PCAH SERIES AIR HANDLER PCAH2/PCAH3/PCAH4 OPERATING MANUAL
1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS GETTING STARTED... 3 ELECTRICAL CONNECTIONS... 3 2.1 POWER CONNECTIONS... 3 2.1.1 PCAH2/PCAH3... 3 2.1.2 PCAH4... 3 2.2 CONTROL WIRING... 4 2.2.1 PCAH2... 4 2.2.2 PCAH3/PCAH4... 4 DIMENSIONAL DATA... 5 3.1 PCAH2/PCAH3... 5 3.2 PCAH4... 6 PLUMBING... 7 4.1 OPEN SYSTEM... 7 4.2 CLOSED SYSTEM... 8 DUCTING... 9 5.1 PCAH2/PCAH3... 9 5.2 PCAH4... 9 5.3 TRADITIONAL DUCTING (LOW VELOCITY)... 9 COMMISSIONING... 9 6.1 WATER SIDE COMMISSIONING... 9 6.1.1 Filling the water heater/boiler and setting system temperature:... 9 6.1.2 To fill the heating loop:... 10 6.1.3 Purging the pump and verifying flow in the heating loop:... 10 6.1.4 Water flow Balancing:... 10 COMISSIONING SHEET... 11 SERVICE AND MAINTENANCE:... 12 WIRING DIAGRAM... 13 8.1 PCAH2... 13 8.2 PCAH3... 14 8.3 PCAH4... 15 SPECIFICATIONS... 16 9.1 PCAH2... 16 9.1.1 Features:... 16 9.1.2 Coil Performance at 70ºF (21.1ºC)... 16 9.1.3 Blower/Motor Performance... 17 9.2 PCAH3... 18 9.2.1 Features:... 18 9.2.2 Coil Performance at 70ºF (21.1ºC)... 18 9.2.3 Blower/Motor Performance... 19 9.3 PCAH4... 20 9.3.1 Features:... 20 9.3.2 Coil Performance at 70ºF (21.1ºC)... 20 9.3.3 Blower/Motor Performance... 21 9.4 ELECTRICAL DATA... 21 WARRANTY... 22 2
1 GETTING STARTED The unit is shipped complete with the following: 1. The air-handler module 2. Return air collar and filter rack 3. Filter Additional items required which are field installed include: a circulator pump, plumbing fittings and valves such as an air purge valve, anti scald valve, shut off valve, gate valves, pipe insulation and drain valves. Also required are duct fittings, a 24 volt thermostat and other accessories such as grills and wire. 2 ELECTRICAL CONNECTIONS 2.1 Power Connections 2.1.1 PCAH2/PCAH3 A single point, hard-wired electrical connection requiring 120VAC service and a dedicated 15 amp fused circuit. 2.1.2 PCAH4 A single split-phase, hard-wired electrical connection requiring 240VAC service and a dedicated 15 amp fused circuit. 3
2.2 Control Wiring 2.2.1 PCAH2 There are 5 available terminals for control connections. Connect low or high to common (+24v) for heating and cooling speeds. Continuous fan if used is typically set to Low. T and T are dry contacts that close when the motor is engaged. This can be used to control a boiler or pump relay. 2.2.2 PCAH3/PCAH4 There are 7 available terminals for control connections. Connect low, medium or high to common (+24v) for heating and cooling speeds. Continuous fan if used is typically set to low. T1, T2 and T3 are dry contacts that close when the motor is engaged according to the table on the electrical schematics (Sections 8.2 & 8.3). These can be used to control a boiler or pump relay. 4
3 DIMENSIONAL DATA 3.1 PCAH2/PCAH3 5
3.2 PCAH4 6
4 PLUMBING All plumbing between components is typically done with ½" (PCAH2, PCAH3) or ¾ (PCAH4) copper pipe and appropriate sweat fittings. All interconnecting piping is to be insulated. System Types: a) An Open System uses hot water from the residential hot water heater to supply both domestic hot water and hot water to the Air Handler for space heat. See schematic on next page. Well systems that incorporate a pressure tank are normally open systems. b) A system becomes closed when a backflow prevention valve or check valve is installed in the cold water pipe upstream of the water heater. The backflow prevention valve does not allow pressure created by the heated water to be relieved into the cold water system. Therefore an expansion tank must be installed. Local codes may require this type of system. A spring loaded check valve must be installed on the return water line close to the Air Handler. Ensure flow arrow points to tank or boiler. An air purge valve should be installed at the high point in the supply line close to the Air Handler. 4.1 Open System 7
4.2 Closed System 8
5 DUCTING 5.1 PCAH2/PCAH3 Air Handler The Air Handler distributes heating, air through a 20x10 rectangular plenum in an up-blast configuration. Return air enters the unit through a 20x10 rectangular duct knock out on the sides, back or bottom. 5.2 PCAH4 Air Handler The Air Handler distributes heating, air through a 20x20 rectangular plenum in an up-blast configuration. Return air enters the unit through a 20x10 rectangular duct knock out on the sides, back or bottom. 5.3 Traditional Ducting (Low Velocity) Good engineering practice should be followed when designing a duct system. Nu-Air recommends the use of HRAI's Residential Air System Design Manual. 6 COMMISSIONING 6.1 Water Side Commissioning 6.1.1 Filling the water heater/boiler and setting system temperature: 1. At this point all valves should be closed and the system dry. 2. Open the cold water supply valve and a hot water tap. 3. Fill the water heater/boiler with water allowing air to escape at the open tap. Shut off the tap when air has stopped escaping. 4. Using the boiler or water heater's control, set the system to operate at your design temperature. See Equipment Selection Chart and preliminary design information forms. 5. Following the manufacturer s instructions, start the water heater and allow it to reach the set point. For cases where high water temperatures are used, an anti-scald valve will be required. Set this to 120 F and verify by measuring the water temperature at the taps. 9
6.1.2 To fill the heating loop: 1. Connect a garden hose to the drain valve and direct water to a floor drain or similar. 2. Open the drain valve. 3. Open the heating loop's hot water supply shut off valve 4. Allow water to flow until only water (no air) is flowing at the drain. 5. Close the hot water shut off valve. 6. Open the return water shut off valve and allow water to flow until no air is escaping at the drain. 7. Close the drain valve. 8. Open the hot water shut off valve. 6.1.3 Purging the pump and verifying flow in the heating loop: 1. Turn on electrical power to the Air Handler. 2. Set the house thermostat well above room temperature to force a call for heat. 3. Check that the circulating pump and fan are operating. 4. Hot water should be entering the fan coil and cooler water leaving. 5. Warm air should be exiting all supply grills/diffusers. 6. Apply the supplied warning label to the water heater near the aqua stat without covering any existing labels. 6.1.4 Water flow Balancing: This step should be done when both the room air temperature and water heater temperature are stabilized. NOTE: Return air temperature needs to be near 70 F ( 21 C). 1. Initiate a call for heat from the room thermostat. 2. Measure the supply (SAT) and return (RAT) air temperatures. 3. Measure the supply (SWT) and return (RWT) water temperatures 4. Calculate the heat output by the formula: Btu/hr = (SAT-RAT) x CFM x 1.08 (See Air Handler spec sheet for CFM at heating speed.) 5. If the design heat loss is not being met at this condition, increase the water heater temperature set point and repeat the previous steps 6. If the water temperature drop in the fan coil is less than 20 F, adjust the throttling valve to reduce water flow. NOTE: T increases above 20 F (11 C) increases water heater efficiency. 7. Repeat until heat loss is met and water temperature drop is greater than or equal to 20 F. 8. The minimum recommended supply air temperature is 115 F. 9. If the supply air temperature or heat output cannot be met at with a 20 F water temperature drop, allow a lower temperature drop across the coil. 10. Important - Verify the anti-scald valve is adjusted properly once final adjustments have been made. [ 140 F ( 60 C) or less] 10
COMISSIONING SHEET PCAH Water Heater Make Model Storage Input Equipment Installed Design Heat Loss Design Heat Gain USGal Btu/hr System Components Installed Heating Loop Shut off Valves Anti-scald Valve Drain Valve Back flow prevention valve Throttling Valve Expansion Tank Air Purge Valve Off Season Circulation control Yes System Start Up Check List Fill Water Heater with Water r Heater at design temperature Fill Heating Loop with Water Purge Circulation Pump Start Air Handler Check Circulation Pump Check Fan Operation Label Water Heater Design Information Total Heat Loss Return Air Temperature 70 Delivered Air Temperature Effective Water Heater Output Heating Speed Airflow F8 Entering Water Temperature Cooling Speed Airflow Return Water Temperature Air handler Output Entering Water Temperature Measured Commissioning Measurements F1 F2 F9 Air handler Return Air Output at EWT Temperature Measured F10 F11 F12 Required Air Required Supply Return Water temp. rise Air Temp. Temperature (F2/(F8x1.08)) F9 + F10 Measured F13 F14 F15 Water temp. drop Actual Supply Air Temp. Anti-scald Outlet Temp. F1 - F12 Measured Measured Notes: The key criteria when comparing commissioning vs design is to meet Btu output, maintain 20 F temperature drop and to ensure domestic water temperature at the fixtures is below 140 F 11
7 SERVICE AND MAINTENANCE: Nu-Air recommends annual service and maintenance by a qualified HVAC contractor. Disconnect the power supply to the Air Handler before attempting any service. Maintenance should include: QUARTERLY 1. Filter Replacement Wipe down all interior surfaces of the cabinet with disinfectant. ANNUALLY 1. Coil cleaning Vacuum with a brush attachment. If necessary, wash with a non toxic coil cleaner taking precautions not to wet motors and electrical components. 2. Fans Vacuum or use a small brush to clean the blades. 3. Check the controls for proper operation. 4. Check boiler/ water heater set point against commissioning report. 5. Inspect the duct work for air leaks (at joints and seams) and blockages (crushed ducts and crimps at elbows). 12
8 WIRING DIAGRAM 8.1 PCAH2 13
8.2 PCAH3 14
8.3 PCAH4 15
9 SPECIFICATIONS 9.1 PCAH2 120V PSC direct drive air handler with hydronic coil (heating). 9.1.1 9.1.2 Features: 2-speed PSC motor. 700 and 650 cfm. 4-row hot water coil Installer configurable return air locations. Left, right, back, bottom Reversible door access 24 VAC, 20VA transformer for thermostat and auxiliary components Relay contact closure for boiler t-stat, pump, etc..05 White Aluminum construction Thermally insulated cabinet Coil Performance at 70ºF (21.1ºC) Air flow (CFM) 700 650 Tube flow (gal/min) 2 3 4 2 3 4 Entering fluid temp. ( F) Total capacity (Btu/hr) Leaving fluid temp. ( F) Water Pressure Drop (ft H2O) Water Velocity (ft/s) 140 35,558 103.8 1.17 1.3 160 46,098 112.8 1.14 1.3 180 56,713 121.6 1.11 1.3 140 41,181 112.1 2.46 1.9 160 53,348 123.6 2.39 1.9 180 65,601 135 2.33 1.9 140 44,284 117.5 4.17 2.5 160 57,307 130.7 4.06 2.5 180 70,409 143.8 3.95 2.5 140 34,469 104.9 1.17 1.3 160 44,679 114.3 1.13 1.3 180 54,963 123.4 1.1 1.3 140 39,549 113.2 2.45 1.9 160 51,217 125.1 2.39 1.9 180 62,964 136.8 2.32 1.9 140 42,273 118.5 4.17 2.5 160 54,683 132 4.05 2.5 180 67,165 145.5 3.95 2.5 16
Air Flow (CFM) 9.1.3 Blower/Motor Performance PCAH2 Air Flow 900 800 700 600 500 400 300 High Low 200 100 0 0 0.2 0.4 0.6 0.8 1 Static Pressure (Inchs H2O) 17
9.2 PCAH3 120V PSC direct drive air handler with hydronic coil (heating). 9.2.1 Features: 3-speed PSC motor. 1150, 1050 and 900 cfm. 4-row hot water coil Installer configurable return air locations. Left, right, back, bottom Reversible door access 24 VAC, 20VA transformer for thermostat and auxiliary components Relay contact closure for boiler t-stat, pump, etc..05 White Aluminum construction Thermally insulated cabinet 9.2.2 Air flow (CFM) 900 1050 1150 Coil Performance at 70ºF (21.1ºC) Tube flow (gal/min) 2 3 4 2 3 4 2 3 4 Entering Water temp. ( F) Total capacity (Btu/hr) Leaving fluid temp. ( F) Water Pressure Drop (ft H2O) Water Velocity (ft/s) 140 38,989 100.3 1.17 1.3 160 50,564 108.3 1.14 1.3 180 62,226 115.9 1.11 1.3 140 46,516 108.5 2.46 1.9 160 60,313 118.9 2.39 1.9 180 74,217 129.1 2.33 1.9 140 51,041 114 4.18 2.5 160 66,127 126.2 4.06 2.5 180 81,323 138.2 3.96 2.5 140 40,992 98.3 1.17 1.3 160 53,171 105.6 1.14 1.3 180 65,442 112.6 1.11 1.3 140 49,590 106.4 2.46 1.9 160 64,323 116.1 2.4 1.9 180 79,173 125.7 2.33 1.9 140 55,059 112 4.18 2.5 160 71,376 123.5 4.07 2.5 180 87,819 134.8 3.96 2.5 140 42,090 97.2 1.17 1.3 160 54,600 104.1 1.14 1.3 180 67,203 110.8 1.11 1.3 140 51,321 105.2 2.47 1.9 160 66,580 114.6 2.4 1.9 180 81,963 123.8 2.34 1.9 140 57,363 110.8 4.18 2.5 160 74,385 122 4.07 2.5 180 91,543 132.9 3.97 2.5 18
Air Flow (CFM) 9.2.3 Blower/Motor Performance PCAH3 Air Flow 1400 1200 1000 800 600 400 High Low Med 200 0 0 0.2 0.4 0.6 0.8 1 Static Pressure (Inchs H2O) 19
9.3 PCAH4 240V PSC direct drive air handler with hydronic coil (heating). 9.3.1 9.3.2 Features: 3-speed PSC motor. 1600, 1350 and 1150 cfm. 3-row hot water coil Installer configurable return air locations. Left, right, back, bottom Reversible door access 24 VAC, 20VA transformer for thermostat and auxiliary components Relay contact closure for boiler t-stat, pump, etc..05 White Aluminum construction Thermally insulated cabinet Coil Performance at 70ºF (21.1ºC) Air flow (CFM) 1150 1350 1600 Tube flow (gal/min) 2 3 4 2 3 4 2 3 4 Entering Water Temp. ( F) Total capacity (Btu/hr) Leaving Water Temp. ( F) Water Pressure Drop (ft H2O) Water Velocity (ft/s) 140 41,453 97.8 0.43 0.8 160 54,190 104.5 0.43 0.8 180 66,650 111.4 0.42 0.8 140 51,000 105.4 0.94 1.2 160 66,118 114.9 0.92 1.2 180 81,345 124.2 0.9 1.2 140 57,018 111 1.61 1.5 160 73,893 122.2 1.57 1.5 180 90,888 133.2 1.54 1.5 140 43,220 96 0.43 0.8 160 56,573 102.1 0.43 0.8 180 69,582 108.4 0.42 0.8 140 53,960 103.4 0.94 1.2 160 69,977 112.3 0.92 1.2 180 86,114 120.9 0.9 1.2 140 60,992 109 1.61 1.5 160 79,079 119.6 1.57 1.5 180 97,301 129.9 1.54 1.5 140 44,903 94.3 0.43 0.8 160 58,852 99.8 0.43 0.8 180 72,380 105.5 0.42 0.8 140 56,959 101.4 0.94 1.2 160 73,888 109.6 0.92 1.2 180 90,946 117.6 0.9 1.2 140 64,986 106.9 1.61 1.5 160 84,291 116.9 1.58 1.5 180 103,746 126.6 1.54 1.5 20
Air Flow (CFM) 9.3.3 Blower/Motor Performance PCAH4 Air Flow 1800 1600 1400 1200 1000 800 600 High Low Med 400 200 0 0 0.2 0.4 0.6 0.8 1 Static Pressure (Inchs H2O) 9.4 Electrical Data PCAH2 PCAH3 PCAH4 Volts 120 120 240 Hz 60 60 60 Amps 4.9 7.6 5.2 Watts (High Speed) 768 912 1248 21
10 WARRANTY YOUR Air Handler TRANSFERABLE WARRANTY Should your PCAH Series Air Handler cease to function within one (1) year of the date of original purchase due to defective material of workmanship of the product, NU-AIR Ventilation Systems Inc. will supply a new or rebuilt part FOB factory to replace the defective part. Delivery, installation, and labor costs are not covered. Warranty Limitations The above warranty does not cover damage to the unit while in your possession (other than damages caused by defective parts or material) due to the following: 1) improper installation or unreasonable use of unit: 2) failure to provide reasonable and necessary maintenance. If the unit is put to commercial use or application other than consumer use, warranty is for a period of one (1) year. This warranty does not cover water heaters, instantaneous water heaters, boilers or condenser units supplied or used with the Air Handler. See water heater, boiler or compressor manufacturer's warranty. P.O. Box 2758 16 Nelson St., Windsor, NS B0N 2T0 Tel: (902) 798-2261 Fax: (902) 798-2557 Email: nuair@nu-airventilation.com Website: www.nu-airventilation.com 22