RK-60
®
AAON
RK SERIES
HEATING • COOLING & COMBINATION
ROOFTOP UNITS
USERS
LISTED
®
!
▲
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of
life.
WARNING
INFORMATION
MANUAL
update 7-2000
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
• EXTINGUISH ANY OPEN FLAME.
• DO NOT TOUCH ANY ELECTRICAL SWITCH.
• DO NOT TRY TO LIGHT ANY APPLIANCE.
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
• DO NOT USE ANY PHONE IN YOUR BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A
NEIGHBOR'S PHONE.
FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER,
CALL THE FIRE DEPARTMENT.
1
AAON
SECTION PAGE NUMBER
OWNER'S INFORMATION …………………………………………………………………………… 03
HEATING / COOLING SYSTEMS …………………………………………………………………… 04
GAS UNIT LIGHTING INSTRUCTIONS …………………………………………………………… 05
PERIODIC INSPECTION PROCEDURES ………………………………………………………… 06
SERVICE, TROUBLE SHOOTING & MAINTENANCE ………………………………………… 08
FILTER INSTALLATION / REPLACEMENT ……………………………………………………… 09
SERVICING ……………………………………………………………………………………………… 10
®
TABLE OF CONTENTS
Gas Heating, Cooling, Electric, Steam, Hot Water & Chilled Water Units
Lubrication
Cleaning
Rooftop Unit Replacement Parts …………………………………………………………… 12
SEQUENCE OF OPERATIONS ……………………………………………………………………… 13
Heating
Cooling
Optional Economizer
VAV Systems …………………………………………………………………………………… 14
Power Exhaust Options
!
▲
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 qualified installer, service agency or the gas supplier.
Owner should pay particular attention to the words: NOTE, CAUTION AND WARNING.
NOTES are intended to clarify or make the installation easier. CAUTIONS are given to prevent
equipment damage. WARNINGS are given to alert owner that personal injury and/or equipment
WARNING
The Clean Air Act of 1990 bans the intentional
venting of refrigerant (CFC's and HCFC's) as of
July 1, 1992. Approved methods of recovery,
recycling or reclaiming must be followed. Fines
and/or incarceration may be levied for noncompliance.
damage may result if installation procedure is not handled properly.
! IMPORTANT
▲
It is the intent of
AAON, Inc.
P83730 (rev. B • 7-00)
AAON, Inc.
reserves the right to change pricing, specifications and/or design of it's products without notice, obligation or liablity.
to provide accurate and current specification information. However, in the interest of product improvement,
© 2000
AAON
&
AAONAIRE
AAON, Inc.
, all rights reserved throughout the world.
are registered trademarks of
2
AAON, Inc.
, Tulsa, OK.
OWNER'S INFORMATION
The units are designed as self-contained heating, cooling
or combination units for outdoor installation only, using
the refrigerant shown on the rating plate, chilled water,
natural or propane gas, electric resistance, steam or hot
water.
WARNING
Failure to observe the following instructions will result
in premature failure of your system, and possible voiding of the warranty.
DIRECT EXPANSION (DX) COOLING UNITS
Never cut off the main power supply to the unit, except
for complete shutdown. When power is cut off from the
unit, any compressors using crankcase heaters cannot
prevent refrigerant migration. This means the compressor will cool down, and liquid refrigerant will accumulate in the compressor. Since the compressor is designed
to pump refrigerant gas, damage may occur when power
is restored.
If power must be cut off for more than an hour, turn the
thermostat system switch to "OFF", and leave it off until
the main power switch has been turned on again for at
least twenty four hours for units with compressor crankcase heaters. This will give the crankcase heater time to
clear any liquid accumulation out of the compressor
before it is required to run.
Always control the system from the thermostat, or control panel, never at the main power supply (except for
emergency or for complete shutdown of the system).
During the cooling season, if the air flow is reduced due
to dirty air filters or any other reason, the cooling coils
will get too cold and 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
SHORTENED BY THIS REDUCED LUBRICATION,
AND THE PUMPING OF EXCESSIVE AMOUNTS OF
LIQUID OIL AND REFRIGERANT.
GAS OR ELECTRIC HEATING
The system is designed to cool or heat a given amount of
air each minute it operates. If this amount of air is
greatly reduced (approximately 1/3 during the heating
season), the heat exchanger / heater coil will overheat,
and may cut the burner / heater off entirely by action of
the safety high temperature limit device which is incorporated in the exchanger or heating area.
GAS HEAT UNITS - Should overheating occur, 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.
!
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W ARNING
Electric shock hazard. Can cause injury or death.
Before attempting to perform any service or
maintenance, turn the electrical power to unit to
OFF at disconnect switch(es). Unit may have
multiple power supplies.
AIRFLOW IS TO BE ADJUSTED AFTER INSTALLATION TO OBTAIN AN AIR TEMPERATURE RISE
WITHIN THE RANGE SPECIFIED ON THE RATING
PLATE.
DUE TO JOB SPECIFICATION REVISIONS, IT MAY
BE NECESSARY TO ADJUST OR CHANGE THE
SHEAVE OR PULLEY TO OBTAIN THE DESIRED
AIRFLOW AT THE TIME OF INSTALLATION.
START-UP TECHNICIAN MUST CHECK BLOWER
MOTOR AMPERAGE TO ENSURE THAT THE AMPERAGE LISTED ON THE MOTOR NAMEPLATE IS
NOT EXCEEDED.
CAUTION: While the following incorrect operations
may not cause damage to the system, they will impair
the performance, and may cause the built-in safety
devices to cut the system off completely.
1. LOW AMBIENT OPERATION
The cooling section of a direct expansion (DX)
unit will not operate properly when the outdoor
temperature is below 55° degrees. Outside air
intake options are recommended if operation
below 55° degrees is expected.
2. MULTIPLE UNIT OPERATION
When several units are used in conditioning the
space, and part or all of them are combination
heating-cooling units, all systems thermostat
switches must be set at either heating or cooling
(or set at "off"). Do not leave part of the systems
switched to the opposite mode. All cooling only
units should be switched to "off" at the thermostat during the heating season.
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.
CONDENSATE PIPING
The unit requires a drain trap to be connected to the
drainpan at the unit. If codes require a condensate drain
line, the line should be the same pipe size as the drain
nipple and should pitch downward toward drain.
The condensate drain pipe ("P" trap) is factory supplied
and is shipped loose in the control access compartment
for field installation. An air break should be used with
long runs of condensate lines.
3
HEATING & COOLING SYSTEMS
NORMAL OPERATION
HEATING
Set the thermostat system switch to "HEAT".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
COOLING
Set the thermostat system switch to "COOL".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
AIR CIRCULATION
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "ON".
Do not change temperature setting.
With these settings, the air circulating blower will run
continuously but the air will not be heated or cooled.
SYSTEM OFF
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "AUTO".
Do not change temperature setting.
With these settings, the system is shut down, with the
exception of the control system power (24 volts), and the
crankcase heater of the compressor (about 60 watts).
DO NOT TURN OFF THE MAIN POWER SWITCH.
NIGHT AND VACANT WEEKEND OPERATION
If it is desired to reduce the operating time during the
night, and during periods when the space is unused,
it is recommended that the temperature setting be
raised about five degrees during these periods of the
cooling season, and lowered about ten degrees during
the heating season.
The units are equipped with a direct spark ignition
system which proves the burner operation during each
call for heat.
Power to the ignition control is 24 volts to reduce hazards. Burner ignition is by a high intensity spark.
When heat is called for, the cooling system is inoperable
except for the indoor blower motor. Actual heating is
accomplished by firing gas into the heat exchanger
assembly.
ELECTRIC HEATING SYSTEM
Heating is accomplished by passing electrical current
through a specified amount of resistance heaters which
will produce the required heat. The indoor blower motor
will energize at the same time as the heaters.
STEAM OR HOT WATER HEATING SYSTEM
Heating is accomplished by passing steam or hot water
through the steam or hot water coil assembly.
COOLING SECTION • DX
All direct expansion refrigeration systems are factory
assembled, charged with refrigerant, tested and operated. On all units 8 ton and larger the refrigerant system
includes multiple circuit evaporator and condenser coils
providing two or more stages of cooling. These systems
are provided with liquid line filter driers, expansion
valves and fully hermetic compressors. Compressors are
equipped with a positive pressure forced lubrication
system. The air cooled condenser coil(s) is constructed of
copper tubes with aluminum fins, the air is pulled
through with propeller fans. The evaporator coil is draw
through, made of copper tubes with aluminum fins.
The refrigeration section of these appliances has been
found acceptable with applicable provisions of "ANSI /
UL 1995" and current "C.S.A. Standard C22.2" by E.T.L.
GAS HEATING SYSTEM
The heating section is for use with natural gas supply
pressure of 6" to 10.5" Water Column. The unit can also
be fired on propane gas with a supply pressure to the
valve of 11" to 12" Water Column. A 1/8" pressure tap
must be supplied by the installer in the piping just ahead
of the gas valve. The rating plate on the furnace shall be
inspected to make sure that the unit is stamped for the
proper gas. The pressure tap on the outlet end of the gas
valve should be removed and the valve adjusted for the
proper manifold pressure to 3.5" on natural gas and
10.5" for propane gas.
The burner area is not sealed and combustion air is
supplied by a centrifugal blower which draws in fresh air
through a protected opening. This air is introduced into
the burner tubes by the action of the induced draft
blower. This insures an even flow of primary and secondary air to the burners.
The heating system and safety controls are 100% tested
on each unit before it leaves the factory.
NOTE: Crankcase Heater Operation
Some units are equipped with a compressor crankcase
heater, which should be energized at least 24 hours prior
to setting the thermostat for cooling operation.
COOLING SECTION • CHILLED WATER
or NON-COMPRESSORIZED UNIT
Chilled water or non-compressorized units have factory
installed coils. These systems are provided with internal
header connections for field connection. Coils are aluminum fin / copper tube construction.
4
GAS UNIT LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
A. This appliance does not have a pilot. It is equipped with an
ignition device which automatically lights the burner.
not try to light the pilot by hand.
Do
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone
in your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the burner. Do
hand.
GAS CONTROL KNOB
SHOWN IN "ON"
POSITION
GAS INLET
not try to light the pilot by
ON
OFF
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,
don't try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and
any gas control which has been under water.
5. Open control access panel.
6. Push in gas control knob slightly and turn clockwise to "OFF".
NOTE: Knob cannot be turned to "OFF" unless knob is pushed
in slightly. Do not force.
7. WAIT five (5) minutes to clear out any gas. Then smell for gas, including
near the floor. If you smell gas, STOP! Follow "B" in the safety
information above on this label. If you don't smell gas, go to the next step.
8. Turn gas control knob counterclockwise to "ON".
9. Close control access panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Open control access panel.
Gas Heating
Section View
Ignition control
4. Push in gas control knob slightly and turn clockwise to
"OFF". Do not force.
5. Close control access panel.
Manifold
Combustion
blower motor
Gas valve
Fan / Limit
switch
5
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