AAON LC-054 User Manual

LC Series
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be
Air-Cooled Condenser Chillers
Installation, Operation
& Maintenance
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
performed by a trained, qualified installer. A copy of this IOM should be kept with the unit.
QUALIFIED INSTALLER
Table of Contents
Safety .............................................................................................................................................. 6
LC Base Model Description............................................................................................................ 8
General Description ...................................................................................................................... 12
Receiving Unit ........................................................................................................................... 12
Chiller ........................................................................................................................................ 12
Wiring Diagrams ....................................................................................................................... 13
General Maintenance ................................................................................................................. 13
Primary Pumping Package ........................................................................................................ 14
Glycol ........................................................................................................................................ 14
Compression/Expansion Tank ................................................................................................... 14
Pressure Relief Valve ................................................................................................................ 14
Manual and Automatic Air Vent ............................................................................................... 14
Dual Pumps ............................................................................................................................... 15
Differential Pressure Gauge and Thermometers ....................................................................... 15
Pipe Insulation ........................................................................................................................... 15
Installation..................................................................................................................................... 15
Lifting the Unit .......................................................................................................................... 15
Locating the Unit ....................................................................................................................... 15
Water Connection ...................................................................................................................... 16
Mounting Isolation .................................................................................................................... 16
Access Doors ............................................................................................................................. 16
Low Ambient Operation ............................................................................................................ 16
LAC Valve ............................................................................................................................. 17
Condenser Flooding ............................................................................................................... 18
Electrical .................................................................................................................................... 18
Startup ........................................................................................................................................... 19
Maintenance .................................................................................................................................. 20
General ...................................................................................................................................... 20
Compressors .............................................................................................................................. 20
Refrigerant Filter Driers ............................................................................................................ 20
Adjusting Refrigerant Charge ................................................................................................... 20
Lubrication ................................................................................................................................ 23
Service ....................................................................................................................................... 23
Replacement Parts ..................................................................................................................... 23
AAON - Longview Warranty, Service and Parts Department .................................................. 23
Warranties ................................................................................................................................. 23
Condenser Tube Inspection ....................................................................................................... 23
Pump Operation ......................................................................................................................... 23
Maintenance Recommendations ............................................................................................... 24
Access Doors ............................................................................................................................. 24
Pump Bearings - Lubrication .................................................................................................... 24
Air Inlet ..................................................................................................................................... 24
Propeller Fans and Motors ........................................................................................................ 24
Recommended Annual Inspection ............................................................................................ 24
Mechanical Cleaning ................................................................................................................. 24
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Air-Cooled Condenser ............................................................................................................... 24
E-Coated Coil Cleaning ............................................................................................................ 24
Recommended Coil Cleaner .................................................................................................. 25
Recommended Chloride Remover ......................................................................................... 25
Appendix - Water Piping Component Information ...................................................................... 27
Water Pressure Relief Valve ..................................................................................................... 27
Automatic Air Vent Valves ....................................................................................................... 27
Pumps: Installation and Operating Instructions ........................................................................ 28
Dual Pump Specific Information ............................................................................................... 33
Valve Operation ........................................................................................................................ 34
Refer to the valve illustrations on the following pages. ............................................................ 34
Suction Guides .......................................................................................................................... 39
Flo-Trex Combination Valve .................................................................................................... 40
LC Series Startup Form ................................................................................................................ 45
Maintenance Log .......................................................................................................................... 48
Literature Change History............................................................................................................. 49
R75390 · Rev. B · 120509
(ACP 30091)
4
Index of Tables and Figures
Tables:
Table 1 - Condenser Flooding ....................................................................................................... 18
Table 2 - Acceptable Refrigeration Circuit Values ....................................................................... 21
Table 3 - R-410A Refrigerant Temperature-Pressure Chart ......................................................... 22
Figures:
Figure 1 - Pressure Relief Valve ................................................................................................... 14
Figure 2 - Piping Schematic of Example System using the LAC Valve ...................................... 17
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ELECTRIC SHOCK, FIRE OR
Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or
Improper servicing could result in
wires prior to disconnecting.
Verify proper operation after
FIRE, EXPLOSION OR CARBON
to replace proper controls
could result in fire, explosion or
to follow safety warnings exactly
in the vicinity of this
Attention should be paid to the following statements:

Safety

NOTE - Notes are intended to clarify the unit installation, operation and maintenance.
CAUTION - Caution statements are given to prevent actions that may result in
equipment damage, property damage, or personal injury.
WARNING - Warning statements are given to prevent actions that could result in
equipment damage, property damage, personal injury or death.
DANGER - Danger statements are given to prevent actions that will result in equipment
damage, property damage, severe personal injury or death.
EXPLOSION HAZARD
property damage.
dangerous operation, serious injury, death, or property damage.
When servicing controls, label all
Reconnect wires correctly.
servicing. Secure all doors with key-lock or nut and bolt.
MONOXIDE POISONING HAZARD
Failure
carbon monoxide poisoning. Failure
could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors and liquids appliance.
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
unattended in
hand mode or manual bypass.
vulnerable to attack by certain chemicals. Polyolester (POE) oils
410A and other
and complete piping
system failure.
CAUTION
VARIABLE FREQUENCY DRIVES
Do not leave VFDs
Damage to personnel or equipment can occur if left unattended. When in hand mode or manual bypass mode VFDs will not respond to controls or alarms.
PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are
used with R­refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings
1. The unit is for outdoor use only. See
General Information section for more information.
2. READ THE ENTIRE INSTALLATION,
OPERATION AND MAINTENANCE MANUAL. OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL.
3. Keep this manual and all literature
safeguarded near or on the unit.
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LC - 038
3 - 0 - A A 0
A - 0 0 0
Series and
Generation
Model Number
-
Unit Size Voltage Blank A1 A2 A3 A4 B1 B2 B3
BASE MODEL
SERIES AND GENERATION
LC
UNIT SIZE
005 = 5 Nominal Tons 006 = 6 Nominal Tons 007 = 7 Nominal Tons
008 = 8 Nominal Tons 012 = 12 Nominal Tons 015 = 15 Nominal Tons 019 = 19 Nominal Tons 021 = 21 Nominal Tons 026 = 26 Nominal Tons 027 = 27 Nominal Tons 029 = 29 Nominal Tons 038 = 38 Nominal Tons 047 = 47 Nominal Tons 054 = 54 Nominal Tons
VOLTAGE
1 = 230V/1Φ/60Hz 2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 8 = 208V/3Φ/60Hz 9 = 208V/1Φ/60Hz
BLANK
0 = Standard

LC Base Model Description

FEATURE A: COOLING
A1: COOLING STYLE
A = R-410A Variable Capacity Scroll Compressors
A2: COOLING CONFIGURATION
0 = Air-Cooled Condenser, Low Water Flow A = Air-Cooled Condenser, High Water Flow
A3: COOLING COATING
0 = Standard 1 = Polymer E-Coated Condenser Coil
A4: COOLING STAGING
A = Shell and Tube Heat Exchanger B = Brazed Plate Heat Exchanger C = Oversized Shell and Tube Heat Exchanger D = Oversized Brazed Plate Heat Exchanger
FEATURE B: BLANK
B1: BLANK
0 = Standard
B2: BLANK
0 = Standard
B3: BLANK
0 = Standard
B G J
G - 0
Feature Number
LC Features Description
:
1A 1B 1C 1D 2
FEATURE 1: BUILDING PUMPING
1A: PUMP OPTIONS
0 = Standard, No Building Pump B = Primary Pumping System
1B: PUMP CONFIGURATION
0 = Standard, No Building Pump A = 1 Pump - Std Eff, 1170 RPM C = dualArm Pump - Std Eff, 1170 RPM D = 1 Pump - Prem Eff, 1170 RPM F = dualArm Pump - Prem Eff, 1170 RPM G = 1 Pump w/ VFD - 1170 RPM J = dualArm Pump w/ 2 VFDs - 1170 RPM K = 1 Pump - Std Eff, 1760 RPM M = dualArm Pump - Std Eff, 1760 RPM N = 1 Pump - Prem Eff, 1760 RPM Q = dualArm Pump - Prem Eff, 1760 RPM R = 1 Pump w/ VFD - 1760 RPM T = dualArm Pump w/ 2 VFDs - 1760 RPM U = 1 Pump - Std Eff, 3520 RPM W = dualArm Pump - Std Eff, 3520 RPM Y = 1 Pump - Prem Eff, 3520 RPM 1 = dualArm Pump - Prem Eff, 3520 RPM 2 = 1 Pump w/ VFD - 3520 RPM 4 = dualArm Pump w/ 2 VFDs - 3520 RPM
1C: PUMP SIZE
0 = Standard, No Building Pump A = Pump 4360 1.5B B = Pump 4360 2B C = Pump 4360 2D D = Pump 4380 1.5x1.5x6 E = Pump 4380 2x2x6 F = Pump 4380/4382 3x3x6 G = Pump 4380/4382 4x4x6 H = Pump 4380 1.5x1.5x8 J = Pump 4380 2x2x8 K = Pump 4380/4382 3x3x8
L = Pump 4380/4382 4x4x8 M = Pump 4380 5x5x8 N = Pump 4380/4382 6x6x8 P = Pump 4380 2x2x10 Q = Pump 4380/4382 3x3x10 R = Pump 4380/4382 4x4x10 S = Pump 4380/4382 6x6x10 T = Pump 4380/4382 8x8x10 U = Pump 4380 4x4x11.5 V = Pump 4380 5x5x11.5 W = Pump 4380 6x6x11.5 Y = Pump 4380 8x8x11.5 Z = Pump 4380 4x4x13 1 = Pump 4380 6x6x13 2 = Pump 4380 8x8x13 3 = Pump 4382 6x6x6 4 = Pump 4382 8x8x8 5 = Pump 4360 3D
1D: PUMP MOTOR
0=Standard, No Building Pump A = 0.5 hp B = 0.75 hp C = 1 hp D = 1.5 hp E = 2 hp F = 3 hp G = 5 hp H = 7.5 hp J = 10 hp
FEATURE 2: WATER CONNECTION LOCATIONS
0 = Standard, Back Water Connections B = Back Water Connection + Factory Installed Pipe Trace Heating Cable
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F
B - 0 0 0 - 0 0 0 - A 0 0 B 0
Feature Number
LC Features Description
3 4 5A 5B 5C 6A 6B 6C 7 8 9 10 11
FEATURE 3: CHILLER ACCESSORIES
0 = Heat Trace and Insulation on Water Evaporator A = Heat Trace and Insulation on Glycol Evaporator D = Heat Trace and Insulation on Water Evaporator with Air Scoop E = Heat Trace and Insulation on Glycol Evaporator with Air Scoop F = Heat Trace and Insulation on Water Evaporator with Air Scoop, Thermometers, and Differential Pressure Gauge H = Heat Trace and Insulation on Glycol Evaporator with Air Scoop, Thermometers, and Differential Pressure Gauge
FEATURE 4: LOW AMBIENT
0 = Standard, Variable Speed Condenser Fans A = Variable Speed Condenser Fans with Low Ambient on One Refrigerant Circuit B = Variable Speed Condenser Fans with Low Ambient on Two Refrigerant Circuits
FEATURE 5: BLANK
5A: BLANK
0 = Standard
5B: BLANK
0 = Standard
5C: BLANK
0=Standard
FEATURE 6: BLANK
6A: BLANK
0=Standard
6B: BLANK
0 = Standard
6C: BLANK
0 = Standard
FEATURE 7: SERVICE OPTIONS
0 = Standard A = Factory Wired 115V Outlet B = Field Wired 115V Outlet
FEATURE 8: BLANK
0 = Standard
FEATURE 9: REFRIGERATION ACCESSORIES
0 = Standard A = Sight Glass B = Compressor Isolation Valves C = Sight Glass and Compressor Isolation Valves
FEATURE 10: POWER OPTIONS
0 = Standard, Power Block A = Power Switch (60 amps) B = Power Switch (100 amps) C = Power Switch (150 amps) D = Power Switch (225 amps) E = Power Switch (400 amps)
FEATURE 11: SAFETY OPTIONS
0 = Standard
B
0 - 0
0 - 0 0 0 A 0 0 0 0 B
Feature Number
LC Features Description
12 13 14A 14B 15 16 17 18 19 20 21 22 23
FEATURE 12: CONTROLS
0 = Standard B = Phase and Brown Out Protection
FEATURE 13: SPECIAL CONTROLS
0 = Standard MCS Magnum Controller A = Standard MCS Magnum with Modem B = Standard MCS Magnum with LonTalk Connection C = Standard MCS Magnum with Diagnostics D = Standard MCS Magnum with LonTalk Connection and Diagnostics E = Standard MCS Magnum with LonTalk Connection and Modem F = Standard MCS Magnum with Diagnostics and Modem G = Standard MCS Magnum with Lontalk Connection, Diagnostics, and Modem
FEATURE 14: BLANK
14A: BLANK
0 = Standard
14B : BLANK
0 = Standard
FEATURE 15: BLANK
0 = Standard
FEATURE 16: BLANK
0 = Standard
FEATURE 17: BLANK
0 = Standard
FEATURE 18: WARRANTY
0 = Standard A = Second to Fifth Year Extended Compressor Warranty
FEATURE 19: CODE OPTIONS
0 = Standard ETL USA Listing
FEATURE 20: BLANK
0 = Standard
FEATURE 21: BLANK
0 = Standard
FEATURE 22: BLANK
0 = Standard
FEATURE 23: TYPE
B = Standard Paint U = Special Price Authorization and Special Paint X = Special Price Authorization w/ Standard Paint
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Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be recovery, recycling, or reclaiming
Coils and sheet metal surfaces
be taken when working with

General Description

LC Series air-cooled condenser chillers are complete self-contained liquid chilling units. They are factory assembled, wired, charged and run-tested. Primary pumping package is available as an optional feature.
present sharp edges and care must
equipment.
Failure to observe the following instructions will result in premature failure of your system and possible voiding of the warranty.
performed by a trained, qualified installer.

Receiving Unit

When received, the unit should be checked
System should be sized in accordance with the American Society of Heating, Refrigeration and Air Conditioning Engineers Handbook.
Installation of LC Series units must conform to the ICC standards of the International Mechanical Code, the International Building Code, and local building, plumbing and waste water codes. All appliances must be electrically grounded in accordance with local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian
for damage that might have occurred in transit. If damage is found it should be noted on the carrier’s Freight Bill. A request for inspection by carrier’s agent should be made in writing at once. Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements.

Chiller

Failure to observe the following instructions will result in premature failure of your system, and possible voiding of the warranty.
Electrical Code CSA C22.1.
The Clean Air Act of 1990 bans the intentional venting of refrigerant as of July 1, 1992. Approved methods of
CRANKCASE HEATER
OPERATION Units are equipped with compressor crankcase heaters, which should be energized at least 24 hours prior to cooling operation, to clear any liquid
must be followed.
refrigerant from the compressors.
Scroll compressors are directional
the wrong direction. Low pressure
disconnected after factory testing. Rotation should be checked by a
gauges and any wiring alteration should only be made at the unit
Rotation must be checked on all
three phase units. All motors, to
an motors,
Never cut off the main power supply to the unit, except for complete shutdown. When power is cut off from the unit, any compressors using crankcase heaters cannot prevent refrigerant migration. This means the compressor will cool down, and liquid refrigerant may accumulate in the compressor. Since the compressor is designed to pump refrigerant gas, damage may occur when power is restored.
MOTORS AND COMPRESSORS of
include and not be limited to pump motors and condenser f should all be checked by a qualified service technician at startup and any wiring alteration should only be made at the unit power connection.
Before unit operation, the main power switch must be turned on for at least twenty four hours for units with compressor crankcase heaters. This will give the crankcase heater time to clear any liquid accumulation out of the compressor before it is required to run.
and will be damaged by operation in
switches on compressors have been
qualified service technician at startup using suction and discharge pressure
power connection.
Always control the system from the control panel, never at the main power supply (except for emergency or for complete shutdown of the system).
The standard compressors must be on a minimum of 4 minutes and off for a minimum of 5 minutes. The cycle rate must be no more than 6 starts per hour.
The variable capacity compressors must be on a minimum of 3 minutes and off for a minimum of 3 minutes. The cycle rate must be no more than 10 starts per hour.
The chiller is furnished with a pressure differential switch that is factory installed between the chilled water supply and return connections. This sensor must not be bypassed since it provides a signal to the unit controller that water flow is present in the heat exchanger and the unit can operate without the danger of freezing the liquid.
The compressor life will be seriously shortened by reduced lubrication, and the pumping of excessive amounts of liquid oil and refrigerant.

Wiring Diagrams

A complete set of unit specific wiring diagram in point-to-point form is laminated in plastic and located inside the control compartment door.

General Maintenance

When the initial startup is made and on a periodic schedule during operation, it is necessary to perform routine service checks on the performance of the chiller. This includes reading and recording suction pressures and checking for normal sub­cooling and superheat.
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14

Primary Pumping Package

Primary pumping uses a single pump to move water (or glycol) through the evaporator and back to the building. This pumping package provides the necessary flow of water to the system. The pump is activated whenever the chiller is given a run signal.
Water enters the unit through the return water piping, and then travels through an air scoop to remove any air that is entrapped in the water. Following this, the water flows through a suction guide with strainer. The end of the suction guide is removable for strainer access. The strainer assembly is composed of two parts, the operational strainer, and the startup strainer, (located inside the operational strainer) which is to be removed 24 hours after startup.
The pump is installed after the suction guide, and before a combination valve (Flo­Trex). This combination valve acts as isolation valve, check valve, and flow balancing valve. The shell and tube or brazed plate evaporator, is placed after the combination valve in the water circuit, with a differential pressure switch installed across its inlet and outlet. This pressure switch closes when the differential pressure increases above the set-point, which should be set 1-2 psig below the pressure drop across the heat exchanger at design flow rate. The closing differential pressure switch signals the control system to indicate flow through the heat exchanger and allow cooling to activate as required to maintain the setpoint. The water exiting the shell and tube or brazed plate evaporator, leaves the unit through the water out connection.

Glycol

Glycol units require a glycol feeder field installed to replace fluid that is lost in the system. Water should not be directly added
to glycol applications as this would dilute the glycol concentration and thereby increase the freezing temperature of the fluid.

Compression/Expansion Tank

As the water temperature in the system increases, the volume that water displaces increases. In order to compensate for these forces, AAON recommends a pre­pressurized diaphragm compression tank that is preset for 12 psig.

Pressure Relief Valve

Required pressure relief valve is installed in the unit. This valve is set at 125 psig. Figure 1 shows inlet pressure versus capacity for this pressure relief valve. See appendix for additional information.
Figure 1 - Pressure Relief Valve

Manual and Automatic Air Vent

A manual air vent is supplied in chillers without pumping packages. With a pumping package option, there is an air scoop installed at the high point of the system. The air vent valve must be in the proper position for operation. Ensure that the small vent cap on the automatic air vent is loosened one to two turns from the closed position, allowing air to be vented from the system. It is advisable to leave the cap on to prevent impurities from entering the valve. See appendix for additional information.

Dual Pumps

When redundant pumping is required, a factory installed dualArm pump can be ordered on units 15 tons and larger. A dualArm pump is a pump with two independent motors and pumps in a single casing. This pump has a swing split-flapper valve in the discharge port to prevent liquid recirculation when only one pump is operating. Isolation valves in the casing allow one pump to be isolated and removed for service while the other pump is still operating.
The controls package will activate the pump when the unit is given a run command. If the controls do not recognize flow in 60 seconds, the second pump will be activated and an alarm signal will be generated. If the second pump does not activate, the cooling will be locked out.

Differential Pressure Gauge and Thermometers

A differential pressure gauge and thermometers are available as a factory installed option when using a factory installed pumping package. Thermometers are installed around the evaporator of the unit. A differential pressure gauge is installed at each pump. This pressure gauge is connected in three places to the water piping: before the suction guide/strainer, after the suction guide and before the pump, and after the pump. There is also a needle valve at each of these points to isolate the pressure. To measure the pressure at any given point, open the needle valve at that point and close the other two needle valves. Instead of two pressure gauges, one pressure gauge is used to minimize calibration and gauge errors.

Pipe Insulation

All evaporators in the LC Series chiller are heat traced and insulated. The water piping and components on standard LC are not heat traced or insulated at the factory. The factory can install heat trace as an optional feature. All water piping shall be leak tested in the field prior to startup, as shipping vibrations may have loosened connections.

Installation

Lifting the Unit

If cables or chains are used to hoist the unit they must be the same length and care should be taken to prevent damage to the cabinet or injury to the installer.
Arrange spreader bars, blocking, or other lifting devices to prevent any damage to the coils or the cabinet of the condensing unit.
Before lifting unit, be sure that all shipping material has been removed from the unit.
All LC Series chillers have lifting channels in the base of the equipment to allow moving and placement without physical damage.
Unit may be positioned with a forklift. Remove the harness used in hoisting. Make sure the unit is properly seated and level.

Locating the Unit

The LC Series chiller is designed for outdoor applications and mounting at ground level or on a rooftop. It must be placed on a level and solid foundation that has been prepared to support its weight. When installed at ground level, a one-piece concrete slab should be used with footings that extend below the frost line. Also with ground level installation, care must be taken to protect the coil fins from damage due to vandalism or other causes. As a standard, all
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The chiller must be operated with liquid flowing through the
attack by certain
chemicals. Polyolester (POE) oils
410A and other
and fittings and complete piping system failure.
LC Series chillers have factory installed louvered sheet metal condenser coil guards.
The placement relative to the building air intakes and other structures must be carefully selected. Airflow to and from the chiller must not be restricted to prevent a decrease in performance and efficiency.
The installation position must provide at least 3 feet of side clearance for proper airflow to the condenser coils. When units are mounted adjacent to each other, the minimum clearance required between the units is 6 feet
Units should not be installed in an enclosure or pit that is deeper than the height of the unit. When recessed installation is necessary, the clearance to maintain proper airflow is at least 6 feet.
LC Series chillers have a vertical air discharge. There must be no obstruction above the equipment. Do not place the unit under an overhang.
For proper unit operation, the immediate area around condenser must remain free of debris that may be drawn in and obstruct airflow in the condensing section.
Consideration must be given to obstruction caused by snow accumulation when placing the unit.

Water Connection

Connect the chiller supply and return water lines. The connection size is listed on the unit rating sheet, along with the designed volumetric flow rate. The maximum operating pressure for the AAON LC Series chiller is 125 psi.
evaporators.
PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to
used with R­refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping

Mounting Isolation

For roof mounted applications or anytime vibration transmission is a factor, vibration isolators may be used.

Access Doors

Access doors are provided to the compressor and electrical compartment. A separate access door is also provided to the evaporator/heat exchanger compartment.

Low Ambient Operation

During low ambient temperatures, it is difficult to start a system because the refrigerant will migrate to the cold part of the system (condenser) and make it difficult for refrigerant to flow. All chiller compressors are provided with factory installed crankcase heaters. The LC Series chiller must have continuous power 24 hours prior to startup. This ensures the compressor will receive sufficient refrigerant vapor at startup.
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