AAON RK-60 User Manual

®
AAON
RK SERIES
HEATING • COOLING & COMBINATION
ROOFTOP UNITS
INSTALLATION
INSTRUCTION
MANUAL
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
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
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.
• 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
®
TABLE OF CONTENTS
SECTION PAGE NUMBER
GENERAL DESCRIPTION …………………………………………………………………………… 03
Unpacking Certification Codes and Ordinances
OWNER'S INFORMATION …………………………………………………………………………… 04
HEATING / COOLING SYSTEMS …………………………………………………………………… 05
INSTALLATION ………………………………………………………………………………………… 06
Setting the Curb / Unit ………………………………………………………………………… 07 Outside Air Hood ……………………………………………………………………………… 08 Electrical Info Gas Piping Info ………………………………………………………………………………… 09 Service Clearances Condensate Piping Info ……………………………………………………………………… 10
GAS UNIT LIGHTING INSTRUCTIONS …………………………………………………………… 11
PERIODIC INSPECTION PROCEDURES ………………………………………………………… 12
Gas Heating, Cooling, Electric, Steam, Hot Water & Chilled Water Units
SERVICE, TROUBLE SHOOTING & MAINTENANCE ………………………………………… 14
Lubrication Cleaning
FILTER INSTALLATION / REPLACEMENT ……………………………………………………… 15
SERVICING ……………………………………………………………………………………………… 16
Rooftop Unit Replacement Parts …………………………………………………………… 18
SEQUENCE OF OPERATIONS ……………………………………………………………………… 19
Heating Cooling Optional Economizer VAV Systems …………………………………………………………………………………… 20 Power Exhaust Options
COMPRESSOR CHECKOUT PROCEDURE ……………………………………………………… 21
IGNITION CONTROL CHECKOUT PROCEDURE ……………………………………………… 22
FACTORY START-UP FORM ………………………………………………………………………… 23
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 damage may result if installation procedure is not handled properly.
It is the intent of
AAON, Inc.
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
AAON, Inc.
, Tulsa, OK.
P83740 (rev. B • 7-00)
2
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.
UNPACKING 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.
CERTIFICATION
• GAS HEAT MODELS (a) Design Certified as a forced air furnace with or without cooling unit. (b) Certified for outdoor installation only. (c) Certified for installation on combustible roof with a minimum of 12" high curb. (d) Certified with Heat Exchanger located downstream from Evaporator coil.
GENERAL DESCRIPTION
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.
NOTE: These units must not be used as a "construc­tion heater" at any time during any phase of construc­tion. Very low return air temperatures, harmful va­pors, and misplacement of the filters will damage the unit and its efficiency.
WARNING
• STEAM OR HOT WATER HEAT MODELS (a) Certified as a forced air furnace with or without cooling unit. (b) Certified for outdoor installation only. (c) Certified for installation on combustible roof with a minimum of 12" high curb. (d) ARI certified coils.
• ELECTRIC HEAT MODELS (a) Certified as an electric warm air furnace with or without cooling unit. (b) Certified for outdoor installation only. (c) Certified for installation on combustible roof with a minimum of 12" high curb.
• COOLING MODELS (a) Certified as a commercial central air-conditioner with or without electrically operated compressor. (b) Certified for outdoor installation only. (c) Certified for installation on combustible roof with a minimum of 12" high curb. (d) ARI certified coils.
CODES AND ORDINANCES System should be sized in accordance with National Warm Air Heating and Air Conditioning Association Literature, or the Guide of American Society of Heating, Refrigeration and Air Conditioning Engineers. The installation must conform with local building codes or, in the absence of local codes with (United States) National Fuel Gas Code "ANSI-Z223.1", (Canada) current CAN / CGA- B149.1 or . 2. Installation Codes for Gas Burning Appliances and Equipment, current C.S.A. Standard C22.1, Canadian Electrical Code Part 1, and C.S.A. Standard B52 Mechanical Refrigeration Code, and Local Plumbing or Waste Water Codes.
! IMPORTANT
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.
3
OWNER'S INFORMATION
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.
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 if gas fired units, the gas supplier. Refer to installation instructions provided with the unit and this manual.
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.
!
WARNING
Scroll compressors will be damaged by
operation with the wrong rotation.
THE LOW PRESSURE SWITCH HAS BEEN
DISCONNECTED AFTER TESTING
AT THE FACTORY.
The wiring must be reconnected and proper
rotation determined at the time of start-up by
a qualified service technician using suction
and discharge pressures gauges.
Any alteration should only be made at
the unit power connection.
4
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.
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.
INSTALLATION IS TO BE ADJUSTED
TO OBTAIN AN AIR TEMPERATURE RISE
WITHIN THE RANGE SPECIFIED ON THE
RATING PLATE.
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.
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.
5
INSTALLATION
12
12
12
12
12
12
12
12
12
12
12
12
12
12
!
CAUTION
!
WARNING
If outside air is in contact with the bottom of the unit, the unit must have the bottom
insulation option or be field insulated.
DO NOT DRILL OR PUNCH HOLES IN BASE OF UNIT FROM INSIDE THE UNIT OR FROM
BELOW TO ATTACH DUCTWORK. LEAKING
MAY OCCUR IF UNIT BASE IS PUNCTURED.
SEE DETAIL "A"
SECTIONAL VIEW OF UNIT ON ROOF CURB
INSULATION MATERIALS MAY
DUCT / FLEX CONNECTOR*
STRUCTURAL STEEL *
BE COMBUSTIBLE
GASKET
COUNTER FLASHING *
WOOD
NAILER *
CANT STRIP *
RIGID
INSULATION *
CURB
ROOF DECK *
DETAIL 'A'
DUCT / UNIT CONNECTION
* FIELD SUPPLIED
ROOFING MATERIAL*
GASKET
WOOD
NAILER *
COUNTER FLASHING *
RIGID
INSULATION *
CANT STRIP *
ROOFING MATERIAL*
ROOF DECK *
DUCT / FLEX CONNECTOR*
DUCT RAIL
CURB
STRUCTURAL STEEL *
WOOD
NAILER *
RIGID
INSULATION *
GASKET
COUNTER FLASHING *
CANT STRIP *
ROOFING MATERIAL*
ROOF DECK *
SOLIDBOTTOM
ACOUSTIC CURB
STRUCTURAL STEEL *
DUCT / FLEX CONNECTOR*
DETAIL 'A'
OPEN BOTTOM CURB
DUCT RAIL CONNECTION
* FIELD SUPPLIED
6
DETAIL 'A'
ACOUSTIC CURB
* FIELD SUPPLIED
INSTALLATION continued
AAON Rooftop units are designed for fast, easy installa­tion. The curb is mounted first and must be located so that duct connections will be clear of structural mem­bers of the building.
SETTING THE CURB When using the factory curb, make openings in roof decking large enough to allow for duct penetrations and workspace only. Do not make openings larger than necessary. Set the curb to coincide with the openings. Make sure the curb is level.
SETTING THE UNIT If cables or chains are used to hoist the unit they must be
the same length and care should be taken to prevent damage to the cabinet / coils or condenser fans. It is recommended lifting the unit with the outside air hood in the downward shipping position, however the unit may be lifted with the outside air hood in the open position.
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 and duct openings. Lower unit while guiding the unit to align with utility opening and duct openings. Be sure that the gasket material has been applied to curb. Continue low­ering the unit until the unit skirt fits around the curb. Make sure the unit is properly seated on the curb and is level.
180" minimum
length
99" minimum
length
LIFTING DETAIL
TYPICAL FOR
2 - 25 TON UNITS
!
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 qualified installer,
service agency or the gas supplier.
Install the gas fired unit to assure the flow
of combustion and ventilating air is not
obstructed from reaching the heater and
that the flue outlet is located at least
120 inches away from any opening
through which combustion products
could enter the building.
LIFTING DETAIL
TYPICAL FOR
26 - 60 TON UNITS
The unit shall be installed so that the rectangular flue (if applicable) is located at least 120" away from any open­ing through which combustion products could enter the building. The unit shall also be installed so that the flow of combustion and ventilating air is not obstructed from reaching the furnace. Do not position flue opening to discharge into a fresh air intake of any other piece of equipment.
!
CAUTION
Where the supply or warm air duct passes
through a combustible roof, a clearance
of one inch must be maintained between
the outside edges of the duct and
combustible material in accordance
with National Fire Protection Association
Standard No. 90A. Provide flashings or
enclosure between structure and roof
and all joints must be sealed with mastic
roofing to ensure a watertight seal.
All roofing work should be performed by
competent roofing contractors to avoid
any possible leakage.
7
INSTALLATION continued
OUTSIDE AIR HOOD For proper unit operation, the air hood must be opened at start-up as shown below:
AIR HOOD SHOWN IN THE SHIPPING POSITION (CLOSED)
ELECTRICAL Check the unit data plate voltage to make sure it agrees with the power supply. Connect power to the unit according to the wiring diagram provided with the unit.
The power and control wiring may be brought up through the utility entry. Protect the branch circuit in accor­dance with code requirements. Control wires should not be run inside the same conduit. The unit must be electrically grounded in accordance with the current National Electric Code, ANSI / NFPA No. 70. In Canada use current C.S.A. Standard C22.1 Canadian Electric Code Part 1. Power wiring is to the unit terminal block or main disconnect. All wiring beyond this point has been done by the manufacturer and cannot be modified without effecting the unit's agency / safety certification.
AIRFLOW IS TO BE ADJUSTED AFTER INSTALLA­TION TO OBTAIN AN AIR TEMPERATURE RISE WITHIN THE RANGE SPECIFIED ON THE RATING PLATE.
Remove shipping screws from each side of the hood in the "closed" postion. Lift hood to the "open" position, seal flange and secure with sheet metal screws.
Air hoods may vary according to unit size and options. The illustration shown is for practical guidelines for all outside air hoods.
Outdoor air intake adjustments should be made accord­ing building ventilation or local code requirements.
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.
NOTE: All units are factory wired for 208 / 230, 460 or 575 volt. If unit is to be connected to a 208v supply, the transformer must be rewired for 208v service. For 208v service interchange the yellow and red conductor on the low voltage control transformer. RED - BLK 208 volt ; YEL - BLK 230 volt.
AIR HOOD SHOWN IN THE OPEN POSITION
!
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.
W ARNING
! CAUTION
On three phase units the rototation must be
checked on ALL MOTORS AND COMPRESSORS.
SCROLL COMPRESSORS ARE DIRECTIONAL.
Rotation must be checked on start-up by a
qualified service technician using
suction and discharge gauges.
Scroll compressors will FAIL if run in the wrong
direction. Blower and condenser rotation
should be checked and only be altered if
necessary at the power connection.
8
SERVICE CLEARANCES
LOCATION
Return Air (Back)
Vent Side (Front)
Left Side
Right Side
Top UNOBSTRUCTED
GAS PIPING Size gas piping to supply the unit with 6" to 10.5" water column pressure for natural gas or 11" water column pressure for propane when all gas consuming devices in the building connected to the same gas system are operating. Install piping in accordance with local codes, the piping must conform with the latest ANSI-Z223.1 National Fuel Gas Code; in Canada, Current Standard CAN / CGA-B149, Installation Codes for Gas Burning Appliances and Equipment. Some utility companies will require pipe sizes larger than the minimum sizes listed.
2 - 7
36" 48"
6"
48"
UNIT SIZE
8 - 15
48" 48"
6"
60"
16 - 25 26 - 60
48" 48"
6"
60"
60" 48" 60" 60"
GAS PIPING SIZES
UNIT SIZE / TONS
02 - 03 69 3/4" 04 90 3/4" 05 - 06 - 07 90 - 180 3/4" 08 - 10 180 - 270 - 351 3/4" 13 - 15 180 - 270 - 390 3/4" 16 - 20 - 25 270 - 390 - 480 3/4" 26 -30 -40 -50 -60 540 - 780 (2) 3/4"
NOTE: Codes may require the use of a manual main gas shut-off valve and union, (furnished by others) installed in the gas line external to the unit.
INPUT / MBH
PIPE SIZE
INSTALLATION continued
!
CAUTION
Some soaps used for leak detection are
corrosive to certain metals. Carefully
rinse piping thoroughly after leak
test has been completed.
The furnace must be isolated by closing the manual shut off valve or disconnected from the gas supply piping during pressure testing of the piping system with pres­sures in excess of 1/2 PSIG.
The flow of combustion and ventilating air shall not be blocked or otherwise obstructed in any way.
NOTE: All gas-fired heat exchangers are completely tested at the factory before shipment. This will remove nearly all of the oils that have been used in the manufac­turing process, however, trace amounts may remain. When performing the initial start-up at the jobsite, it is highly recommended that people or any other living animals, that may be sensitive to the residual odors or gases, NOT be present in the conditioned space during the start-up. In all cases, including the initial factory firing and testing, any of the gases will be under the acceptable level of concentration for human occupancy.
!
WARNING
Those sensitive to odors or gases from trace
amounts of residual oils should NOT be present
in the conditioned space during the start-up
of a gas-fired installation.
GAS PIPING is to be supported DIRECTLY AT CON­NECTION TO UNIT and must not be strained or bent and shall be supported by metal straps, blocks or hooks at intervals not to exceed that shown in the following table:
GAS PIPING SUPPORT
SIZE OF PIPE
1/2" 6' 3/4" or 1" 8' 1 1/4" or larger (horizontal) 10' 1 1/4" or larger (vertical) every floor level
Pipe joint compounds used on all gas piping connections shall be resistant to the action of petroleum gases.
An 1/8" NPT plugged tap is required immediately ahead of the unit gas control valve.
All piping connections shall be checked with a soap solution for gas leaks before operating the appliance.
INTERVALS (feet)
After electrical power is turned on, set unit controls for heating, and check for operation.
When checking burner operation, flames should be observed as blue with slight or no yellow tipping. There should be no sign of flames floating or lifting off or away from the main burners.
NOTE: In case emergency shut down is required, turn off the main manual gas shut-off valve and disconnect main electrical power to unit. These devices should be properly labeled by the installer.
!
WARNING
DO NOT USE OPEN FLAME OR OTHER SOURCE
OF IGNITION FOR LEAK TESTING.
When pressure testing the gas supply piping, the
furnace must be isolated or disconnected by
closing the individual manual shut-off valve from
the gas supply. Gas valves can be damaged if
subjected to more than 0.5 psig pressure.
9
INSTALLATION continued
GAS PIPING CAPACITIES
Nominal
Iron Pipe
Size, Inches
3/4" 278 115 79 55 1" 520 215 150 100 1 1/4" 1050 440 305 210 1 1/2" 1600 670 460 320 2 3050 1270 870 610 2 1/2" 4800 2000 1400 980
*At gas pressure of 0.5 PSIG or less and a pressure drop of 0.5 inches of water. Specific gravity = 0.60.
Gas Shut-off Valve*
*Gas piping field installed by others
Gas piping information is typical for one gas valve. For units with dual heat exchangers, duplicate gas piping to number two gas valve.
Max. Capacity of Gas Pipe in Cubic Ft. Per Hour*
LENGTH OF PIPE, FEET
10 50 100 200
Utility
Access
Union*
Heat
Exchanger
Gas
Valve
GAS PIPING ILLUSTRATION
In compliance with the ANSI Standard, installations exceeding 2-psi or less than 5-psi nominal require a tested and approved over-pressure protection device for use with the regulator.
For proper heater operation, pressure to the regulator MUST NOT BE greater than 5-psi.
CONDENSATE PIPING The RK equipment is furnished with drain connections and 'P' traps are furnished with the equipment in the same quantity as the drain connections. On the 'A', 'B' and 'C' cabinet models (2 - 25 ton) require one drain connection. On the 'D' cabinet models (26 - 60 ton) all 3 of the drain connections must be used and individually trapped to ensure a minimum amount of condensate will be present in the drain pans. Drainage of condensate directly onto the roof may be acceptable in certain areas, refer to applicable codes. If condensate is to drain directly onto the roof, a small drip pad should be placed below the drain to protect the roof from possible damage.
When condensate is piped into the building drainage system, the drain pipe should penetrate the roof exter­nal to the unit itself. The drain line should be pitched away from the unit at least 1/8 inch per foot. On longer runs, an air break should be used to ensure proper
drainage.
Drain pans in any air conditioning equipment, even when they have a built-in slope to the drain, will have moisture present and will require periodic cleaning to prevent any build up of algae of bacteria. Cleaning of the drain pans will also prevent any possible plugging of the drain lines and an overflow of the pan itself. All cleaning of the drain pans and inside of the equipment should be done by qualified personnel.
FOR PROPER UNIT OPERATION,
DRAIN TRAP MUST BE INSTALLED AS SHOWN.
USE ABS TYPE CEMENT TO JOIN THE CONNECTIONS.
2 to 25 ton Models Require (1) Connection.
26 to 60 ton Models Require (3) Connections.
Optional Gas Pressure Regulator
GAS PRESSURE REGULATOR & OVER-PRESSURE PROTECTION DEVICE On applications where gas service to the unit is greater than 10.5"w.c. and less than 2-psi, a gas pressure regu­lator must be installed. At supply pressures in excess of 2-psi and less than 5­psi, ANSI Z21.80 line regulator standard requires a means (an over-pressure protection device / OPD) to limit the downstream pressure to 2-psi maximum, in the event of regulator failure.
Typical 'P' trap
connection
10
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.
4. Push in gas control knob slightly and turn clockwise to "OFF". Do not force.
5. Close control access panel.
11
PERIODIC INSPECTION PROCEDURES
GAS HEATING UNITS
1. The flow of combustion and ventilating air shall not be blocked or otherwise obstructed in any way. The indoor blower, evaporator coil and filters should be inspected monthly.
2. Once each year, before unit is turned on for the heating season, a qualified serviceman should inspect all flue product carrying areas of the furnace and main burners for continued safe operation.
WARNING: At least once each year, a qualified ser­viceman should check out all of the items listed under the servicing and trouble shooting and maintenance section of this manual.
3. If the induced draft blower/motor assembly has to be replaced, care must be taken to provide an air­tight seal between the blower housing and the burner box. High temperature silicone sealant must be used to ensure a good seal.
4. GAS BURNERS THE BURNERS SHOULD NEVER REQUIRE CLEAN­ING. If cleaning becomes necessary, it indicates faulty operation of the unit. The cleaning should only be done by a qualified service agency and only after consultation with an AAON Service Representative. It is recommended that if the gas burners require cleaning, call an AAON Service Engineer at (918) 583-2266.
5. HEAT EXCHANGER The necessity for cleaning the exchanger could indicate faulty operation and should only be checked by a quali­fied service agency and only after they have discussed the problem with a Service Representative.
Heat Exchanger prior to installation in unit.
Note dimple construction.
Manifold
Burner Horn (typ)
Spark Rod
Flame Sensor
Burner Assembly
12
Combustion Motor
Flue Outlet
PERIODIC INSPECTION PROCEDURES Continued
COOLING
1.
2. Set thermostat in cooling mode and place the "fan" switch to on. Check blower for correct operating direction, amperage and voltage.
3. PACKAGED UNITS - Check compressor(s) operation. Check the amperage and compare to the nameplate data (check amperage load side of the com­pressor contactor).
4. DX COIL UNITS - If applicable check remote condenser as per the manufacturer's recommendations.
5. CHILLED WATER UNITS - Check remote chiller operations as per the manufacturers instructions. Check coolant flow valves for correct operation and settings.
HEATING • NATURAL GAS
1. Before turning on the main electrical power switch, be sure that all gas supply lines have been purged of air.
2. Turn gas valve to "ON" position.
3. Turn main electrical power switch to "ON" and set the thermostat to call for heat. The vent motor should operate. The control will automatically supply energy to the spark gap and the gas valve after the thermostat contact closes.
Main Power Switches are on and power is to the unit.
HEATING • ELECTRIC
1. Set thermostat in the heat mode.
2. Set thermostat to call for heat to engage all electric heat strips. Check blower for proper rotation and voltage.
3. Measure the amperage and voltage. Compare them to the nameplate data.
HEATING • STEAM OR HOT WATER
1. Set thermostat in the heat mode.
2. Observe supply blower for proper rotation and voltage.
3. Check boiler or hot water operations according to the manufacturers instructions.
4. Check control flow valves for correct operation and settings per manufacturers instructions.
NOTE: Should any of the above functions not perform properly, the following sequence of operations are given for the various heating and cooling modes with various control systems for an additional analysis in the case of any problems.
ELECTRIC, STEAM, HOT WATER, COOLING & CHILLED WATER UNITS
4. The sensing probe detects the presence of the flame. (Should no flame be detected in 10 seconds, the ignition system will recycle. If no flame is detected in 3 tries, the ignition system will lockout.)
5. Adjust thermostat to a low temperature setting to open contacts. The main gas flames should be extin­guished.
NOTE: The evaporator blower is controlled by the ignition system. In the fan "Auto" mode the blower comes on 45 seconds after flame is proved and goes off 120 seconds after the thermostat opens.
1. Indoor blower, coils and filters should be in­spected monthly.
2. Once each year, before unit is turned on for the heating season, a qualified serviceman should inspect the unit for proper operation.
3. Inspect all valves and steam traps in accor­dance with manufacturers recommendations.
WARNING: All of the items listed under the service, trouble shooting and maintenance section of this manual should be performed once a year.
!
CAUTION
Before leaving installation, a complete
operating cycle should be observed
to verify that all components
are functioning properly.
13
SERVICING, TROUBLE SHOOTING & MAINTENANCE
LUBRICATION All original blower motors and bearings are furnished with an orginal factory charge of lubrication. Some applications will require that bearings be re-lubricated periodically. The schedule will depend on the operating duty, temperature variations or other severe atmospheric conditions.
Electric shock hazard. Shut off all electrical power to unit to avoid shock hazard or injury from rotating parts.
!
W ARNING
Bearings should be re-lubricated when at normal oper­ating temperatures, but not running. Rotate the fan shaft by hand and add only enough grease to purge the seals. DO NOT OVERLUBRICATE.
Recommended greases are:
SHELL OIL - DOLIUM R CHEVRON OIL - SRI No. 2 TEXACO INC. - PREMIUM RB
SERVICE In the event the unit is not functioning correctly and a service company is required, a company with service technicians qualified and experienced in both gas, elec­tric heating and air conditioning be permitted to service the systems in order to keep warranties in effect. The service tech may call the factory if assistance is required.
BEFORE CALLING, HE SHOULD HAVE THE MODEL AND SERIAL NUMBER OF THE UNIT AVAILABLE FOR THE CUSTOMER SERVICE DEPARTMENT TO HELP ANSWER QUESTIONS REGARDING THE UNIT.
CLEANING Inspect unit interior at the beginning of each heating and cooling season and as operating conditions require.
COILS Evaporator coil(s) should be inspected and cleaned an­nually to ensure there is no obstruction to air flow.
Condenser coil(s) should be inspected monthly. Clean condenser coils annually and as required by location or outdoor air conditions.
CONDENSATE DRAIN Check and clean each year at start of cooling season.
BLOWER Inspect blower and blower section to keep free of dust or debris. TURN OFF POWER BEFORE ATTEMPTING TO CLEAN BLOWER WHEEL.
Typical slide-out blower section
AAON, Inc.
Phone: 918-583-2266 Fax: 918-382-6364
Customer Service Department
COMMON CAUSES OF REDUCED AIR FLOW
A. DIRTY FILTERS - Filters must be inspected and replaced on a regular basis. It is strongly recommended that the media be replaced monthly. Clean filters are your best insurance against premature system breakdown.
Do not permit the unit to be operated unless the filters are in place. Operation of the unit without filters will result in a clogged evaporator coil - a very expensive service job to correct.
B. OBSTRUCTION TO AIR FLOW - Supply and return air grilles must be kept clear so air can be freely discharged and drawn from the system.
14
FILTER INSTALLATION / REPLACEMENT
Open filter access door. Slide filters towards you and inspect. Replace old filters with the size indicated on each filter or as shown in the filter chart below. Be sure arrow points towards the blower. (Filters should be checked every 30 days and replaced or cleaned as necessary).
IT IS IMPORTANT TO KEEP COILS, BLOWER AND FILTERS CLEAN !
Slide-out filters
Optional Economizer
Optional R/A smoke detector location
NOTE: CHART REFLECTS STANDARD FACTORY SUPPLIED FILTERS AND SIZES.
CONTACT FACTORY FOR SPECIAL OPTIONAL FILTER PACKAGES.
FILTERS
6
2
UNIT SIZE
13 & 15
6
3
16 - 25
26 - 40 50 & 60
2 41012
FILTER SIZE
(Type)
16" x 20"
Throwaway (Qty)
16" x 20"
Pleated (Qty)
16" x 25"
Pleated (Qty)
20" x 25"
Pleated (Qty)
20" x 32"
Replaceable Media
24" x 40"
Replaceable Media
17" x 47"
Replaceable Media
FILTERS SHOULD BE REPLACED EVERY 30 DAYS OR AS REQUIRED.
2 - 5
4
2
6 & 7
4
2
8 & 10
15
SERVICING
TROUBLE
ELECTRIC HEATING
SYSTEM OFF
EVAPORATOR MOTOR WILL NOT RUN
BLOWER DOESN'T DELIVER AIR
BLOWER COMES ON, BUT LITTLE OR NO HEAT
SYSTEM OFF
POSSIBLE CAUSE
1. Check power at line side of contactor(s).
2. Thermostat not set for heating.
1. Overload relay tripped.
2. Heater Relay not energized.
3. Blower Contactor not energized.
4. Capacitor shorted or open (PSC motors only).
1. Blower running backwards.
2. Dirty air filters.
3. Dirty coils.
4. Duct obstruction.
5. Belts loose.
1. One or more heater contactors are open.
2. Limit switches are open.
3. Heater relay open.
4. Heat strips burned out.
GAS HEATING
1. Check power and gas supply.
2. Check thermostat switches and settings.
3. Check 24 volt power to ignition control.
BURNER WON'T COME ON
COMBUSTION AIR BLOWER WON'T RUN
BURNER GOES "OFF" ON HIGH LIMIT
IGNITION ON, BURNER WON'T LIGHT
1. Check for power at main gas valve.
2. Defective gas valve.
3. Loose or broken connection to gas valve.
4. Check limit controls for open.
5. Check continuity of differential pressure switch with motor turning. If open, replace differential pressure switch.
6. Defective ignition control.
1. Thermostat not calling for heat.
2. Relay not closing. (No power to motor)
3. Motor stuck or winding open.
4. Internal motor overload open.
1. Unit blower not coming on. (Check fan control)
2. Blower motor running backward.
3. Filters dirty.
4. Ducts obstructed or dampers closed.
5. Manifold gas pressure too high.
1. Hand valve "off" (turn to on)(main gas valve).
2. Gas off or very low pressure.
3. Check for power at main gas valve.
4. Check continuity of differential pressure switch with motor turning. If open, replace differential pressure switch.
5. Sparker sensor out of adjustment.
6. Main orifice blocked.
SUPPLY FAN BLOWER WON'T RUN
1. Defective Ignition Control.
2. See cooling trouble shooting page 19.
16
SERVICING Continued
TROUBLE
STEAM AND HOT WATER HEATING
SYSTEM OFF
BLOWER MOTOR WILL NOT RUN
BLOWER DOESN'T DELIVER AIR
BLOWER COMES ON, BUT LITTLE OR NO HEAT
COOLING PACKAGE and UNITS with REMOTE CONDENSERS
SYSTEM OFF
POSSIBLE CAUSE
1. Check power at line side of contactor(s).
2. Thermostat not set for heating.
1. Overload relay tripped.
2. Heater Relay not energized.
3. Blower Contactor not energized.
1. Blower running backwards.
2. Dirty air filters.
3. Dirty coils.
4. Duct obstruction.
5. Belts loose.
1. Check steam traps, valves, and steam or hot water supply in accordance with manufactures instructions.
2. Faulty thermostat.
1. Check power at lineside of contactor(s).
2. Thermostat not set for cooling.
3. High pressure control tripped.
4. Low pressure switch open (loss of charge).
CONDENSER FAN WILL NOT RUN
EVAPORATOR BLOWER WILL NOT RUN
COMPRESSOR SHORT CYCLES
FAN MOTOR RUNS HOT AND CUTS OUT
COMPRESSOR WILL NOT START
BLOWER DOES NOT DELIVER AIR
1. Overload thermal protector open in motor.
2. Motor run capacitor open or shorted.
3. Motor failed.
4. Fan or shaft stuck.
REFER TO MFG'S
INSTRUCTIONS
IF REMOTE
CONDENSER
1. Overload thermal protector open in motor.
2. Relay not closing.
3. Motor failed.
4. Capacitor shorted or open (PSC motors only).
5. Stuck shaft or blower wheel.
1. Check for low refrigeration charge.
2. Compressor overload setting.
3. Ambient temperature too low.
4. Filters dirty or air flow restricted.
REFER TO MFG'S
INSTRUCTIONS
IF REMOTE
CONDENSER
5. Evaporator blower not running.
1. Line voltage too high.
1. Line voltage too low.
2. Limit switches are open.
3. Overload or pressure control tripped.
REFER TO MFG'S
INSTRUCTIONS
IF REMOTE
CONDENSER
1. Blower running backwards.
2. Dirty filters.
3. Duct obstruction.
4. Belts loose.
17
SERVICING Continued
TROUBLE
POSSIBLE CAUSE
COOLING - CHILLED WATER
SYSTEM OFF
EVAPORATOR BLOWER WILL NOT RUN
FAN MOTOR RUNS HOT AND CUTS OUT
BLOWER DOES NOT DELIVER AIR
BLOWER COMES ON, BUT LITTLE OR NO COOLING
1. Check power at line side of contactor(s).
2. Thermostat not set for cooling.
1. Overload thermal protector open in motor.
2. Contactor not closing.
3. Motor failed.
1. Line voltage too high.
1. Blower running backwards.
2. Dirty air filters.
3. Duct obstruction.
4. Belt loose.
1. Check supply water and temperature.
2. Check water control valves operation.
3. Check water temperature rise entering and leaving unit to determine if adequate water is flowing.
ROOFTOP UNIT REPLACEMENT PARTS
Replacement parts for AAON equipment may be obtained from AAON. When ordering parts, always reference the unit model number, serial number and part number.
AAON, Inc.
Customer Service Department
2425 South Yukon Ave • Tulsa, Oklahoma 74107
Phone: 918-583-2266 • Fax: 918-382-6364
ALWAYS USE AAON SPECIFIED PARTS
18
I. GENERAL INFORMATION
SEQUENCE OF OPERATIONS
A. HEATING
1. Natural Gas When the thermostat calls for heating, W1 makes R to the heat relay (HR) all N.O. (Normally open) contacts close and all N.C. (normally closed) contacts open. The combustion motor starts and as the pressure decreases in the flue outlet box the ignition control is energized. The control sends 24 VAC to the main gas valve and high voltage to the ignitor. If a burner flame has been detected after 10 seconds, the spark is extinguished and the flame continues. If a flame has not been detected after 10 seconds, the gas valve closes, the spark ceases and the induced draft blower continues to purge the heat ex­changer. After 45 seconds of purge, the ignition system will attempt to light the burners again. Should no flame be detected after 3 tries, the ignition control locks out the system.
On a fault the gas train is shut down by a main limit located in the heat exchanger area or by an auxiliary limit mounted in the supply air fan housing.
2. LP (Propane) Gas The sequence for LP Gas is the same as above but upon non-proof of burner the gas train will enter a 100% lockout condition.
3. Electric When the thermostat calls for heat 'W1' makes 'R' to the heat relay 'HR'. All N.O. contacts close, and all N.C. contacts open. The heat relay makes 'R' to the first stage of electric heat.
On a fault condition the main limit located in the supply air or the auxiliary limit located in the supply air fan housing will remove power from all contactors.
If additional heating is required a second set of elements can be turned on by 'W2'. OPTIONAL - When available the electric heat can be sequenced to provide a constant discharge air tempera­ture.
B. COOLING
1. Packaged Units When the thermostat calls for cooling from the space, 'Y1' makes 'R' to 'CC1' through the LPS (low pressure switch), HPS (high pressure switch) and optional GOT (guaran­tee off timer). On units 26 through 60 tons 'CC3' is also made. If additional cooling is required 'CC2' and 'CC4' (on 26-60 ton) are made through their respective pressure switches and timers.
2. DX Only - Coil Units When the thermostat calls for cooling from the space, the condensing unit is energized (refer to manufacturers instructions for sequence of operation). The evaporator blower contactor is energized simultaneously with the condensing section.
3. Chilled Water Coil Units The blower contactor is energized to provide supply air on a signal from the space thermostat. All other controls are by others.
C. OPTIONAL ECONOMIZER When cooling is called for and the unit has the econo­mizer option installed, temperature switch ECS (or En­thalpy) allows the economizer operation when the out­side air reaches the required setpoint. (Some options use dry bulb sensing and some options use enthalpy sensing to determine the outside air (O.A.) condition). When the economizer is in operation 'Y1' controls the opening and closing of the dampers, 'Y2' is then able to control the compressors which 'Y1' normally controls. A modulating economizer is also available. The operation is the same as the standard economizer except that the motor modulates the damper position to maintain a preset mixed air temperature.
4. Steam or Hot Water This option adds a steam coil down stream of the cooling coil (if supplied). Connections and controls are provided by others.
19
SEQUENCE OF OPERATIONS Continued
II. VAV (Variable Air Volume) SYSTEMS
When a call for cooling is received, the controller board stages on compressors to maintain a field set supply air temperature. As different zones become satisfied their VAV boxes will close. (Boxes and controls are supplied and installed by others). This in turn causes the supply duct pressure to rise. The VAV controller board senses this increase in pressure and modulates the supply fan speed to maintain the required field set supply air pres­sure setpoint.
Normally VAV units are cooling only units. There are certain applications where electric or gas heat is used to provide morning warmup. When gas or electric heat is used for morning warmup the airflow will not be allowed to vary. The fan speed control will be disabled until a call for cooling is received, then the heating system will be locked out and VAV will be enabled.
III. POWER EXHAUST OPTIONS
When space over pressurization occurs, due to econo­mizer operation, a power exhaust will be utilized to provide relief. Two types of power exhaust control are available.
POWER EXHAUST w/ FULL MODULATING ECON.
In the unit "OFF" or in the minimum economizer posi­tion, the power exhaust is off. As the economizer begins to modulate open, an end switch (adjustable) closes which starts the power exhaust fan motor. The power exhaust operates until the economizer modulates below the end switch setting or the unit is shut off.
POWER EXHAUST w/ FULL MODULATING ECON. WITH BUILDING PRESSURE CONTROL
In the unit "OFF" or in the minimum economizer position the power exhaust is off. As the economizer begins to modulate open, an end switch (adjustable) closes which starts the power exhaust fan motor. The amount of exhaust air is controlled by a set of dampers in response to the unit mounted building static pressure controller. The power exhaust operates until the economizer modu­lates below the end switch setting or the unit is shut off. (NOTE: Static pressure sensing tubing is field supplied and installed).
A. Three position economizer, an On/Off power ex­haust will be utilized to exhaust when economizer is called for.
The end switch located on the economizer O. A. Damper section is field adjustable to allow for differences in building design. The switch engages and disengages the power exhaust motor(s) through a contactor. The end switch is in the 24 VAC circuit.
B. Full modulating economizer, a full modulating power exhaust will control the amount of actual ex­hausted air by means of a building sensing pressure control which opens or closes according to desired pres­sure in the space.
POWER EXHAUST w/ 3 POSITION ECON.
In the unit "OFF" or in the minimum economizer posi­tion, the power exhaust fan is off. When the unit goes to 100% outside air operation, the power exhaust fan motor starts and operates until the unit is shut off or the economizer goes back to minimum position.
20
COMPRESSOR CHECKOUT PROCEDURE
CONTROL PANEL NOT SET FOR COOLING
NO POWER TO
CONTACTOR
COMPRESSOR
WON'T RUN
POWER TO CONTACTOR
ALL 3 LEGS
POWER TO
UNIT
NO POWER TO
UNIT
CONTACTOR
OPEN
CONTACTOR
CLOSED
CHECK UNIT FUSES
AND WINDING
CHECK CIRCUIT BREAKER AT
POWER DISTRIBUTION PANEL
NO 24 VOLT POWER
TO HOLDING COIL
POWER TO HOLDING COIL
COMPRESSOR
HUMS
COMPRESSOR DOESN'T HUM
MOTOR WINDING OPEN
COMPRESSOR
NO POWER TO COMPRESSOR
HOLDING COIL BURNED OUT
STUCK COMPRESSOR
GROUNDED WINDING
POWER TO ALL 3 LEGS
COMPRESSOR LOW AMBIENT LOCKOUT OPEN
REVERSE LEADS
REPLACE
COMPRESSOR
MOTOR
WINDING OPEN
INTERNAL
OVERLOAD OPEN
THERMOSTAT NOT CALLING FOR COOLING
LO PRESSURE SWITCH OPEN
HI PRESSURE SWITCH OPEN
(TEMPERATURE OUTSIDE BELOW 55 DEG.)
TRANSFORMER OPEN
BROKEN OR LOOSE CONTROL
REPLACE CONTACTOR
COMPRESSOR RUNS
COMPRESSOR
DOESN'T RUN
REPLACE
COMPRESSOR
IF COMPRESSOR DOME IS HOT,
IT MAY BE LOCKED OUT ON
INTERNAL OVERLOAD.
WAIT FOR RESET, IT COULD TAKE
AS LONG AS 2 HOURS.
REPLACE LEADSBROKEN LEADS
REPLACE
COMPRESSOR
COMPRESSOR RUNS
COMPRESSOR CYCLES
OR
(Poor Cooling)
CHECK COMPRESSOR
ROTATIONAL
DIRECTION
HIGH HEAD PRESSURE
LOW HEAD
HIGH SUCTION
PRESSURE
LOW
SUCTION
PRESSURE
LOW AIR (CONDENSER)
OVERCHARGE OF REFRIGERANT
AIR IN SYSTEM
DIRTY CONDENSER COIL
DEFECTIVE COMPRESSOR VALVES
LOW AIR (EVAPORATOR)
LOW REFRIGERANT CHARGE
RESTRICTED FEEDER TUBE
BAD EXPANSION VALVE POWER ELEMENT
21
REPLACE COMPRESSOR
CHECK FILTERS,
OR DIRTY EVAPORATOR COIL
OR LOOSE BELT
IGNITION CONTROL CHECKOUT PROCEDURE
CHECK GAS SUPPLY FOR OBSTRUCTIONS
NO
OR CLOSED VALVES
IS GAS PRESSURE
PER MANUFACTURE'S
SPECIFICATIONS ?
SPARK IS PRESENT
BUT BURNER
WILL NOT LIGHT
NO SPARK
ON
CALL FOR HEAT
IS THERE 24v AT
IGNITION CONTROL ?
SHOULD BE CLOSED
CHECK FUSES
CHECK GAS VALVE WIRING FOR PROPER, TIGHT CONNECTIONS
IS 24v AVAILABLE
IGNITION CONTROL ?
IS IGNITION CONTROL
YES
NO
LOCKED OUT ?
CHECK TRANSFORMER AND / OR THERMOSTAT
FOR MALFUNCTION
REPLACE AS NECESSARY.
REPLACE OPEN LIMIT
YES
NO
AT
YES
NO
NO
YES
IS 24v AVAILABLE AT
GAS VALVE ?
YES
REPLACE
GAS VALVE
RESET BY TURNING
YES
NO
THE THERMOSTAT
THEN BACK TO HEAT
IS SPARK GAP 0.10 ?
IS SPARK GAP
LOCATED IN GAS
STREAM ?
IS FLAME SENSOR CABLE SECURELY
TO "OFF"
NO
CORRECTION NECESSARY
NO
ATTACHED ?
IS SENSOR
CERAMIC CRACKED
YES
YES
NO
OR BROKEN ?
IS ELECTRODE
CERAMIC CRACKED
OR BROKEN ?
REGAP TO 0.10
NO
YES
REPLACE
SENSOR
ASSEMBLY
YES
NO
NO
IS SENSOR
LOCATED IN
BURNER FLAME ?
YES
REPLACE ELECTRODE
IS HIGH VOLTAGE CABLE
FIRMLY ATTACHED AND
IN GOOD CONDITION ?
REPLACE CABLE
CHECK SENSOR
CABLE
CONTINUITY
REPLACE IGNITION
CONTROL
YES
NO
NOT O.K.
O.K.
REPLACE CONTROL
REPLACE CABLE
OR CORRECT CONNECTION
22
AAON , Inc.
FACTORY START-UP FORM
JOB NAME:
ADDRESS:
CITY, STATE:
START-UP CONTRACTOR:
START-UP CHECK LIST • GENERAL CHECKS
Inspect Unit For Damage:
Check All Fans For Free Movement:
Verify All Copper Tubing Is Isolated So It Doesn't Rub:
Check & Tighten All Electrical Terminals:
Tighten All Set Screws On Pulleys, Bearings & Fans:
Additional Checks and Notes:
EVAPORATOR BLOWER ASSEMBLY POWER EXHAUST ASSEMBLY
FAN(S) ALIGNMENT: BELT(S) TENSION:
CHECK FAN ROTATION: VAV CONTROLS:
NAMEPLATE AMPS:
MOTOR MAKE / AMPS
1
2
1 Ø
3 Ø
COOLING TEST • AMB. TEMP: °F
COMP. No.& AMPS
L1 L2 L3
1
2
3
4
5
6
7
8
1 Ø
3 Ø
Crankcase
Heater
Amps
Head
Pressure
PSIG
Pressure
Suction
PSIG
DATE:
MODEL No:
SERIAL No:
RTU No:
Verify All Air Filters Are Installed:
Inspect Economizer Damper Assembly:
Verify Voltage:
Verify Transformer Tap On 208/230v Equip.:
Open Outside Air Hood (if applicable):
FAN(S) ALIGNMENT: BELT(S) TENSION:
CHECK FAN ROTATION: AUTO AIR BALANCE:
NAMEPLATE AMPS:
MOTOR MAKE / AMPS
1
2
1 Ø
3 Ø
CONDENSER ASSEMBLY
NAMEPLATE AMPS:
MOTOR MAKE & AMPS
1
2
3
4
5
6
7
8
1 Ø
3 Ø
HEATING TEST • NATURAL GAS • LP GAS HEATING TEST • ELECTRIC •
NATURAL GAS PROPANE (L.P.)
VERIFY INLET GAS PRESSURE: W.C. (refer to data plate)
PURGE AIR FROM LINES:
VERIFY PILOT SPARK:
MANIFOLD PRESSURE
SINGLE STAGE: W.C.
1st STAGE LOW FIRE: W.C.
2nd STAGE HIGH FIRE: W.C.
1
212
313
414
515
616
717
818
919
10 20
HEATER No.& AMPS
MISC. CONTROLSECONOMIZER
TYPE: MOTOR TYPE:
WIRING: GEARS:
OPERATION:
ECON. CHG.OVER • TYPE: OPERATION:
START-UP TECHNICIAN: START-UP VERIFIED BY:
23
11
AAON
®
ROOFTOP
UNITS
RK SERIES
INSTALLATION
INSTRUCTION
MANUAL
AAON, Inc.
2425 South Yukon
Tulsa, Oklahoma 74107
ph: (918) 583-2266 • fax: (918) 583-6094
P83740 (rev. B • 7-2000)
24
Loading...