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.
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
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
9
10
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
11
12
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.
13
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
15
16
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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