Aaon LL-035 Installation Manual

LL Series

Chillers and Outdoor Mechanical Rooms

Failure to follow safety warnings

installation, operation and service

, adjustment, alteration, service or maintenance can cause serious injury, death or

A copy of this IOM should be kept with the unit.

do not use any phone in your

from a phone remote from the

If you cannot reach your gas

and service must be

by a Factory Trained

WARNING

Installation, Operation

& Maintenance

FIRE OR EXPLOSION HAZARD

exactly could result in serious injury, death or property damage.

Be sure to read and understand the

instructions in this manual.

Improper installation

property damage.

Do not store gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.  Do not touch any electrical switch;

building.

 Leave the building immediately.  Immediately call you gas supplier

building. Follow the gas supplier’s instructions.



supplier call the fire department.

Startup performed Service Technician.

Table of Contents

Safety .............................................................................................................................................. 7

LL Series Feature String Nomenclature ....................................................................................... 11

General Information ...................................................................................................................... 19

Codes and Ordinances ............................................................................................................... 19

Receiving Unit ........................................................................................................................... 19

Storage ....................................................................................................................................... 19

Outdoor Mechanical Room ....................................................................................................... 20

Wiring Diagrams ....................................................................................................................... 21

General Maintenance ................................................................................................................. 21

Chiller Primary Pumping .......................................................................................................... 21

Chiller Primary/Secondary Pumping ........................................................................................ 21

Boiler System ............................................................................................................................ 22

Boiler Primary/Secondary Pumping .......................................................................................... 22

Make Up Water ......................................................................................................................... 23

Compression/Expansion Tank ................................................................................................... 23

Pressure Relief Valve ................................................................................................................ 24

Automatic Air Vent ................................................................................................................... 24

Dual Pumps ............................................................................................................................... 24

Pressure Gauges and Thermometers ......................................................................................... 24

Pipe Insulation ........................................................................................................................... 25

Installation..................................................................................................................................... 26

Outdoor Mechanical Room Placement...................................................................................... 26

Curb and Steel Mount Installation ............................................................................................ 26

Lifting and Handling ................................................................................................................. 27

Water Connection ...................................................................................................................... 28

Gas Connection ......................................................................................................................... 29

Boiler Exhaust Connection ........................................................................................................ 29

Boiler Intake Connection .......................................................................................................... 31

Mounting Isolation .................................................................................................................... 31

Access Doors ............................................................................................................................. 31

Low Ambient Operation ............................................................................................................ 31

LAC Valve ............................................................................................................................. 31

OROA Valve ......................................................................................................................... 32

ORI/ORD Valves ................................................................................................................... 33

Condenser Flooding ............................................................................................................... 34

Electrical .................................................................................................................................... 35

Startup ........................................................................................................................................... 38

Axial Flow Condenser Fans ...................................................................................................... 39

General ...................................................................................................................................... 42

Compressors .............................................................................................................................. 42

Refrigerant Filter Driers ............................................................................................................ 42

Evaporator/Heat Exchangers ..................................................................................................... 42

Adjusting Refrigerant Charge ................................................................................................... 42

Lubrication ................................................................................................................................ 47

Air-Cooled Condenser ............................................................................................................... 47

E-Coated Coil Cleaning ............................................................................................................ 47

Recommended Coil Cleaner .................................................................................................. 48

Recommended Chloride Remover ......................................................................................... 48

Evaporative-Cooled Condenser ................................................................................................. 48

Severe Service ....................................................................................................................... 49

Safety ..................................................................................................................................... 49

Performance ........................................................................................................................... 50

Warranties .............................................................................................................................. 50

Condenser Tube Inspection ................................................................................................... 50

Freeze Protection ................................................................................................................... 50

Recirculating Water System .................................................................................................. 50

Startup .................................................................................................................................... 50

Cleanliness ............................................................................................................................. 50

Storage ................................................................................................................................... 50

Pump Operation ..................................................................................................................... 51

Running.................................................................................................................................. 51

Condenser Fan Motors ........................................................................................................... 51

Water Make Up Valve ........................................................................................................... 51

Water Treatment System ....................................................................................................... 52

Sequence of Operation for LL Series units without Diagnostics .......................................... 53

Sequence of Operation for LL Series units with Diagnostics ................................................ 53

Pump Maintenance ................................................................................................................ 54

Fan Motor Maintenance ......................................................................................................... 54

Access Doors ......................................................................................................................... 54

Bearings - Lubrication ........................................................................................................... 54

Recommended Monthly Inspection ....................................................................................... 54

Mist Eliminators .................................................................................................................... 55

Air Inlet .................................................................................................................................. 55

Stainless Steel Base Pan ........................................................................................................ 55

Propeller Fans and Motors ..................................................................................................... 55

Recommended Annual Inspection ......................................................................................... 55

Cleaning ................................................................................................................................. 55

Water Quality ......................................................................................................................... 55

Mechanical Cleaning ............................................................................................................. 56

Service ....................................................................................................................................... 56

Replacement Parts ..................................................................................................................... 57

AAON Warranty, Service and Parts Department ...................................................................... 57

Appendix - Water Piping Component Information ...................................................................... 58

Water Pressure Reducing Valve ................................................................................................ 58

Water Pressure Relief Valve ..................................................................................................... 60

Automatic Air Vent Valves ....................................................................................................... 60

Pumps - Installation and Operating Instructions ....................................................................... 62

Pump Piping - General .............................................................................................................. 64

Pump Operation ......................................................................................................................... 64

General Care .............................................................................................................................. 65

Dual Pump Specific Information ............................................................................................... 67

Horizontal and Vertical Expansion Tanks ................................................................................ 72

Suction Guides .......................................................................................................................... 73

Glycol Auto Fill Unit ................................................................................................................ 74

Flo-Trex Combination Valve .................................................................................................... 76

LL Series Startup Form ................................................................................................................. 81

Maintenance Log .......................................................................................................................... 87

Literature Change History............................................................................................................. 88

R10100 · Rev. B · 140226

Index of Tables and Figures

Tables:

Table 1 - Service Clearances......................................................................................................... 26

Table 2 - Mounting Dimensions ................................................................................................... 27

Table 3 - Boiler Rated Input Capacity .......................................................................................... 29

Table 4 - Condenser Flooding....................................................................................................... 35

Table 5 - Return/Exhaust Fan Pin Location .................................................................................. 40

Table 6 - Return/Exhaust Fan Pin Location .................................................................................. 40

Table 7 - Fan Assembly Bushing Torque Specifications.............................................................. 41

Table 8 - Filter Drier Maximum Pressure Drop............................................................................ 42

Table 9 - Acceptable Refrigeration Circuit Values ....................................................................... 44

Table 10 - R-134a Refrigerant Temperature-Pressure Chart ........................................................ 45

Table 11 - R-410A and R-22 Refrigerant Temperature-Pressure Chart ....................................... 46

Table 12 - Recirculating Water Quality Guidelines ..................................................................... 55

Figures:

Figure 1 - Backflow Preventer ...................................................................................................... 23

Figure 2 - Pressure Relief Valve ................................................................................................... 24

Figure 3 - Curb Mounting with Dimensions ................................................................................. 26

Figure 4 - Steel Mounting Rail with Dimensions ......................................................................... 27

Figure 5 - Marked Lifting Points .................................................................................................. 27

Figure 6 - LL Series Lifting Detail ............................................................................................... 28

Figure 7 - Boiler Vent Shipping Covers ....................................................................................... 29

Figure 8 - Boiler Vent Components .............................................................................................. 30

Figure 9 - Correct Vent Pipe Connection ..................................................................................... 30

Figure 10 - Incorrect Vent Pipe Connection ................................................................................. 31

Figure 11 - Piping Schematic of Example System using the LAC Valve. ................................... 32

Figure 12 - Piping Schematic of Example System using the OROA Valve. ................................ 33

Figure 13 - Piping Schematic of Example System using the ORI/ORD Valve. ........................... 34

Figure 14 - Terminal Block ........................................................................................................... 36

Figure 15 - Evaporative-Cooled Condenser Section Layout ........................................................ 37

Figure 16 - Fan with the HUB on the top and RET on the bottom. .............................................. 39

Figure 17 - Bushing Mount Location............................................................................................ 39

Figure 18 - RET with Pin in Groove 4 .......................................................................................... 39

Figure 19 - Fan HUB and RET Castings ...................................................................................... 40

Figure 20 - Pitch Insert ................................................................................................................. 41

Figure 21 - Replaceable Core Filter Driers ................................................................................... 42

Figure 22 - Proper Unit Location .................................................................................................. 49

Figure 23 - Improper Unit Locations ............................................................................................ 50

Figure 24 - Water Makeup Valve ................................................................................................. 52

Safety

ELECTRIC SHOCK, FIRE OR

Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or

Improper servicing could result in dangerous operation, serious injury,

Before servicing, disconnect all electrical power to the furnace.

wires prior to disconnecting.

Verify proper operation after servicing. Secure all doors with

WARNING

Attention should be paid to the following statements:

Improper installation, adjustment, alteration, service or maintenance can cause property damage,

WARNING

Do not use any phone in the

and check all gas connections

CAUTION

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.

death, or property damage.



More than one disconnect may be provided.

 When servicing controls, label all

Reconnect wires correctly.



key-lock or nut and bolt.

personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician. A copy of this IOM should be kept with the unit.

WHAT TO DO IF YOU SMELL GAS

 Do not try to turn on unit.  Shut off main gas supply.  Do not touch any electric switch. 

 Never test for gas leaks with an

 Use a gas detection soap solution

QUALIFIED INSTALLER

building.

open flame.

and shut off valves.

FIRE, EXPLOSION OR CARBON

Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly

and liquids in the vicinity of this

Electric shock hazard. Before

to the unit, including remote disconnects, to avoid shock hazard

WARNING

Do not leave VFDs unattended in hand mode or manual bypass.

WARNING

electrical components. Only a

licensed electrician or

live electrical components shall

70E, an OSHA

regulation requiring an Arc Flash

marked for identification of where

opriate Personal Protective

followed.

WARNING

All field installed wiring must be completed by qualified personnel. Field installed wiring must comply

local and state

to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code

WARNING

and overload protection may be a

e Variable Frequency

CAUTION

MONOXIDE POISONING HAZARD

could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors

appliance.

servicing, shut off all electrical power

or injury from rotating parts. Follow proper Lockout-Tagout procedures.

During installation, testing, servicing, and troubleshooting of the equipment it may be necessary to work with live

qualified individual properly trained in handling

perform these tasks.

Standard NFPA-

Boundary to be field established and

appr Equipment (PPE) be worn, should be

GROUNDING REQUIRED

with NEC/CEC, electrical code requirements. Failure

requirements.

VARIABLE FREQUENCY DRIVES

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.

Electric motor over-current protection

function of th Drive to which the motors are wired. Never defeat the VFD motor overload feature. The overload ampere setting must not exceed 115% of the electric motors FLA rating as shown on the motor nameplate.

(Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils

410A and other

and fittings and complete piping system failure.

CAUTION

To prevent injury or death lifting

WARNING

Door compartments containing hazardous voltage or rotating parts

h door latches to

bolts requiring tooled

If you do not replace the

shipping hardware with a pad lock

CAUTION

Always use a pressure regulator,

ges to control

incoming pressures when pressure

WARNING

on all

should be checked for proper

CAUTION

in place of refrigerant and dry

A violent

WARNING

not use alkaline chemical coil

CAUTION

UNIT HANDLING

equipment capacity shall exceed unit weight by an adequate safety factor. Always test-lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage, injury or death.

valves and gau

testing a system. Excessive pressure may cause line ruptures, equipment damage or an explosion which may result in injury or death.

are equipped wit allow locks. Door latch are shipped with nut and access.

always re-install the nut & bolt after closing the door.

Do not use oxygen, acetylene or air

nitrogen for leak testing. explosion may result causing injury or death.

PVC (Polyvinyl Chloride) and CPVC

used with Rrefrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping

Rotation must be checked MOTORS AND COMPRESSORS of 3 phase units at startup by a qualified service technician. Scroll compressors are directional and can be damaged if rotated in the wrong direction. Compressor rotation must be checked using suction and discharge gauges. Fan motor rotation

operation. Alterations should only be made at the unit power connection

To prevent damage to the unit, do not use acidic chemical coil cleaners. Do

cleaners with a pH value greater than

8.5, after mixing, without first using an aluminum corrosion inhibitor in the cleaning solution.

coil cleaning

Failure to follow

WARNING

water or steam on refrigerant coils will cause high pressure inside the

CAUTION

Door compartments containing hazardous voltage or rotating parts

h door latches to

bolts requiring tooled

If you do not replace the

CAUTION

used in hydrofluorocarbon (HFC) refrigeration systems. Refer to the compressor label for the proper

CAUTION

To prevent motor overheating compressors must cycle off for a

To maintain the proper oil level compressors must cycle on for a

The cycle rate must not exceed 6 starts per hour.

WARNING

Some chemical compounds are caustic or toxic. Use these substances only in accordance with the manufacturer’s usage instructions. instructions may result in equipment damage, injury or death.

Do not clean DX refrigerant coils with hot water or steam. The use of hot

coil tubing and damage to the coil.

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME

minimum of 5 minutes.

5 MINUTE MINIMUM ON TIME

minimum of 5 minutes.

Polyolester (POE) and Polyvinylether (PVE) oils are two types of lubricants

compressor lubricant type.

are equipped wit allow locks. Door latch are shipped with nut and access. shipping hardware with a pad lock always re-install the nut & bolt after closing the door.

1. Startup and service must be performed

by a Factory Trained Service Technician.

2. The unit is for outdoor use only. See

General Information section for more information.

3. Use only with type of the gas approved

for the boiler. Refer to the boiler rating plate.

4. Provide adequate combustion ventilation

air to the boiler.

5. Every unit has a unique equipment

nameplate with electrical, operational, and unit clearance specifications. Always refer to the unit nameplate for specific ratings unique to the model you have purchased.

6. READ THE ENTIRE INSTALLATION,

OPERATION AND MAINTENANCE MANUAL. OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL.

7. Keep this manual and all literature

safeguarded near or on the unit.

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 F

B–K5E–KJG–A0C0CBA–E

– 0 F

0 0B0

GEN

Model Options

Unit Feature Options

BASE MODEL

SERIES AND GENERATION

UNIT SIZE

035 = 35 ton Capacity 050 = 50 ton Capacity 055 = 55 ton Capacity 060 = 60 ton Capacity 067 = 67 ton Capacity 075 = 75 ton Capacity 085 = 85 ton Capacity 090 = 90 ton Capacity 092 = 92 ton Capacity 104 = 104 ton Capacity 105 = 105 ton Capacity 115 = 115 ton Capacity 118 = 118 ton Capacity 120 = 120 ton Capacity 125 = 125 ton Capacity 140 = 140 ton Capacity 150 = 150 ton Capacity

170 = 170 ton Capacity 180 = 180 ton Capacity 181 = 181 ton Capacity 185 = 185 ton Capacity 210 = 210 ton Capacity 230 = 230 ton Capacity 240 = 240 ton Capacity 245 = 245 ton Capacity 275 = 275 ton Capacity 300 = 300 ton Capacity 335 = 335 ton Capacity 360 = 360 ton Capacity 365 = 365 ton Capacity 450 = 450 ton Capacity 540 = 540 ton Capacity

LL Series Feature String Nomenclature

VOLTAGE

2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 8 = 208V/3Φ/60Hz

BLANK

0 = Standard

MODEL OPTION A: COOLING

A1: COOLING STYLE

B = R-134a Variable Capacity Oil-Free Magnetic Bearing Centrifugal Compressors D = R-410A Dual Circuited Scroll Compressors E = R-410A Independently Circuited Scroll Compressors M = R-410A VFD Compatible Scroll Compressors

A2: COOLING CONFIGURATION

0 = Air-Cooled Condenser, Low Water Flow A = Air-Cooled Condenser, High Water Flow B = Evap-Cooled Condenser, Low Water Flow C = Evap-Cooled Condenser, High Water Flow

A3: COOLING COATING

0 = Standard 1 = Polymer E-Coated Condenser Coil 2 = Stainless Steel Condenser Coil Casing

A4: COOLING STAGING

A = Shell and Tube Heat Exchanger C = Oversized Shell and Tube Heat Exchanger (Glycol) V = Shell and Tube Heat Exchanger + All Variable Speed Compressors W = Oversized Shell and Tube Heat Exchanger (Glycol) + All Variable Speed Compressors

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

CBA–E

– 0 F

0 0

GEN

Model Options

Unit Feature Options

MODEL OPTION B: HEATING

B1: HEATING TYPE

0 = No Boiler

A = Natural Gas Fired Boiler

B = Propane Fired Boiler

B2: BOILER QUANTITY

0 = No Boiler

1 = 1 Boiler

2 = 2 Boilers

3 = 3 Boilers

4 = 4 Boilers

B3: BOILER HEATING CAPACITY

0 = No Boiler

A = 500 MBH Modulating High Flow

B = 750 MBH Modulating High Flow

C = 1,000 MBH Modulating High Flow

D = 1,500 MBH Modulating High Flow

E = 500 MBH Modulating Low Flow

F = 750 MBH Modulating Low Flow

G = 1,000 MBH Modulating Low Flow

H = 1,500 MBH Modulating Low Flow

FEATURE 1: BUILDING PUMPING

1A: PUMP OPTIONS

0 = Standard - No Building Pump

A = Common Water Connections

B = Primary Pumping System

C = Primary/Secondary Pumping System

1B: PUMP CONFIGURATION

0 = Standard - No Building Pump D = 1 Pump - Prem Eff, 1170 RPM E = 2 Single Pumps - Prem Eff, 1170 RPM F = dualArm Pump - Prem Eff, 1170 RPM G = 1 Pump w/ VFD - Prem Eff, 1170 RPM H = 2 Single Pumps w/ 2 VFDs - Prem Eff, 1170 RPM J = dualArm Pump w/ 2 VFDs - Prem Eff, 1170 RPM N = 1 Pump - Prem Eff, 1760 RPM P = 2 Single Pumps - Prem Eff, 1760 RPM Q = dualArm Pump - Prem Eff, 1760 RPM R = 1 Pump w/ VFD - Prem Eff, 1760 RPM S = 2 Single Pumps w/ 2 VFDs - Prem Eff, 1760 RPM T = dualArm Pump w/ 2 VFDs - Prem Eff, 1760 RPM Y = 1 Pump - Prem Eff, 3520 RPM Z = 2 Single Pumps - Prem Eff, 3520 RPM 1 = dualArm Pump - Prem Eff, 3520 RPM 2 = 1 Pump w/ VFD - Prem Eff, 3520 RPM 3 = 2 Single Pumps w/ 2 VFDs - Prem Eff, 3520 RPM 4 = dualArm Pump w/ 2 VFDs - Prem Eff, 3520 RPM

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

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 K = 15 hp L = 20 hp M = 25 hp N = 30 hp P = 40 hp Q = 50 hp R = 60 hp S = 75 hp

FEATURE 2: WATER CONNECTION LOCATION

0 = Back Water Connections A = Front Water Connections B = Bottom Water Connection

FEATURE 3: CHILLER ACCESSORIES

0 = Standard A = Glycol System D = Air Separator E = Options A + D F = Thermometers & Pressure Gauges + Option D G = Thermometers & Pressure Gauges + Option E

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

FEATURE 4: LOW AMBIENT

0 = Standard - None

A = One Refrigerant Circuit

B = Two Refrigerant Circuits

C = Three Refrigerant Circuits

D = Four Refrigerant Circuits

E = Five Refrigerant Circuits

F = Six Refrigerant Circuits

G = Seven Refrigerant Circuits

H = Eight Refrigerant Circuits

FEATURE 5: RECIRCULATING PUMP

5A: PUMP CONFIGURATION

0 = Standard - No Recirculating Pump

D = 1 Pump/Barrel - Prem Eff, 1170 RPM

E = 2 Single Pumps/Barrel - Prem Eff, 1170 RPM

F = dualArm Pump/Barrel - Prem Eff, 1170 RPM

G = 1 Pump/Barrel w/ VFD - Prem Eff, 1170 RPM

H = 2 Single Pumps/Barrel w/ 2 VFDs - Prem Eff,

1170 RPM

J = dualArm Pump/Barrel w/ 2 VFDs - Prem Eff,

1170 RPM

N = 1 Pump/Barrel - Prem Eff, 1760 RPM

P = 2 Single Pumps/Barrel - Prem Eff, 1760 RPM

Q = dualArm Pump/Barrel - Prem Eff, 1760 RPM

R = 1 Pump/Barrel w/ VFD, Prem Eff, 1760 RPM

S = 2 Single Pumps/Barrel w/ 2 VFDs, Prem Eff,

1760 RPM

T = dualArm Pump/Barrel w/ 2 VFDs, Prem Eff,

1760 RPM

Y = 1 Pump/Barrel -Prem Eff, 3520 RPM

Z = 2 Single Pumps/Barrel - Prem Eff, 3520 RPM

1 = dualArm Pump/Barrel - Prem Eff, 3520 RPM

2 = 1 Pump/Barrel w/ VFD - Prem Eff, 3520 RPM

3 = 2 Single Pumps/Barrel w/ 2 VFDs - Prem Eff,

3520 RPM

4 = dualArm Pump/Barrel w/ 2 VFDs - 3520 RPM

5B: PUMP SIZE

0 = Standard - No Recirculating 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

5C: PUMP MOTOR

0=Standard - No Recirculating Pump A = 0.50 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 K = 15 hp L = 20 hp M = 25 hp N = 30 hp P = 40 hp Q = 50 hp R = 60 hp S = 75 hp

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

FEATURE 6: BOILER BUILDING

PUMP

6A: PUMP CONFIGURATION

0 = Standard - No Boiler

D = 1 Pump - Prem Eff, 1170 RPM

E = 2 Single Pumps - Prem Eff, 1170 RPM

F = dualArm Pump - Prem Eff, 1170 RPM

G = 1 Pump w/ VFD - Prem Eff, 1170 RPM

H = 2 Single Pumps w/ 2 VFDs - Prem Eff, 1170

RPM

J = dualArm Pump w/ 2 VFDs - Prem Eff, 1170 RPM

N = 1 Pump - Prem Eff, 1760 RPM

P = 2 Single Pumps - Prem Eff, 1760 RPM

Q = dualArm Pump - Prem Eff, 1760 RPM

R = 1 Pump w/ VFD - Prem Eff, 1760 RPM

S = 2 Single Pumps w/ 2 VFDs - Prem Eff, 1760

RPM

T = dualArm Pump w/ 2 VFDs - Prem Eff, 1760

RPM

Y = 1 Pump - Prem Eff - 3520 RPM

Z = 2 Single Pumps - Prem Eff, 3520 RPM

1 = dualArm Pump - Prem Eff, 3520 RPM

2 = 1 Pump w/ VFD - Prem Eff, 3520 RPM

3 = 2 Single Pumps w/ 2 VFDs - Prem Eff, 3520

RPM

4 = dualArm Pump w/ 2 VFDs - Prem Eff, 3520

RPM

6B: PUMP SIZE

0 = Standard - No Boiler

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

6C: PUMP MOTOR

0 = Standard - No Boiler A = 0.50 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 K = 15 hp L = 20 hp M = 25 hp N = 30 hp P = 40 hp Q = 50 hp R = 60 hp S = 75 hp

FEATURE 7: SERVICE OPTIONS

0 = Standard A = 115V Outlet, Factory Wired B = 115V Outlet, Field Wired

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

FEATURE 8: REFRIGERATION

OPTIONS

0 = Standard

B = VFD Controlled Condenser Fans (Air-Cooled)

D = Hot Gas Bypass - All Circuits

E = Options B + D

FEATURE 9: REFRIGERATION

ACCESSORIES

0 = Standard

A = Sight Glass

B = Compressor Isolation Valves

C = Options A + B

FEATURE 10: POWER OPTIONS

0 = Standard Power Block

A = Power Switch (225 Amps)

B = Power Switch (400 Amps)

C = Power Switch (600 Amps)

D = Power Switch (800 Amps)

E = Power Switch (1200 Amps)

F = Dual Point Power Block (2)

G = Dual Point Power Switch (2 x 225 Amps)

H = Dual Point Power Switch (2 x 400 Amps)

J = Dual Point Power Switch (2 x 600 Amps)

K = Dual Point Power Switch (2 x 800 Amps)

L = Dual Point Power Switch (2 x 1200 Amps)

FEATURE 11: SAFETY OPTIONS

0 = No Boiler

A = Standard, Boiler w/ UL/FM/CSD-1 Certification

B = Boiler w/ IRI Gas Train

C = Boiler w/ IRI Gas Train and Proof of Closure

D = Boiler w/ Low Water Cutoff

E = Options B + D

F = Options C + D

FEATURE 12: CONTROLS

0 = Standard A = Touchscreen Unit Controls Interface B = Phase and Brown Out Protection F = Options A + B

FEATURE 13: SPECIAL CONTROLS

0 = MCS Magnum Controller A = w/ Diagnostics C = w/ Diagnostics and Modbus Connection D = w/ Diagnostics and N2 Connection E = w/ Diagnostics and LonTalk Connection G = w/ Modem H = w/ Diagnostics and Modem K = w/ Diagnostics, Modbus Connection and Modem L = w/ Diagnostics, N2 Connection and Modem M = w/ Diagnostics, LonTalk Connection and Modem Q = w/ Modbus Connection R = w/ N2 Connection S = w/ LonTalk Connection V = w/ Modbus Connection and Modem W = w/ N2 Connection and Modem Y = w/ LonTalk Connection and Modem 1 = w/ BACnet IP Connection 2 = w/ Diagnostics and BACnet IP Connections 3 = w/ Diagnostics, BACnet IP Connection and Modem 4 = w/ BACnet IP Connection and Modem 5 = w/ BACnet MS/TP Connection 6 = w/ Diagnostics and BACnet MS/TP Connection 7 = w/ Diagnostics, BACnet MS/TP Connection and Modem 8 = w/ BACnet MS/TP Connection and Modem

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

FEATURE 14: COMPRESSION TANK

14A: CHILLER COMPRESSION TANK

0 = No Chiller Compression Tank

A = AX-15V

B = AX-20V

C = AX-40V

D = AX-60V

E = AX-80V

F = AX-100V

G = AX-120V

H = AX-180V

J = AX-200V

K = AX-240V

L = AX-260V

M = AX-280V

N = 1000-L

P = 1200-L

Q = 1600-L

R = 2000-L

14B: BOILER COMPRESSION TANK

0 = No Boiler Compression Tank

A = AX-15V

B = AX-20V

C = AX-40V

D = AX-60V

E = AX-80V

F = AX-100V

G = AX-120V

H = AX-180V

J = AX-200V

K = AX-240V

L = AX-260V

M = AX-280V

N = 1000-L

P = 1200-L

Q = 1600-L

R = 2000-L

FEATURE 15: OPTION BOXES

0 = Standard A = 2ft Option Box B = 4ft Option Box C = 6ft Option Box D = 8ft Option Box E = 10ft Option Box F = 12ft Option Box

FEATURE 16: CABINET OPTIONS

0 = Standard A = Electrical Vestibule Heating B = Fan/Coil Vestibule Cooling F = Options A + B

FEATURE 17: CABINET OPTIONS

0 = Standard A = Access Door Windows

FEATURE 18: CUSTOMER CODE

0 = Standard A = Second to Fifth Year Extended Compressor Warranty

LL Series Feature String Nomenclature

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D2345A5B5C6A6B6C7891011121314A

14B1516171819202122

– 0 7 5 – 3 – 0 –

B0A–A2C:C

RJG

– 0 FB–K5E–KJG–A0C0

A–E

– 0 F

0 0B0

Model Options

Unit Feature Options

GEN

FEATURE 19: CODE OPTIONS

0 = Standard - ETL U.S.A. Listing

A = M.E.A. (New York)

B = Chicago - Cool + Gas

H = ETL U.S.A. + Canada Listing

FEATURE 20: UNIT

CONFIGURATION

0 = Standard (One Piece Unit)

A = Two Piece Unit

FEATURE 21: EVAPORATIVE-

COOLED CONDENSER

0 = Standard - No Evaporative-Cooled Condenser

A = No Sump Heater

B = Sump Heater

FEATURE 22: BLANK

0 = Standard

FEATURE 23: TYPE

B = Standard Paint

U = Special Price Authorization and Special Paint

X = Special Price Authorization and Standard Paint

General Information

Improper installation, adjustment, alteration, service or maintenance can cause property damage,

WARNING

July 1, 1992. Approved methods of recovery, recycling, or reclaiming

CAUTION

metal surfaces

be taken when working with

Failure to observe the following instructions will result in premature failure of your system and possible

WARNING

AAON LL Series chiller outdoor

mechanical rooms are complete self-

contained liquid chilling units. They are

assembled, wired, charged, and run-tested.

Models are available for air-cooled and

evaporative-cooled applications. Chiller

primary and primary/secondary pumping

packages and boilers with pumping package

are available as optional features.

personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician.

Codes and Ordinances

LL Series units have been tested and

certified, by ETL, in accordance with UL

Safety Standard 1995/CSA C22.2 No. 236.

System should be sized in accordance with

the American Society of Heating,

Refrigeration and Air Conditioning

Engineers Handbook.

Installation of LL 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

Electrical Code CSA C22.1.

The Clean Air Act of 1990 bans the intentional venting of refrigerant as of

must be followed.

Coils and sheet present sharp edges and care must

equipment.

voiding of the warranty.

Receiving Unit

When received, the unit should be checked 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.

Storage

If installation will not occur immediately following delivery, store equipment in a dry protected area away from construction traffic and in the proper orientation as marked on the packaging with all internal packaging in place. Secure all loose-shipped items.

Outdoor Mechanical Room

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 include and not be limited to pump

Units may be equipped with compressor crankcase heaters,

clear any liquid refrigerant from the

CAUTION

motor overheating

compressors must cycle off for a

To maintain the proper oil level compressors must cycle on for a

The cycle rate must not exceed 6 starts per hour.

WARNING

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME

To prevent

minimum of 5 minutes.

5 MINUTE MINIMUM ON TIME

minimum of 5 minutes.

Failure to observe the following instructions

will result in premature failure of your

system, and possible voiding of the

warranty.

CRANKCASE HEATER

OPERATION

which should be energized at least 24 hours prior to cooling operation, to

compressors.

Never turn 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. The compressor is designed to

pump refrigerant gas and damage may occur

when power is restored if liquid enters the compressor.

MOTORS AND COMPRESSORS of

motors and condenser fan motors, 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 24 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.

Never cut off the main power supply to the unit, except for complete shutdown. Always control the system from the building management system, or control panel, never at the main power supply (except for emergency or for complete shutdown of the system).

Scroll compressors must be on a minimum

of 5 minutes and off for a minimum of 5

minutes. The cycle rate must be no more

than 6 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.

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

diagrams in both ladder and point-to-point

form are 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 and boiler.

This includes reading and recording suction

pressures and checking for normal sub-

cooling and superheat. See the evaporative-

cooled condenser and air-cooled condenser

sections in this manual for specific details.

Chiller Primary Pumping

Primary pumping uses a single pump to

move water (or glycol) through the chiller

barrel and back to the building. This

pumping package provides a constant 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 separator 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 evaporator barrel 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 setpoint, 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 chiller barrel leaves the unit through the water out connection.

Chiller Primary/Secondary Pumping

Primary/secondary pumping option provides variable flow to the system. It consists of a constant flow pump for the chiller heat exchanger and a variable flow pump for the building. The controls package senses differential pressure across the pump with pressure transducers installed at the suction and discharge, and varies the speed of the pump using a VFD in order to maintain a given differential pressure across the pump.

The primary/secondary pumping package is essentially composed of two piping loops

coupled together. The primary loop has a

constant flow rate in order to keep the chiller

heat exchanger from freezing, and the

secondary, variable flow loop, provides

water to the building. The two loops are

coupled via a water line that compensates

for excess flow in either loop. As the flow in

the secondary loop decreases below the flow

in the primary loop, excess flow bypasses

the building loop and circulates through the

bypass water line. On the other hand, as the

flow in the secondary loop increases above

the flow in the primary loop, excess flow

bypasses the chiller and circulates through

the bypass water line.

The secondary pump has its own suction

guide, combination valve, and isolation

valve, similar to the primary pump, with the

addition of an air separator to remove any

air that is entrapped in the water.

Boiler System

Optional boilers and pumping packages are

factory installed. The boiler system uses a

primary/secondary pumping package. There

can be 1-4 boilers in parallel and each boiler

has its own primary pump. The heating loop

must be designed to return at least 120°F

water to the boiler during normal operation.

Failure to return 120°F water to the boiler

will create condensation, which will reduce

the life of the heat exchanger and void the

boiler warranty. See unit submittal for unit

specific piping schematics. See the Thermal

Solutions Boiler “Installation, Operating,

and Service Instructions” that are included

with the unit for additional information

about the boiler.

Once the boiler is given a run signal, the

boiler secondary pump will be activated and

the controls package will stage boilers as

necessary to maintain the leaving water

temperature setpoint.

The controls package will also control the speed of the secondary pump in the boiler system to maintain differential pressure across the pump similar to the chiller secondary pump.

Boiler Primary/Secondary Pumping

Water enters the unit through the return water piping, and then travels 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 primary/secondary pumping package provides variable flow to the system. It consists of a constant flow pump for the boiler, and a variable flow pump for the building. The controls package senses differential pressure across the pump with pressure transducers installed at the suction and discharge, and varies the speed of the pump using a VFD in order to maintain a given differential pressure across the pump.

The primary/secondary pumping package is essentially composed of two piping loops coupled together. The primary loop has a constant flow rate in order to maintain water temperature through the boiler, and the secondary, variable flow loop, provides water to the building. The two loops are coupled via a water line that compensates for excess flow in either loop. As the flow in the secondary loop decreases below the flow in the primary loop, excess flow bypasses

the building loop and circulates through the

bypass water line. On the other hand, as the

flow in the secondary loop increases above

the flow in the primary loop, excess flow

bypasses the boiler and circulates through

the bypass water line.

The secondary pump includes suction guide,

combination valve, and isolation valve with

the addition of an air separator to remove

any air that is entrapped in the water.

See appendix for additional information on

the installation, operation and maintenance

of pumps.

Make Up Water

A city make up water connection is provided

to replace water that is lost from the system.

Glycol units require a glycol feeder

(optional factory installed or 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.

The makeup water connection is provided

with a backflow preventer that has isolation

valves on the inlet and outlet for service.

Figure 1 shows the pressure drop versus

flow rate for the backflow preventer.

Figure 1 - Backflow Preventer

There is a pressure-reducing valve after the

backflow preventer. This valve reduces the

city water pressure to maintain the operating pressure of the system. This valve is adjustable from 10-35 psig with a factory setting of 30 psig. The system pressure varies with the height of the system. The pressure-reducing valve setting should be set so that the pressure at the high point in the system is high enough to vent air from the system (usually 4 psig). There should be air vents at all parts in the system where air could be trapped. If the pressure is not high enough throughout the system, flashing could occur in the piping or the pump could cavitate. There is an isolation valve on the inlet and outlet of the pressure-reducing valve for service.

The pressure reducing valve fills the system at a reduced rate. There is a bypass around the pressure reducing valve for the initial fill of the system to increase the initial fill speed. After the initial system fill, this valve should be closed.

Compression/Expansion Tank

As the water temperature in the system increases, the volume that water displaces increases. In order to compensate for these expansion forces, a compression or expansion tank must be used. The factory installed tank option includes a prepressurized diaphragm compression tank that is preset for 12 psig.

The factory pre-charge pressure may need to be field adjusted. The tank must be precharged to system design fill pressure before placing into operation. Remove the pipe plug covering the valve enclosure. Check and adjust the charge pressure by adding or releasing air.

If the system has been filled, the tank must be isolated from the system and the tank emptied before charging. This ensures that

all fluid has exited the diaphragm area and

proper charging will occur.

If the pre-charge adjustment is necessary, oil

and water free compressed air or nitrogen

gas may be used. Check the pre-charge

using an accurate pressure gauge at the

charging valve and adjust as required. Check

air valve for leakage. If evident, replace the

Schrader valve core. Do not depend on the

valve cap to seal the leak. After making sure

the air charge is correct, replace the pipe

plug over the charging valve for protection.

Purge air from system before placing tank

into operation. All models have system

water contained behind the diaphragm.

It is recommended that the pre-charge be

checked annually to ensure proper system

protection and long life for the vessel.

Pressure Relief Valve

Required pressure relief valve is installed in

the unit. This valve is set at 125 psig. Figure

2 shows inlet pressure versus capacity for

this pressure relief valve. See appendix for

additional information.

Figure 2 - Pressure Relief Valve

Automatic Air Vent

There is an automatic air vent installed at the

high point of the system inside the pumping

package compartment. The air vent valve must be in the proper position for operation. Ensure that the small vent cap is loosened 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, factory installed dual pumps or two single pumps can be ordered. A dual pump is a pump with two independent motors and pumps in a single casing. This dual 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.

When redundant pumping is required with high flow rates, two independent pumps may be installed in parallel. Each pump will have its own suction guide/strainer, combination valve, and isolation valves.

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. See appendix for additional information.

Pressure Gauges and Thermometers

Pressure gauges and thermometers are available as a factory installed option. Thermometers are installed on the inlet and outlet of the unit. One 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.

One gauge is used so that the calibration of

the pressure gauge is irrelevant in the

calculation of the differential pressure.

Pipe Insulation

The water piping and components on units

with pumping packages are not insulated at

the factory. Insulation should be installed on

the water piping after the system has been

checked for leaks.

Installation

Unit Size

35-540 tons

Front -

(Controls Side)

Back

100”

Ends

100”

Top

Unobstructed

CAUTION

Outdoor Mechanical Room Placement

The AAON LL Series 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.

The placement relative to the building air

intakes and other structures must be

carefully selected. Be sure to observe the

dimensions that are on the rating plate of the

chiller for operational and service

clearances.

Table 1 - Service Clearances

Location

Unit specific curb drawing is included with job submittal. See SMACNA Architectural Sheet Metal Manual for curb installation details.

All roofing work should be performed by competent roofing contractors to avoid any possible leakage.

Units require rail support along all four sides of the unit base.

When installed at ground level, a one-piece concrete slab should be used with footings that extend below the frost line. Care must also be taken to protect the coil and fins

100”

from damage due to vandalism or other causes.

If unit is elevated a field supplied catwalk is recommended to allow access to unit service

Condenser coils and fans must be free of any

obstructions in order to start and operate

properly with a correct amount of airflow.

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.

doors.

This unit ships with a curb gasket that is 1¼” wide and 1½” tall. It is recommended that this or another similar gasket be used between the curb and the unit to reduce vibration from the unit to the building.

Consideration must be given to obstruction

caused by snow accumulation when placing

the unit.

Curb and Steel Mount Installation

Make openings in the roof decking large

enough to allow for water piping, electrical,

and gas penetrations and workspace only.

Do not make openings larger than necessary.

Set the curb to coincide with the openings.

Make sure curb is level.

Figure 3 - Curb Mounting with Dimensions

Tons

A B C

35-115

(Scroll)

125-365

(Scroll)

90-540

(Centrifugal)

Figure 4 - Steel Mounting Rail with

Dimensions

Table 2 - Mounting Dimensions

100” 96” 92” 97”

unit is properly seated on the curb and is level.

Do not push, pull or lift the unit from anything other than its base.

Figure 5 - Marked Lifting Points

142” 138” 134” 139”

Lifting and Handling

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. See Figure 6 for additional

information.

Before lifting unit, be sure that all shipping

material has been removed from unit. Secure

hooks and cables at all lifting points/ lugs

provided on the unit.

Hoist unit to a point directly above the curb

or mounting rail. Be sure that the gasket

material has been applied to the curb or

mounting rail.

Carefully lower and align unit with utility

and duct openings. Lower the unit until the

unit skirt fits around the curb. Make sure the

Lifting slot locations are unit specific.

(Chlorinated Polyvinyl Chloride) are

attack by certain

chemicals. Polyolester (POE) oils

410A and other

and fittings and complete piping system failure.

CAUTION

The chiller must be operated only with liquid flowing through the

WARNING

Unit must be rigged at all marked lifting points.

Water Connection

Connect the 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 AAON LL Series

units is 125 psi.

evaporators.

Figure 6 - LL Series Lifting Detail

PVC (Polyvinyl Chloride) and CPVC

vulnerable to

used with Rrefrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping

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