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PACE │ Installation & Assembly Manual

Issue Date: 07/03/2018

Form PA102.20-N1

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Table of Contents5
Section 1 - General Information and Safety13
Introduction13
Warranty13
Responsibility for Safety13
Section 2 - Product Description15
Typical Operation15
Ventilation System15
Economizer System (Typical)15
FIGURE 1 - Cutaway Showing Segmented Construction15
Heating and Cooling System16
Cleaning16
Hand Orientation16
AHU Identification (ID)16
FIGURE 2 - AHU and Coil Hand Identification16
AHU ID Label17
Skid ID Label17
Segment ID Box17
FIGURE 3 - AHU ID Label17
FIGURE 4 - Skid ID Label17
FIGURE 5 - Example of Segment ID Box17
Shipped Loose Parts18
Direction of Airflow18
TABLE 1 - Definition of Segment Ids18
Section 3 - Handling, Storage, and Installation19
Delivery and Storage19
Short Term19
Long Term20
Inspection, Damage, and Shortage20
Check Doors and Latches21
Indoor Ahus21
Outdoor Ahus21
Shipped Loose Parts21
Lifting Weights21
Moving the AHU21
Rigging21
FIGURE 6 - Metal Spacers on Doors21
Using Fork Lift in Special Circumstances22
Come-A-Longs (Power Pulls)22
Proper Lifting with Shackles22
FIGURE 7 - Recommended Lifting with Multiple Points22
FIGURE 8 - Typical Come-A-Longs22
FIGURE 9 - Proper Lifting with Shackle with Corner Connector Corners22
Preparing the Site23
Clearance for Outdoor Ahus23
FIGURE 10 - Proper Lifting with Shackle at Lifting Lug23
FIGURE 11 - Proper Lifting with Base Rail23
Assembling the PACE Provided Curb24
FIGURE 12 - Minimum Service Clearances24
FIGURE 13 - Typical Curb Assembly25
Clearance and Mounting for Indoor Ahus26
FIGURE 14 - no Base Rail - Housekeeping Pad Required to Accommodate Trap Height26
FIGURE 15 - no Housekeeping Pad - Base Rail Required to Accommodate Trap Height26
FIGURE 16 - with Base or Base Rail and Housekeeping Pad26
Installing Ceiling Suspended Ahus27
FIGURE 17 - Ceiling Suspended AHU on Structural Steel27
Tools Required to Install AHU28
Installing Outdoor AHU28
Single Piece Outdoor AHU28
FIGURE 18 - Tools Needed to Assemble Shipping Splits28
Multi-Piece Outdoor AHU29
FIGURE 19 - Shipping Split Examples29
FIGURE 20 - Shipping Split Examples Using Structural Steel Baserails30
FIGURE 21 - Applying Gasket Square, Neoprene Gasket and Caulk to Raceway Split30
Setting up the Sections31
FIGURE 22 - Typical Come-A-Longs31
FIGURE 23 - Electrical Connector (Not Connected)31
FIGURE 24 - Electrical Connectors (Connected)31
FIGURE 25 - Remove and Reposition Shipping Split Angle31
Pulling the AHU Sections Together32
FIGURE 26 - Come-A-Long Attached to a Section32
FIGURE 27 - Bring Shipping Splits Together32
FIGURE 28 - Applying Caulk to Seams32
Installing Hood with Moisture Eliminators33
Outdoor Air Temperature And/Or Humidity Sensors33
FIGURE 29 - Installing Gaskets33
FIGURE 30 - Corner Connector Hole Plug (P/N 021-19568-000)33
Installing Indoor AHU34
FIGURE 32 - Use Gasket (P/N 028-11883-010) at Shipping Split34
FIGURE 31 - Installing Hood with Optional Moisture Eliminators34
Installing an AHU with Expanded Cabinet35
FIGURE 34 - Assembly of End Channel Shipping Split with an Expanded Cabinet35
FIGURE 33 - Use Gasket (P/N 028-11873-010) to Door Frame at Shipping Split35
Setting up and Pulling AHU Sections Together36
FIGURE 35 - Come-A-Long Attached to a Section36
FIGURE 36 - Remove Lifting Lugs in Expanded Cabinet36
FIGURE 37 - Electrical Connector (Not Connected)36
FIGURE 38 - Electrical Connectors (Connected)36
FIGURE 39 - Remove and Reposition Shipping Split Angle37
FIGURE 40 - Bring Shipping Splits Together37
FIGURE 41 - Fasten Bottom Lifting Lugs37
Installing a Tiered AHU38
FIGURE 42 - Corner Connector Hole Plug (P/N 021-19568-000)38
FIGURE 43 - Tiered AHU38
FIGURE 44 - Second Tier Tie-Down Fastener Pack (P/N 386-03419-000)38
FIGURE 45 - Apply Gaskets to Top Panel on Bottom Tier38
FIGURE 46 - Guide Brackets Together39
FIGURE 47 - Lights Tier Transition Drawing39
Assembling the End Channel Shipping Split40
FIGURE 48 - Assembling the End Channel Shipping Split with Energy Recovery Wheel40
Installing Damper Actuator41
FIGURE 49 - Installing the Direct Coupled Actuator41
Installing Multi-Zone (MZ) Dampers42
FIGURE 50 - Installing MZ Damper42
Installing Field Supplied MZ Damper Actuators43
Shipped Loose Parts43
FIGURE 51 - Damper Shaft Extension Kit (P/N 026-33715-002)43
FIGURE 52 - Second Tier Tie-Down Fastener Pack (P/N 386-03419-000)43
FIGURE 53 - Bottom Raceway Shipping Split Fastener Pack (P/N 386-03418-000)43
Pipe Chase, Hoods and Seam Caps44
FIGURE 54 - Base Rail Shipping Split Fastener Pack (P/N 386-03417-000)44
FIGURE 55 - Top Raceway Bracket Assembled (P/N 386-04747-000)44
FIGURE 56 - Neoprene Gasket - 1/4 In. X 2 In. X 25 Ft (P/N 028-15954-010)44
FIGURE 57 - Neoprene Gray Gasket - 1/4 in X 3/4 in X 35 Ft (P/N 028-11873-010) for Door44
FIGURE 58 - Phillips Hex Head Screw (P/N 021-32268-011) for Indoor Unit Seam Cap44
FIGURE 59 - Hex Head Screw for Outdoor Roof Seam Cap, Pipe Chase, and Rain Hood - 1/4 In-14 X 1 in44
FIGURE 60 - Butyl Tape - 3/16 in X 3/4 in X 40 Ft (P/N 013E-03327-010)44
FIGURE 61 - Polyurethane Caulk (Grey: P/N 021-19568-000; Champagne: P/N 013-03317-040) for Pipe Chase45
FIGURE 62 - Roof Seam Cap (Assembled)45
FIGURE 63 - Pipe Chase, Trim Angle, and Cover45
FIGURE 64 - Hood45
Additional Parts46
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 - Shipping Split Corner Gasket - 3.5 X 3. 5 (P/N 028-11883-010)46
FIGURE 69 - Spare Fan Belt46
FIGURE 70 - Conduit (P/N 025-39024-001) and SJO Cord (P/N 025-35746-001)46
Air Filters47
Maintaining and Replacing Filters47
FIGURE 71 - Typical Filter Types47
FIGURE 72 - Filter Latches48
TABLE 2 - Koch Filter Clips - Single Filter Application49
TABLE 3 - Koch Filter Clips - Pre-Filter / Final Filter Application49
TABLE 4 - AAF Clips for Filter Frames - Single Filter Application49
Filter Installation Installing a 2 In. Pleated Filter50
FIGURE 73 - Correctly Installed Latch Pin (P/N 026-35788-702)50
TABLE 5 - AAF Pre-Filter/Final Filter Application50
Installing a 4 In. Pleated Filter51
FIGURE 74 - Fully Installed Filter51
FIGURE 75 - Correctly Installed Latch Pin (P/N 026-35788-604)51
FIGURE 76 - Place End of Latch over Filter Frame51
Installing a Single Headered (SH) Filter52
Installing a 2 In. Pre-Filter Combined with a SH Final Filter52
FIGURE 77 - Correctly Installed Cartridge Filter52
FIGURE 78 - Correctly Installed Latch Pin (P/N 026-35788-604)52
FIGURE 79 - Correctly Installed Cartridge with Pleats52
Installing a Multi-Cell SBM Double Headered (DH) Filter53
FIGURE 80 - Correct Use of Knockouts53
FIGURE 81 - Correct Latchout/Knockout Configuration53
FIGURE 82 - Frame with Four Latches Installed on the Sides53
FIGURE 83 - Spring Latch Pulled and Fastened in Filter Hole53
Installing a 2 In. and 4 In. Pre-Filter Combined with a DH Final Filter54
FIGURE 84 - Correct Latchout/Knockout Configuration (P/N 026-35788-612)54
FIGURE 85 - Spring Latch Pulled and Fastened in Filter Hole54
FIGURE 86 - Installing Pre-Filter Latch54
FIGURE 87 - Position Pre-Filter in Front of Final Filter55
FIGURE 88 - Spring End of Latch55
FIGURE 89 - Completed Assembly55
Hepa Filters56
Koch HEPA Filter Frame56
FIGURE 90 - Installation of Koch HEPA Filters56
Welded Bevel Seal Frame57
Visual Control Filter Clamps57
HEPA Filter Applications57
FIGURE 91 - Koch HF57
FIGURE 92 - Hepa Filter (Cross Section)57
FIGURE 94 - Installing Hepa Filter58
FIGURE 93 - Visual Control Filter Clamps58
TABLE 6 - Visual Control Filter Clamps for HEPA Filters58
FIGURE 95 - Installing Welded Bevel Seal Filter59
Filling Inertia Fan Base60
Thrust Restraint Replacement and Adjustment60
Rear Discharge Orientation60
FIGURE 96 - Supply Fan Restraint60
FIGURE 97 - Thrust Restraint Assembly61
FIGURE 98 - Plenum Fan Thrust Restraint61
Aligning Sheaves62
Using a Straightedge62
Using a String62
Belt Replacement Tensioning and Sheave Alignment for Top Mount63
FIGURE 99 - Alignment Using Straight Edge63
FIGURE 100 - Alignment Using String63
FIGURE 101 - Sheave Angular Misalignment64
FIGURE 102 - Motor Base Lowered64
FIGURE 103 - Sheave Angular Alignment64
FIGURE 104 - Sheave Angular Misalignment64
Steam Humidifier65
UVC Emitter Lamps65
Two Types of Lamps65
FIGURE 105 - V-Max Grid Lamps65
FIGURE 106 - Installing V-Mod Lamp65
FIGURE 107 - Installing V-Max Grid Lamps65
FIGURE 108 - UV Control Panel Wiring (8 Amps)67
FIGURE 109 - UV Control Panel Wiring (Greater than 8 Amps)68
Air Measuring Device Connections70
Air Measuring at the Fan Inlets70
Air Measuring at Unit Outside Air Inlets70
FIGURE 110 - High and Low Connections for an in Fan Air Monitoring System70
FIGURE 111 - High and Low Connections and Associated Tubing for Fan Mounted Air Monitoring System70
FIGURE 112 - Port Locations for Fan Mounted Air Monitoring System70
Back Draft Dampers for Dual Fans and Fan Arrays71
Installing the Pipe Chase71
Tools and Materials71
Preparing Pipe Chase for Installation71
FIGURE 113 - Counterbalance Locked into Place for Shipping71
FIGURE 114 - Counterbalance Unlocked for Start-Up71
Apply Gaskets72
Attach Pipe Chase72
FIGURE 117 - Install Pipe Chase Base Rail to AHU Base Rail72
FIGURE 115 - Install Gasket under Roof Overhang72
FIGURE 116 - Apply Gasket to Pipe Chase72
FIGURE 118 - Install Flanges72
Seal Pipe Chase to AHU73
Install Cover Angles73
FIGURE 119 - Apply Caulk to Base Rail73
FIGURE 120 - Apply Caulk between Pipe Chase and AHU73
FIGURE 121 - Install Pipe Chase to Roof73
Install Base Rail Covers (if Applicable)74
FIGURE 122 - Install Cover Angle74
FIGURE 123 - Position Cover Angle Properly74
FIGURE 124 - Properly Install Screws74
FIGURE 125 - Apply Base Rail Cover74
Installing External Vent Piping for Outdoor Ahus75
Condensate Drain Arrangement75
FIGURE 126 - Gas Furnace Fuel Venting System75
FIGURE 127 - Gas Furnace Condensate Drain Trap76
TABLE 7 - TSP and Drain Trap76
General Electrical Information77
Power Connections77
Single Point Power77
FIGURE 128 - Single Point Power Connection77
Motors for Supply, Return, and Exhaust Fans78
Wiring the Energy Recovery Wheel78
FIGURE 131 - Access Electrical Box78
FIGURE 129 - Typical Motor Data/Name Plate78
FIGURE 130 - Another Typical Motor Data/Name Plate78
FIGURE 132 - Typical Power Wiring of Energy Recovery Wheel78
Wiring the Gas Heat Device79
FIGURE 133 - Gas Burner Component Locations79
FIGURE 134 - Main Power and Control Panel with Cover Open79
Wiring the Electric Heat Device80
Power Options80
Disconnect Switch Options80
FIGURE 135 - Typical Electrical Heat Control Panel Interior Wiring and Components80
FIGURE 136 - Typical Field and Power Connections80
Control Options81
Installing Electrical Heat Option81
FIGURE 137 - Pressure Probe Direction82
FIGURE 138 - Air Flow Switch Connections82
TABLE 8 - Maximum Current83
Electric Humidifier84
Humidifier84
FIGURE 139 - Layout of Typical Humidifier Panel84
FIGURE 140 - Supply Power Knockouts84
FIGURE 141 - Humidifier Points84
Field Penetrations for Piping and Electrical Connections85
Tools Required85
Material Required85
Procedure85
FIGURE 142 - Penetrations and Grommet Details86
Lights for Ahus87
Piping Connections87
FIGURE 143 - AHU with Lights Tier Transition Drawing87
FIGURE 144 - Pipe Chase Enclosure87
Coil Piping88
Staggered Coils88
FIGURE 145 - Factory Coil Connections88
FIGURE 146 - Staggered Coil - Angled Wall88
Hot and Chilled Water Coils89
FIGURE 147 - Split Coil - Opposite Side Connections89
FIGURE 148 - Chilled Water Coil Connections Example - (Not for Construction)89
FIGURE 149 - Hot Water Piping with 2-Way Valve Example (Not for Construction)90
FIGURE 150 - Hot Water Piping with Diverting Valve Example (Not for Construction)90
Water Treatment91
Freeze Protection91
Steam Coils91
Steam Distributing Coils91
Steam Control91
Steam Traps91
FIGURE 151 - Steam Coil Piping Arrangements92
Drains and Traps93
Condensate Drain Piping93
FIGURE 152 - Drain Trap Showing Water Location for Draw through Operation93
FIGURE 153 - Trap Detail for Drain Pan in Negative Environment (Draw Through)93
FIGURE 154 - Trap Detail for Drain Pan in Positive Environment (Blow Through)93
Elevating AHU for Gravity Floor Drain Connections94
Duct Connections94
Duct Connection Guidelines94
Flanged Duct or Sleeves94
FIGURE 155 - Combining Drain Lines94
FIGURE 156 - Recommended Discharge Duct Arrangement When Turns Are Required94
Raw or Straight Edge Duct or Sleeves95
Sound and Vibration Transmission95
Installing Top Discharge Outdoor AHU Duct95
Installing Front and Rear Discharge Outdoor AHU Duct95
FIGURE 157 - Duct Arrangement for Flange and Raw Edge Ducts95
FIGURE 159 - Roof to Duct Installation (Horizontal Discharge)96
FIGURE 158 - Duct Penetration of Roof96
Vertical Tube Integral Face and Bypass (VIFB) and Integral Face and Bypass (IFB)97
Shipping Bolts (VIFB Only)97
Piping Suggestions97
Flexible Connectors (VIFB Only)97
Freezing Conditions97
FIGURE 160 - IFB Coil (Horizontal Tubes Available with Steam and Hot Water)98
FIGURE 161 - VIFB Coil (Face-Mounted Actuator Shown)98
FIGURE 162 - Hot Water Piping Schematic for 2-Row Coil VIFB98
FIGURE 163 - Hot Water Piping for IFB99
FIGURE 164 - Steam Piping for VIFB100
Refrigeration101
DX Direct Expansion Coils101
FIGURE 165 - Typical Piping and Sundries at the DX Coil102
FIGURE 166 - DX Coil Circuiting Types102
Available Coil Arrangements103
FIGURE 167 - Non-Stacked Coil Design (Special Quote)103
FIGURE 168 - Non-Stacked Coil Design (Standard)103
FIGURE 169 - Stacked Coil Design (Standard)104
FIGURE 170 - Stack Coil Designs (Special Quote)104
Thermostatic Expansion Valves (TXV)105
Hot Gas Bypass (HGBP)105
DX Coil Circuiting and Staging105
FIGURE 171 - Stacked Coil Circuiting105
FIGURE 172 - One Coil Circuit Per Refrigerant Circuit105
FIGURE 173 - Two Coil Circuit Per Refrigerant Circuit105
Advantages of Multiple Control Stages106
Maintaining Adequate Airflow106
FIGURE 174 - Three Compressor Unit106
FIGURE 175 - Six Compressor Unit106
VAV Systems107

Pace PAI - Page 14

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