Aaon RL-070 Installation Manual

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Page 1

RL SERIES

Packaged Rooftop Units & Outdoor Air Handling Units

Installation, Operation,

& Maintenance

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.

WARNIN

FIRE OR EXPLOSION HAZARD

o Do not store gasoline or other flammable

o WHAT TO DO IF YOU SMELL GAS

o Startup and service must be performed by a

WARNIN

vapors and liquids in the vicinity of this or any other appliance

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

use any phone in your building.

 Leave the building immediately.  Immediately call your gas supplier from a

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

 If you cannot reach your gas supplier, call

the fire department.

Factory Trained Service Technician.

Page 2

Page 3

Table of Contents

Safety .............................................................................................................................................. 8

RL Series Feature String Nomenclature ....................................................................................... 13

General Information ...................................................................................................................... 22

Certification of Gas Heat Models ............................................................................................. 22

Certification of Steam or Hot Water Heat Models ................................................................... 22

Certification of Electric Heat Models ....................................................................................... 22

Certification of Cooling Models ............................................................................................... 22

Codes and Ordinances .............................................................................................................. 22

Receiving Unit .......................................................................................................................... 23

Storage ...................................................................................................................................... 23

Packaged Direct Expansion (DX) Units ................................................................................... 23

Gas or Electric Heating ............................................................................................................. 24

Wiring Diagrams ....................................................................................................................... 24

Condensate Drain Pan ............................................................................................................... 24

Installation..................................................................................................................................... 25

Locating Units ........................................................................................................................... 25

Curb Installation ....................................................................................................................... 25

Duct Connection ....................................................................................................................... 26

Lifting the Unit ......................................................................................................................... 27

Reassembling Split Units .......................................................................................................... 29

Electrical Connection of Split Units ......................................................................................... 30

Outside Air Rain Hood ............................................................................................................. 30

End Flashing Installation .......................................................................................................... 30

Vestibule Exhaust Fan .............................................................................................................. 31

Electrical ................................................................................................................................... 31

Gas Heating ............................................................................................................................... 33

Piping Sizing Example .......................................................................................................... 33

Inlet and Manifold Pressures ................................................................................................ 33

Gas Pressure Regulator & Overpressure Protection Device ............................................... 34

Piping Supports ..................................................................................................................... 34

Additional Gas Piping Considerations ................................................................................. 34

Leak Testing .......................................................................................................................... 34

Rain Hoods ............................................................................................................................ 35

Condensate Drain Piping .......................................................................................................... 36

Draw-Through Coils ................................................................................................................. 37

Hot Water/Steam Heating and Chilled Water Cooling Coils ................................................... 38

Evaporative-Cooled Condenser ................................................................................................ 38

Energy Recovery Units ............................................................................................................. 40

Startup ........................................................................................................................................... 47

Supply, Return, and Exhaust Backward Curved Fans .............................................................. 47

Airflow Adjustment ................................................................................................................ 47

Power Return and Exhaust Axial Flow Fans ............................................................................ 48

Adjustable Fan Cycling Switch Procedure ............................................................................... 51

RL Prop Assembly .................................................................................................................... 53

Spring Isolator Adjustment ....................................................................................................... 53

Page 4

Back Draft Damper Setup ......................................................................................................... 54

Filters ........................................................................................................................................ 55

Cartridge Filter Installation ....................................................................................................... 55

Adjusting Refrigerant Charge ................................................................................................... 55

Before Charging .................................................................................................................... 55

Checking Liquid Sub-Cooling ............................................................................................... 56

Checking Evaporator Superheat ........................................................................................... 56

Adjusting Sub-cooling and Superheat Temperatures ........................................................... 57

Refrigerant Filter Driers ............................................................................................................ 57

Indirect Gas Heat Startup .......................................................................................................... 59

Access Doors ............................................................................................................................ 60

Operation....................................................................................................................................... 61

Indirect Gas Heater Operation .................................................................................................. 61

Electric Heating Operation ....................................................................................................... 61

Steam or Hot Water Preheating and Heating Operation ........................................................... 61

Packaged DX Cooling Operation ............................................................................................. 61

Chilled Water or Non-Compressorized DX Cooling Operation ............................................... 61

Maintenance .................................................................................................................................. 62

Gas Heating ............................................................................................................................... 62

Direct Fired Gas Heat ............................................................................................................... 62

Ignition Sequence of Operations: ............................................................................................. 63

Safeties: ..................................................................................................................................... 63

Initial Start-up Procedure: ......................................................................................................... 64

First Firing or Restart after Extended Shut-down: .................................................................... 64

General Maintenance Instructions: ........................................................................................... 64

Inspection and Maintenance of Gas Ports: ............................................................................... 65

DX Cooling ............................................................................................................................... 65

Condensate Drain Pans ............................................................................................................. 66

Supply Fans ............................................................................................................................... 66

Lubrication ............................................................................................................................ 66

Phase and Brownout Protection Module .................................................................................. 66

Filter Replacement .................................................................................................................... 69

Evaporative-Cooled Condenser ................................................................................................ 69

Severe Service ........................................................................................................................... 69

Safety ........................................................................................................................................ 69

Performance .............................................................................................................................. 70

Warranties ................................................................................................................................. 70

Condenser Tube Inspection ...................................................................................................... 70

Freeze Protection ...................................................................................................................... 70

Recirculating Water System ..................................................................................................... 70

Pre Start-Up .............................................................................................................................. 70

Cleanliness ................................................................................................................................ 71

Storage ...................................................................................................................................... 71

Pump Operation ........................................................................................................................ 71

Running ..................................................................................................................................... 71

Condenser Fan Motors .............................................................................................................. 71

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Water Makeup Valve ................................................................................................................ 71

Water Treatment System .......................................................................................................... 72

Sequence of Operations ............................................................................................................ 73

Pump Maintenance ................................................................................................................... 73

Fan Motor Maintenance ............................................................................................................ 74

Access Doors ............................................................................................................................ 74

Bearings - Lubrication .............................................................................................................. 74

Recommended Monthly Inspection .......................................................................................... 74

Mist Eliminators ....................................................................................................................... 74

Air Inlet ..................................................................................................................................... 74

Stainless Steel Base Pan ........................................................................................................... 74

Propeller Fans and Motors ........................................................................................................ 74

Recommended Annual Inspection ............................................................................................ 74

Cleaning .................................................................................................................................... 74

Water Quality ............................................................................................................................ 75

Mechanical Cleaning ................................................................................................................ 76

Air-Cooled Condenser .............................................................................................................. 76

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

Replacement Parts ......................................................................................................................... 89

Warranty, Service and Parts Department ...................................................................................... 89

RL Series Startup Form ................................................................................................................ 91

Maintenance Log .......................................................................................................................... 96

Literature Change History............................................................................................................. 97

R10091 · Rev. B · 160425

Page 6

Index of Tables and Figures

Tables

Table 1 - Unit Clearances ........................................................................................................................... 25

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

Table 3 - Gas Piping Connections............................................................................................................... 33

Table 4 - Natural Gas Maximum Piping Capacities (ft

Table 5 - Piping Support Intervals .............................................................................................................. 34

Table 6 - Draw-Through Drain Trap Dimensions....................................................................................... 37

Table 7 - Blow-Through Drain Trap Dimensions ....................................................................................... 38

Table 8 - Plenum Fan Set Screw Specifications ......................................................................................... 48

Table 9 - Return/Exhaust Fan Pin Location in the Bushing Mount ............................................................ 50

Table 10 - Return/Exhaust Fan Pin Location in the Grooves ..................................................................... 50

Table 11 - Prop Assembly Bushing Torque Specifications ........................................................................ 53

Table 12 - Acceptable Sub-Cooling and Superheat Temperatures ............................................................. 57

Table 13 - Filter Drier Maximum Pressure Drop ........................................................................................ 57

Table 14 - R-410A Refrigerant Temperature-Pressure Chart ..................................................................... 58

Table 15 - Recirculating Water Quality Guidelines .................................................................................... 75

Table 16 - RL-045, RL-060, and RL-070 Standard Filters ......................................................................... 78

Table 17 - RL-045, RL-060, and RL-070 Standard Filters ......................................................................... 78

Table 18 - RL-075, RL-090, and RL-095 Standard Filters ......................................................................... 78

Table 19 - RL-075, RL-090, and RL-095 Standard Filters ......................................................................... 79

Table 20 - RL-100, RL-110, RL-120, RL-125, and RL-135 Standard Filters ............................................ 79

Table 21 - RL-100, RL-110, RL-120, RL-125, and RL-135 Standard Filters ............................................ 79

Table 22 - RL-134, RL-150, RL-155, and RL-170 Standard Filters .......................................................... 79

Table 23 - RL-134, RL-150, RL-155, and RL-170 Standard Filters .......................................................... 79

Table 24 - RL-180, RL-181, RL-190, RL-210, RL-230, and RL-240 Standard Filters .............................. 80

Table 25 - RL-180, RL-181, RL-190, RL-210, RL-230, and RL-240 Standard Filters .............................. 80

Table 26 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters ........................................... 80

Table 27 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters ........................................... 81

Table 28 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters .................................................... 82

Table 29 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters .................................................... 82

Table 30 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters ........................................... 83

Table 31 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters ........................................... 84

Table 32 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters .................................................... 85

Table 33 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters .................................................... 86

Table 34 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters ........................................... 87

Table 35 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters .................................................... 87

Table 36 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters ........................................... 88

Table 37 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters .................................................... 88

Table 38 - RL-045 to RL-125 and RL-135 Energy Recovery Wheel Filters .............................................. 89

Table 39 - RL-134 and RL-150 to RL-240 Energy Recovery Wheel Filters .............................................. 89

/hr) ........................................................................ 33

Page 7

Figures

Figure 1 - RL Series Unit Orientation ......................................................................................................... 25

Figure 2 - Curb Mounting ........................................................................................................................... 26

Figure 3 - Curb Detail ................................................................................................................................. 26

Figure 4 - Curb Mounting with Dimensions ............................................................................................... 27

Figure 5 - Steel Mounting Rail with Dimensions ....................................................................................... 27

Figure 6 - Marked Lifting Points ................................................................................................................ 27

Figure 7 - Unit Base and Sides.................................................................................................................... 29

Figure 8 - Unit Roof Flange Splice Detail .................................................................................................. 29

Figure 9 - Air Hood Shown in the Open Position ....................................................................................... 30

Figure 10 - Factory Supplied End Flashings ............................................................................................... 31

Figure 11 - Vestibule Exhaust Fan .............................................................................................................. 31

Figure 12 - Terminal Block ......................................................................................................................... 32

Figure 13 - Gas Heater Rain Hood .............................................................................................................. 35

Figure 14 - Gas Heater Rain Hood Screws ................................................................................................. 36

Figure 15 - Draw-Through Drain Trap ....................................................................................................... 37

Figure 16 - Blow-Through Drain Trap ....................................................................................................... 37

Figure 17 - Evaporative-Cooled Cond. Section, Including Field Water Connections and Base Cutout ..... 39

Figure 18 - Air Volume Band ..................................................................................................................... 47

Figure 19 - Air Volume Band Tab Locations ............................................................................................. 47

Figure 20 - Securing Air Volume Band Ends ............................................................................................. 48

Figure 21 - Plenum Fan Gap Tolerances .................................................................................................... 48

Figure 22 - Fan with the HUB on the top and RET on the bottom. ............................................................ 49

Figure 23 - Fan Bushing Mount Location ................................................................................................... 49

Figure 24 - RET shown with pin in groove 4 ............................................................................................. 49

Figure 25 - HUB and RET .......................................................................................................................... 49

Figure 26 - Rear Isolator Detail .................................................................................................................. 54

Figure 27 - Fan Assembly Detail ................................................................................................................ 54

Figure 28 - Blower Assembly ..................................................................................................................... 54

Figure 29 - Closed Back Draft Damper ...................................................................................................... 55

Figure 30 - Open Back Draft Damper ......................................................................................................... 55

Figure 31 - Top Clip and Side Spring Fastener Securing Filters in Place .................................................. 55

Figure 32 - Replaceable Core Filter/Drier .................................................................................................. 57

Figure 33 - Lockable Door Handles ............................................................................................................ 60

Figure 34 - Typical Factory Mutual (FM) Gas Piping Schematic for a Direct Fired Heater ...................... 63

Figure 35 - Removing Piping Scale with Pin Vise ..................................................................................... 65

Figure 36 - Proper Unit Location ................................................................................................................ 69

Figure 37 - Improper Unit Locations .......................................................................................................... 70

Figure 38 - Water Makeup Valve ............................................................................................................... 72

Page 8

Safety

CAUTIO

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

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

Electric shock hazard. Before Electric shock hazard. Shut off all

servicing, shut off all electrical power electrical power to the unit to avoid

to the unit, including remote shock hazard or injury from rotating

disconnects, to avoid shock hazard parts.

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

building.

open flame.

and check all gas connections and shut off valves.

WARNIN

Page 9

CAUTIO

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.

WARNING

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

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

WARNING

ROTATING COMPONENTS

stopped rotating.

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.

WARNIN

GROUNDING REQUIRED

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

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.

Page 10

CAUTIO

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

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

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

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.

WARNING

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.

WARNIN

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.

WARNIN

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

WARNIN

damage, injury or death.

Page 11

CAUTIO

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.

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.

Cleaning the cooling tower or condenser water loop with harsh chemicals such as hydrochloric acid (muriatic acid), chlorine or other chlorides, can damage the refrigerant-to-water heat exchanger. Care should be taken to avoid allowing chemicals to enter the refrigerant-to-water heat exchanger. 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.

OPEN LOOP APPLICATIONS

WARNING

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.

To prevent motor overheating compressors must cycle off for a minimum of 5 minutes.

To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes.

The cycle rate must not exceed 6 startsper hour.

1. Startup and service must be performed

by a Factory Trained Service Technician.

2. Use only with type of the gas approved

for the furnace. Refer to the furnace rating plate.

3. The unit is for outdoor use only. See

General Information section for more information.

WATER FREEZING

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME

5 MINUTE MINIMUM ON TIME

WARNIN

Page 12

4. 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.

5. Always install and operate furnace

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

6. The supply and return air ducts shall 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.

7. Clean furnace, duct, and components

upon completion of the construction setup. Verify furnace operating conditions including input rate, temperature rise, and ESP.

8. 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.

9. READ THE ENTIRE INSTALLATION,

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

10. Keep this manual and all literature

safeguarded near or on the unit.

Page 13

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B3

L–100–3–0–B

BASE MODEL

SERIES AND GENERATION

UNIT SIZE

045 = 45 Nominal Tons 060 = 60 Nominal Tons 070 = 70 Nominal Tons 075 = 75 Nominal Tons 090 = 90 Nominal Tons 095 = 95 Nominal Tons 100 = 100 Nominal Tons 110 = 110 Nominal Tons 120 = 120 Nominal Tons 125 = 125 Nominal Tons 134 = 134 Nominal Tons 135 = 135 Nominal Tons 150 = 150 Nominal Tons 155 = 155 Nominal Tons 170 = 170 Nominal Tons 180 = 180 Nominal Tons 181 = 181 Nominal Tons 190 = 190 Nominal Tons 210 = 210 Nominal Tons 230 = 230 Nominal Tons 240 = 240 Nominal Tons

VOLTAGE

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

INTERIOR PROTECTION

0 = Standard A = Interior Corrosion Protection

06–3 5 2 : BEBE–D0 0–QFY–P0

1A1B1C1D23

5A5B5C6A6B6C78910111213

0DBB000–00–0BB00AB0B

–

14A14B1516171819202122

Model Option A: COOLING

A1: COOLING STYLE

B = Blow-Through, R-410A, Dual Circuited C = Draw-Through, R-410A, Dual Circuited D = Blow Through - R-134a Variable Capacity OilFree Magnetic Bearing Centrifugal Compressors E = Draw Through - R-134a Variable Capacity OilFree Magnetic Bearing Centrifugal Compressors F = Blow-Through AHU w/ Vestibule G = Draw-Through AHU w/ Vestibule H = Blow-Through AHU w/ Front Control Panel J = Draw-Through AHU w/ Front Control Panel M = Blow-Through AHU w/ End Control Panel N = Draw-Through AHU w/ End Control Panel R = Blow-Through, R-410A, Independ Circuited S = Draw-Through, R-410A, Independ Circuited 7 = Blow-Through, R410A VFD Compatible Compressors 8 = Draw-Through, R410A VFD Compatible Compressors

A2: COOLING CONFIGURATION

0 = No Cooling A = Air-Cooled Cond, 4 Row High CFM Evap B = Air-Cooled Cond, 6 Row High CFM Evap C = Air-Cooled Cond, 4 Row Low CFM Evap D = Air-Cooled Cond, 6 Row Low CFM Evap E = Evap-Cooled Cond, 4 Row High CFM Evap F = Evap-Cooled Cond, 6 Row High CFM Evap G = Evap-Cooled Cond, 4 Row Low CFM Evap H = Evap-Cooled Cond, 6 Row Low CFM Evap J = Water-Cooled Cond, 4 Row High CFM Evap K = Water-Cooled Cond, 6 Row High CFM Evap L = Water-Cooled Cond, 4 Row Low CFM Evap M = Water-Cooled Cond, 6 Row Low CFM Evap U = Chilled Water, 4 Row High CFM V = Chilled Water, 4 Row Low CFM W = Chilled Water, 6 Row High CFM Y = Chilled Water, 6 Row Low CFM Z = Chilled Water, 8 Row High CFM 1 = Chilled Water, 8 Row Low CFM 2 = Non-Compressorized, 4 Row High CFM Evap 3 = Non-Compressorized, 4 Row Low CFM Evap 4 = Non-Compressorized, 6 Row High CFM Evap 5 = Non-Compressorized, 6 Row Low CFM Evap

Page 14

RL Series Feature String Nomenclature

352

:BEBE

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE

–

Model Option A: COOLING

A3: COOLING COATING

0 = Standard 1 = Polymer E-Coated, Cooling Coil Only 2 = SS Coil Casing, Cooling Coil Only 6 = Polymer E-Coated, Evap and Cond B = Polymer E-Coated, Cond Only

A4: COOLING STAGING

0 = No Cooling 2 = 2 Stage 3 = 3 Stage 4 = 4 Stage 6 = 6 Stage 8 = 8 Stage A = Single Serp, 8 FPI B = Half Serp, 8 FPI H = 2 Stage, Shell & Tube J = 3 Stage, Shell & Tube K = 4 Stage, Shell & Tube L = 6 Stage, Shell & Tube M = 8 Stage, Shell & Tube N = Single Serp, 10 FPI P = Half Serp, 10 FPI Q = Single Serp, 12 FPI R = Half Serp, 12 FPI Z = All Compressors Variable Speed

Model Option B: HEATING

B1: HEATING STYLE

0 = No Heat 1 = Electric Heat 2 = Natural Gas Single Rack 3 = Natural Gas Double Rack 4 = High Altitude Natural Gas Single Rack 5 = High Altitude Natural Gas Double Rack A = Steam, Standard B = Steam, Polymer E-coated C = Steam Distributing, Standard D = Steam Distributing, Polymer E-Coated E = Hot Water, Standard F = Hot Water, Polymer E-Coated

5A5B5C6A6B6C78910111213

D0 0–QFY–P0

–

B2: HEATING DESIGNATION

0 = No Heat 1 = Heat 1 2 = Heat 2 3 = Heat 3 4 = Heat 4 5 = Heat 5 6 = Heat 6 7 = Heat 7 8 = Heat 8 A = 1 Row Coil A B = 1 Row Coil B C = 1 Row Coil C D = 1 Row Coil D E = 2 Row Coil A F = 2 Row Coil B G = 2 Row Coil C H = 2 Row Coil D

B3: HEATING STAGING

0 = No Heat 1 = 2 Stage 2 = 4 Stage 3 = 8 Stage 4 = 12 Stage H = Single Serpentine J = Half Serpentine

14A14B1516171819202122

0DBB000–00–0BB00AB0B

–

Page 15

RL Series Feature String Nomenclature

EBE

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–352 :

Feature 1: RETURN/OUTSIDE AIR

1A: RETURN/OUTSIDE AIR SECTION

0 = Standard, Manual Outside Air A = Economizer B = Econ with Power Exhaust C = Econ with Power Return D = Energy Recovery Wheel (Total), Small E = ERW (Total), Medium F = ERW (Total), Large G = ERW (Total), Extra Large H = ERW (Sens), Small J = ERW (Sens), Medium K = ERW (Sens), Large L = ERW (Sens), Extra Large M = 100% Outside Air (No Return Air) N = Motorized Outside Air (w/ Return Air) P = Motorized Outside Air (No Return Air) Q = Power Return + ERW (Total) Small R = Power Return + ERW (Total), Medium S = Power Return + ERW (Total), Large T = Power Return + ERW (Total), Extra Large U = Power Return + ERW (Sens), Small V = Power Return + ERW (Sens), Medium W = Power Return + ERW (Sens), Large Y = Power Return + ERW (Sens), Extra Large Z = Power Return, Plenum

1B: RETURN AIR BLOWER CONFIGURATION

0 = None A = 1 Blower, Standard Eff B = 2 Blowers, Standard Eff C = 1 Blower, Premium Eff D = 2 Blowers, Premium Eff E = 1 Blower, Premium Eff, 1 VFD F = 2 Blowers, Premium Eff, 1 VFD G = 2 Blowers, Premium Eff, 2 VFDs H = 1 Blower, Premium Eff, 1 Field Installed VFD J = 2 Blowers, Premium Eff, 1 Field Installed VFD K = 2 Blowers, Premium Eff, 2 Field Installed VFDs L = 1 Blower, Premium Eff, 1 VFD w/ Bypass M = 2 Blowers, Premium Eff, 1 VFD w/ Bypass N = 2 Blowers, Premium Eff, 2 VFDs w/ Bypass

D0 0–QFY–P0

–

5A5B5C6A6B6C78910111213

0DBB000–00–0BB00AB0B

–

1C: RETURN AIR BLOWER

0 = None A = 36” Axial Flow, 6 Blades B = 42” Axial Flow, 9 Blades C = 42” Axial Flow, 12 Blades D = 48” Axial Flow, 16 Blades E = 27” Backward Curved F = 30” Backward Curved G = 33” Backward Curved H = 36.5” Backward Curved J = 42.5” Backward Curved

1D: RETURN AIR MOTOR

0 = None D = 3 hp, 1170 rpm E = 5 hp, 1170 rpm F = 7.5 hp, 1170 rpm G = 10 hp, 1170 rpm H = 15 hp, 1170 rpm J = 20 hp, 1170 rpm K = 25 hp, 1170 rpm L = 30 hp, 1170 rpm M = 40 hp, 1170 rpm N = 50 hp, 1170 rpm T = 3 hp, 1760 rpm U = 5 hp, 1760 rpm V = 7.5 hp, 1760 rpm W = 10 hp, 1760 rpm Y = 15 hp, 1760 rpm Z = 20 hp, 1760 rpm 1 = 25 hp, 1760 rpm 2 = 30 hp, 1760 rpm 3 = 40 hp, 1760 rpm 4= 50 hp, 1760 rpm

14A14B1516171819202122

Page 16

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–3 5 2 : BEBE

Feature 2: OUTSIDE AIR CONTROL

0 = None A = 3 Position Actuator, Sensible B = 3 Position Actuator, Enthalpy C = Full Mod Actuator, Sensible D = Full Mod Actuator, Enthalpy E = DDC Actuator F = Constant Volume OA G = Constant Volume OA, 3 Pos Act, Sensible H = Constant Volume OA, 3 Pos Act, Enthalpy J = Constant Volume OA, Full Mod Act, Sensible K = Constant Volume OA, Full Mod Act, Enthalpy L = Constant Volume OA, DDC Act M = CO N = CO P = CO Q = CO R = CO

Override, 3 Pos Actuator, Sensible

Override, 3 Pos Actuator, Enthalpy

Override, Full Mod Actuator, Sensible

Override, Full Mod Actuator, Enthalpy

Override, DDC Actuator

S = Dual Min Pos, Full Mod Act, Sensible T = Dual Min Pos, Full Mod Act, Enthalpy U = 2 Position Actuator

Feature 3: DISCHARGE LOCATIONS

0 = Bottom Discharge A = Front Discharge B = Back Discharge C = Top Discharge D = End Discharge

Feature 4: RETURN LOCATIONS

0 = Bottom Return A = End Return B = Front Return High CFM w/o ERW or PE C = Front Return Low CFM w/o ERW or PE D = Back Return High CFM w/o ERW or PE E = Back Return Low CFM w/o ERW or PE F = Front Return High CFM w/ ERW or PE G = Front Return Low CFM w/ ERW or PE H = Back Return High CFM w/ ERW or PE J = Back Return Low CFM w/ ERW or PE K = Bottom Return w/ RA Bypass, 2’ Box L = Bottom Return w/ RA Bypass, 4’ Box M=Bottom Return High CFM Or w/o RA on 100% OA N=End Return High CFM w/o ERW or PE

–

D0 0

5A5B5C6A6B6C78910111213

–

FY–P0

0DBB000–00–0BB00AB0B

–

14A14B1516171819202122

Feature 5: SUPPLY AIR BLOWER

5A: SUPPLY AIR BLOWER CONFIGURATION

0 = 1 Blower, Standard Eff A = 2 Blowers, Standard Eff B = 3 Blowers, Standard Eff C = 4 Blowers, Standard Eff D = 1 Blower, Prem Eff E = 2 Blowers, Prem Eff F = 3 Blowers, Prem Eff G = 4 Blowers, Prem Eff H = 1 Blower, Prem Eff, w/ 1 VFD J = 2 Blowers, Prem Eff, w/ 1 VFD K = 2 Blowers, Prem Eff, w 2 VFDs L = 3 Blowers, Prem Eff, w/ 1 VFD M = 3 Blowers, Prem Eff, w/ 3 VFDs N = 4 Blowers, Prem Eff, w/ 1 VFD Q = 4 Blowers, Prem Eff, w/ 4 VFDs R = 4 Blowers, Prem Eff, w/ 2 VFDs S = 1 Blower, Prem Eff, w/ 1 Field Installed VFD T = 2 Blowers, Prem Eff, w/ 1 Field Installed VFD U = 2 Blowers, Prem Eff, w/ 2 Field Installed VFDs V = 3 Blowers, Prem Eff, w/ 1 Field Installed VFD W = 3 Blowers, Prem Eff, w/ 3 Field Installed VFDs Y = 4 Blowers, Prem Eff, w/ 1 Field Installed VFD Z = 4 Blowers, Prem Eff, w/ 4 Field Installed VFDs 1 = 4 Blowers, Prem Eff, w/ 2 Field Installed VFDs 2 = 1 Blower, Prem Eff, w/ 1 VFD w/ Bypass 3 = 2 Blowers, Prem Eff, w/ 1 VFD w/ Bypass 4 = 2 Blowers, Prem Eff, w 2 VFDs w/ Bypass 5 = 3 Blowers, Prem Eff, w/ 1 VFD w/ Bypass 6 = 3 Blowers, Prem Eff, w/ 3 VFDs w/ Bypass 7 = 4 Blowers, Prem Eff, w/ 1 VFD w/ Bypass 8 = 4 Blowers, Prem Eff, w/ 4 VFDs w/ Bypass 9 = 4 Blowers, Prem Eff, w/ 2 VFDs w/ Bypass

Page 17

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–352 :BEBE–D00–Q

Feature 5: SUPPLY AIR BLOWER

5B: SUPPLY AIR BLOWER

A = 27” Backward Curved B = 30” Backward Curved C = 33” Backward Curved D = 36.5” Backward Curved E = 42.5” Backward Curved F = 27” Backward Curved w/ Damper G = 30” Backward Curved w/ Damper H = 33” Backward Curved w/ Damper J = 36.5” Backward Curved w/ Damper K = 42.5” Backward Curved w/ Damper

5C: SUPPLY AIR MOTOR

D = 3 hp, 1170 rpm E = 5 hp, 1170 rpm F = 7.5 hp, 1170 rpm G = 10 hp, 1170 rpm H = 15 hp, 1170 rpm J = 20 hp, 1170 rpm K = 25 hp, 1170 rpm L = 30 hp, 1170 rpm M = 40 hp, 1170 rpm N = 50 hp, 1170 rpm T = 3 hp, 1760 rpm U = 5 hp, 1760 rpm V = 7.5 hp, 1760 rpm W = 10 hp, 1760 rpm Y = 15 hp, 1760 rpm Z = 20 hp, 1760 rpm 1 = 25 hp, 1760 rpm 2 = 30 hp, 1760 rpm 3 = 40 hp, 1760 rpm 4 = 50 hp, 1760 rpm

5A5B5C6A6B6C78910111213

–

0DBB000–00–0BB00AB0B

–

14A

14B1516171819202122

Feature 6: FILTERS

6A: PRE FILTER TYPE

0 = 2” Pleated, 30% Eff, Std Pos A = 4” Pleated, 30% Eff, Std Pos B = 2” Perm Filter with Replaceable Media, Std Pos C = 2” Ple Pre, 30% Eff/12” Cart, 65% Eff, Std Pos D = 2” Ple Pre, 30% Eff/12” Cart, 85% Eff, Std Pos E = 2” Ple Pre, 30% Eff/12” Cart, 95% Eff, Std Pos F = 4” Ple Pre, 30% Eff/12” Cart, 65% Eff, Std Pos G = 4” Ple Pre, 30% Eff/12” Cart, 85% Eff, Std Pos H = 4” Ple Pre, 30% Eff/12” Cart, 95% Eff, Std Pos J = 2” Ple Pre, 30% Eff/30” Bag, 85% Eff, Std Pos K = 2” Ple Pre, 30% Eff/30” Bag, 95% Eff, Std Pos L = 4” Ple Pre, 30% Eff/30” Bag, 85% Eff, Std Pos M = 4” Ple Pre, 30% Eff/30” Bag, 95% Eff, Std Pos N = 2” Pleated, 30% Eff, Pre Pos P = 4” Pleated, 30% Eff, Pre Pos Q = 2” Perm Filter with Replaceable Media, Pre Pos R = 2” Ple Pre, 30% Eff/12” Cart, 65% Eff, Pre Pos S = 2” Ple Pre, 30% Eff/12” Cart, 85% Eff, Pre Pos T = 2” Ple Pre, 30% Eff/12” Cart, 95% Eff, Pre Pos U = 4” Ple Pre, 30% Eff/12” Cart, 65% Eff, Pre Pos V = 4” Ple Pre, 30% Eff/12” Cart, 85% Eff, Pre Pos W = 4” Ple Pre, 30% Eff/12” Cart, 95% Eff, Pre Pos Y = 2” Ple Pre, 30% Eff/30” Bag, 85% Eff, Pre Pos Z = 2” Ple Pre, 30% Eff/30” Bag, 95% Eff, Pre Pos 1 = 4” Ple Pre, 30% Eff/30” Bag, 85% Eff, Pre Pos 2 = 4” Ple Pre, 30% Eff/30” Bag, 95% Eff, Pre Pos

6B: FINAL FILTER TYPE

0 = None A = 12” Cart, 85% Eff, Filter Box A B = 12” Cart, 85% Eff, Filter Box B C = 12” Cart, 85% Eff, Filter Box C D = 12” Cart, 95% Eff, Filter Box A E = 12” Cart, 95% Eff, Filter Box B F = 12” Cart, 95% Eff, Filter Box C G = 30” Bag, 85% Eff, Filter Box A H = 30” Bag, 85% Eff, Filter Box B J = 30” Bag, 85% Eff, Filter Box C K = 30” Bag, 95% Eff, Filter Box A L = 30” Bag, 95% Eff, Filter Box B M = 30” Bag, 95% Eff, Filter Box C N = Pre Filter Box A - No Final Filter P = Pre Filter Box B - No Final Filter Q = Pre Filter Box C - No Final Filter

Page 18

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–352 :BEBE–D00–QFY–P0

Feature 6: FILTERS

6C: FILTER OPTIONS

0 = Standard - None A = Clogged Filter Switch, Pre Filters B = Clogged Filter Switch, Final Filters C = Magnehelic Gauge, Pre Filters D = Magnehelic Gauge, Final Filters E = Option A + B F = Option A + C G = Option A + D H = Option B + C J = Option B + D K = Option A + B + C L = Option A + B + D M = Option A + C + D N = Option B + C + D P = Option A + B + C + D

Feature 7: REFRIGERATION CONTROL

0 = Standard A = 5 Min TDR Off B = 20 Sec TDR C = 115V Outlet, Field Wired D = 115V Outlet, Factory Wired E = Option A + B F = Option A + C G = Option A + D H = Option A + B + C J = Option A + B + D K = Option B + C L = Option B + D

Feature 8: REFRIGERATION OPTIONS

0 = Standard A = Hot Gas Bypass Lead Stage B = Hot Gas Reheat C = Modulating Hot Gas Reheat D = Hot Gas Bypass Lead and Lag Stages E = Option A + B F = Option A + C G = Option B + D H = Option C + D J = Sub-cooling Coil, Reheat Position K = Option A + J L = Option D + J

5A5B5C6A6B6C78910111213

14A

14B1516171819202122

–

0DBB0

–00–

0BB00AB0B

Feature 9: REFRIGERATION ACCESSORIES

0 = Standard A = Sight Glass B = Compressor Isolation Valves C = Options A + B D = Condenser Fan VFD's E = Options A + D F = Options B + D G = Options A + B + D

Feature 10: POWER OPTIONS

0 = Standard Power Block A = Power Switch (225 Amps) B = Power Switch (400 Amps) C = Power Switch (600 Amps) D = Power Switch (800 Amps) E = Power Switch (1200 Amps)

Feature 11: SAFETY OPTIONS

0 = Standard A = RA and SA Firestat B = RA Smoke Detector C = SA Smoke Detector D = Options B + C E = Options A + B F = Options A + C G = Options A + D H = SA High Static Pressure Switch J = Options A+H K = Options B+H L = Options C+H M = Options B+C+H N = Options A+B+H P = Options A+C+H Q = Options A+B+C+H

Page 19

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–352 :BEBE–D00–QFY–P0

Feature 12: CONTROLS

0 = Standard, Terminal Block A = Low Limit Controls B = Phase and Brown Out Protection C = ERW Defrost D = ERW Rotation Detection F = Option A + B G = Option A + C H = Option A + D K = Option B + C L = Option B + D N = Option C + D Q = Option A + B + C R = Option A + B + D T = Option A + C + D V = Option B + C + D Y = Option A + B + C + D

Feature 13: SPECIAL CONTROLS

0 = Standard D = VAV Unit Controller E = Constant Volume Unit Controller F = MakeUp Air Unit Controller H = Field Installed DDC Control by Others J = Factory Installed DDC Controls by Others 5 = Field Installed DDC Controls w/ iso relays 6 = Factory Installed DDC Controls by other w/ relays

Feature 14: PREHEAT

14A: PREHEAT CONFIGURATION

0 = No Preheat C = Hot Water Coil, OA Preheat D = Steam Distributing Coil, OA Preheat E = Hot Water Coil, Preheat 4ft Box F = Steam Distributing Coil, Preheat 4ft Box

14B: PREHEAT SIZING

0 = No Preheat A = Heat Qty A B = Heat Qty B C = Heat Qty C D = Heat Qty D

5A5B5C6A6B6C78910111213

14A

14B1516171819202122

0DBB0

–

–00–

0BB

B0B

Feature 15: OPTION BOXES

0 = Standard A = 2 ft Box After Heat B = 2 ft Box After Cooling C = 2 ft Box After Pre Filter D = 2 ft Box After Return E = 4 ft Box After Heat F = 4 ft Box After Cooling G = 4 ft Box After Pre Filter H = 4 ft Box After Return J = 6 ft Box After Heat K = 6 ft Box After Cooling L = 6 ft Box After Pre Filter M = 6 ft Box After Return N = 8 ft Box After Heat P = 8 ft Box After Cooling Q = 8 ft Box After Pre Filter R = 8 ft Box After Return S = 2 ft Box After Preheat Coil T = 4 ft Box After Preheat Coil U = 6 ft Box After Preheat Coil V = 8 ft Box After Preheat Coil

Feature 16: INTERIOR CABINET OPTIONS

0 = Standard B = Marine Service Lights

Feature 17: CABINET OPTIONS

0 = Standard A = Access Door Windows B = Burglar Bars C = Perf Liner, SA Plenum D = Perf Liner, RA Plenum F = Option A + B G = Option A + C H = Option A + D K = Option B + C L = Option B + D N = Option C + D Q = Option A + B + C R = Option A + B + D T = Option A + C + D V = Option B + C + D Y = Option A + B + C + D

Page 20

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–352 :BEBE–D00–QFY–P0

Feature 18: CUSTOMER CODE

0 = None

Feature 19: CODE OPTIONS

0 = Standard ETL USA Listing A = MEA, New York B = Chicago Code, Cool and Gas C = Chicago Code, Cool and Electric D = Chicago Code, Cool Only E = Chicago Code, Gas Only F = Chicago Code, Electric Only G = Chicago Code, No Cool No Heat H = ETL USA + Canada Listing

Feature 20: CRATING

0 = Standard, One Piece Unit A = Two Piece Unit

5A5B5C6A6B6C78910111213

14A

14B1516171819202122

0DBB000–00–0BB

–

00AB

Feature 21: EVAPORATIVE-COOLED AND WATER-COOLED CONDENSER

0 = None A = No Sump or Vest Heaters B = Sump and Vest Heaters C = Balancing Valves D = Single Point Water Connection E = Condenser Vest Heater F = Motorized Shutoff Valves G = Head Pressure Control H = Option C + D J = Option C + E K = Option C + F L = Option C + G M = Option D + E N = Option D + F P = Option D + G Q = Option E + F R = Option E + G S = Option F + G T = Option C + D + E U = Option C + D + F V = Option C + D + G W = Option D + E + F Y = Option D + E + G Z = Option E + F + G 1 = Option C + D + E + F 2 = Option C + D + E + G 3 = Option C + D + F + G 4 = Option C + E + F + G 5 = Option C + D + E + F + G

Page 21

RL Series Feature String Nomenclature

Model Options Unit Feature Options

GEN

SIZE

VLT

CONFIGA1A2A3A4B1B2B31A1B1C1D234

L–100–3–0–BE0 6–3 5 2 : BEBE–D0 0–QFY–P0

Feature 22: CONTROL VENDORS

0 = None A = WattMaster Orion Controls System B = JENEsys Controls System C = WattMaster Orion Controls System with Specials D = JENEsys Controls System with Specials E = MCS Controls F = MCS Controls w/ diagnostics G = MCS Controls w/ modem H = MCS Controls w/ diagnostics and modem J = MCS Controls w/ diagnostics and touchscreen interface K = MCS Controls w/ diagnostics, touchscreen, modem L = Option E with BACnet IP, Modbus, N2 M = Option F with BACnet IP, Modbus, N2 N = Option G with BACnet IP, Modbus, N2 P = Option H with BACnet IP, Modbus, N2 Q = Option J with BACnet IP, Modbus, N2 R = Option K with BACnet IP, Modbus, N2 S = Option E with BACnet MSTP T = Option F with BACnet MSTP U = Option G with BACnet MSTP V = Option H with BACnet MSTP W = Option J with BACnet MSTP Y = Option K with BACnet MSTP Z = Option E with Lontalk 1 = Option F with Lontalk 2 = Option G with Lontalk 3 = Option H with Lontalk 4 = Option J with Lontalk 5 = Option K with Lontalk

5A5B5C6A6B6C78910111213

Feature 23: TYPE

B = Standard Paint U = Special Pricing Authorization with Special Paint X = Special Pricing Authorization with Standard Paint

14A14B1516171819202122

0DBB000–00–0BB00AB

–

Page 22

CAUTIO

General Information

RL Series packaged rooftop and outdoor air handling units have been designed for outdoor installation only.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician.

These units must not be used for heating or cooling 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.

Certification of Gas Heat Models

a. Certified as a forced air furnace with or

b. Certified for outdoor installation only. c. Certified for installation on combustible

d. Certified with heat exchanger located

Certification of Steam or Hot Water Heat Models

a. Certified as a forced air furnace with or

b. Certified for outdoor installation only. c. Certified for installation on combustible

WARNING

without cooling.

roof with a minimum of 12” high curb.

downstream of evaporator coil.

without cooling unit.

roof with a minimum of 12” high curb.

Certification of 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.

Certification of Cooling Models

a. Certified as a commercial central air

conditioner with or without electrically operated compressors.

b. Certified for outdoor installation only. c. Certified for installation on 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

RL Series units have been tested and certified, by ETL, in accordance with UL Safety Standard 1995/CSA C22.2 No. 236, ANSI Safety Standard Z83.8-2006/CSA 2.62006, ANSI Z83.4-2004, and ANSI Z83.18-

2004.

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

Installation of RL Series units must conform to the International Code Council (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 current National Fuel Code ANSI Z223.1/NFPA 54 or the National Gas & Propane Installation Code CSA B149.1, and CSA B52 Mechanical Refrigeration Code. All appliances must be electrically grounded in accordance with local codes, or in the absence of local codes, the National Electric Code, ANSI/NFPA 70, and/or the Canadian Electrical Code CSA C22.1.

Page 23

CAUTIO

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 this equipment.

WARNING

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

WARNING

Receiving Unit

When received, the unit should be checked for damage that might have occurred in transit. If damage is found, it should be noted on the carrier’s Freight Bill. A request for inspection by carrier’s agent should be made in writing at once. Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements.

Storage

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

Packaged Direct Expansion (DX) Units

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

All refrigerant systems include evaporator and condenser coils. Each unit includes 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 turn 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 may cool down and liquid refrigerant may accumulate in the compressor. The compressor is designed to pump refrigerant gas and damage may occur when power is restored if liquid enters the compressor.

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

Page 24

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 emergency or complete shutdown of the unit.

During the cooling season, if the airflow 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.

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

Polyolester (POE) and Polyvinylether (PVE) oils are two types of lubricants used in hydrofluorocarbon (HFC) refrigeration systems. Refer to the compressor label for the proper compressor lubricant type.

Note: Low Ambient Operation

Air-cooled DX units without a low ambient option, such as condenser fan cycling 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.

Note: Multiple Units with Multiple Thermostats

When several heating and cooling units are used to condition a space, all unit thermostat switches must be set in either heating mode,

cooling mode or off. Do not leave part of the units switched to the opposite mode. Cooling only units should be switched off at the thermostat during the heating season.

Gas or Electric Heating

The unit is designed to heat a given airflow. If this amount of air is reduced the gas heat exchanger or electric heating coil may overheat, and may turn 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 blower 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.

Wiring Diagrams

Unit specific wiring diagrams in both ladder and point-to-point form 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. Units include drain pan connections on both the front and back sides of the unit. See Installation section of this manual for more information.

If codes require a condensate drain line, 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

Page 25

break should be used with long runs of

CAUTIO

condensate lines.

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

Installation

AAON equipment is designed to be easily installed and serviced.

Locating Units

The curb should be mounted first and must be located so that duct connections will be clear of structural members of the building.

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.

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.

Table 1 - Unit Clearances

Location Clearance

Front 100”

Back 100”

Left End 100”

Right End 100”

Top Unobstructed

WARNING

Figure 1 - RL Series Unit Orientation

Condenser coils and fans must be free of any obstructions in order to start and operate properly with a correct amount of airflow.

For proper unit operation, the immediate area around the condenser must remain free of debris that may be drawn in and obstruct airflow in the condensing section.

Consideration must be given to obstruction caused by snow accumulation when placing the unit.

Curb Installation

Make openings in the 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 curb is level.

Unit specific curb drawing is included with job submittal. See SMACNA Architectural

Sheet Metal Manual and HVAC Duct Construction Standards for curb installation

details.

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

Page 26

CAUTIO

Where the supply or warm air duct passes through a combustible roof, a clearance of 1 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.

For horizontal return and discharge applications, total height of mounting rail and unit base rail must be high enough so that adequate condensate drain p-trap can be included. Units require steel mounting rail support along all four sides of the unit base.

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

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

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

Duct Connection

Figure 2 - Curb Mounting

Rubber Gasket

Duct

Wood Nailer

Rigid

Installation

Curb

Structural

Steel

Counter

Cant Strip *

Roong Material

Roof Deck

Detail ‘A’

* Field Supplied

Figure 3 - Curb Detail

Page 27

Figure 4 - Curb Mounting with Dimensions

with the outside air hood in the open position. Before lifting unit, be sure that all shipping material has been removed from the unit. Secure hooks and cables at all marked lifting points provided on the unit.

Hoist unit to a point directly above the curb and duct openings. Be sure that the gasket material has been applied to the curb.

Carefully lower and align unit with utility and duct openings. Lower the unit until the unit skirt fits around the curb. Make sure the unit is properly seated on the curb and is level.

Figure 5 - Steel Mounting Rail with

Dimensions

Table 2 - Mounting Dimensions

Tons A B C D

45-135 100” 96” 92” 97”

134-230 142” 138” 134” 139”

Lifting the Unit

If cables or chains are used to hoist the unit they must be the same length. See figure on the next page for dimensions.

It is recommended to lift the unit with the outside air hood in the downward shipping position. However, the unit may be lifted

Figure 6 - Marked Lifting Points

Page 28

Page 29

Reassembling Split Units

CAUTIO

Some RL Series units are built and shipped in two separate sections.

Shipping covers should be removed from the ends where the sections will connect.

Lifting and setting the largest section first is recommended, checking for the correct location and position.

In order to simplify the connection of the two sections, it is important to position and set the second section as close as possible to the first section. This will allow the use of a come-along tool, to pull the second section against the first section. One come-along tool is required on each side of the unit, connected at the base slots. The two sections must be tightly adjoined before the splicing parts can be installed.

All parts required for splicing the sections together are factory provided. Neoprene gasket is provided to be applied on ends of both sections.

Once the unit is completely assembled, it is important to visually inspect all exposed areas and fill any gaps with butyl caulking.

Splicing

1. Align base rail and side sections.

2. Check roof alignment and connecting

flange.

3. Fill post seam with butyl caulking.

Apply butyl caulking between roof flange sections.

4. Attach splice plate to outside of post to

cover seam. Splice plate is typically required on both sides of the unit.

5. Install factory provided roof splice cap

over the two sections connecting flange and secure with screws along the length of the cap.

6. Apply butyl caulking to all seams and

perimeter of splice and to the perimeter of the roof splice cap against the roof of the unit.

Figure 7 - Unit Base and Sides

Attach splice cap with screws from each side of the cap only. Do not install screws from the to

Figure 8 - Unit Roof Flange Splice Detail

Page 30

CAUTIO

Electrical Connection of Split Units

Before attempting to make wire connections between sections it is important to refer to the unit specific wiring diagram located in the unit controls compartment to obtain additional details related to the wiring of the specific unit.

Adjoining sections are factory wired and ready for field connection. The electrical wiring is unit specific and designed according to the overall unit configuration.

A factory supplied and mounted terminal block is located in the main section of the unit that must be used in making the roughin wire connections.

Each wire being spliced from section to section is tagged at both ends according to its termination. Junctions for wiring the sections together are separated according to voltage.

All wire terminations MUST BE made before applying power to the unit. The unit will not operate unless all circuits are made.

Outside Air Rain Hood

For proper unit operation, the outside air hood must be opened at start-up as shown below:

Remove shipping screws from each side of the closed hood.

Lift hood outward to the open position and secure with sheet metal screws. Apply butyl caulking along the top and both sides of the rain hood. Take care to seal the top corners where the rain hood attaches to the unit.

Outdoor air intake adjustments should be made according to building ventilation or local code requirements.

Air hoods vary according to unit size and options. Figure below is shown as a practical guideline for all outside air rain hoods.

Figure 9 - Air Hood Shown in the Open

Position

End Flashing Installation

On RL Series D and E cabinet units which are 142” wide (RL-150, 155, 180, 190, 210,

230) the cabinet width will overhang the trailer on each side.

In order to secure and protect the unit during transit the sheet metal end flashings have been removed from the unit. The slot created at the base of each end of the unit allows the unit to set firmly on the trailer deck.

Sheet metal flashings are shipped loose with the unit and once the unit is set into place the flashings must be installed on each end of the unit to complete the finished seal at the base. The flashings are unit specific and designed to cover the slot at each end of the unit to prevent water run-off into the curb.

Failure to attach and seal the end of unit with the flashings will result in water leakage into the curb.

Page 31

Figure 10 - Factory Supplied End Flashings

CAUTIO

In order to prevent water leakage into the roof curb, the factory provided sheet metal flashings MUST BE attached to the unit base to cover the shipping slots at both ends of the unit.

Vestibule Exhaust Fan

Prior to unit operation of units with service vestibules the exhaust fan shipping support must be removed from the exterior of the unit

The exhaust fan also includes a factory provide exterior rain hood which must be installed.

Figure 11 - Vestibule Exhaust Fan

Electrical

Verify the unit nameplate agrees with power supply. Connect power and control field wiring as shown on the unit specific wiring diagram provided laminated and attached to the door in the controls compartment.

Electric shock hazard. Before attempting to perform any installation, service, or maintenance, shut off all electrical power to the unit at the disconnect switches. Unit may have multiple power supplies. Failure to disconnect power could result in dangerous operation, serious injury, death or property damage.

WARNIN

Route power and control wiring, separately, through the utility entry in the base of the unit. Do not run power and signal wires in the same conduit.

Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 167°F (75°C).

Protect the branch circuit in accordance with code requirements. The unit 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.

Wire power leads to the unit’s terminal block or main disconnect. All wiring beyond this point has completed by the manufacturer and cannot be modified without effecting the unit’s agency/safety certification.

Installing Contractor is responsible for proper sealing of the electrical and gas entries into the unit Failure to seal the entries may result in damage to the unit and property.

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CAUTIO

Figure 12 - Terminal Block

Startup technician must check for proper motor rotation and check blower motor amperage listed on the motor nameplate is not exceeded. Motor overload protection may be a function of the variable frequency drive and must not be bypassed.

Note: All units are factory wired for 208/230V, 460V, or 575V. If unit is to be connected to a 208V supply, the transformer must be rewired to 208V service. For 208V service interchange the yellow and red conductor on the low voltage control transformer. Red-Black for 208V Yellow-Black for 230V

Wire control signals to the unit’s low voltage terminal block located in the controls compartment.

If any factory installed wiring must be replaced, use a minimum 221°F (105°C) type AWM insulated conductors.

Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Supply air blower, exhaust air blower, return air blower, and condenser fan motors should all be checked by a qualified service technician at startup and any wiring alteration should only be made at the unit power connection. Variable frequency drives are programmed to automatically rotate the fan in the correct rotation. Do not rely on fans with variable frequency drives for compressor rotation.

Scroll compressors are directional and will be damaged by operation in the wrong direction. Low pressure switches on compressors have been disconnected after factory testing. Rotation should be checked by a qualified service technician at startup using suction and discharge pressure gauges and any wiring alteration should only be made at the unit power connection.

Page 33

Gas Heating

Read the entire gas heating installation section of this manual before beginning installation of the gas heating section.

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

WARNING

FOR YOUR SAFETY

Gas piping must be installed in accordance with local codes, or 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.

Table 3 - Gas Piping Connections

Model

Option

1, 2, 3,

or 4

Quantity of

Heat

Exchangers

Connections

Quantity Size

8 or less 1 2”

5 or 6 10 or 12 1 3”

Do not use gas piping smaller than unit gas connections. Natural gas pipe runs longer than 20 feet may require a larger supply pipe than the unit connection size. Some utility companies may also require pipe sizes larger than the minimum sizes listed.

See unit nameplate for unit gas heating capacities or the Unit Rating Sheet, which can be obtained from the AAON sales representative.

Table 4 - Natural Gas Maximum Piping Capacities (ft3/hr)

- Specific Gravity = 0.6, Supply Pressure ≤ 0.5 psi, Pressure Drop = 0.5” w.c.

Length of Pipe

Pipe Size

20 ft 50 ft. 100 ft. 150 ft. 200 ft.

2” 2785 1696 1165 936 801

2-1/2” 4437 2703 1857 1492 1277

3” 7843 4778 3284 2637 2257

3-1/2” 11484 6995 4808 3861 3304

4” 15998 9745 6698 5378 4603

Piping Sizing Example

A 100 ft pipe run is needed for a 1710 MBH natural gas heater. The natural gas has a rating of 1000 BTU/ft

and a specific gravity of 0.6 (Obtain these values from the local gas supplier.)

1710

MBH

1000

BTU

=×

1710 ft3/hr

Inlet and Manifold Pressures

For natural gas units, the minimum inlet gas pressure to the unit is 6” w.c. and maximum inlet gas pressure to the unit is 10.5” w.c. For propane units, the minimum inlet gas pressure to the unit is 11” w.c. and the maximum inlet gas pressure to the unit is 13” w.c. A field provided 1/8” NPT pressure tap is required to be installed in the piping

From the natural gas maximum capacities table, at 100 ft and 1710 ft3/hr the required minimum pipe size is 2-1/2”.

just upstream of the shutoff valve for test gage connection to allow checking of the gas supply pressure at the unit.

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CAUTIO

A factory installed pressure tap on the outlet end of the gas valve can be used to verify a manifold pressure of 3.5” w.c. for natural gas, or 10.5” w.c. for propane. For two stage gas valves, the low stage setting should be set at 1.1” w.c. for natural, 5.0” w.c. for propane. For modulating heaters, the safety shut-off valve would be set following the instructions above, then from a provided pressure tap in the gas train immediately preceding the burner manifold the modulating valve is set maintain a maximum of 3.5” w.c. and a minimum of 0.4” w.c.

Heater should be disconnected from the gas supply piping during pressure testing of the supply piping system with pressures in excess of ½ psi. Gas valves can be damaged if subjected to more than ½ psi.

Gas Pressure Regulator & Overpressure Protection Device

A gas pressure regulator must be installed if natural gas supply pressure to the unit is greater than 10.5” w.c. and if propane gas supply pressure is greater than 13” w.c. Regulators must comply with the latest edition of the Standard for Line Pressure Regulators, ANSI Z21.80/CSA 6.22.

Both a gas pressure regulator and overpressure protection device (OPD) must be installed if gas supply pressure to the unit is greater than 2 psi (55.4” w.c.) and less than 5 psi (138.4” w.c.), in compliance with ANSI Z21.80/CSA 6.22. For proper heater operation, pressure to the regulator MUST NOT be greater than 5 psi (138.4” w.c.).

Piping Supports

Gas supply piping must be supported directly at the connection to the unit and at

intervals listed in the following table with metal straps, blocks, or hooks. Piping should not be strained or bent.

Table 5 - Piping Support Intervals

Pipe Size

Support

Intervals

1/2” to 3/4” Every 6 ft

3/4” to 1” Every 8 ft

1-3/4” or Larger (Horizontal) Every 10 ft

1-1/4” or Larger (Vertical) Every Floor

Additional Gas Piping Considerations

Local codes will usually require a field provided and installed manual main shutoff valve and union external the unit. Main shutoff valve should be labeled. A field provided 1/8” NPT pressure tap is required to be installed in the piping just upstream of the shutoff valve for test gage connection to allow checking of the gas supply pressure at the unit. A drip leg should be installed near the unit connection to trap sediment and condensate. Pipe joint compounds used on all gas piping connections should be resistant to liquid petroleum gases.

Leak Testing

All components of gas supply system, including manual shut off valves and the piping in the interior of the unit, should be leak tested with a soap solution before operating the appliance and at least on an annual basis thereafter.

Do not use open flame or other source of ignition for leak testing. Fire or explosion could result causing property damage, personal injury, or death.

DANGER

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CAUTIO

The gas pipe in the unit should be checked for leaks before startup. Leak checking is the responsibility of the installing contractor. All connections should be checked for leaks annually after installation. Failure to leak check could result in fire, explosion, or other hazardous situations.

DANGER

LEAK CHECK GAS PIPE

Some soaps used for leak detection can be corrosive to certain metals. Rinse piping thoroughly after leak test has been completed.

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 startup 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 startup. 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.

Those sensitive to odors or gases from trace amounts of residual oils should NOT be present in the conditioned space during the startup of a gas fired installation.

WARNING

Installation of the gas heaters should be adjusted to obtain an air temperature rise within the range specified on the rating plate.

Rain Hoods

Gas heating units include factory provided exterior rain hoods. The hoods are fastened in place with sheet metal screws. Higher heating capacity units will have two banks of gas fired heat exchanges (see Figure 13). All of the provided hoods must be installed after the unit is set in place.

Figure 13 - Gas Heater Rain Hood

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CAUTIO

Figure 14 - Gas Heater Rain Hood Screws

All exterior heater rain hoods must be in place before the gas fired heater is initially started. Improper and dangerous operating conditions will otherwise result.

WARNING

Condensate Drain Piping

Unit is equipped with 2 or more condensate drain pan connections. A drain line with ptrap must be installed on every drain connection, with the p-trap not to exceed 6” from the drain connection. The lines should be the same pipe size or larger than the drain connection and pitched away from the unit at least 1/8 inch per foot. 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 into the unit.

All drain connections must be used and individually trapped to ensure a minimum amount of condensate accumulation in the drain pans. ABS type cement should be used to join the drain pipe connections.

Note: The drain pan connections are 1.5” MPT fitting.

Condensate drain trapping and piping should conform to all applicable governing codes. Drainage of condensate directly onto the roof may be acceptable in certain areas, refer to local codes. If condensate is to drain directly onto the roof a drip pad should be placed below the drain to protect the roof from possible damage.

Draw-through cooling coils will have a negative static pressure in the drain pan area. This will cause an un-trapped drain to back up due to air being pulled up through the condensate drain piping. Blow-through coils will have a positive static pressure in the drain pan. The condensate piping on these drain pans must be trapped to prevent pressure loss through the drain.

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Draw-Through Coils

Figure 15 - Draw-Through Drain Trap

The X dimension on the draw-through trap should be at least equal to the absolute value of the negative static pressure in the drain pan plus one inch. To calculate the static pressure at the drain pan add the pressure drops of all components upstream of the drain pan, including the cooling coil, and add the return duct static pressure. Include the dirt allowance pressure drop for the filters to account for the worst-case scenario.

The height from top of the bottom bend of the trap to the bottom of the leaving pipe must be at least equal to one half of the X dimension. This ensures that enough water is stored in the trap to prevent losing the drain seal during unit startup

Note: The absolute value of the fan inlet pressure will always be greater than or equal to the absolute value of the static pressure in the drain pan on draw-through units, so the fan inlet pressure is a safe value to use for the drain pan static pressure.

Table 6 - Draw-Through Drain Trap

Dimensions

Draw-Through

Drain Pan Pressure Trap Dimensions

Negative Static X X/2

(inches of water) (inch) (inch)

-0.50 1.50 0.75

-1.00 2.00 1.00

-1.50 2.50 1.25

-2.00 3.00 1.50

-2.50 3.50 1.75

-3.00 4.00 2.00

-3.50 4.50 2.25

-4.00 5.00 2.50

-4.50 5.50 2.75

-5.00 6.00 3.00

-5.50 6.50 3.25

-6.00 7.00 3.50

-6.50 7.50 3.75

-7.00 8.00 4.00

-7.50 8.50 4.25

-8.00 9.00 4.50

Blow-Through Coils

Figure 16 - Blow-Through Drain Trap

The Y dimension of blow-through traps should be at least equal to the value of the positive pressure in the drain pan plus one inch. This ensures that there will be enough water stored in the trap to counter the static pressure in the drain pan. To find the pressure subtract any pressure drops between the drain pan and the supply fan from the fan discharge pressure. The worstcase scenario for blow-through coils is the

Page 38

CAUTIO

minimum pressure drop, so do not include dirt allowance pressure drops for filters.

The bottom of the leaving pipe should be at least one half inch lower than the bottom of the drain pan connection. This ensures proper drainage when the unit is not running.

Note: It may be necessary to fill the trap manually, or the trap can be filled automatically by operating the unit until enough condensate collects to fill the trap. The trap will then be filled when the unit is turned off.

Table 7 - Blow-Through Drain Trap

Dimensions

Blow-Through

Drain Pan Pressure Trap Dimension

Positive Static Y

(inches of water) (inch)

0.5 1.5

1.0 2.0

1.5 2.5

2.0 3.0

2.5 3.5

3.0 4.0

3.5 4.5

4.0 5.0

4.5 5.5

5.0 6.0

5.5 6.5

6.0 7.0

6.5 7.5

7.0 8.0

7.5 8.5

8.0 9.0

All condensate drains must be trapped individually before they are connected to a common line.

All condensate drain connections must be used. Drain pans are sloped towards connections.

Hot Water/Steam Heating and Chilled Water Cooling Coils

Internal header connections are provided for field connection of control valves and piping. Chilled water piping case will be provided in the base of the unit, through the drain pan, for routing water piping.

Installing Contractor is responsible for proper sealing of the water piping entries into the unit Failure to seal the entries may result in damage to the unit and property.

Evaporative-Cooled Condenser

There are two field water connections that must be made for the evaporative-cooled condenser. There is a 3/4” PVC socket city makeup water connection and a 2” PVC socket drain connection. This drain should connect to a sanitary sewer or other code permitted drain. These connections can go through the base or the wall of the unit.

There is a cutout in the base with a cap that is 1” tall and the cap is sealed to the unit base to prevent any leaks in the unit from penetrating into the building. Any piping through the base should go through a field cutout in this cap. The pipes must be sealed to the cap once the piping is complete to prevent any leaks in the unit from penetrating into the building.

Page 39

A field cutout must be made in the wall if the evaporative-cooled condenser piping is to go through the unit wall. This cutout must be sealed once the piping is installed to prevent water from leaking into the unit.

Figure 17 - Evaporative-Cooled Cond. Section, Including Field Water Connections and Base

Cutout

Page 40

Energy Recovery Units

General Information

AAONAIRE® units have been equipped with an energy recovery wheel. This section is provided to assure the energy recovery feature will be properly setup to perform in accordance with the job specifications for your particular application.

The Energy Recovery Cassette consists of a frame wheel, wheel drive system, and energy transfer segments. Segments are removable for cleaning or replacement. The segments rotate through counter flowing exhaust and outdoor air supply streams where they transfer heat and/or water vapor from the warm, moist air stream to the cooler and/or drier air stream.

The initial setup and servicing of the energy recovery wheel is very important to maintain

WARNIN

Energy Recovery Wheel

proper operation efficiency and building occupant comfort.

Normal maintenance requires periodic inspection of filters, the cassette wheel, drive belts, air seals, wheel drive motor, and its electrical connections.

Wiring diagrams are provided with each motor. When wired according to wiring diagram, motor rotates clockwise when viewed from the shaft/pulley side.

By carefully reviewing the information within this section and following the instructions, the risk of improper operation and/or component damage will be minimized.

It is important that periodic maintenance be performed to help assure trouble free operation.

Initial Mechanical Check and Setup

Outdoor units equipped with outside air intake will have an outside air hood. The outside air hood must be opened prior to unit operation.

Outdoor air intake adjustments should be made according to building ventilation, or local code requirements.

After the unit installation is complete, open the cassette access door and determine that the energy wheel rotates freely when turned by hand. Apply power and observe that the wheel rotates at approximately 30 RPM. If the wheel does not rotate when power is applied, it may be necessary to readjust the “diameter air seals”.

Page 41

Air Seal Adjustments

Pile type air seals across both sides of the energy wheel diameter are factory adjusted to provide close clearance between the air seal and wheel. Racking of the unit or cassette during installation, and/or mounting of the unit on a non-level support or in other than the factory orientation can change seal clearances. Tight seals will prevent rotation.

Cross Section of Air Seal Structure

Wheel to Air Seal Clearance

To check wheel to seal clearance; the energy recovery wheel is accessible inside the walk-in cabinet.

A business card or two pieces of paper can be used as a feller gauge, (typically each .004” thick) by placing it between the face of the wheel and pile seal.

Using the paper, determine if a loose slip fit exist between the pile seal and wheel when the wheel is rotated by hand.

To adjust air seal clearance, loosen all seal plate retaining screws holding the separate seal retaining plates to the bearing support channels and slide the seals plates away from the wheel. Using the paper feeler gauge, readjust and retighten one seal plate at a time to provide slip fit clearance when the wheel is rotated by hand.

Confirm that the wheel rotates freely. Apply power to the unit and confirm rotation.

Airflow Balancing and Checking

High performance systems commonly have complex air distribution and fan systems. Unqualified personnel should not attempt to adjust fan operation, or air circulation, as all systems have unique operations characteristics. Professional air balance specialists should be employed to establish actual operating conditions, and to configure the air delivery system for optimal performance.

Controls

A variety of controls and electrical accessories may be provided with the equipment. Identify the controls on each unit by consulting appropriate submittal, or order documents, and operate according to the control manufacturer’s instructions. If you cannot locate installation, operation, or maintenance information for the specific controls, then contact your sales representative, or the control manufacturer for assistance.

Do not alter factory wiring. Deviation from the supplied wiring diagram will void all warranties, and may result in equipment damage or personal injury. Contact the factory with wiring discre

Routine Maintenance and Handling

Handle cassettes with care. All cassettes should be lifted by the bearing support beam. Holes are provided on both sides of the bearing support beams to facilitate rigging as shown in the following illustration.

WARNIN

ancies.

Page 42

CAUTIO

Lifting Hole Locations

Routine maintenance of the Energy Recovery Cassettes includes periodic cleaning of the Energy Recovery Wheel as well as inspection of the Air Seals and Wheel Drive Components as follows:

Cleaning

The need for periodic cleaning of the energy recovery wheel will be a function of operating schedule, climate and contaminants in the indoor air being exhausted and the outdoor air being supplied to the building.

The energy recovery wheel is “selfcleaning” with respect to dry particles due to its laminar flow characteristics. Smaller particles pass through; larger particles land on the surface and are blown clear as the flow direction is reversed. Any material that builds up on the face of the wheel can be removed with a brush or vacuum. The primary need for cleaning is to remove oil based aerosols that have condensed on energy transfer surfaces.

A characteristic of all dry desiccants, such films can close off micron sized pores at the surface of the desiccant material, reducing

the efficiency by which the desiccant can adsorb and desorb moisture and also build up so as to reduce airflow.

In a reasonably clean indoor environment such as a school or office building, measurable reductions of airflow or loss of sensible (temperature) effectiveness may not occur for several years. Measurable changes in latent energy (water vapor) transfer can occur in shorter periods of time in applications such as moderate occupant smoking or cooking facilities. In applications experiencing unusually high levels of occupant smoking or oil based aerosols such as industrial applications involving the ventilation of machine shop areas for example, annual washing of energy transfer may be necessary to maintain latent transfer efficiency. Proper cleaning of the energy recovery wheel will restore latent effectiveness to near original performance.

To clean, gain access to the energy recovery wheel and remove segments. Brush foreign material from the face of the wheel. Wash the segments or small wheels in a 5% solution of non-acid based coil cleaner or alkaline detergent and warm water.

Do Not use acid based cleaners, aromatic solvents, steam or temperatures in excess of 170°F; damage to the wheel may occur!

Soak in the solution until grease and tar deposits are loosened (Note: some staining of the desiccant may remain and is not harmful to performance). Before removing, rapidly run finger across surface of segment to separate polymer strips for better cleaning action. Rinse dirty solution from segment

Page 43

and remove excess water before reinstalling in wheel.

Air Seals Four adjustable diameter seals are provided on each cassette to minimize transfer of air between the counter flowing airstreams.

To adjust diameter seals, loosen diameter seal adjusting screws and back seals away from wheel surface. Rotate wheel clockwise until two opposing spokes are hidden behind the bearing support beam. Using a folded piece of paper as a feeler gauge, position paper between the wheel surface and diameter seals.

Adjust seals towards wheel surface until a slight friction on the feeler gauge (paper) is detected when gauge is moved along the length of the spoke. Retighten adjusting screws and recheck clearance with “feeler” gauge.

Wheel Drive Components

The wheel drive motor bearings are prelubricated and no further lubrication is necessary.

The wheel drive pulley is secured to the drive motor shaft by a combination of either a key or D slot and set screw.

The set screw is secured with removable locktite to prevent loosening. Annually confirm set screw is secure. The wheel drive belt is a urethane stretch belt designed to provide constant tension through the life of the belt. No adjustment is required. Inspect the drive belt annually for proper tracking and tension. A properly tensioned belt will turn the wheel immediately after power is applied with no visible slippage during startup.

Installation Considerations Energy recovery cassettes are incorporated within the design of packaged units, packaged air handlers and energy recovery ventilators. In each case, it is recommended that the following considerations be addressed:

Accessibility

The cassette and all its operative parts; i.e.: motor, belt, pulley, bearings, seals and energy transfer segments must be accessible for service and maintenance. This design requires that adequate clearance be provided outside the enclosure. Where cassettes are permanently installed in a cabinet, access to both sides of the cassette must be provided.

Orientation & Support

The Energy Recovery Cassette may be mounted in any orientation. However, care must be taken to make certain that the cassette frame remains flat and the bearing beams are not racked.

Frame

Bearing beams shown racked

Wheel

Bearing beams (2)

Flat surface

Avoid Racking of Cassette Frame

To verify, make certain that the distance between wheel rim and bearing beam is the same at each end of the bearing beam, to within 1/4 of an inch (dimension A & B).

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CAUTIO

This amount of racking can be compensated for by adjusting the diameter seals.

If greater than 1/4 inch (dimension C), racking must be corrected to ensure that drive belt will not disengage from wheel.

Operation

Keep hands away from rotating wheel! Contact with rotating wheel can cause physical injury.

Startup Procedure

1. By hand, turn wheel clockwise (as viewed from the pulley side), to verify wheel turns freely through 360º rotation.

2. Before applying power to drive motor, confirm wheel segments are fully engaged in wheel frame and segment retainers are completely fastened. (See Segment Installation Diagram).

3. With hands and objects away from moving parts, activate unit and confirm wheel rotation. Wheel rotates clockwise (as viewed from the pulley side).

4. If wheel has difficulty starting, turn power off and inspect for excessive interference between the wheel surface and each of the four (4) diameter seals. To correct, loosen diameter seal adjusting screws and back adjustable diameter seals away from surface of wheel, apply power to confirm wheel is free to rotate, then re-adjust and tighten hub and diameter seals, as shown in hub seal adjustment diagram.

5. Start and stop wheel several times to confirm seal adjustment and to confirm belt is tracking properly on wheel rim (approximately 1/4” from outer edge of rim).

Diameter Seal Adjustment

Hub Seal Adjustment

Service

Disconnect electrical power before servicing energy recovery cassette. Always keep hands away from bearing support beam when installing or removing segments. Failure to do so could result in severe injury to fingers or hand.

Page 45

Segment Installation & Replacement

Wheel segments are secured to the wheel frame by a Segment Retainer which pivots on the wheel rim and is held in place by a Segment Retaining Catch.

Segment Retainer

To install wheel segments follow steps one through five below. Reverse procedure for segment removal.

1. Unlock two segment retainers (one on each side of the selected segment opening.

2. With the embedded stiffener facing the motor side, insert the nose of the segment between the hub plates.

Segment Installation

3. Holding segment by the two outer corners, press the segment towards the center of the wheel and inwards against the spoke flanges. If hand pressure does not fully seat the segment, insert the flat tip of a screw driver between the wheel rim and outer corners of the segment and apply downward force while guiding the segment into place.

4. Close and latch each Segment Retainer under Segment Retaining Catch.

5. Slowly rotate the wheel 180º. Install the second segment opposite the first for counterbalance. Rotate the two installed segments 90º to balance the wheel while the third segment is installed. Rotate the wheel 180º again to install the fourth segment opposite the third. Repeat this sequence with the remaining four segments.

Wheel Drive Motor and Pulley Replacement

1. Disconnect power to wheel drive motor.

2. Remove belt from pulley and position temporarily around wheel rim.

3. Loosen set screw in wheel drive pulley using a hex head wrench and remove pulley from motor drive shaft.

4. While supporting weight of drive motor in one hand, loosen and remove (4) mounting bolts.

5. Install replacement motor with hardware kit supplied.

6. Install pulley to dimension as shown and secure set screw to drive shaft.

7. Stretch belt over pulley and engage in groove.

8. Follow start-up procedure.

Belt Replacement

1. Obtain access to the pulley side bearing access plate if bearing access plates are provided. Remove two bearing access plate retaining screws and the access plate.

2. Using hexagonal wrench, loosen set screw in bearing locking collar. Using light

Page 46

CAUTIO

hammer and drift (in drift pin hole) tap collar in the direction of wheel rotation to unlock collar. Remove collar.

3. Using socket wrench with extension, remove two nuts which secure bearing housing to the bearing support beam. Slide bearing from shaft. If not removable by hand, use bearing puller.

4. Form a small loop of belt and pass it through the hole in the bearing support beam. Grasp the belt at the wheel hub and pull the entire belt down.

Note: Slight hand pressure against wheel rim will lift weight of wheel from inner race of bearing to assist bearing removal and installation.

Protect hands and belt from possible sharp edges of hole in Bearing Support Beam.

5. Loop the trailing end of the belt over the shaft (belt is partially through the opening).

6. Reinstall the bearing onto the wheel shaft, being careful to engage the two locating pins into the holes in the bearing support beam. Secure the bearing with two self-locking nuts.

7. Install the belts around the wheel and pulley according to the instructions provided with the belt.

8. Reinstall diameter seals or hub seal and tighten retaining screws. Rotate wheel in clockwise direction to determine that wheel rotates freely with slight drag on seals.

9. Reinstall bearing locking collar. Rotate collar by hand in the direction the wheel rotates (see label provided on each cassette for wheel rotation).

10. Lock in position by tapping drift pin hole with hammer and drift. Secure in position by tightening set screw.

11. Reinstall Bearing Access Cover.

12. Apply power to wheel and ensure that the wheel rotates freely without interference.

Belt Replacement

Page 47

Startup

(See back of the manual for startup form)

Supply, Return, and Exhaust Backward Curved Fans

RL Series units are equipped with direct drive backward curved fan assemblies that are selected to deliver the air volume specified according to unit size and job requirements. This is either done with air volume bands in the blower wheels or with VFDs. Field airflow adjustment may be required at startup.

Air volume bands for the wheels are sized according to the unit’s air delivery specifications and can also be ordered from the factory for field installation.

Airflow Adjustment

If reduced air volume is required an air volume band or larger air volume band can be installed within the blower wheel to reduce the amount of air delivered by the wheel.

If the unit is factory equipped with the air volume band and additional air volume is required, the band can be removed from the wheel.

Use fan program in AAONEcat32™ to determine the new band size for the required CFM and static pressure.

The following photos of a wheel are provided for practical guidelines only in order to identify the air band location in the wheel. Actual field installation of the air band into the wheel will require access into and through the blower wheel venture, which may require removal of the fan motor and wheel.

Air volume bands are made of aluminum, sized and equipped with easy bend tabs that

are to be inserted into pre-punched slots provided on the wheel. Once the band has been inserted into the slots, it MUST BE secured by bending the tabs over from the back side of the wheel and also MUST BE secured from the inside by connecting the ends together with a pop-rivet in the holes provided on the ends of the band.

Figure 18 - Air Volume Band

If the band is field installed, a hand held pop-rivet tool is recommended for connecting the band ends together. Caution must be taken to assure that the band is tightly installed and no damage, denting or alteration to the wheel or blades occurs during the installation.

Figure 19 - Air Volume Band Tab Locations

Page 48

Figure 20 - Securing Air Volume Band Ends

For single set screw applications, tighten the set screw to the required torque setting (Table 8) using a calibrated torque wrench. For double set screw applications, tighten one set screw to half of the required torque setting (Table 8) using a calibrated torque wrench. Tighten the second set screw to the full required torque setting then tighten the first set screw to the full required torque setting.

Table 8 - Plenum Fan Set Screw

Specifications

SET SCREW

DIAMETER

1/4" 80

5/16" 126

3/8" 240

7/16" 384

1/2" 744

TORQUE (IN-LBS)

The gap tolerances that are allowed between the blower and the inlet cone for the RL plenum fan blowers are shown in Figure 21. The inlet cone can be moved as necessary to center the cone in relation to the blower. The blower can be moved on the motor shaft to set the correct overlap. These tolerances are critical to the performance of the blower.

Figure 21 - Plenum Fan Gap Tolerances

Power Return and Exhaust Axial Flow Fans

Blade Pitch Angle Setting Instructions

Step 1: Determine the new required pitch for the fan blades

Use the fan program in AAONEcat32™.

Step 2: Maintain the balance of fan

Mark the HUB/RET castings across a single joint, so the fan can be reassembled in the same orientation.

Mark the location of any balancing weight. Balancing weight will be on the outer bolt circle, in the form of washers, and/or longer bolts, or an additional balancing nut.

Number the blades and blade sockets, so that they can be replaced into their original positions.

Page 49

Bushing Mount

Figure 22 - Fan with the HUB on the top and

RET on the bottom.

Step 3: Determine the direction of rotation

Right, R, is clockwise when facing the discharge side of the fan and Left, L, is counterclockwise when facing the discharge side of the fan.

Step 4: Determine the bushing mount location

The bushing mount is the center section of the hub through which the fan is mounted to the shaft, and typically contains either setscrews or a center-tapered hole where the bushing inserts. Location A is with the bushing mount on air inlet side of the fan. Location B is with the bushing mount on air discharge side of the fan.

Step 5: Determine the pin location groove

Disassemble fan on a flat surface and note in which groove the pin is located.

1 2 3 4

Figure 24 - RET shown with pin in groove 4

Step 6: Determine whether the pin is in the HUB or RET

Bushing Bushing

A B

Figure 23 - Fan Bushing Mount Location

Bushing

Mount

Figure 25 - HUB and RET

Page 50

Step 7: Determine the current blade pitch and the pin location for the new blades

Table 9 - Return/Exhaust Fan Pin Location in the Bushing Mount

Type

Type Rot.

Step 8: Replace fan blades in the new pin location and reassemble the fan

Replace the blades with the pin in the 1, 2, 3, or 4 groove position of either the HUB or RET. Assemble the fan making sure to place the blades in their previous blade sockets, to match up the previous orientation of HUB

Bushing

Mount

A - RET - RET RET RET HUB HUB HUB HUB

B - HUB - HUB HUB HUB RET RET RET RET

R - 4 - 3 2 1 4 3 2 1 L - 1 - 2 3 4 1 2 3 4

20° 25° 28° 30° 33° 35° 38° 40° 45° 50°

Table 10 - Return/Exhaust Fan Pin Location in the Grooves

20° 25° 28° 30° 33° 35° 38° 40° 45° 50°

Blade Pitch Angle

and RET and to replace any balancing weights in their previous locations. Tighten bolts in a cross pattern to 5-6 ft-lbs. of torque.

Page 51

Adjustable Fan Cycling Switch Procedure

Recommended Settings

The switch will come factory set to cut-in at 425psi (+/– 5psi) or a differential of 155psi (and open at 270psi (+/– 5psi)).

To adjust the fan cycle switch you will need a flathead screwdriver.

Settings for CUT IN and DIFFERENTIAL PRESSURE are indicated with two slider gauges.

Cut In Differential

Each adjustment screw sits above the setting that it controls.

Page 52

Cut In Gauge

To lower the pressure set point for the CUT IN gauge, turn the adjustable screw clockwise.

Differential Gauge

Cut In Gauge

To raise the pressure set point for the CUT IN gauge, turn the adjustable screw counter clockwise.

Differential Gauge

To raise the pressure set point for the DIFFERENTIAL Gauge, turn the adjustable screw clockwise.

NOTE: The pressure values on the gauge should be verified with gauges on the refrigerant line. The gauge scale is for illustration purposes only.

To lower the pressure set point for the DIFFERENTIAL Gauge, turn the adjustable screw counter clockwise.

Page 53

RL Prop Assembly

The prop assembly bushings should be tightened to the specifications listed in Table

11.

Table 11 - Prop Assembly Bushing Torque

Specifications

BUSHING

H X 1.125" 95

H X 1.375" 95 SH X 1.125" 108 SH X 1.375" 108 SD X 1.125" 108 SD X 1.375" 108 SD X 1.625" 108 SD X 1.875" 108

SK X 2.125" 180

TIGHTENING TORQUE

(IN-LBS.)

Spring Isolator Adjustment NOTE: Resonance issues are possible when

both internal and external spring isolation are used. When an external spring isolated curb is used, internal fan spring isolators should be locked down to prevent resonance issues.

All spring isolators must be adjusted, prior to unit startup, to avoid mechanical damage or reduced performance.

1. On all four isolators, secure the

adjustment bolt and rotate the locking bolt counter-clockwise approximately four full rotations. This will allow the locking bolt to spin when the adjustment bolt is turned (See Figure 26).

2. Take two full counter-clockwise turns on

each adjustment bolt and continue to evenly compress the springs until the wooden shipping supports can be removed and discarded.

3. Adjust all four isolators until 1¼”

clearance is obtained between all spring brackets and spring supports. Rotating the adjustment bolts counter-clockwise

will raise the blower frame and increase the clearance.

4. Adjusting only the front isolators,

increase the clearance on the front brackets by approximately ¼”. This will result in a gap between the front of the blower frame and the upper corners of the neoprene gasket. The front isolators should be adjusted until this gap measures approximately ¼” for units with three or four blowers, or two blowers in a vertical configuration (shown in Figure 27). For units with a single blower, or two blowers positioned side by side, the gap should be approximately 1/8”.

Page 54

5. Check all isolators to ensure that the

spring, spring cap and spring base plate are aligned. The position of the spring cap should be adjusted such that the spring is straight up and down. Adjustments can be made by applying horizontal pressure to the locking bolt.

6. Individually tighten all four locking

bolts while the adjustment bolts are held in position.

Figure 27 - Fan Assembly Detail

Figure 26 - Rear Isolator Detail

Back Draft Damper Setup

The counter balance is shipped loose and may need to be installed during start-up on some applications. Not all applications will require the use of the counter balance on the back draft dampers. If the unit is equipped with back draft dampers on the supply fan, the fans should be started without the counter balance and the operation of the back draft dampers should be observed. If

Figure 28 - Blower Assembly

the back draft dampers do not open completely, then the counter balance can be installed to assist with the opening of the back draft dampers. The counter balance should be installed in the horizontal position when the back draft dampers are held closed (see Figure 29).

Page 55

CAUTIO

Figure 29 - Closed Back Draft Damper

The back draft damper will remain open with no back pressure on the damper (see Figure 30). The damper will close completely when back pressure is applied.

Figure 30 - Open Back Draft Damper

Filters

Do not operate the unit without filters in place. Unit should be checked for correct filter placement during startup. Operation of the equipment without filters will result in clogged cooling and heating coils.

Cartridge Filter Installation

Cartridge filters may be held in their proper orientation and placement with channels, spring fasteners, or clips.

Figure 31 - Top Clip and Side Spring

Fastener Securing Filters in Place

Before completing startup and leaving the unit a complete operating cycle should be observed to verify that all components are functioning properly.

Adjusting Refrigerant Charge

Adjusting the charge of a system in the field must be based on determination of liquid sub-cooling and evaporator superheat. On a system with a TXV liquid sub-cooling is more representative of the charge than evaporator superheat but both measurements must be taken.

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

CAUTION

Before Charging

Unit being charged must be at or near full load conditions before adjusting the charge.

Units equipped with hot gas reheat must be charged with the hot gas reheat valves

Page 56

closed while the unit is in cooling mode to get the proper charge. After charging, unit should be operated in reheat (dehumidification) mode to check for correct operation.

After adding or removing charge the system must be allowed to stabilize, typically 10-15 minutes, before making any other adjustments.

The type of unit and options determine the ranges for liquid sub-cooling and evaporator superheat. Refer to the table below when determining the proper sub-cooling.

Checking Liquid Sub-Cooling

Measure the temperature of the liquid line as it leaves the condenser coil.

Read the gauge pressure at the liquid line close to the point where the temperature was taken. You must use liquid line pressure as it will vary from discharge pressure due to condenser coil pressure drop.

Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart.

Subtract the measured liquid line temperature from the saturated temperature to determine the liquid sub-cooling.

Compare calculated sub-cooling to the table below for the appropriate unit type and options.

Checking Evaporator Superheat

Measure the temperature of the suction line close to the compressor.

Read gauge pressure at the suction line close to the compressor.

Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart.

Subtract the saturated temperature from the measured suction line temperature to determine the evaporator superheat.

For refrigeration systems with tandem compressors, it is critical that the suction superheat setpoint on the TXV is set with one compressor running. The suction superheat should be 10-13°F with one compressor running. The suction superheat will increase with both compressors in a tandem running. Inadequate suction superheat can allow liquid refrigerant to return to the compressors which will wash the oil out of the compressor. Lack of oil lubrication will destroy a compressor. Liquid subcooling should be measured with both compressors in a refrigeration system running.

Compare calculated superheat to the table below for the appropriate unit type and options.

Page 57

Table 12 - Acceptable Sub-Cooling and

CAU

Superheat Temperatures

Air-Cooled Condenser

Sub-Cooling

Sub-Cooling with

Hot Gas Reheat

Superheat

12-18°F

15-22°F

10-15°F

Evaporative-Cooled Condenser

Sub-Cooling

Sub-Cooling with

Hot Gas Reheat

Superheat

6-10°F

8-12°F

10-15°F

Water-Cooled Condenser

Sub-Cooling

Sub-Cooling with

Hot Gas Reheat

Superheat

One compressor running in tandem

Two compressors running in tandem

6-10°F

8-12°F

10-15°F

Adjusting Sub-cooling and Superheat Temperatures

The system is overcharged if the sub-cooling temperature is too high and the evaporator is fully loaded (low loads on the evaporator result in increased sub-cooling) and the evaporator superheat is within the temperature range as shown in the table above (high superheat results in increased sub-cooling).

Correct an overcharged system by reducing the amount of refrigerant in the system to lower the sub-cooling.

Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor discharge pressure.

TION

DO NOT OVERCHARGE!

The system is undercharged if the superheat is too high and the sub-cooling is too low.

Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub-cooling.

If the sub-cooling is correct and the superheat is too high, the TXV may need adjustment to correct the superheat.

Refrigerant Filter Driers

Each refrigerant circuit contains a replaceable core filter drier. Replacement is recommended when there is excessive pressure drop across the assembly or moisture is indicated in a liquid line sight glass.

Table 13 - Filter Drier Maximum Pressure

Drop

Circuit Loading Max Pressure Drop

100% 5 psig

50% 2.5 psig

The filter driers are provided with pressure taps and shutoff valves for isolation when changing the core. For safety purposes a service manifold must be attached prior to filter maintenance.

Figure 32 - Replaceable Core Filter/Drier

Page 58

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

PSIG PSIG PSIG PSIG PSIG

R-410A R-22

(°F)

78.3 43.1

80.0 44.2

81.8 45.3

83.6 46.5

85.4 47.6

87.2 48.8

89.1 50.0

91.0 51.2

92.9 52.4

94.9 53.7

96.8 55.0

98.8 56.2

100.9 57.5

102.9 58.8

105.0 60.2

R-410A R-22

(°F)

142.2 84.1

144.8 85.7

147.4 87.4

150.1 89.1

152.8 90.8

155.5 92.6

158.2 94.4

161.0 96.1

163.8 98.0

166.7 99.8

169.6 101.6

172.5 103.5

175.4 105.4

178.4 107.3

181.5 109.3

R-410A R-22

(°F)

234.9 143.6

238.6 146.0

242.3 148.4

246.0 150.8

249.8 153.2

253.7 155.7

257.5 158.2

261.4 160.7

265.4 163.2

269.4 165.8

273.5 168.4

277.6 171.0

281.7 173.7

285.9 176.4

290.1 179.1

R-410A R-22

(°F)

364.1 226.4

110

369.1 229.6

111

374.2 232.8

112

379.4 236.1

113

384.6 239.4

114

389.9 242.8

115

395.2 246.1

116

400.5 249.5

117

405.9 253.0

118

411.4 256.5

119

416.9 260.0

120

422.5 263.5

121

428.2 267.1

122

433.9 270.7

123

439.6 274.3

124

R-410A R-22

(°F)

140

141

142

143

144

145

146

147

148

149

150

540.1 337.4

547.0 341.6

553.9 345.9

560.9 350.3

567.9 354.6

575.1 359.0

582.3 363.5

589.6 368.0

596.9 372.5

604.4 377.1

611.9 381.7

107.1 61.5

109.2 62.9

111.4 64.3

113.6 65.7

115.8 67.1

118.1 68.6

120.3 70.0

122.7 71.5

125.0 73.0

127.4 74.5

129.8 76.1

132.2 77.6

134.7 79.2

137.2 80.8

139.7 82.4

184.5 111.2

187.6 113.2

190.7 115.3

193.9 117.3

197.1 119.4

200.4 121.4

203.6 123.5

207.0 125.7

210.3 127.8

213.7 130.0

217.1 132.2

220.6 134.5

224.1 136.7

227.7 139.0

231.3 141.3

100

101

102

103

104

105

106

107

108

109

294.4 181.8

298.7 184.6

303.0 187.4

307.5 190.2

311.9 193.0

316.4 195.9

321.0 198.8

325.6 201.8

330.2 204.7

334.9 207.7

339.6 210.8

344.4 213.8

349.3 216.9

354.2 220.0

359.1 223.2

445.4 278.0

125

451.3 281.7

126

457.3 285.4

127

463.2 289.2

128

469.3 293.0

129

475.4 296.9

130

481.6 300.8

131

487.8 304.7

132

494.1 308.7

133

500.5 312.6

134

506.9 316.7

135

513.4 320.7

136

520.0 324.8

137

526.6 329.0

138

533.3 333.2

139

Page 59

Indirect Gas Heat Startup

Page 60

Access Doors

Lockable access doors are provided to the services vestibule and to sections of the unit which may require maintenance or servicing. After startup is completed, if necessary, locks should be used with the doors to prevent unauthorized access.

Figure 33 - Lockable Door Handles

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Operation

Unit operations should be controlled with thermostat, or unit controller, never at the main power supply, except for emergency or complete shutdown of the unit.

Indirect Gas Heater Operation

When heat (G and W1, W2, etc.) is called for the combustion motor starts and the ignition control is energized. The control sends 24 VAC to the gas valve and high voltage to the igniter. If a burner flame has been detected within 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 will lock out the system. Power to the ignition control must be cycled to reset the heater control.

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 fan compartment.

Electric Heating Operation

When a call for heating (G and W1, W2, etc.) is made the supply fan motors and electric resistance heaters will energize. Heating is accomplished by passing electrical current through a specified amount of resistance heaters which will produce the required heat.

On a fault condition the main limit located in the supply air or the auxiliary limit located downstream of the supply fan will remove power from all contactors.

Steam or Hot Water Preheating and Heating Operation

Valve control for steam and hot water heating coils are by others. Heating is accomplished by passing steam or hot water through the steam or hot water coil assembly.

Packaged DX Cooling Operation

When a call for cooling (G and Y1, Y2, etc.) is made the supply fan motors and compressors will energize.

To prevent motor overheating compressors must cycle off for a minimum of 5 minutes.

To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes.

The cycle rate must not exceed 6 starts per hour.

Chilled Water or Non-Compressorized DX Cooling Operation

Controls for chilled water cooling coils and non-compressorized DX coil are by others.

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME

5 MINUTE MINIMUM ON TIME

WARNIN

Page 62

Maintenance

(See back of the manual for maintenance log)

At least once each year, a qualified service technician should check out the unit. Fans, evaporator coils and filters should be inspected monthly.

Gas Heating

Once a year, before the unit is in operation for the heating season, a qualified service technician should inspect all flue product carrying areas of the furnace and main burners for continued safe operation.

Make sure all gas supply lines have been purged of air before turning on the electrical power switch. Turn the gas valve to the on position (see startup instructions). Turn the main electrical power on and set the controls to the heating mode of operation.

The combustion ventilation motor should operate. The control will automatically supply power to the igniter and the gas valve after the heating call is made.

WARNING

DANGER

LEAK CHECK GAS PIPE

The flame 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 after 3 tries, ignition system will lockout.

The supply fans are controlled by the ignition system. In the fan “Auto” mode the fans come on 45 seconds after the flame is proven and go off 120 seconds after the cooling call is removed.

Furnace combustion ventilation air and flue openings should be checked annually for debris and obstructions. If vent extensions are used they must meet category III requirements.

The gas burner and heat exchanger should never require cleaning. If cleaning is necessary, this indicates faulty operation of the unit. Cleaning should only be done by a qualified service agency and only after consultation with an AAON service representative.

If 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.

Direct Fired Gas Heat

Direct fired burners mix gaseous fuel and outside air to fire directly into the unit air stream. Therefore, all available heat (minus the heat of vaporization) is released directly into the air stream. Optimal performance demands that air velocities be uniform across the entire burner. The profile plates around the burner are adjustable to maintain the required velocity. Adequate building relief must be designed and incorporated into the building. Non-recirculating units (100% outside air) must not be connected to any form of return duct. The outside air must be ducted directly outdoors.

Page 63

Figure 34 - Typical Factory Mutual (FM) Gas Piping Schematic for a Direct Fired Heater

The burner comes with a pilot to ignite the flame and the pilot includes an adjustable orifice. An ignition transformer and spark igniter provide the spark to ignite the pilot and the pilot lights the main burner. The pilot and main burner flames are verified with a flame rod or UV flame supervisor. Capacity is controlled by a modulating gas valve.

Ignition Sequence of Operations:

1. Pre-purge of the burner with fresh air for

30 seconds. Ignition will not proceed if flame is detected.

2. Pre-ignition of the sparker for 2 seconds

in air only

3. Open the pilot gas valve for 10 seconds

and verify pilot flame detection. Safety shutdown occurs if pilot is not detected by the end of 10 seconds.

4. When pilot flame is proven, the sparker

is deactivated, main gas valve 1 and 2 are opened and the vent valve is closed.

5. The pilot valve is deactivated after a 10

second main flame establishing time.

6. The modulating gas valve can modulate

to maintain capacity based on 0-10 VDC input to the modulating gas valve controller (the modulating gas valve

controller sends a 0-20 VDC signal to the modulating gas valve).

Safeties:

1. There is an air flow proving switch

which is a differential pressure switch that is mounted across the supply blower bulkhead wall. This switch needs 0.5” wc to activate.

2. There is an adjustable air side high

pressure switch on the inlet to the burner profile plate. This setting is application specific and the setpoint can be located on the unit nameplate.

3. There is an adjustable air side low

pressure switch on the outlet of the burner profile plate. This setting is application specific and the setpoint can be located on the unit nameplate.

4. There are door interlock switches on the

air stream access doors upstream and downstream of the burner. These interlock switches will deactivate the heater if the doors are open.

5. There is a main limit switch downstream

of the burner. This setting is shown on the unit nameplate.

6. There is an adjustable manual reset high

gas pressure switch on Main Gas Valve

2. This switch should be set to trip at

Page 64

125% of the maximum manifold gas pressure as shown on the unit nameplate.

7. There is an adjustable manual reset low

gas pressure switch on Main Gas Valve

1. This switch should be set to trip at the minimum manifold gas pressure as shown on the unit nameplate.

8. There is an automatic reset valve

proving switch located between the main shut off valves. This switch should be set at 50% of the incoming gas pressure.

Initial Start-up Procedure:

1. Bleed air from main gas line.

2. Verify proper incoming gas pressure. a. Refer to the unit nameplate for

determining the minimum gas supply pressure for obtaining the maximum gas capacity for which the heater is specified.

3. Adjust incoming gas pressure with main regulator (on blocking valve actuator) to required gas manifold pressure as shown on unit nameplate.

4. Activate supply fan for heating call.

5. Verify that all dampers in are the correct position before and after activating the heating call.

6. Verify that the supply air, outside air and return air (if applicable) flow rates are correct as ordered.

7. Activate a call for heat.

8. With the main burner hand valve closed, open pilot valve to ignite the pilot. This may take several attempts in order to bleed any air from the line.

9. Verify pilot flame size, color and signal. The pilot should be adjusted during lighting to a hard, blue flame. Pilot signal should be between 1.25 VDC and 5 VDC. It is better to be closer to 5 VDC. Adjust pilot pressure as necessary.

10. After the pilot has ignited, open the main burner hand valve to ignite the burner

11. Measure the gas manifold pressure and adjust as necessary

12. Verify that the airside differential

pressure across the burner profile plates meets the unit specifications

13. Verify flame length and color.

Troubleshoot if the flame has yellow tips. Slight yellow tipping is acceptable with liquid propane.

First Firing or Restart after Extended Shut-down:

Before start-up or after an extended period shut down, the integrity of the system should be checked by authorized service technician. Check the condition of the mixing plates, burner body drillings, as well as the general mechanical installation of the burner and piping. Check all bolted connections of the burner after the first firing and tighten as necessary.

General Maintenance Instructions:

Makeup heat installations should be maintained and inspected at a minimum of once per season. More frequent maintenance and inspections should be performed in applications that operate all year. As a minimum the following procedure should be followed…

1. Completely shut the system down. Lock

out the power supply to prevent accidental start-up.

2. Inspect the burners carefully, including

the upstream and downstream sides of the mixing plates as well as the burner body face. Any accumulation of scale or foreign material on either side of the mixing plates should be removed with a wire brush. Visually inspect the holes in the mixing plates to verify that all of the holes are opened without blockage. Clean any carbon build-up present and troubleshoot for cause.

3. Replace or tighten any missing or loose

fasteners. Always use zinc plated or stainless metric fasteners.

Page 65

4. Ensure that all vents to the atmosphere are clean and free from obstruction.

5. Inspect and clean all drip legs in the gas lines.

6. Inspect all electrical components, connections and terminals. Clean and tighten as necessary.

7. Clean ignition electrodes if necessary.

8. Put system back into operation and observe the complete operation of the burners through the full firing range. There is an observation viewport window in the gas piping compartment.

9. Observe the flame pattern and take any necessary steps to correct any velocity and/or air distribution problems.

10. Test the ignition spark and adjust gap if necessary. Clean any carbon build-up on

ignition probes and troubleshoot for cause.

11. Inspect all valves and piping for

operation and clean as necessary.

12. Inspect UV sensor observation window.

Clean any dust or debris present.

Inspection and Maintenance of Gas Ports:

1. Conduct an initial inspection within the

first month after commissioning. Visually check the gas ports of new burner assemblies for any piping scale or debris. Use pin vise with drill bit to remove (see below).

2. Annual inspections are normally

adequate once the initial piping debris is removed. The operating conditions of the burner will determine how frequently the maintenance is actually required.

Figure 35 - Removing Piping Scale with Pin Vise

DX Cooling

Set unit controls to cooling mode of operation with supply fans on. Check the fans for correct operating direction,

amperage and voltage. Check compressor operation, rotation, amperage and voltage to the unit nameplate (check the amperage on the load side of the compressor contactor).

Page 66

CAUTIO

Condensate Drain Pans

Drain pans will have moisture present and require periodic cleaning to prevent microbial growth. Cleaning of the drain pans will also prevent any possible plugging of the drain lines and overflow of the pan itself. Cleaning of the drain pans and inside of the unit should be done only by qualified personnel.

Supply Fans

Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.

WARNING

Blower wheels and bands must be inspected for excessive dust build up periodically and cleaned if required. Excessive dust build up on blower wheels may cause an unbalanced state; leading to vibration and/or component failure. Damages due to excessive dust build up will not be covered under factory warranty.

Lubrication

All original fan motors and bearings are furnished with factory lubrication. Some applications will require that bearings be relubricated periodically. The schedule will depend on the operating duty, temperature variations or other severe atmospheric conditions.

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 OVER LUBRICATE.

Phase and Brownout Protection Module

The DPM is a Digital Phase Monitor that monitors line voltages from 200VAC to 240VAC 1ɸ and 200VAC to 600VAC 3ɸ. The DPM is 50/60 Hz self-sensing. DPM should be wired according to unit specific wiring diagram include in the control compartment

When the DPM is connected to the line voltage, it will monitor the line and if everything is within the setup parameters, the output contacts will be activated. If the line voltages fall outside the setup parameters, the output relay will be deenergized after the trip delay.

Once the line voltages recover, the DPM will re-energize the output relay after the restart time delay. All settings and the last 4 faults are retained, even if there is a complete loss of power.

Page 67

DPM Setup Procedure

With the supply voltage active to the module, you can setup all of the DPM’s settings without the line voltage connected.

To change the setpoint parameters use the right arrow key to advance forward through the setpoint parameters and the left arrow to backup if needed. When each parameter is displayed use the up/down keys to change and set the parameter.

After adjustments are made or if no adjustments are made it will take 2 to 4 minutes before the DPM energizes the output relay unless there is an out of tolerance issue with the incoming line voltage.

Recommended Default Set-up

Line Voltage 460VAC, 3Ø Over & Undervoltage ±10% Trip Time Delay 5 Seconds Re-Start Time Delay 2 Minutes Phase Imbalance 5%

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Screens

Manufacturer’s Screen

R-K Electronics DPM v0.0.00

Average Voltage Screen

VAvg Imb Hz

460 0 60 off

Default – the default screen shows the real time voltage detected in each of the 3 phases:

A-B B-C C-A

460 459 461 ON

Voltage Selection Screen (Vertical Format) Default = 460V, 3Ø 200, 1Ø; 208, 1Ø; 220, 1Ø; 230, 1Ø; 240, 1Ø; 200, 3Ø; 208, 3Ø; 220, 3Ø; 230, 3Ø; 240, 3Ø; 380, 3Ø; 415, 3Ø; 440, 3Ø; 460, 3Ø; 480 3Ø; 575, 3Ø; 600, 3Ø;

Over/Under voltage Percentage Screen (Vertical Format) Default = 10%

7% 8% 9% 10% 11% 12% 13% 14% & 15%

Trip Time Delay Screen (Vertical Format) Default = 5 sec

2S, 3S, 4S, 5S, 6S, 27S, 8S, 9S & 10S

Re-Start Time Delay Screen (Vertical Format) Default = 2 sec

Manual, 2S, 3S, 4S, 5S, 6S, 7S, 8S, 9S, 10S, 30S, 1M, 2M, 3M & 4M

Phase Imbalance Percentage Screen (Vertical Format) Default = 5%

3% 4% 5% 6% 7% 8% 9% & 10%

Fault Screen (Vertical Format)

“0” most recent faults, “1” previous fault “2” third oldest fault & “3” fourth oldest fault.

Fault Words:

“Phase a Loss” (There is no voltage sensed on 3-L1/S) “Voltage Low” (Average line voltage is less than selected Undervoltage Percentage) “Voltage High” (Average line voltage is more than selected Overvoltage Percentage) “Imbalance” (One phase is lower than the average voltage by more than the Imbalance

percentage) “Phase Loss (One phase is more than 30% below the Line Voltage selection) “Bad Rotation” (The phase rotation sequence is reversed) “Bad Freq” (Line frequency out of allowable range of 45 to 65 Hz)

Page 69

Filter Replacement

Monthly filter inspection is required to maintain optimum unit efficiency.

Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.

WARNING

It is strongly recommended that filter media be replaced monthly. Filters are located either upstream of the evaporator coil, upstream of the blow-through supply blowers, or in the final filter position. Replace filters with the size indicated on each filter or as shown in the tables below. Arrow on the replacement filters must point on the direction of airflow.

Evaporative-Cooled Condenser

Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water spray and discharging it from the unit with the hot, saturated air. As the spray water evaporates, it leaves behind the mineral content and impurities of the supply water. If these residuals are not purged from the water distribution system, they will become concentrated and lead to scaling, corrosion, sludge build-up and biological fouling.

A water treatment monitoring and control system has been furnished with this unit. Be sure to read the complete manual that has been furnished. All water treatment is a combination of bleed water and chemical treatment for proper control of the residuals and to prevent any biological contamination.

Batch-loading chemicals into the unit

WARNING

is NOT PERMITTED. The control system must regulate the chemical feed.

Severe Service

The following recommended maintenance procedures are basic requirements for normal operating environments. For severe operating conditions, the frequency of inspection and service should be increased. Air containing industrial and chemical fumes, salt, dust, or other airborne contaminates and particulates will be absorbed by the recirculating water system and may form solutions and deposits harmful to the products and personnel.

Safety

The recirculating water system contains chemical additives for water quality control and biological contaminants removed from the air by the washing action of the water. Personnel exposed to the saturated effluent, drift, or direct contact should use proper precaution. Proper location of the evaporative-cooled condenser requires good judgment to prevent the air discharge from entering fresh air intakes or to avoid allowing contaminated building exhaust from entering the condenser.

Figure 36 - Proper Unit Location

Follow local and national codes in locating the evaporative-cooled condenser but as minimum the evaporative-cooled condenser

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sump must be 15 feet from the nearest intake.

The evaporative-cooled condenser must be thoroughly cleaned on a regular basis to minimize the growth of bacteria, including Legionella Pneumophila, to avoid the risk of sickness or death. Service personnel must wear proper personal protective equipment. Do not attempt any service unless the fan motor is locked out.

WARNING

Figure 37 - Improper Unit Locations

Performance

Improper location of the evaporative-cooled condenser may seriously degrade the capacity of the equipment. Make sure the equipment is located such that discharge air from the condenser does not enter the condenser air inlet.

Warranties

Please refer to the limitation of warranties in effect at the time of purchase.

Condenser Tube Inspection

The coil is leak tested at 450 P.S.I.G. before shipment. AAON will not be responsible for loss of refrigerant. It is the responsibility of the installer to verify that the system is sealed before charging with refrigerant. If the unit is operated during low ambient temperature conditions, freeze protection for the recirculating water system must be provided.

Freeze Protection

In order to prevent water temperatures from dropping below 50°F, this unit is equipped with a VFD on the fan motors when the refrigeration system is operating.

Recirculating Water System

Electric sump heaters are available to keep the sump water from freezing when the refrigeration system is not operating. An electric resistance heater is supplied in the vestibule when sump heaters are selected.

Note: The condenser should not be operated with the fan on and the pump cycled on and off to maintain head pressure control under any conditions. The unit is equipped with a water temperature controller which varies fan speed to maintain sump water temperature. This unit is not equipped with a compressor discharge pressure controller for fan speed modulation and therefore cannot be operated without water flow.

Pre Start-Up

Do not start the evaporative-cooled condenser or compressors without installation of proper water treatment chemicals. Contact your local water treatment expert for correct selection of

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water treatment chemical, adjustment of chemical feed and bleed rates.

Cleanliness

Dirt and debris may accumulate in the sump during shipping and storage. The sump should be cleaned prior to start-up to prevent clogging the water distribution system. Any surfaces that show contamination should be cleaned ONLY with a commercial stainless steel cleaner to restore the initial appearance. The inlet screens should be inspected for foreign material.

Storage

Pumps removed from service and stored, must be properly prepared to prevent excessive rusting. Pump port protection plates must not be removed until the pump is ready to connect to the piping. Rotate the shaft periodically (At least monthly) to keep rotating element free and bearings fully functional.

For long term storage, the pump must be placed in a vertical position in a dry environment. Internal rusting can be prevented by removing the plugs at the top and bottom of the casing and drain or air blow out all water to prevent rust buildup or the possibility of freezing. Be sure to reinstall the plugs when the unit is made operational. Rust-proofing or packing the casing with moisture absorbing material and covering the flanges is acceptable. When returning to service be sure to remove the drying agent from the pump.

Pump Operation

Before initial start of the pump, check as follows:

1. Be sure that pump operates in the direction indicated by the arrow on the pump casing. Check rotation each time motor leads have been disconnected.

2. Check all connections of motor and starting device with wiring diagram. Check voltage, phase and frequency of line circuit with motor name plate.

3. Check suction and discharge piping and pressure gauges for proper operation.

4. Turn rotating element by hand to assure that it rotates freely.

Running

Periodically inspect pump while running, but especially after initial start-up and after repairs.

1. Check pump and piping for leaks. Repair immediately.

2. Record pressure gauge readings for future reference.

3. Record voltage, amperage per phase, and kW.

Condenser Fan Motors

The direct-drive condenser motors on AAON evaporative-cooled condensers are 1200-rpm premium efficiency motors controlled by a VFD. These motors are totally enclosed air over motors with weep holes in the bottom end bell so that any condensation can drain out of the motor. The motors have a small electric resistance heater installed inside the casing to keep the motors warm when they are deactivated. The heaters are designed to keep the interior of the motor 10°F warmer than the surrounding ambient temperature. This prevents condensation from forming inside the motor. Ensure that fan is tightly mounted to the motor shaft and the motor mounting bolts are aligned and secure.

Water Makeup Valve

The sump water level is controlled by a set of conductivity probes at different levels in the sump. This water level controller is located in the vestibule behind the condenser pump. There are four conductivity probes in

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this controller. There is a reference probe (shown as “ref” on the wiring diagram). This probe is one of the two longest probes. The other long probe is the low water level probe (shown as “lo” on the wiring diagram). The medium length probe is for the medium water level (shown as “med” on the wiring diagram). The short probe is for the high water level (shown as “hi” on the wiring diagram). There is a solenoid valve in the makeup water line that is activated by the water level controller. The water level controller determines the level of water in the sump based on conductivity between two probes. If the controller sees conductivity between two probes, it knows that water is at least at the level of that probe.

If the water in the sump is below the low probe, it will not allow the condenser pump or the sump heater to operate. It will activate the makeup water solenoid to try to fill the sump assuming water is flowing to the unit. Once water is above the low probe, it will allow the condenser pump and sump heater (if ordered and the ambient temperature is below 40°F) to operate. The makeup water solenoid will remain activated until water gets to the high water level. When the water gets to the high water level, the makeup water solenoid will deactivate until water gets to the medium water level. In normal operation, the water level should swing between the medium and high water levels. The maximum high water level should be 1” below the overflow drain which occurs after the makeup water valve shuts off when the water level reaches the high level probe.

Figure 38 - Water Makeup Valve

Makeup water supply pressure should be maintained between 15 and 60 psig for proper operation of the valve. The makeup water valve assembly should be inspected monthly and adjusted as required. Replace the valve seat if leakage occurs when the valve is in the closed position.

Water Treatment System

All AAON evaporative-cooled condensers come equipped with a water treatment system that should be maintained by a local water treatment professional trained in the water treatment of evaporative condensers. This system consists of a controller, three chemical pumps and storage tanks, a conductivity sensor, a motorized ball valve for water bleed, and a water meter. One chemical pump and tank is typically used for a de-scaling chemical to prevent scale from forming in the condenser. The other two pumps and tanks are typically used for two different biocides (to kill any microorganisms that could grow in the condenser). Two biocides are used to prevent organisms from becoming resistant to one chemical.

The mineral content of the water must be controlled. All makeup water has minerals

Page 73

in it. As water is evaporated from the condenser, these minerals remain. As the mineral content of the water increases, the conductivity of the water increases. The water treatment controller monitors this conductivity. As the water conductivity rises above set point, the controller will open a motorized ball valve on the discharge side of the condenser pump and dumps water into the condenser drain until conductivity is lowered. While the motorized ball valve is opened, the controller will not disperse chemicals.

The chemicals are dispersed by the water treatment controller based on the scheduled input by the water treatment professional.

The water meter measures the quantity of makeup water used by the condenser.

Any water treatment program must be compatible with stainless steel, copper, aluminum, ABS plastic and PVC. Batch feed processes should never be used as concentrated chemicals can cause corrosion. Never use hydrochloric acid (muriatic acid) as it will corrode stainless steel.

Sequence of Operations

On a call for cooling, the condenser pump is activated. A pressure switch in the pump discharge is bypassed for six seconds by a time delay relay in order for the pump to establish recirculating water flow. If flow is not proven within the six seconds, the pressure switch opens, breaking the safety circuit, thereby shutting down the entire system. This pressure switch is set to close at 3 psi and open at 1 psi. A Johnson Controls S350C measures the water temperature in the pump discharge line. If the sump water temperature exceeds 105°F, the cooling system will be shut down thereby preventing damage to the evaporative condenser.

If a fault occurs in the evaporative condenser fan motor VFD, normally closed fault terminals on the VFD will interrupt the safety circuit, thereby shutting down the system.

If the VFD does fault and cannot be reset, there is a VFD bypass switch mounted near the VFD. This switch has four positions— line, off, drive, and test. The “line” position will bypass the VFD, sending power to the motor. In this position, the condenser fans will run at full speed. The “off” position will not allow power to pass through the switch. This functions as a disconnect switch. The “drive” position runs power through the VFD. This is the normal operation for the switch. The “test” position routes power to the VFD but not to the motor. This is useful for running tests on the VFD without sending power to the motor.

A Johnson Controls A350P controls the VFD speed. This device sends a 0-10 VDC signal to the VFD. This controller is set to maintain a sump temperature of 70°F. On a rise in sump temperature, the controller increases the voltage to the VFD, increasing the speed of the condenser fans. Conversely, on a drop in sump temperature, the controller will decrease the voltage to the VFD, decreasing the speed of the condenser fans.

An outside air thermostat does not allow the condenser to operate when the ambient temperature is below 35°F.

Pump Maintenance

Cleaning - Remove oil, dust, water, and chemicals from exterior of motor and pump. Keep motor air inlet and outlet open. Blow out interior of open motors with clean compressed air at low pressure.

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Labeled Motors - It is imperative for repair of a motor with Underwriters’ Laboratories label that original clearances be held; that all plugs, screws, other hardware be fastened securely, and that parts replacements be exact duplicates or approved equals. Violation of any of the above invalidates Underwriters’ Label.

Fan Motor Maintenance

Same as pump maintenance

Access Doors

If scale deposits or water is found around the access doors, adjust door for tightness. Adjust as necessary until leaking stops when door is closed.

Bearings - Lubrication

Every 6 months or after a prolonged shut down. Use waterproof, lithium based grease. Below 32°F - Esso Exxon or Beacon 325. Above 32°F – Mobil Mobilox EP2, Shell Alvania EP2 or Texaco RB2.

Recommended Monthly Inspection

1. Clean sump section interior. Dirt and

other impurities which have accumulated in the sump should be removed from the sump area. Shut off makeup water ball valve and open the drain connection for flushing of the sump.

2. Clean dirt out of sump using a water hose (not a pressure washer).

3. Clean sump suction strainer.

4. Check water operating level.

5. Inspect fan motor(s) and water circulation

pump(s) and lubricate per the lubrication nameplate or manufacture’s recommendations.

6. Inspect axial fans and eliminators removing any debris which may have accumulated during operation.

7. Inspect the water distribution system to insure that nozzles and spray orifices are functioning correctly. The inspection should

be made with the circulation pump on and fans off.

Mist Eliminators

The mist eliminators must be correctly positioned when they are replaced during cleaning or service.

Air Inlet

Inspect the air inlet louvers and mist eliminators into the condenser section on a monthly basis to remove any paper, leaves or other debris that may block the airflow.

Stainless Steel Base Pan

The base pan under the tube bundles is stainless steel and may sometimes become tarnished due to contamination. These surfaces should be inspected yearly to ensure they remain clean of any contamination that may result in damage. Any surfaces that show contamination should be cleaned ONLY with a commercial stainless steel cleaner to restore the initial appearance.

Propeller Fans and Motors

The fans are directly mounted on the motor shafts and the assemblies require minimal maintenance except to assurance they are clear of dirt or debris that would impede the airflow.

Recommended Annual Inspection

In addition to the above maintenance activities, a general inspection of the unit surface should be completed at least once a year. Remove spray header and flush out.

Cleaning

Mechanical cleaning, including pressure washing, should never be performed as surfaces and seals could be damaged. Chemical cleaning that is safe for stainless steel, copper, aluminum, ABS plastic and PVC is the only acceptable means of cleaning the evaporative-cooled condenser.

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A proper water treatment program should reduce cleaning needs.

Water Quality

Table 15 - Recirculating Water Quality

Guidelines

PH 6.5 to 9.0

Hardness as CaCO

Alkalinity as CaCO3 500 PPM Max

Total Dissolved Solids 2000 PPM Max

Chlorides as NaCl 1500 PPM Max

Sulfates 750 PPM Max

500 PPM Max

Cycles of concentration (the ratio of dissolved solids in recirculated water to dissolved solids in makeup), should be determined and monitored frequently by a competent water treatment expert.

To limit cycles of concentration to maintain the above guideline, it is necessary to “bleed” a certain portion of the recirculated water. This is achieved automatically with a solenoid valve actuated by a conductivity meter set at the desired conductivity corresponding to the desired cycles of concentration. It should be noted that these are guidelines and even though these individual values are met, under certain conditions the water quality can be aggressive. For example, water with very low alkalinity and levels of chlorides and sulfates approaching maximum recommended levels can be corrosive.

All AAON evaporative-cooled condensers are furnished with a bleed system fitting and valve to continuously remove a small portion of the recirculated water to keep the water quality within the above listed parameters. This device is located on the discharge side of the pump. It is important to note that since “bleed” rate is a function of evaporation rate (i.e., amount of heat rejected), if the bleed setting is manual based on design heat load, too much water

will be removed when the heat load is less that design.

The AAON evaporative-cooled condenser is equipped with a desuperheater. The desuperheater coil is located above the eliminators. Approximately 22% of the total heat of rejection is accomplished with the desuperheater. Water usage of the AAON evaporative-cooled condenser is approximately 22% less than evaporative condensers not equipped with a desuperheater.

One method of calculating evaporation and bleed in gallons per minute (gpm) is shown as follows:

Evaporation Rate











,( ⁄)



×









×

⁄







Bleed Rate





Page 76

Example: A unit has 100 ton cooling capacity with a compressor EER = 15

Total Heat of Rejection

.

= Unit Capacity in Tons × 12000 ×

.

= 100 × 12000 ×

= 1,473,040 Btu/hr

Total Full Load Heat of Rejection via Evaporation

= Total Heat of Rejection × (1 – fraction of heat rejected by desuperheater) = 1,473,040 Btu/hr × (1 – 0.22) = 1,148,971 Btu/hr

Note that approximately 22% of the total heat of rejection is accomplished with the desuperheater at full load. So, the fraction of heat rejected by the desuperheater (in the equation above) is approximately 0.22 at full load and increases as the ambient dry bulb decreases.

Evaporation Rate

,,( 

,( ⁄

= 2.19 gpm

Assuming 4 cycles of concentration:

Bleed Rate

.



= 0.73 gpm

󰇡

1

⁄) ⁄)



󰇢

󰇡

1



󰇢

Mechanical Cleaning

Do not attempt to mechanically clean the copper tubing in the evaporative-cooled condenser. Do not use wire brushes or any other mechanical device on the copper tubing. Severe damage may result. Contact your water treatment expert for

recommendations on chemical cleaning procedures.

Air-Cooled Condenser

The air-cooled condenser section rejects heat by passing outdoor air over the fin tube coils for cooling of the hot refrigerant gas from the compressors. The heated air will discharge from the top of the section through the axial flow fans.

The condenser coils should be inspected yearly to ensure unrestricted airflow. If the installation has a large amount of airborne dust or other material, the condenser coils should be cleaned with a water spray in a direction opposite to airflow. Care must be taken to prevent bending of the aluminum fins on the copper tubes.

E-Coated Coil Cleaning

Documented routine cleaning of e-coated coils is required to maintain coating warranty coverage for fin and tube and microchannel coils.

WARNIN

Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.

Surface loaded fibers or dirt should be removed prior to water rinse to prevent restriction of airflow. If unable to back wash the side of the coil opposite of the coils entering air side, then surface loaded fibers or dirt should be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges

Page 77

CAUTIO

bent over) if the tool is applied across the fins.

Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

A monthly clean water rinse is recommended for coils that are applied in coastal or industrial environments to help to remove chlorides, dirt, and debris. It is very important when rinsing, that water temperature is less than 130°F and pressure is than 900 psig to avoid damaging the fin edges. An elevated water temperature (not to exceed 130°F) will reduce surface tension, increasing the ability to remove chlorides and dirt.

High velocity water from a pressure washer or compressed air should only be used at a very low pressure to prevent fin and/or coil damages. The force of the water or air jet may bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdowns may occur.

Quarterly cleaning is essential to extend the life of an e-coated coil and is required to maintain coating warranty coverage.

Coil cleaning shall be part of the unit’s regularly scheduled maintenance procedures. Failure to clean an will void the warranty and may result in reduced efficiency and durability.

e-coated coil

Harsh chemicals, household bleach, or acid cleaners should not be used to clean outdoor or indoor e-coated coils. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion and attack the e-coating. If there is dirt below the surface of the coil, use the recommended coil cleaners.

For routine quarterly cleaning, first clean the coil with the below approved coil cleaner. After cleaning the coils with the approved cleaning agent, use the approved chloride remover to remove soluble salts and revitalize the unit.

Recommended Coil Cleaner The following cleaning agent, assuming it is used in accordance with the manufacturer’s directions on the container for proper mixing and cleaning, has been approved for use on e-coated coils to remove mold, mildew, dust, soot, greasy residue, lint, and other particulate:

Enviro-Coil Concentrate, Part Number HEC01.

Recommended Chloride Remover CHLOR*RID DTS™ should be used to remove soluble salts from the e-coated coil, but the directions must be followed closely. This product is not intended for use as a degreaser. Any grease or oil film should first be removed with the approved cleaning agent.

Remove Barrier - Soluble salts adhere themselves to the substrate. For the effective use of this product, the product must be able to come in contact with the salts. These salts may be beneath any soils, grease or dirt; therefore, these barriers must be removed

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prior to application of this product. As in all surface preparation, the best work yields the best results.

Apply CHLOR*RID DTS - Apply directly onto the substrate. Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed. This may be accomplished by use of a pump-up sprayer or conventional spray gun. The method does not matter, as long as the entire area to be cleaned is wetted. After the substrate has been thoroughly wetted, the salts will be soluble and is now only necessary to rinse them off.

Rinse - It is highly recommended that a hose be used, as a pressure washer will damage the fins. The water to be used for the rinse is recommended to be of potable quality, though a lesser quality of water may be used if a small amount of CHLOR*RID DTS is added. Check with CHLOR*RID

Table 16 - RL-045, RL-060, and RL-070 Standard Filters

Standard Position (Upstream of the Cooling Coils)

Feature

0 18 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 A 18 / 16” x 25” 4” Pleated, 30% Eff, MERV 8 B 18 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 17 - RL-045, RL-060, and RL-070 Standard Filters

Feature

N 18 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 P 18 / 16” x 25” 4” Pleated, 30% Eff, MERV 8 Q 18 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 18 - RL-075, RL-090, and RL-095 Standard Filters

Feature

0 24 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 A 24 / 16” x 25” 4” Pleated, 30% Eff, MERV 8

Quantity / Size

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

International, Inc. for recommendations on lesser quality rinse water.

Type

Pre Filter

Type

Pre Filter

Type

Pre Filter

Page 79

B 24 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 19 - RL-075, RL-090, and RL-095 Standard Filters

Pre Position (Upstream of the Blow-Through Fans)

Feature

N 24 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 P 24 / 16” x 25” 4” Pleated, 30% Eff, MERV 8 Q 24 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 20 - RL-100, RL-110, RL-120, RL-125, and RL-135 Standard Filters

Feature

0 36 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 A 36 / 16” x 25” 4” Pleated, 30% Eff, MERV 8 B 36 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 21 - RL-100, RL-110, RL-120, RL-125, and RL-135 Standard Filters

Feature

N 36 / 16” x 25” 2” Pleated, 30% Eff, MERV 8 P 36 / 16” x 25” 4” Pleated, 30% Eff, MERV 8 Q 36 / 16” x 25” 2” Permanent Filter Frame, Replaceable Media

Table 22 - RL-134, RL-150, RL-155, and RL-170 Standard Filters

Feature

0 48 / 16” x 20” 2” Pleated, 30% Eff, MERV 8 A 48 / 16” x 20” 4” Pleated, 30% Eff, MERV 8 B 48 / 16” x 20” 2” Permanent Filter Frame, Replaceable Media

Table 23 - RL-134, RL-150, RL-155, and RL-170 Standard Filters

Feature

N 48 / 16” x 20” 2” Pleated, 30% Eff, MERV 8 P 48 / 16” x 20” 4” Pleated, 30% Eff, MERV 8

Quantity / Size

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

Type

Pre Filter

Type

Pre Filter

Type

Pre Filter

Type

Pre Filter

Type

Pre Filter

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Q 48 / 16” x 20” 2” Permanent Filter Frame, Replaceable Media

Table 24 - RL-180, RL-181, RL-190, RL-210, RL-230, and RL-240 Standard Filters

Standard Position (Upstream of the Cooling Coils)

Feature

0 72 / 16” x 20” 2” Pleated, 30% Eff, MERV 8 A 72 / 16” x 20” 4” Pleated, 30% Eff, MERV 8 B 72 / 16” x 20” 2” Permanent Filter Frame, Replaceable Media

Table 25 - RL-180, RL-181, RL-190, RL-210, RL-230, and RL-240 Standard Filters

Feature

N 72 / 16” x 20” 2” Pleated, 30% Eff, MERV 8 P 72 / 16” x 20” 4” Pleated, 30% Eff, MERV 8 Q 72 / 16” x 20” 2” Permanent Filter Frame, Replaceable Media

Table 26 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters

Feature

6A 6B Pre Filter High Efficiency Filter

D 20 / 24” x 24”

E 20 / 24” x 24”

Quantity / Size

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

20 / 24” x 24”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Type

Pre Filter

Type

Pre Filter

Type

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Page 81

G 20 / 24” x 24”

H 20 / 24” x 24”

Feature

6A 6B Pre Filter High Efficiency Filter

S 20 / 24” x 24”

T 20 / 24” x 24”

Table 27 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters

20 / 24” x 24”

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

20 / 24” x 24”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Type

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

12” Cartridge,

65% Eff, MERV 11

12”Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Page 82

V 20 / 24” x 24”

W 20 / 24” x 24”

Feature

6A 6B Pre Filter High Efficiency Filter

K 16 / 24” x 24”

M 16 / 24” x 24”

Table 28 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters

Table 29 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters

20 / 24” x 24”

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

16 / 24” x 24”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

16 / 24” x 24”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Type

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

12” Cartridge,

65% Eff, MERV 11

12”Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

Page 83

Pre Position (Upstream of the Blow-Through Fans)

Feature

6A 6B Pre Filter High Efficiency Filter

Z 16 / 24” x 24”

2 16 / 24” x 24”

Table 30 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters

Feature

6A 6B Pre Filter High Efficiency Filter

D 25 / 24” x 24”

E 25 / 24” x 24”

Quantity / Size

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

16 / 24” x 24”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

16 / 24” x 24”

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

25 / 24” x 24”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

Type

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

Type

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Page 84

G 25 / 24” x 24”

H 25 / 24” x 24”

Feature

6A 6B Pre Filter High Efficiency Filter

S 25 / 24” x 24”

T 25 / 24” x 24”

Table 31 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

25 / 24” x 24”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

25 / 24” x 24”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12”Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Type

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Page 85

V 25 / 24” x 24”

W 25 / 24” x 24”

Feature

6A 6B Pre Filter High Efficiency Filter

K 20 / 24” x 24”

K 25 / 24” x 24”

L P 20 / 24” x 24”

Table 32 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

25 / 24” x 24”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

Standard Position (Upstream of the Cooling Coils)

Quantity / Size

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

20 / 24” x 24”

25 / 24” x 24”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12”Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

65% Eff, MERV 11

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Type

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

Page 86

M 20 / 24” x 24”

M 25 / 24” x 24”

Table 33 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters

Feature

6A 6B Pre Filter High Efficiency Filter

Z 20 / 24” x 24”

Z 25 / 24” x 24”

1 P 20 / 24” x 24”

25 / 24” x 24”

Pre Position (Upstream of the Blow-Through Fans)

Quantity / Size

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

20 / 24” x 24”

25 / 24” x 24”

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Type

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

Page 87

2 20 / 24” x 24”

2 25 / 24” x 24”

Table 34 - RL-045 to RL-125 and RL-135 High Efficiency Cartridge Filters

Feature 6B Quantity / Size

B 20 / 24” x 24”

E 20 / 24” x 24”

Table 35 - RL-045 to RL-125 and RL-135 High Efficiency Bag Filters

Feature 6B Quantity / Size

H 16 / 24” x 24” 2” Pleated, 30” Bag,

25 / 24” x 24”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

12 / 24” x 24”

4 / 24” x 20”

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Final Filter Position

Pre Filter High Efficiency Filter

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

Final Filter Position

Pre Filter High Efficiency Filter

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

Type

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Type

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

Page 88

L 16 / 24” x 24”

Table 36 - RL-134 and RL-150 to RL-240 High Efficiency Cartridge Filters

Feature 6B Quantity / Size

B 25 / 24” x 24”

E 25 / 24” x 24”

Table 37 - RL-134 and RL-150 to RL-240 High Efficiency Bag Filters

Feature 6B Quantity / Size

G 15 / 24” x 24” 2” Pleated, 30” Bag,

15 / 24” x 24”

5 / 24” x 20”

15 / 24” x 24”

5 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

24 / 24” x 24”

8 / 24” x 20”

30% Eff, MERV 8 85% Eff, MERV 13

2” Pleated,

30% Eff, MERV 8

Final Filter Position

Pre Filter High Efficiency Filter

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

4” Pleated,

30% Eff, MERV 8

Final Filter Position

Pre Filter High Efficiency Filter

30” Bag,

95% Eff, MERV 14

Type

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

12” Cartridge,

85% Eff, MERV 13

12” Cartridge,

95% Eff, MERV 14

Type

Page 89

5 / 24” x 20” 30% Eff, MERV 8 85% Eff, MERV 13

H 20 / 24” x 24”

L 20 / 24” x 24”

J 25 / 24” x 24”

M 25 / 24” x 24”

Table 38 - RL-045 to RL-125 and RL-135 Energy Recovery Wheel Filters

Feature

D, H, Q, U 8 / 18” x 24”

F, K, S, W 16 / 16” x 20”

Table 39 - RL-134 and RL-150 to RL-240 Energy Recovery Wheel Filters

Feature

D, H, Q, U 6 / 20” x 25”

E, J, R, V 8 / 20” x 25” F, K, S, W 14 / 20” x 24” G, L, T, Y 18 / 18” x 24”

Replacement Parts

Parts for AAON equipment may be obtained from your local AAON representative. Reference the unit serial number and part number when ordering parts.

AAON

15 / 24” x 24”

5 / 24” x 20”

Quantity / Size

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

2” Pleated,

30% Eff, MERV 8

Type

Pre Filter

4” Pleated, 30% Eff, MERV 8 E, J, R, V 8 / 18” x 24”

Type

Pre Filter

4” Pleated, 30% Eff, MERV 8

Warranty, Service and Parts Department

2424 S. Yukon Ave. Tulsa, OK 74107 Ph: 918-583-2266 Fax: 918-382-6364 www.aaon.com

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

30” Bag,

85% Eff, MERV 13

30” Bag,

95% Eff, MERV 14

Page 90

Note: Before calling, technician should have model and serial number of the unit available for the service department to help answer questions regarding the unit.

Page 91

RL Series Startup Form

Date:______________ Job Name:_____________________________________________________________________ Address:______________________________________________________________________ Model Number:_________________________________________________________________ ______________________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________________ Address:__________________________________________________ _________________________________________________________

Pre Startup Checklist

1. Is there any visible shipping damage? Yes No

2. Is the unit level? Yes No

3. Are the unit clearances adequate for service and operation? Yes No

4. Do all access doors open freely and are the handles operational? Yes No

5. Have all electrical connections been tested for tightness? Yes No

6. Does the electrical service correspond to the unit nameplate? Yes No

7. On 208/230V units, has transformer tap been checked? Yes No

Installing contractor should verify the following items.

8. Has overcurrent protection been installed to match the unit nameplate requirement? Yes No

9. Have all set screws on the fans been tightened? Yes No

10. Do all fans rotate freely? Yes No

11. Is all copper tubing isolated so that it does not rub? Yes No

12. Has outside air rain hood been opened? Yes No

13. Have the damper assemblies been inspected? Yes No

14. Are the air filters installed with proper orientation? Yes No

15. Have condensate drain and p-trap been connected? Yes No

Supply Fan Assembly

Alignment

Check Rotation

Number hp L1 L2 L3

1 2 3 4

Band Size_____________________

VFD Frequency________________

VAV Controls_________________

Phone:_____________

Nameplate Amps________

Page 92

Energy Recovery Wheel Assembly

Wheel(s) Spin Freely

Check Rotation

FLA____________

Number hp L1 L2 L3

1 2

Power Return Assembly

Alignment

Check Rotation

Nameplate Amps________

Number hp L1 L2 L3

1 2

Power Exhaust Assembly

Alignment

Check Rotation

Nameplate Amps________

Number hp L1 L2 L3

1 2

Outside Air/Economizer Dampers

Operation Check

Damper Actuator Type:

Economizer Changeover Type and Operations:

Damper Wiring Check

Gears Check

Ambient Temperature

Ambient Dry Bulb Temperature ________°F Ambient Wet Bulb Temperature ________°F

Unit Configuration

Water-Cooled Condenser Air-Cooled Condenser No Water Leaks Evaporative-Cooled Condenser Condenser Safety Check Water Flow ________GPM Water Inlet Temperature ________°F Water Outlet Temperature ________°F

Page 93

Compressors / DX Cooling

Head

Pressure

Number/stage L1 L2 L3

1 2 3 4 5 6 7 8

Ambient DB Temperature ________°F Ambient WB Temperature ________°F

Coil Entering Air DB Temperature ________°F Coil Entering Air WB Temp ________°F

Coil Leaving Air DB Temperature ________°F Coil Leaving Air WB Temp ________°F

Refrigeration System 1

Saturated

Temperature

Refrigeration System 2

Saturated

Temperature

Refrigeration System 3

Saturated

Temperature

Refrigeration System 4

Saturated

Temperature

Discharge

Suction

Liquid

Discharge

Suction

Liquid

Discharge

Suction

Liquid

Discharge

Suction

Liquid

Pressure

PSIG

Line

Suction

Pressure

PSIG

Sub-cooling Superheat

N/A N/A N/A

N/A

Sub-cooling Superheat

N/A N/A N/A

N/A

Sub-cooling Superheat

N/A N/A N/A

N/A

Sub-cooling Superheat

N/A N/A N/A

N/A

Crankcase

Heater

Amps

Page 94

Condenser Fans

Alignment

Check Rotation

Nameplate Amps________

Number hp L1 L2 L3

1 2 3 4 5 6

Evaporative-Cooled Condenser Pumps

Check Rotation

Number hp L1 L2 L3

1 2

Water/Glycol System

1. Has the entire system been flushed and pressure checked? Yes No

2. Has the entire system been filled with fluid? Yes No

3. Has air been bled from the heat exchangers and piping? Yes No

4. Is the glycol the proper type and concentration (N/A if water)? Yes No

5. Is there a minimum load of 50% of the design load? Yes No

6. Has the water piping been insulated? Yes No

7. What is the freeze point of the glycol (N/A if water)? ________________________________

Gas Heating

Natural Gas Propane Purge Air from Lines Verify Pilot Spark Stage Manifold Pressure (w.c.) Stage Manifold Pressure (w.c.)

1 2 3 4 5 6 7 8 9 10

11 12

Page 95

Electric Heating

Stages__________

Limit Lockout Aux. Limit Lockout

Stage Amps Stage Amps

1 2 3 4 5 6 7 8 9 10

11 12

Page 96

Maintenance Log

This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any service, repair or adjustments. AAON Service and Warranty Departments are available to advise and provide phone help for proper operation and replacement parts. The responsibility for proper start-up, maintenance and servicing of the equipment falls to the owner and qualified licensed technician.

Entry Date Action Taken Name/Tel.

Page 97

Literature Change History

May 2011

Update of RL IOM to match the format of other current AAON literature. Update of filter sizes, unit startup form, fan airflow adjustment, and spring isolator adjustment. Addition of direct fire gas heat information, figure/table captions, and backdraft damper setup.

May 2012

Update of startup form.

June 2012

Added compressor lubricant warning. Added “Storage” section on page 54.

July 2013

Updated the feature string nomenclature options.

October 2013

Added cautions calling for the need to seal water, electrical, and gas entries into the unit.

February 2014

Added section for cartridge filter installation. Updated the direct fire gas heat section.

May 2014

Added e-coated coil cleaning section.

November 2014

Added energy recovery wheel installation, maintenance, and startup information. Plenum fan screw specifications updated. Warranty and replacement parts information updated. P-traps are no longer factory provided.

January 2016

Updated Phase and Brownout Protection Module section .

April 2016

Added the Adjustable Fan Cycling Switch Procedure section.

Page 98

Page 99

Page 100

AAON

2425 South Yukon Ave.

Tulsa, OK 74107-2728

Phone: 918-583-2266

Fax: 918-583-6094

www.aaon.com

RL Series

Installation, Operation, &

Maintenance

R10091 · Rev. B · 160425

It is the intent of AAON to provide accurate and current product information. However, in the interest of product improvement, AAON reserves the right to change pricing, specifications, and/or design of its product without notice, obligation, or liability.

AAON

and AAONAIRE® are registered trademarks of AAON, Inc., Tulsa, OK.