 to 10 VDC or 4 to 20 mA The controller modulates a separate SCR for...

Page 82: ...R HEATER AIR FLOW PICK UP TUBE TOWARDS BLOWER ATTACHED TO HIGH PORT OF AIR FLOW SWITCH PICK UP TUBE TOWARDS BLOWER ATTACHED TO LOW PORT OF AIR FLOW SWITCH TOP VIEW OF UNIT POSITIVE PRESSURE AIR BLOWN...

Page 83: ...ductors at 100 of rated load if indicated on the wiring dia gram The line current for a single or three phase load is calculated as follows kW x 1000 Voltage Single Phase Line Current kW x 1000 Voltag...

Page 84: ...beginning or ending on the inside of the pressurized or conditioned areas i e AHU must have the conduit openings sealed to prevent air from passing through it Figure 139 Layout of Typical Humidifier P...

Page 85: ...door units with champagne paint Exacto knife Clean up supplies Procedure See Figure 120 on page OT 1 Make sure any components bulkheads or other obstructions are disconnected from panel inside and out...

Page 86: ...PTH A GROMMET HOLE DIAMETER B GROMMET LIP DIAMETER C MARKED GROMMET HOLE DIAMETER CUT OUT D PANEL HOLE CUT DIAMETER E 3 4 1 7 8 1 1 8 3 4 1 028 11872 000 2 375 0 500 3 125 0 749 2 50 1 1 4 1 1 2 1 3 8...

Page 87: ...inside the AHU the field provided and installed insulation is required Whenever possible the piping should be brought down through outdoor AHUs within the pipe chase as shown in Figure 144 on page 87...

Page 88: ...may cause damage to the header Hold a backup wrench firmly on the coil connec tion so that when tightening the connecting pip ing the torque is not transmitted to the coil head er which could damage t...

Page 89: ...m valve or preheat coil can actually cause the coil to retain condensate due to a reduced pressure in the coil thus exposing condensate in the tubes to freezing conditions With modulating steam below...

Page 90: ...ALVE PT PLUG GATE VALVE W HOSE BIB GLOBE VALVE HOT WATER SUPPLY HOT WATER RETURN 2 WAY CONTROL VALVE ECCENTRIC REDUCER STRAINER SUPPLY VENT RETURN RETURN SUPPLY COIL COIL PT PLUG DRAIN UNION GLOBE VAL...

Page 91: ...he trap More than a two inch drop is required to protect the coil from freezing The return main should be located below the trap Steam Control Continuous steam supply ensures long coil life and minimi...

Page 92: ...STEAM COIL STEAM COIL PITCHED IN CASING 12 MIN 12 MIN SINGLE COIL VERTICAL AIR FLOW 12 MIN 12 MIN 12 MIN COILS IN PARALLEL AIR FLOW MAY HAVE COMMON SUPPLY AND SINGLE TRAP INDIVIDUAL COIL TRAP PREFERR...

Page 93: ...vent this condensate water buildup as shown in Figure 152 on page 93 Figure 152 Drain Trap Showing Water Location for Draw Through Operation LD06342 Drain Pan Drain Nipple Drain Pan Drain Pan NO 1 Fan...

Page 94: ...talled according to AMCA Standards 200 and 201 at a minimum Duct turns and transitions must be made care fully to hold friction loss to a minimum Avoid short turns Duct elbows should contain splitters...

Page 95: ...eference sourc es are available regarding acoustic design Installing Top Discharge Outdoor AHU Duct For outdoor PAO top duct connection the installer is responsible for sealing the duct to the roof pa...

Page 96: ...and roof penetration openings Duct systems should not be pressurized without sufficient time for curing the sealant systems Fol low the sealant manufacturer s recommendations for applying the sealant...

Page 97: ...pressure differential across the trap not the boiler pressure Traps should be of types that pass condensate and air at saturated steam temperature Inverted bucket traps should incor porate thermostat...

Page 98: ...s Available with Steam and Hot Water LD09630 FACE DAMPERS CLOSED BYPASS OPEN STEAM IN STEAM OUT ACTUATOR Figure 161 VIFB Coil Face Mounted Actuator Shown LD09631 Figure 162 Hot Water Piping Schematic...

Page 99: ...n Assembly Manual PACE SECTION 3 HANDLING STORAGE AND INSTALLATION Issue Date 07 03 2018 3 Figure 163 Hot Water Piping for IFB LD09633 3 4 in 19 1 mm AUTOMATIC AIR VENT IN TOP HEADER HOT WATER RETURN...

Page 100: ...BLE CONNECTOR 8 in 203 2mm 8 in 203 2mm MIN NON VENTING TRAPS STEAM PRESSURE BELOW 15 PSIG 103 4 KPa 1 2 in 12 7 mm THERMOSTATIC TRAP FOR AIR REMOVAL NON VENTING TRAP NON VENTING TRAP CONDENSATE FLOW...

Page 101: ...cuit to oper ate while the other circuit is turned off Interlaced coils provide excellent temperature control at full and part loads as well as good thermal expansion valve TXV superheat control which...

Page 102: ...itting Sight Glass Sporlan Asc Hot Gas Fitting Thermal Expansion Valve Txv Equalizer Line Suction Line Suction Line Txv Equalizer Line 1 7 8 45 Ball Value Liquid Line Drier Liquid Line Solenoid Valve...

Page 103: ...E factory if ap plication assistance is needed to convert the split face to a full face operation Figure 168 Non Stacked Coil Design Standard LD09143a D1 H1 D2 D1 H1 H2 1 Distributor Circuit 2 Distrib...

Page 104: ...dy H1 H2 2 Distributor Circuits 50 50 Interlaced SQ Required D1 D2 H1 H2 2 Distributor Circuits Face Split SQ Required Single HDR Body H1 D1 D2 H2 2 Distributor Circuits Row Split SQ Required Single H...

Page 105: ...critical to use HGBP with return duct air temperature or suction pressure control but it provides better capacity control at low loads The Venturi type distributor furnished with the DX coils may be o...

Page 106: ...ore control stages used the more precise the control of the air temperature will be Smaller incre mental changes in capacity will result in a more con sistent DX coil leaving air temperature which wil...

Page 107: ...a box closes the duct static pressure increases The duct static pres sure sensor controls the AHU supply fan Since an in crease in duct pressure relates to a decrease in the re quired zone airflow the...

Page 108: ...right by Johnson Controls 2018 ALL RIGHTS RESERVED Form PA102 20 N1 718 Issue Date July 3 2018 Supersedes PA102 20 N1 1017 800 861 1001 www johnsoncontrols com PACE is a trademark of Johnson Controls...

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