AAON RM-030 User Manual
AAON
HEATING • COOLING & COMBINATION
®
RM SERIES
ROOFTOP UNITS
USERS
INFORMATION
MANUAL
!
▲
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
WARNING
FOR YOUR SAFETY
DO NOT STORE OR USE GASOLINE OR OTHER
FLAMMABLE VAPORS AND LIQUIDS IN THE
VICINITY OF THIS OR ANY OTHER APPLIANCE.
7-2003
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
• EXTINGUISH ANY OPEN FLAME.
• DO NOT TOUCH ANY ELECTRICAL SWITCH.
• DO NOT TRY TO LIGHT ANY APPLIANCE.
• DO NOT USE ANY PHONE IN YOUR BUILDING.
• IMMEDIATELY CALL YOUR GAS SUPPLIER FROM A
NEIGHBOR'S PHONE.
FOLLOW THE GAS SUPPLIER'S INSTRUCTIONS.
• IF YOU CANNOT REACH YOUR GAS SUPPLIER,
CALL THE FIRE DEPARTMENT.
1
AAON
®
TABLE OF CONTENTS
SECTION PAGE NUMBER
OWNER'S INFORMATION ………………………………………………………………………………3 - 4
HEATING / COOLING SYSTEMS …………………………………………………………………… 4 - 5
Gas Unit Lighting Instructions
PERIODIC INSPECTION PROCEDURES…………………………………………………………… 6 - 7
SERVICE, TROUBLE SHOOTING & MAINTENANCE ……………………………………………8
Lubrication
Cleaning
FILTER INSTALLATION / REPLACEMENT ……………………………………………………… 9
SERVICING …………………………………………………………………………………………… 10 - 12
Rooftop Unit Replacement Parts
SEQUENCE OF OPERATIONS ……………………………………………………………………… 13
Heating
Cooling
Optional Economizer
VAV Systems …………………………………………………………………………………… 14
Power Exhaust Options
! IMPORTANT
▲
The Clean Air Act of 1990 bans the
intentional venting of refrigerant (CFC's and
HCFC's) as of July 1, 1992. Approved
methods of recovery, recycling or reclaiming
must be followed. Fines and/or incarceration
may be levied for non-compliance.
Owner should pay particular attention to the words: NOTE, CAUTION AND WARNING.
NOTES are intended to clarify or make the installation easier. CAUTIONS are given to prevent
equipment damage. WARNINGS are given to alert owner that personal injury and/or equipment damage
may result if installation procedure is not handled properly.
It is the intent of
AAON, Inc.
R15700 (7-03)
AAON, Inc.
reserves the right to change pricing, specifications and/or design of it's products without notice, obligation or liablity.
to provide accurate and current specification information. However, in the interest of product improvement,
© 2003
AAON
&
AAONAIRE
AAON, Inc.
, all rights reserved throughout the world.
are registered trademarks of
Improper installation, adjustment, alteration,
service or maintenance can cause property
damage, personal injury or loss of life.
Installation and service must be performed
by a qualified installer, service agency
2
!
▲
AAON, Inc.
WARNING
or the gas supplier.
, Tulsa, OK.
The units are designed as self-contained heating, cooling
or combination units for outdoor installation only, using
the refrigerant shown on the rating plate, chilled water,
natural or propane gas, electric resistance, steam or hot
water heating.
WARNING
Failure to observe the following instructions will result
in premature failure of your system, and possible voiding of the warranty.
DIRECT EXPANSION (DX) COOLING UNITS
Never cut off the main power supply to the unit, except
for complete shutdown. When power is cut off from the
unit, compressors with crankcase heaters cannot prevent refrigerant migration. The compressor will cool
down, and liquid refrigerant will accumulate in the
compressor. The compressor is designed to pump only
refrigerant gas and damage may occur when power is
restored.
If power must be cut off for more than an hour, turn the
thermostat system switch to "OFF", and leave it off until
the main power switch has been turned on again for at
least twenty four hours on units with compressor crankcase heaters. This will give the crankcase heater time to
clear liquid accumulation out of the compressor before it
is required to run.
Always control the system from the thermostat, or control panel, never at the main power supply (except in an
emergency or complete shutdown of the system).
During the cooling season, if the air flow is reduced due
to dirty air filters or other reasons, the cooling coils will
get too cold and result in excessive liquid return to the
compressor. As the liquid concentration accumulates,
oil is washed out of the compressor, leaving it starved for
lubrication.
The compressors must be on a minimum of 4 minutes
and off for a minimum of 5 minutes. The cycle rate must
not exceed 8 starts per hour.
THE COMPRESSOR LIFE WILL BE SERIOUSLY
SHORTENED BY RESULTING REDUCED LUBRICATION, AND THE PUMPING OF EXCESS AMOUNTS
OF LIQUID OIL AND REFRIGERANT.
GAS OR ELECTRIC HEATING
The system is designed to heat a given amount of air each
minute it operates. If the amount of air heated is greatly
reduced (approximately 1/3 capacity), the heat exchanger / heater coil temperature will increase above
acceptable level and result in shut down by a high
temperature safety switch incorporated either in the
heat exchanger or the heater area.
GAS HEAT UNITS - WARNING: If, due to safety switch
shut off or gas supply shut off failure; ALWAYS CLOSE
MANUAL GAS VALVE TO UNIT PRIOR TO ANY
ELECTRICAL SERVICE.
PROLONGED OVERHEATING OF THE HEAT
EXCHANGER WILL SHORTEN ITS LIFE.
OWNER'S INFORMATION
!
▲
Electric shock hazard. Can cause injury or
death. Before attempting to perform any
service or maintenance, turn the electrical
power to unit to OFF at disconnect switch(es).
Unit may have multiple power supplies.
AIRFLOW IS TO BE ADJUSTED AFTER
INSTALLATION TO OBTAIN AN AIR
TEMPERATURE RISE WITHIN THE RANGE
SPECIFIED ON THE RATING PLATE.
DUE TO JOB SPECIFICATION REVISIONS,
IT MAY BE NECESSARY TO ADJUST OR
CHANGE THE SHEAVE OR PULLEY TO
OBTAIN THE DESIRED AIRFLOW
AT THE TIME OF INSTALLATION.
START-UP TECHNICIAN MUST CHECK BLOWER
MOTOR AMPERAGE TO ENSURE THAT THE
AMPERAGE LISTED ON THE MOTOR NAMEPLATE
CAUTION: While the following incorrect operations
may not cause damage to the system, they will impair
the performance, and may cause the built-in safety
devices to cut the system off completely.
1. LOW AMBIENT OPERATION
The cooling section of a direct expansion (DX) unit
will not operate properly when the outdoor temperature is below 55°F. Outside air intake options are
necessary if operation below 55°F is expected.
2. MULTIPLE UNIT OPERATION
When several units are used in conditioning the
space, and any are combination heating-cooling
units, all system thermostat switches must be set at
either heating, cooling, or set at "off". Do not run
part of a system switched to an opposite mode.
Cooling only units should be switched to "off" at the
thermostat during the heating season.
WIRING DIAGRAMS
A complete set of unit specific wiring diagrams in both
ladder and point-to-point form are laminated in plastic
and located inside the control compartment door.
CONDENSATE PIPING
A drain trap is to be connected to the drainpan. If codes
require a condensate drain line, it should be the same
pipe size as the drain nipple and should pitch downward
toward drain.
The condensate drain pipe ("P" trap) is factory supplied
and shipped in the control access compartment for field
installation. An air break should be used with long runs
of condensate lines.
3
W ARNING
! CAUTION
▲
IS NOT EXCEEDED.
OWNERS INFORMATION continued
!
WARNING
Those sensitive to odors or gases from
trace amounts of residual oils
should NOT be present in the
conditioned space during the start-up
of a gas-fired installation.
HEATING & COOLING SYSTEMS
NORMAL OPERATION
IMPORTANT NOTICE:
All gas-fired heat exchangers are completely tested at
the factory before shipment. This will remove nearly all
of the oils that have been used in the manufacturing
process, however, trace amounts may remain. When
performing the initial start-up at the jobsite, it is highly
recommended that people or any other living animals,
that may be sensitive to the residual odors or gases, NOT
be present in the conditioned space during the start-up.
In all cases, including the initial factory firing and
testing, any of the gases will be under the acceptable
level of concentration for human occupancy.
NOTE: In case emergency shut down is required, turn
off the main manual gas shut-off valve and disconnect
main electrical power to unit. These devices should be
properly labeled by the installer.
HEATING
Set the thermostat system switch to "HEAT".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
COOLING
Set the thermostat system switch to "COOL".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
AIR CIRCULATION
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "ON".
Do not change temperature setting.
With these settings, the air circulating blower will run
continuously but the air will not be heated or cooled.
SYSTEM OFF
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "AUTO".
Do not change temperature setting.
With these settings, the system is shut down, with the
exception of the control system power (24 Vac), and the
crankcase heater of the compressor (approx. 60W).
GAS HEATING SYSTEM
The heating section is for use with natural gas supply
pressure of 6" to 10.5" Water Column. The unit may also
utilize propane gas with a supply pressure to the valve
of 11" to 12" Water Column. The rating plate on the
furnace must be inspected to make sure the unit is
stamped for proper gas. A 1/8" pressure tap should be
field supplied by the installer in the piping just ahead of
the gas valve. The pressure tap on the outlet end of the
gas valve can be checked to verify manifold pressure of
3.2" to 3.5" for natural gas.
Combustion air is supplied by a centrifugal blower
which draws in outside air through a protected opening.
This induced draft blower introduces the air to the
burner tubes which assures even primary and secondary
air flow.
All heating system and related safety controls are 100%
tested on each unit prior to shipment.
The units are equipped with a direct spark ignition
system which proves the burner operation during each
call for heat. Power to the ignition control is 24 Vac to
reduce hazards. Burner ignition is by a high intensity
spark.
DO NOT TURN OFF THE MAIN POWER SWITCH.
NIGHT AND VACANT WEEKEND OPERATION
To reduce the operation time during low load periods,
it is recommended that the temperature setting be
increased five degrees during these periods of the cooling
season, and decreased ten degrees during the heating
season.
When heat is called for, the cooling system is inoperable
except for the indoor blower motor. Heating is accomplished by firing gas into the heat exchanger assembly.
4
GAS UNIT LIGHTING INSTRUCTIONS
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A FIRE OR EXPLOSION MAY
RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE.
A. This appliance does not have a pilot. It is equipped with an
ignition device which automatically lights the burner.
not try to light the pilot by hand.
Do
B. BEFORE OPERATING smell all around the appliance area
for gas. Be sure to smell next to the floor because some gas
is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone
in your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition device which
automatically lights the burner. Do
hand.
GAS CONTROL KNOB
SHOWN IN "ON"
POSITION
GAS INLET
not try to light the pilot by
ON
OFF
• If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,
don't try to repair it, call a qualified service technician. Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect the
appliance and to replace any part of the control system and
any gas control which has been under water.
5. Open control access panel.
6. Push in gas control knob slightly and turn clockwise to "OFF".
NOTE: Knob cannot be turned to "OFF" unless knob is pushed
in slightly. Do not force.
7. WAIT five (5) minutes to clear out any gas. Then smell for gas, including
near the floor. If you smell gas, STOP! Follow "B" in the safety
information above on this label. If you don't smell gas, go to the next step.
8. Turn gas control knob counterclockwise to "ON".
9. Close control access panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions
"To Turn Off Gas To Appliance" and call your service
technician or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service
is to be performed.
3. Open control access panel.
ELECTRIC HEATING SYSTEM
Heating is accomplished by passing electrical current
through a specified amount of resistance heaters which
produce the required heat. The indoor blower motor
energizes at the same time as the heaters.
STEAM OR HOT WATER HEATING SYSTEM
Heating is accomplished by passing steam or hot water
through the steam or hot water coil assembly.
COOLING SECTION • DX
All direct expansion refrigeration systems are factory
assembled, charged with refrigerant, tested and operated. On all units 8 ton and larger the refrigerant
system includes multiple circuit evaporator and condenser coils providing two or more stages of cooling.
These systems are provided with liquid line filter driers,
expansion valves and fully hermetic compressors.
Compressors are equipped with a positive pressure
forced lubrication system.
4. Push in gas control knob slightly and turn clockwise to
"OFF". Do not force.
5. Close control access panel.
The air cooled condenser coil(s) are constructed of copper
tubes and mechanically bonded aluminum fins and air
pulled through by propeller fans. The evaporator coil is
draw through type constructed of copper tubes and
mechanically bonded aluminum fins.
The refrigeration section of these appliances has been
found acceptable with applicable provisions of "ANSI /
UL 1995" and current "C.S.A. Standard C22.2" by E.T.L.
NOTE: Crankcase Heater Operation
Some units are equipped with a compressor crankcase
heater, which should be energized at least 24 hours prior
to setting the thermostat for cooling operation.
COOLING SECTION • CHILLED WATER
or NON-COMPRESSORIZED UNIT
Chilled water or non-compressorized units have factory
installed coils. Systems are provided with internal
header connections for field piping. Coils are constructed of copper tubes and mechanically bonded aluminum fins.
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