AAON M2-036 User Manual

M2 Series

Modular Indoor Air Handling Units,

Modular Outdoor Air Handling Units,

Self Contained Units & Packaged Rooftop Units

Installation, Operation

& Maintenance

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death or property damage.

Be sure to read and understand the installation, operation and service instructions in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage.

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

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;

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

 If you cannot reach your gas

Installation and service must be performed by a qualified installer, service agency or the gas supplier.

do not use any phone in your building.

from a phone remote from the building. Follow the gas supplier’s instructions.

supplier call the fire department.

WARNIN

Table of Contents

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

Model Number Nomenclature ...................................................................................................... 13

M2 Base Model Description ......................................................................................................... 14

Fan Module Description ............................................................................................................... 15

Filter Module Description ............................................................................................................. 16

Mixing Box Module Description .................................................................................................. 17

Heat Module Description .............................................................................................................. 18

Blank Module Description ............................................................................................................ 19

Coil Module Description............................................................................................................... 20

Control Panel Module Description ............................................................................................... 21

Energy Recovery Module Description .......................................................................................... 22

Condenser Module Description .................................................................................................... 23

Typical Configurations ................................................................................................................. 24

Unit Orientation ............................................................................................................................ 25

General Information ...................................................................................................................... 26

Codes and Ordinances ............................................................................................................... 27

Receiving Unit ........................................................................................................................... 27

Storage ....................................................................................................................................... 28

Packaged Direct Expansion (DX) Units .................................................................................... 28

Gas or Electric Heating ............................................................................................................. 29

Wiring Diagrams ....................................................................................................................... 29

Condensate Drain Pan ............................................................................................................... 29

Installation..................................................................................................................................... 30

Locating Units ........................................................................................................................... 30

Lifting the Unit .......................................................................................................................... 31

Indoor Floor Mounted Units ..................................................................................................... 34

Indoor Suspended Units ............................................................................................................ 34

Module Assembly ..................................................................................................................... 35

Refrigerant Piping ..................................................................................................................... 39

Determining Refrigerant Line Size ........................................................................................... 40

Water-Cooled Condenser .......................................................................................................... 44

Open Loop Applications ........................................................................................................ 44

Freezing Water in the Heat Exchanger .................................................................................. 45

Water Piping .......................................................................................................................... 46

Water-Cooled Condenser Safeties ......................................................................................... 49

Electrical .................................................................................................................................... 49

Cutting Electrical Openings ................................................................................................... 50

Thermostat Control Wiring .................................................................................................... 51

Condensate Drain Piping ........................................................................................................... 52

Blower Wheels .......................................................................................................................... 53

Air Adjustment ...................................................................................................................... 54

Waterside Economizer .............................................................................................................. 55

Hot Water and Steam Coils ....................................................................................................... 56

Chilled Water Coils ................................................................................................................... 56

Electric Heating ......................................................................................................................... 56

Gas Fired Duct Furnace ............................................................................................................. 57

Duct Furnace Component Identification ................................................................................... 59

Furnace Maintenance ................................................................................................................ 66

Troubleshooting ........................................................................................................................ 67

Startup ........................................................................................................................................... 68

Filters ......................................................................................................................................... 68

Check Out .................................................................................................................................. 68

Commissioning .......................................................................................................................... 69

Operation ................................................................................................................................... 70

Adjusting Refrigerant Charge ................................................................................................... 70

Maintenance .................................................................................................................................. 74

Fan Assembly ............................................................................................................................ 74

Bearings ..................................................................................................................................... 74

Belts ........................................................................................................................................... 75

Indoor Coils ............................................................................................................................... 76

Refrigeration Cycle ................................................................................................................... 76

E-Coated Coil Cleaning ............................................................................................................ 76

Recommended Coil Cleaner .................................................................................................. 77

Recommended Chloride Remover ......................................................................................... 77

Energy Recovery Wheel ............................................................................................................ 77

Electric Heating ......................................................................................................................... 79

Steam or Hot Water Heating ..................................................................................................... 79

Cleaning .................................................................................................................................... 79

Chilled Water ............................................................................................................................ 79

Lubrication ................................................................................................................................ 79

Replacement Parts ..................................................................................................................... 80

AAON-Longview Customer Service Department .................................................................... 80

Filter Replacement .................................................................................................................... 80

Appendix A - Heat Exchanger Corrosion Resistance ................................................................... 82

Refrigerant Piping Diagrams ........................................................................................................ 84

M2 Series Startup Form ................................................................................................................ 91

Maintenance Log .......................................................................................................................... 97

R40681 · Rev. B · 120509

(ACP 30752)

Index of Tables and Figures

Tables:

Table 1 - Minimum Clearances ..................................................................................................... 31

Table 2 - Glycol Freezing Points .................................................................................................. 46

Table 3 - Freezing Points .............................................................................................................. 48

Table 4 - Coaxial Heat Exchanger Pressure Drops (WCC- & WHP-) ......................................... 48

Table 5 - Brazed Plate Heat Exchanger Pressure Drops (WCC- & WHP-) ................................. 49

Table 6 - Control Wiring ............................................................................................................... 51

Table 7 - Drain Trap Dimensions ................................................................................................. 52

Table 8 - Blow-Through Drain Trap Dimensions......................................................................... 53

Table 9 - Gas Heater Troubleshooting .......................................................................................... 64

Table 10 - Gas Heater Troubleshooting Continued ...................................................................... 65

Table 11 - Problems, Causes and Solutions .................................................................................. 67

Table 12 - Acceptable Air-Cooled Refrigeration Circuit Values ................................................. 71

Table 13 - Acceptable Water-Cooled Refrigeration Circuit Values ............................................. 71

Table 14 - R-410A Refrigerant Temperature-Pressure Chart ....................................................... 73

Table 15 - Bearing Setscrew Torque Recommendations .............................................................. 75

Table 16 - Fan Bearing Lubrication Schedule .............................................................................. 79

Table 17 - M2-005 and M2-008 Filters ........................................................................................ 80

Table 18 - M2-011 and M2-014 Filters ........................................................................................ 80

Table 19 - M2-018 and M2-022 Filters ........................................................................................ 81

Table 20 - M2-026 Filters ............................................................................................................. 81

Table 21 - M2-032 and M2-036 Filters ........................................................................................ 81

Figures:

Figure 1 - Typical Configurations ................................................................................................. 24

Figure 2 - Unit Orientation ........................................................................................................... 25

Figure 3 - Lockable Handle .......................................................................................................... 28

Figure 4 - Service Access Clearance ............................................................................................ 31

Figure 5 - M2 Series Unit Four Point Lifting ............................................................................... 32

Figure 6 - M2 Series Unit Eight Point Lifting .............................................................................. 33

Figure 7 - Unit Suspension ........................................................................................................... 34

Figure 8 - Module Assembly Schematic ....................................................................................... 36

Figure 9 - Bulb Gasket .................................................................................................................. 37

Figure 10 - Applying Bulb Gasket ................................................................................................ 37

Figure 11 - Gasket Application ..................................................................................................... 37

Figure 12 - Bolted Base Rail ......................................................................................................... 37

Figure 13 - Bar Clamp .................................................................................................................. 38

Figure 14 - Self-Tapping Screw .................................................................................................... 38

Figure 15 - Strap Types................................................................................................................. 38

Figure 16 - Strap Locations........................................................................................................... 38

Figure 17 - Strap Installation ........................................................................................................ 39

Figure 18 - Draw-Through Drain Trap ......................................................................................... 52

Figure 19 - Blow-Through Drain Trap ......................................................................................... 53

Figure 20 - Supply Fan Banding ................................................................................................... 55

Figure 21 - Sediment Trap ............................................................................................................ 58

Figure 22 - Horizontal Configuration ........................................................................................... 59

Figure 23 - Vertical Configuration ............................................................................................... 59

Figure 24 - Gas Valve ................................................................................................................... 59

Figure 25 - 1.2” w.c. Manifold ..................................................................................................... 61

Figure 26 - 3.5” w.c. Manifold ..................................................................................................... 61

Figure 27 - Flame Sensor Current Check ..................................................................................... 62

Figure 28 - Angular Misalignment ............................................................................................... 75

Figure 29 - Parallel Misalignment ................................................................................................ 75

Figure 30 - Belt Deflection ........................................................................................................... 75

Figure 31 - Energy Recovery Wheel ............................................................................................ 78

Figure 32 - Standard Split System Piping ..................................................................................... 84

Figure 33 - Modulating Hot Gas Reheat with Hot Gas Bypass Split System Piping ................... 85

Figure 34 - Hot Gas Bypass Split System Piping ......................................................................... 86

Figure 35 - Modulating Hot Gas Reheat Split System Piping ...................................................... 87

Figure 36 - Heat Pump Split System Piping ................................................................................. 88

Figure 37 - Heat Pump with Factory Installed Modulating Hot Gas Reheat Split System Piping 89 Figure 38 - Heat Pump with Field Installed Modulating Hot Gas Reheat Split System Piping ... 90

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.

Attention should be paid to the following statements:

ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD

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

Improper servicing could result in dangerous operation, serious injury, death, or property damage.

 Before servicing, disconnect all

 When servicing controls, label all

 Verify proper operation after

electrical power to the furnace. More than one disconnect may be provided.

wires prior to disconnecting. Reconnect wires correctly.

servicing. Secure all doors with key-lock or nut and bolt.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a trained, qualified installer. 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.  Do not use any phone in the

 Never test for gas leaks with an

 Use a gas detection soap solution

QUALIFIED INSTALLER

building.

open flame.

and check all gas connections and shut off valves.

Electric shock hazard. Before servicing, shut off all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures.

FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD

Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance.

During installation, testing, servicing, and troubleshooting of the equipment it may be necessary to work with live electrical components. Only a qualified licensed electrician or individual properly trained in handling live electrical components shall perform these tasks.

Standard NFPA-70E, an OSHA regulation requiring an Arc Flash Boundary to be field established and marked for identification of where appropriate Personal Protective Equipment (PPE) be worn, should be followed.

WARNING

ROTATING COMPONENTS

Unit contains fans with moving parts that can cause serious injury. Do not open door containing fans until the power to the unit has been disconnected and fan wheel has stopped rotating.

GROUNDING REQUIRED

All field installed wiring must be completed by qualified personnel. Field installed wiring must comply with NEC/CEC, local and state electrical code requirements. Failure to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code requirements.

VARIABLE FREQUENCY DRIVES

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

WARNIN

CAUTIO

Electric motor over-current protection and overload protection may be a function of the Variable Frequency 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.

To prevent injury or death lifting 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.

WARNING

UNIT HANDLING

Rotation must be checked on all 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 should be checked for proper operation. Alterations should only be made at the unit power connection

Failure to properly drain and vent coils when not in use during freezing temperature may result in coil and equipment damage.

Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death.

Prior to connection of condensing water supply, verify water pressure is less than maximum pressure shown on unit nameplate. To prevent injury or death due to instantaneous release of high pressure water, relief valves should be field supplied on system water piping.

WATER PRESSURE

Always use a pressure regulator, valves and gauges to control incoming pressures when pressure testing a system. Excessive pressure may cause line ruptures, equipment damage or an explosion which may result in injury or death.

CAUTIO

To prevent damage to the unit, do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than

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

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

WARNING

Door compartments containing hazardous voltage or rotating parts are equipped with door latches to allow locks. Door latch are shipped with nut and bolts requiring tooled access. If you do not replace the shipping hardware with a pad lock always re-install the nut & bolt after closing the door.

Do not clean DX refrigerant coils with hot water or steam. The use of hot water or steam on refrigerant coils will cause high pressure inside the coil tubing and damage to the coil.

Cleaning the cooling tower or the condenser water loop with harsh chemicals, such as hydrochloric acid (muriatic acid) or chlorine, can damage the water-cooled condenser. Care should be taken to avoid allowing chemicals to enter the water-cooled condenser. See Appendix A - Heat Exchanger Corrosion Resistance for more information.

Failure of the condenser as a result of chemical corrosion is excluded from coverage under AAON Inc. warranties and the heat exchanger manufacturer’s warranties.

WARNIN

OPEN LOOP APPLICATIONS

Failure of the condenser due to freezing will allow water to enter the refrigerant circuit and will cause extensive damage to the refrigerant circuit components. Any damage to the equipment as a result of water freezing in the condenser is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.

WATER FREEZING

Disconnect all power, close all isolation valves and allow equipment to cool before servicing equipment to prevent serious injury. Equipment may have multiple power supplies. Electric resistance heating elements and hot water or steam heating coils may have automatic starts. Hot water will circulate even after power is off.

HOT PARTS

PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils used with R-410A and other refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings and complete piping system failure.

Do not weld or cut foam panel with plasma cutters or a cutting torch – When burnt the foam produces dangerous fumes.

WARNING

Do not work in a closed area where refrigerant or nitrogen gases may be leaking. A sufficient quantity of vapors may be present and cause injury or death.

Never attempt to open an access door or remove a panel while the unit is running. Pressure in the unit can cause excessive force against the panel.

Ensure that sufficient dampers will be open to provide air path before fan is allowed to run.

1. Use only with type of the gas approved

for the furnace. Refer to the furnace rating plate.

2. Provide adequate combustion ventilation

air to the furnace. If a vent duct extension is used, a class III approved vent is required. See the Locating Units and Gas Heating sections of the Installation section of the manual.

3. Always install and operate furnace

within the intended temperature rise range and duct system external static pressure (ESP) as specified on the unit nameplate.

4. The supply and return air ducts must be

derived from the same space. It is recommended ducts be provided with access panels to allow inspection for duct tightness. When a down flow duct is used with electric heat, the exhaust duct should be an L shaped duct.

5. Clean furnace, duct and components

upon completion of the construction setup. Verify furnace operating

conditions including input rate, temperature rise and ESP.

6. 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.

7. READ THE ENTIRE INSTALLATION,

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

8. Keep this manual and all literature

safeguarded near or on the unit.

Model Number Nomenclature

Base Model Number Individual Module Model Numbers

Identifies the main unit features and options. Identifies module configurations, features and

options.

M2-H-011-R-2-A-A-0-C-0

Complete Model Number

A complete unit model number consists of a base model number followed by a series of individual module numbers. In the individual module model number, the three numbers after the three letter Module ID indicate the position of the module in unit assembly, increasing in value from the

MBH-101-A-00-00000-00000-0-0 FTA-102-P-A0-00000-00000-0-0 SFA-103-F-B0-A000C-00000-0-0 CLF-104-C-00-210F0-410F0-0-0 SFA-105-0-AA-CPTB0-00000-0-0 PEC-201-K-BI-A0000-00000-0-0 FTE-203-P-B0-00000-00000-0-0

return/outside air section to the discharge air section and from the bottom to the top. In the above example, the cooling coil module, CLF-104-C-00-CPTB0-00000-0-0, would be the fourth module on the bottom row of the unit.

Series and

Generation

Type

011

Unit Size

BASE MODEL

SERIES AND GENERATION

M2 = Modular 2

TYPE

H = Horizontal V = Vertical

UNIT SIZE

005 = 5 ft 008 = 8 ft 011 = 11 ft2 Coil 014 = 14 ft2 Coil 018 = 18 ft 022 = 22 ft 026 = 26 ft 032 = 32 ft 036 = 36 ft

SUPPLY AIRFLOW

L = Left Hand R = Right Hand

VOLTAGE

1 = 230V/1Φ/60Hz 2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 6 = 380-415V/3Φ/50Hz 7 = 265V/1Φ/60Hz 8 = 208V/3Φ/60Hz 9 = 208V/1Φ/60Hz

Coil

Generation

M2 Base Model Description

Model Numbe

Supply

Airflow

Voltage Assembly Wiring Paint

ASSEMBLY

A = Factory Assembled B = Loose Boxes

WIRING

0 = None A = Control Wiring in Fan Box B = Control Wiring in Control Box

PAINT

0 = None A = Standard White Exterior B = Special Color Exterior

BASE RAIL

B = 8” High C = 6” High D = 10” High

SPECIAL

0 = None A = Special Pricing Authorization

Base

Rail

Special

Fan Module Description

SFA

Module ID Position

MODULE ID

SFA = Belt Driven Supply, Control Panel SFB = Vertical Belt Driven Supply, Control Panel SFC = Belt Drive Supply, Top Discharge, Control Panel SFD = Belt Driven Supply, No Control Panel SDB = Direct Drive Supply, Control Panel SDD = Direct Drive Supply, Top Discharge, Control Panel PEA = Belt Driven Power Exhaust PEC = Belt Driven Power Exhaust, Top Discharge EDB = Direct Drive Power Exhaust EDD = Direct Drive Power Exhaust, Top Discharge RFA = Belt Driven Power Return RDB = Direct Drive Power Return

POSITION

### = Level and Position of Module in Air Handling Unit

MOTOR SIZE

E = 1 hp F = 2 hp G = 3 hp H = 5 hp J = 7.5 hp K = 10 hp L = 15 hp M = 20 hp N = 25 hp

BLOWER

0 = None A = 15” Backward Curved Plenum B = 18” Backward Curved Plenum C = 22” Backward Curved Plenum D = 27” Backward Curved Plenum E = 30” Backward Curved Plenum F = 33” Backward Curved Plenum G = 37” Backward Curved Plenum H = 24” Backward Curved Plenum J = 15” BC Plenum - 50% Width K = 18” BC Plenum - 30% Width L = 2 x 18” Backward Curved Plenum M = 2 x 22” Backward Curved Plenum N = 2 x 24” Backward Curved Plenum P = 2 x 27” Backward Curved Plenum

103

Motor

Size

B 0

Blower Isolation

Model Numbe

A 00 0C

Motor

Type

ISOLATION

I = Fan Isolation

- Rubber-in-Shear Isolation on 005, 008, 011 & 014

- Spring Isolation on 018, 022, 026, 032 & 036

MOTOR TYPE

A = Standard Efficiency 1760 rpm B = Premium Efficiency 1760 rpm C = Premium Eff. 1760 rpm with VFD D = Premium Eff. 1760 rpm with VFD and Bypass E = Premium Efficiency 1170 rpm F = Premium Eff. 1170 rpm with VFD

BLANK

00 = Standard

PULLEYS

## = Pulley Combination

SAFETY CONTROL

0 = None A = Phase & Brownout Protection

BLANK

0000 = Standard

BLANK

0 = Standard

TYPE

0 = None X = Special Pricing Authorization

Blank Pulleys

Control

0 0000

Safety

Blank Blank Type

Filter Module Description

FTA

Module ID Position

MODULE ID

FTA = Small Flat Filter FTC = Cartridge Filter FTE = Medium Flat Filter FTF = Large Flat Filter FTG = G Flat Filter FTH = Cartridge Filter with Flat Pre-Filter FTI = I Flat Filter FTK = Extra Large Flat Filter

POSITION

### = Level and Position of Module in Air Handling Unit

FILTER TYPE

P = Pleated C = Cartridge

FILTERS

A0 = 2” Pleated, 30% Eff. B0 = 4” Pleated, 30% Eff. C0 = 4” Pleated, 65% Eff. or 12” Cartridge, 65% Eff. D0 = 4” Pleated, 85% Eff. or 12” Cartridge, 85% Eff. E0 = 4” Pleated, 95% Eff. or 12” Cartridge, 95% Eff.

SAFETY CONTROL

0 = None 2 = Firestat

BLANK

0000 = Standard

102

Filter Type

Filters

Model Numbe

0 0000

Safety

Control

0 00 00

Blank

Filter Type

Second

Filters

SECOND FILTER TYPE

Blank

Options

Second

0 = Type C = Cartridge

SECOND FILTERS

C0 = 12” Cartridge, 65% Eff. D0 = 12” Cartridge, 85% Eff. E0 = 12” Cartridge, 95% Eff.

BLANK

00 = Standard

FILTER OPTIONS

0 = None A = Magnehelic Gauge B = Clogged Filter Switch C = Magnehelic Gauge & Clogged Filter Switch

TYPE

0 = None X = Special Pricing Authorization

Filter

Type

Mixing Box Module Description

MBH

Module

MODULE ID

MBA = Vertical Damper MBB = Horizontal Top Damper MBC = Vertical & Horizontal Top Damper MBD = Vertical Damper with Filter MBE = Horizontal Top Damper with Filter MBF = Horizontal Bottom Damper MBH = Vertical & Horizontal Bottom Damper MBI = Horizontal Bottom Damper with Filter MBJ = Vertical & Horizontal Top Damper with Filter MBK = Vertical & Horizontal Bottom Damper with Filter

POSITION

### = Level and Position of Module in Air Handling Unit

ACTUATOR

0 = None A = Two Position Actuator B = DDC Actuator

FILTERS

00 = None A0 = 2” Pleated, 30% Eff. B0 = 4” Pleated, 30% Eff. C0 = 4” Pleated, 65% Eff. D0 = 4” Pleated, 85% Eff. E0 = 4” Pleated, 95% Eff.

101

Position Position Filters

Model Numbe

0 0000

Safety

Control

0 0000

Blank

Bypass

Open

SAFETY CONTROL

0 = None 2 = Firestat

BLANK

0000 = Standard

BYPASS OPEN

0 = None A = Top Open B = Bottom Open

BLANK

0000 = Standard

FILTER OPTIONS

0 = None A = Magnehelic Gauge B = Clogged Filter Switch C = Options A + B

TYPE

0 = None X = Special Pricing Authorization

Blank

Filter

Options

Type

PHA

Module

MODULE ID

PHA = Electric Heat PHB = Hot Water Coil PHC = Hot Water Coil with Filter PHD = Electric Heat with Filter RHC = Hot Gas Reheat Coil

POSITION

### = Level and Position of Module in Air Handling Unit

FUNCTION

H = Heating D = Dehumidification B = Heating and Dehumidification

FILTERS

00 = None A0 = 2” Pleated, 30% Eff. B0 = 4” Pleated, 30% Eff. C0 = 4” Pleated, 65% Eff. D0 = 4” Pleated, 85% Eff. E0 = 4” Pleated, 95% Eff.

101

Position Function Filters Rows FPI Circuiting Coating kW Stages Blank

HEATING COIL

ROWS

1 = 1 Row 2 = 2 Rows

FPI

08 = 8 Fins Per Inch 10 = 10 Fins Per Inch 12 = 12 Fins Per Inch

CIRCUITING

F = Single Serpentine H = Half Serpentine

COATING

0 = Standard P = Polymer E-Coating S = Stainless Steel Coil Casing H = Stainless Steel Coil Casing & Copper Fins

Heat Module Description

Model Numbe

0 00 0 0

ELECTRIC HEAT

A = 7 kW (5.25 kW) B = 14 kW (10.5 kW) C = 21 kW (15.75 kW) D = 28 kW (21.0 kW) E = 42 kW (31.5 kW) F = 56 kW (42.0 kW) G = 70 kW (52.5 kW) H = 35 kW (26.25 kW) J = 84 kW (63 kW) K = 112 kW (84.0 kW) L = 126 kW (94.5 kW) M = 168 kW (126 kW) N = 10 kW (7.5kW) P = 20 kW (15 kW) Q = 30 kW (22.5 kW) R = 40 kW (30 kW) S = 50 kW (37.5 kW) T = 80 kW (60 kW) U = 100 kW (75 kW) V = 120 kW (90 kW) W = 160 kW (120 kW)

STAGES

01 = 1 Stage 02 = 2 Stage 03 = 3 Stage 04 = 4 Stage

BLANK

00 = Standard

FILTER OPTIONS

0 = Standard A = Magnehelic Gauge B = Clogged Filter Switch C = Options A + B

TYPE

0 = None X = Special Pricing Authorization

E 02 00

Filter

Options

Type

Blank Module Description

BBA

Module

MODULE ID

BBA = Small BBB = Medium BBC = Large BBD = XL BBE = XXL BBF = XXXL CBA = Small with Drain Pan CBB = Medium with Drain Pan CBC = Large with Drain Pan CBD = XL with Drain Pan CBE = XXL with Drain Pan CBF = XXXL with Drain Pan

POSITION

### = Level and Position of Module in Air Handling Unit

DRAIN PAN TYPE

0 = None A = Auxiliary

AIRWAY TYPE

AR = Top Open, Right Hand End Panel AL = Top Open, Left Hand End Panel

101

Position

Drain

Pan

Type

Airway

Type

Model Numbe

0 0000

Safety

Control

0 0000

Blank

SAFETY CONTROL

0 = None 2 = Firestat

BLANK

0000 = Standard

BYPASS OPENING

0 = None A = Top Opening B = Bottom Opening

BLANK

0000 = Standard

BLANK

0 = Standard

TYPE

0 = None X = Special Pricing Authorization

Bypass

Opening

Blank Blank Type

CBL

Module

Coil Module Description

101

Position

MODULE ID

CBL = Chilled Water or DX CLC = DX + Hot Gas Reheat CLF = Hot Water + Chilled Water or DX CLG = Electric Heat + Chilled Water or DX CLI = Hot Water or Chilled Water Face Bypass CLM = Chilled Water or DX, Optional Size

POSITION

### = Level and Position of Module in Air Handling Unit

COOLING TYPE

0 = None C = Chilled Water D = DX E = DX or Hot Gas Bypass

ELECTRIC HEAT

A = 7 kW (5.3 kW) B = 14 kW (10.5 kW) C = 21 kW (15.8 kW) D = 28 kW (21.0 kW) H = 35 kW (26.3 kW) E = 42 kW (35.0 kW) F = 56 kW (42.0 kW) G = 70 kW (52.5 kW) J = 84 kW (47.7 kW) K = 112 kW (53.0 kW) L = 126 kW (58.3 kW) M = 168 kW (63.6 kW)

STAGES

1 = 1 Stage 2 = 2 Stage 3 = 3 Stage 4 = 4 Stage

HEATING COIL

ROWS

1 = 1 Row 2 = 2 Rows

FPI

08 = 8 Fins Per Inch 10 = 10 Fins Per Inch 12 = 12 Fins Per Inch

Cooling

Type

0 0

kW Stages Rows FPI Circuiting Coating Rows FPI Circuiting Coating

Model Numbe

0 00 0 0

CIRCUITING

F = Single Serpentine H = Half Serpentine

COATING

0 = Standard P = Polymer E-Coating S = Stainless Steel Coil Casing H = Stainless Steel Coil Casing & Copper Fins

COOLING COIL

ROWS

4 = 4 Rows 6 = 6 Rows 8 = 8 Rows

FPI

08 = 8 Fins Per Inch 10 = 10 Fins Per Inch 12 = 12 Fins Per Inch

CIRCUITING

F = Single Serpentine H = Half Serpentine S = DX Single Circuit I = DX Dual Circuit, Interlaced

COATING

0 = Standard P = Polymer E-Coating S = Stainless Steel Coil Casing H = Stainless Steel Coil Casing & Copper Fins

DRAIN PAN

S = Stainless Steel

TYPE

0 = None X = Special Pricing Authorization

4 10 F 0

Drain

Pan

Type

Control Panel Module Description

Model Numbe

TRA

Module

MODULE ID

TRA = Small TRB = Medium TRC = Large TRD = XL TRE = XXL TRF = XXXL

POSITION

### = Level and Position of Module in Air Handling Unit

BLANK

0 = Standard

BLANK

00 = Standard

101

Position Blank Blank

0 0000

Safety

Options

Blank Blank Blank Type

SAFETY OPTIONS

0 = None 2 = Firestat

BLANK

0000 = Standard

BLANK

00000 = Standard

BLANK

0 = Standard

TYPE

0 = None X = Special Pricing Authorization

00000

Energy Recovery Module Description

Model Numbe

HRA

Module

MODULE ID

HRA = AAONAIRE Energy Recovery Wheel

POSITION

### = Level and Position of Module in Air Handling Unit

WHEEL SIZE

A = Standard

BLANK

00 = Standard

101

Position

Wheel

Size

Blank Blank Blank Blank Type

00000

BLANK

00000 = Standard

BLANK

00000 = Standard

BLANK

0 = Standard

TYPE

0 = None X = Special Pricing Authorization

00000

Condenser Module Description

WCC

Module

MODULE ID

WCC = Water-Cooled Condenser WHP = Water-Source Heat Pump

POSITION

### = Level and Position of Module in Air Handling Unit

COMPRESSOR TYPE

A = Scroll B = Two Step D = Variable Capacity Compressor T = Tandem Compressors

TONNAGE

06 = 6 Ton Capacity 08 = 8 Ton Capacity 10 = 10 Ton Capacity 13 = 13 Ton Capacity 16 = 16 Ton Capacity 20 = 20 Ton Capacity 25 = 25 Ton Capacity 30 = 30 Ton Capacity 35 = 35 Ton Capacity 40 = 40 Ton Capacity 45 = 45 Ton Capacity 50 = 50 Ton Capacity 60 = 60 Ton Capacity

HEAT EXCHANGER TYPE

A = Copper Coaxial Heat Exchanger B = Cupronickel Coaxial Heat Exchanger C = Brazed Plate Heat Exchanger

101

Position

Compressor

Type

Tonnage

Model Numbe

Exchanger

A 000 A

Heat

Type

A 0000

Blank Glycol

BLANK

000= Standard

GLYCOL

A = 0-10%, Standard Heat Exchanger B = 20-50%, Oversized Heat Exchanger

SAFETY CONTROL

A = WattMaster WSHP Control C = Phase & Brown Out Protection

BLANK

0000 = Standard

SOUND BLANKET

0 = None A = Special Pricing Authorization

TYPE

0 = None X = Special Pricing Authorization

Safety

Control

Blank

Sound

Blanket

Type

M2 Series Typical Configurations

M2 Series units have been designed as practical, high performance alternative to expensive custom air handling equipment.

Figure 1 - Typical Configurations

Fan Only

AAONAIRE® (HRU) Energy Recovery Unit

AAONAIRE®(HRU) with:

- DX or Chilled Water Cooling

- Hot Water, Steam or Electric Heat

Filter and Fan

Blow-Through

Draw-Through

Top Discharge

AAONAIRE®(HRU) with:

- DX or Chilled Water Cooling

- Hot Water, Steam or Electric Heat

- Outside Air and Return Air Mixing

AAONAIRE®(HRU) with:

- DX or Chilled Water Cooling

- Hot Water, Steam or Electric Heat

- Outside Air and Return Air Mixing

- Return Air Bypass

Unit Orientation

Determine left hand or right hand orientation/connections:

M2 Series Top View

Right Hand Side

Return Air Supply Air

Connections & service

access on left side for

left hand orientation

AIRFLOW

Filter Coil Supply Fan

Left Hand Side

Consider the airflow to be

hitting the back of your head.

Figure 2 - Unit Orientation

General Information

M2 Series modular indoor air handling units, modular outdoor air handling units, self contained units and packaged rooftop units have been designed for either indoor or outdoor installation. Flexible connectors are required on all duct connections to minimize air leaks.

M2 Series units are designed for safe operation when installed, operated and maintained within design specifications and the instructions in this manual. It is necessary to follow these instructions to avoid personal injury or damage to equipment or property during equipment installation, startup, operation and maintenance.

Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a trained, qualified installer or service agency. A copy of this IOM should be kept with the unit.

These units must not be used as a “construction heater” at anytime during any phase of construction. Very low return air temperatures, harmful vapors, and misplacement of the filters will damage the unit and its efficiency.

This equipment is protected by a standard limited warranty under the condition that initial installation, service, startup and maintenance is performed according to the instructions set forth in this manual. This manual should be read in its entirety prior to installation and before performing any service or maintenance work.

Equipment described in this manual is available with many optional accessories. If you have questions after reading this manual in its entirety, consult other factory documentation or contact your AAON Sales Representative to obtain further information before manipulating this equipment or its optional accessories

Certification of Gas Heat Models

a. Certified as a Category III forced air

furnace with or without cooling.

b. Certified for indoor and outdoor

installation.

c. Certified for installation on a

combustible roof with a minimum of 12” high curb.

Certification of Steam or Hot Water Heat Models

a. Certified as a forced air heating system

with or without cooling.

b. Certified for indoor and outdoor

installation.

Certification of Electric Heat Models

a. Certified as an electric warm air furnace

with or without cooling.

b. Certified for indoor and outdoor

installation only.

c. Certified for installation on a

combustible roof with a minimum of 12” high curb.

Certification of Cooling Models

a. Certified as a commercial central air

conditioner with or without electrically operated compressors.

b. Certified for indoor and outdoor

installation only.

c. Certified for installation on a

combustible roof with a minimum of 12” high curb.

d. Certified with refrigerant R-410A coils

or with chilled water cooling coils.

Codes and Ordinances

System should be sized in accordance with the American Society of Heating, Refrigeration and Air Conditioning Engineers Handbook.

Installation of M2 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. In the absence of local codes installation must conform to the current (United States) National Fuel Gas Code ANSI-Z223.1/NFPA 54 or the current (Canada) National Fuel & Propane Installation Code CSA B149.1 or B149.2, and Mechanical Refrigeration Code CSA B52. 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 July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed.

Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment.

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

If repairs must be made to damaged goods, then the factory should be notified before any repair action is taken in order to protect the warranty. Certain equipment alteration, repair, and manipulation of equipment without the manufacturer’s consent may void the product warranty. Contact the AAON-Longview Warranty Department for assistance with handling damaged goods, repairs, and freight claims: (903) 236-4403.

Note: Upon receipt check shipment for items that ship loose such as filters and remote sensors. Consult order and shipment documentation to identify potential looseshipped items. Loose-shipped items may have been placed inside unit cabinet for security. Installers and owners should secure

all doors with locks or nuts and bolts to prevent unauthorized access.

Figure 3 - Lockable Handle

The warranty card must be completed in full and returned to AAON not more that 3 months after unit is delivered.

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.

Packaged Direct Expansion (DX) Units

All DX refrigeration systems are factory assembled, leak tested, charged with refrigerant, and run tested.

All DX refrigerant systems include an evaporator, condenser, liquid line filter driers, thermal expansion valves (TXV) and scroll compressors. Compressors are equipped with a positive pressure forced lubrication system.

Some units are equipped with compressor crankcase heaters, which should be energized at least 24 hours prior to cooling operation, to clear any liquid refrigerant from the compressors.

CRANKCASE HEATER

OPERATION

Never cut off the main power supply to the unit, except for servicing, emergency, or complete shutdown of the unit. When power is cut off from the unit crankcase heaters cannot prevent refrigerant migration into the compressors. 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 power to the unit must be off for more than an hour, turn the thermostat system switch to "OFF", or turn the unit off at the control panel, and leave the unit off until the main power switch has been turned on again 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 started.

Always control the unit from the thermostat, or control panel, never at the main power supply, except for servicing, emergency or complete shutdown of the unit.

During the cooling season, if the air flow is reduced due to dirty air filters or any other reason, the cooling coils can get too cold which will cause excessive liquid to return

to the compressor. As the liquid concentration builds up, oil is washed out of the compressor, leaving it starved for lubrication.

The compressor life will be seriously shorted by reduced lubrication and the pumping of excessive amounts of liquid oil and refrigerant.

Note: Low Ambient Operation Air-cooled DX units without a low ambient option, such as condenser fan cycling, ECM driven condenser fans or the 0°F low ambient option, will not operate in the cooling mode of operation properly when the outdoor temperature is below 55°F. Low ambient and/or economizer options are recommended if cooling operation below 55°F is expected.

Gas or Electric Heating

The unit is designed to heat a given amount of air while operating. If this amount of air is greatly reduced, approximately 1/3 during the heating season, the gas heat exchanger or electric heating coil may overheat, and may cut the burner or heater off entirely by action of the safety high temperature limit devices which are factory mounted at the heat exchanger and supply fan areas.

Airflow should be adjusted after installation to obtain an air temperature rise within the range specified on the unit rating plate at the required external static pressure.

Should overheating occur with a gas heat exchanger, or the gas supply fail to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply.

Prolonged overheating of the heat exchanger will shorten its life.

If unit has not been selected as a 100% outside air unit (make up air unit) the return air duct must be sealed to the unit and the return air temperature must be maintained between 55°F and 80°F.

Wiring Diagrams

Unit specific wiring diagrams are laminated and affixed inside the controls compartment door.

Condensate Drain Pan

Unit requires drain traps to be connected to the condensate drain pan of the unit.

For condensate drain lines, the line should be the same pipe size or larger than the drain connection, include a p-trap, and pitch downward toward drain. An air break should be used with long runs of condensate lines.

Unit should not be operated without a p-trap. Failure to install a p-trap may result in overflow of condensate water.

An auxiliary / emergency drain pan is recommended for all indoor applications where there is a risk of water damage to surrounding structure or furnishings. Refer to local codes.

Installation

AAON equipment has been designed for quick and easy installation.

Locating Units

Verify rooftop, foundation or mounting frame can support the total unit weight, including accessory weights.

Before setting the unit into place, caution must be taken to provide clearance for unit doors that must be accessible for periodic service. These areas contain the controls, safety devices, refrigerant or water piping, shut-off valves and filters.

A minimum clearance equal to the width of the unit is required on the access panel side of the unit to ensure there is enough room to slide out coils and energy recovery wheels, and to access filters, fans and other internal components.

Depending on natural gas and propane heating module orientations, the combustion air inlets or vent (flue) gas discharges may be located in the unit roof or sides. There must be 6 feet of clearance between these roofs/sides and building walls, parapets, adjacent buildings, or equipment. If equipment is for replacement and required clearances are not available, contact AAON for recommendations.

When locating gas fired units, it is recommended the unit be installed so that the flue discharge vents are located at least 120 inches away from any opening through which combustion products could enter the building.

Distances from adjacent public walkways, adjacent buildings, operable windows and building openings, shall conform to local codes and/or the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the National Gas & Propane Code, CSA B149.1

For gas fired unit, do not position flue opening to discharge into a fresh air intake of any other piece of equipment. Unit should also be installed so that the flow of combustion intake air is not obstructed from reaching the furnace.

Outdoor vent opening must not be blocked by snow. A minimum 12” curb must be used or the vent outlet shall be greater than 12” off the ground/roof.

Flue gas is dangerously hot and contains containments. The user is responsible for determining if vent gases may degrade building materials.

The National Gas and Propane Installation Code, B149.1 specifies a 6 ft. horizontal vent terminal clearance to gas and electric meters and relief devices.

+ 70 hidden pages