AAON RM-030 User Manual
AAON
HEATING • COOLING & COMBINATION
®
RM SERIES
ROOFTOP UNITS
INSTALLATION
INSTRUCTION
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
GENERAL DESCRIPTION …………………………………………………………………………… 03
Unpacking
Certification
Codes and Ordinances
OWNER'S INFORMATION …………………………………………………………………………… 04
HEATING / COOLING SYSTEMS …………………………………………………………………… 05
INSTALLATION ………………………………………………………………………………………… 06
Setting the Curb / Unit ………………………………………………………………………… 07
Service Clearances
Outside Air Hood………………………………………………………………………………… 08
Electrical
Gas Piping………………………………………………………………………………………… 09
Condensate Piping ……………………………………………………………………………… 10
GAS UNIT LIGHTING INSTRUCTIONS …………………………………………………………… 11
PERIODIC INSPECTION PROCEDURES ………………………………………………………… 12
Gas Heating, Cooling, Electric, Steam, Hot Water & Chilled Water Units
SERVICE, TROUBLE SHOOTING & MAINTENANCE ………………………………………… 14
Lubrication
Cleaning
FILTER INSTALLATION / REPLACEMENT ……………………………………………………… 15
SERVICING ……………………………………………………………………………………………… 16
Rooftop Unit Replacement Parts …………………………………………………………… 18
SEQUENCE OF OPERATIONS ……………………………………………………………………… 19
Heating
Cooling
Optional Economizer
VAV Systems …………………………………………………………………………………… 20
Power Exhaust Options
COMPRESSOR CHECKOUT PROCEDURE ……………………………………………………… 21
IGNITION CONTROL CHECKOUT PROCEDURE ……………………………………………… 22
FACTORY START-UP FORM ………………………………………………………………………… 23
Owner should pay particular attention to the words: NOTE, CAUTION AND WARNING.
NOTES are intended to clarify or make the installation easier. CAUTIONS are given to prevent
equipment damage. WARNINGS are given to alert owner that personal injury and/or equipment
damage may result if installation procedure is not handled properly.
It is the intent of
AAON, Inc.
AAON, Inc.
reserves the right to change pricing, specifications and/or design of it's products without notice, obligation or liablity.
to provide accurate and current specification information. However, in the interest of product improvement,
© 2003
AAON
&
AAONAIRE
AAON, Inc.
, all rights reserved throughout the world.
are registered trademarks of
AAON, Inc.
, Tulsa, OK.
R15690 (7-03)
2
The units are designed as self-contained heating, cooling
or combination units for outdoor installation only, using
the refrigerant shown on the rating plate, chilled water,
natural or propane gas, electric resistance, steam or hot
water.
UNPACKING
When received, the unit should be checked for damage
that might have occurred in transit. If damage is found,
it should be noted on the carrier's Freight Bill. A request
for inspection by carrier's agent should be made in
writing at once.
CERTIFICATION
• GAS HEAT MODELS
(a) Design Certified as a forced air furnace with or without cooling unit.
(b) Certified for outdoor installation only.
(c) Certified for installation on combustible roof with a minimum of 12" high curb.
(d) Certified with heat exchanger located downstream from evaporator coil.
GENERAL DESCRIPTION
!
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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
NOTE: These units must not be used as a
"construction heater" at any time during any phase
of construction. Very low return air temperatures,
harmful vapors, and misplacement of the filters
will damage the unit and its efficiency.
WARNING
or the gas supplier.
• STEAM OR HOT WATER HEAT MODELS
(a) Certified as a forced air furnace with or without cooling unit.
(b) Certified for outdoor installation only.
(c) Certified for installation on combustible roof with a minimum of 12" high curb.
(d) ARI certified hot water coils.
• ELECTRIC HEAT MODELS
(a) Certified as an electric warm air furnace with or without cooling unit.
(b) Certified for outdoor installation only.
(c) Certified for installation on combustible roof with a minimum of 12" high curb.
• COOLING MODELS
(a) Certified as a commercial central air-conditioner with or without electrically operated compressor.
(b) Certified for outdoor installation only.
(c) Certified for installation on combustible roof with a minimum of 12" high curb.
(d) ARI certified coils.
CODES AND ORDINANCES
System should be sized in accordance with National
Warm Air Heating and Air Conditioning Association
Literature, or the Guide of American Society of Heating,
Refrigeration and Air Conditioning Engineers. The
installation must conform with local building codes or, in
the absence of local codes with (United States) National
Fuel Gas Code "ANSI-Z223.1", (Canada) current CAN /
CGA- B149.1 or . 2. Installation Codes for Gas Burning
Appliances and Equipment, current C.S.A. Standard
C22.1, Canadian Electrical Code Part 1, and C.S.A.
Standard B52 Mechanical Refrigeration Code, and Local
Plumbing or Waste Water Codes.
! IMPORTANT
▲
The Clean Air Act of 1990 bans the
intentional venting of refrigerant (CFC's and
HCFC's) as of July 1, 1992. Approved
methods of recovery, recycling or reclaiming
must be followed. Fines and/or incarceration
may be levied for non-compliance.
3
OWNER'S INFORMATION
WARNING
Failure to observe the following instructions will result
in premature failure of your system, and possible voiding of the warranty.
DIRECT EXPANSION (DX) COOLING UNITS
Never cut off the main power supply to the unit, except
for complete shutdown. When power is cut off from the
unit, 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.
WARNING: Improper installation, adjustment, alteration, service, or maintenance can cause property damage, personal injury or loss of life. Installation and
service must be performed by a qualified installer, service agency or if gas fired units, the gas supplier. Refer
to installation instructions provided with the unit and
this manual.
CAUTION: While the following incorrect operations
may not cause damage to the system, they will impair
the performance, and may cause the built-in safety
devices to cut the system off completely.
1. LOW AMBIENT OPERATION
The cooling section of a direct expansion (DX) unit
will not operate properly when the outdoor temperature is below 55°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.
!
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WARNING
Scroll compressors will be damaged by
operation with the wrong rotation.
THE LOW PRESSURE SWITCH HAS BEEN
DISCONNECTED AFTER TESTING
AT THE FACTORY.
The wiring must be reconnected and proper
rotation determined at the time of start-up by
a qualified service technician using suction
and discharge pressures gauges.
Any alteration should only be made at
the unit power connection.
4
HEATING & COOLING SYSTEMS
NORMAL OPERATION
HEATING
Set the thermostat system switch to "HEAT".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
COOLING
Set the thermostat system switch to "COOL".
Set the thermostat fan switch to "AUTO" or "ON".
Set the thermostat temperature at the desired point.
AIR CIRCULATION
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "ON".
Do not change temperature setting.
With these settings, the air circulating blower will run
continuously but the air will not be heated or cooled.
SYSTEM OFF
Set the thermostat system switch to "OFF".
Set the thermostat fan switch to "AUTO".
Do not change temperature setting.
With these settings, the system is shut down, with the
exception of the control system power (24 Vac), and the
crankcase heater of the compressor (approx. 60W).
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.
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.
INSTALLATION IS TO BE ADJUSTED
TO OBTAIN AN AIR TEMPERATURE RISE
WITHIN THE RANGE SPECIFIED ON THE
RATING PLATE.
The units are equipped with a direct spark ignition
system which proves the burner operation during each
call for heat. Power to the ignition control is 24 Vac to
reduce hazards. Burner ignition is by a high intensity
spark.
When heat is called for, the cooling system is inoperable
except for the indoor blower motor. Heating is accomplished by firing gas into the heat exchanger assembly.
ELECTRIC HEATING SYSTEM
Heating is accomplished by passing electrical current
through a specified amount of resistance heaters which
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
include liquid line filter driers, expansion valves and
fully hermetic compressors. Compressors are equipped
with a positive pressure forced lubrication system. The
air cooled condenser coil(s) are constructed of copper
tubes and mechanically bonded aluminum fins and air is
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.
5
INSTALLATION
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CAUTION
!
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WARNING
If outside air is in contact with the bottom
of the unit, the unit must have the bottom
insulation option or be field insulated.
DO NOT DRILL OR PUNCH HOLES IN BASE
OF UNIT FROM INSIDE THE UNIT OR FROM
BELOW TO ATTACH DUCTWORK. LEAKING
MAY OCCUR IF UNIT BASE IS PUNCTURED.
SEE DETAIL "A"
SECTIONAL VIEW OF UNIT ON ROOF CURB
INSULATION MATERIALS MAY
DUCT /
FLEX
CONNECTOR*
STRUCTURAL
STEEL *
BE COMBUSTIBLE
GASKET
COUNTER
FLASHING *
WOOD
NAILER *
CANT STRIP *
RIGID
INSULATION *
CURB
ROOF
DECK *
DETAIL 'A'
DUCT / UNIT CONNECTION
* FIELD SUPPLIED
ROOFING
MATERIAL*
GASKET
WOOD
NAILER *
COUNTER
FLASHING *
RIGID
INSULATION *
CANT STRIP *
ROOFING
MATERIAL*
ROOF
DECK *
DUCT /
FLEX
CONNECTOR*
DUCT RAIL
CURB
STRUCTURAL
STEEL *
WOOD
NAILER *
RIGID
INSULATION *
GASKET
COUNTER
FLASHING *
CANT STRIP *
ROOFING
MATERIAL*
ROOF
DECK *
SOLIDBOTTOM
ACOUSTIC CURB
STRUCTURAL
STEEL *
DUCT / FLEX CONNECTOR*
DETAIL 'A'
OPEN BOTTOM CURB
DUCT RAIL CONNECTION
* FIELD SUPPLIED
6
DETAIL 'A'
ACOUSTIC CURB
* FIELD SUPPLIED
AAON Rooftop units are designed for fast, easy installation. The curb is mounted first and must be located so
duct connections will clear any structural members of
the building.
SETTING THE CURB
When using the factory curb, make openings in roof
decking large enough to allow for duct penetrations and
workspace only. Do not make openings larger than
necessary. Set the curb to coincide with the openings.
CURB MUST BE LEVEL.
SETTING THE UNIT
If cables or chains are used to hoist the unit they must be
the same length and care should be taken to prevent
damage to the cabinet / coils or condenser fans.
It is recommended the unit be hoisted with the outside air
hood in the shipped position. However the unit may be
hoisted with the outside air hood in an open position.
Before lifting unit, be sure that all shipping material is
removed from unit. Secure hooks and cables at all lifting
points / lugs provided on the unit.
INSTALLATION continued
Prior to setting the unit onto the roof curb, be sure that
the gasket material has been applied to curb on all
surfaces meeting with the unit.
Hoist unit to a point directly above the curb and duct
openings. Carefully lower and align the unit with utility
and duct openings unit perimeter fits around the curb.
Make sure the unit is properly seated on the curb and is
level.
Gas fired units should be installed so that the flue
discharge vent is located a minimum 120" away from any
opening through which combustion products might enter the building. Unit location must assure combustion
and ventilation air flows are never obstructed.
Never point flue discharge in direction of fresh air intake
for other equipment.
99" minimum
length
!
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IMPORTANT
PRIOR TO SETTING THE UNIT ON THE CURB.
To insure proper isolation and seal
between the unit & curb, gasket material
MUST BE APPLIED to the curb on
ALL SURFACES meeting with the unit.
!
▲
WARNING
Improper installation, adjustment,
alteration, service or maintenance can
cause property damage, personal injury
or loss of life. Installation and service must
be performed by a qualified installer,
service agency or the gas supplier.
Install the gas fired unit to assure the flow
of combustion and ventilating air is not
obstructed from reaching the heater and
that the flue outlet is located at least
120 inches away from any opening
through which combustion products
could enter the building.
LIFTING DETAIL
TYPICAL FOR
2 - 30 TON UNITS
SERVICE CLEARANCES
LOCATION
Front - Control Door Side
Back - Return Air End
Left Side
Right Side - Access Doors
Top UNOBSTRUCTED
!
▲
CAUTION
2 - 7
48"
48"
6"
60"
UNIT SIZE
8 - 15 16 - 30
48"
48"
6"
60"
Where the supply or warm air duct passes
through a combustible roof, a clearance
of one inch must be maintained between
the outside edges of the duct and
combustible material in accordance
with National Fire Protection Association
Standard No. 90A. Provide flashings or
enclosure between structure and roof
and all joints must be sealed with mastic
roofing to ensure a watertight seal.
All roofing work should be performed
by qualified roofing contractors.
7
48"
48"
6"
60"
INSTALLATION continued
OUTSIDE AIR HOOD
CAUTION: Prior to unit operation, the outside air hood
must be opened as shown below:
APPLY
SILICONE CAULKING
ON TOP &
BOTH SIDES
OF AIR HOOD
AIR HOOD SHOWN IN THE OPEN POSITION
Remove shipping screws from each side of the hood in the
"closed" postion. Lift hood to the "open" position, seal
flange and secure with sheet metal screws.
Air hoods may vary according to unit size and options.
The illustration shown is for practical guidelines for all
outside air hoods.
ELECTRICAL
Verify the unit data plate voltage agrees with the power
supply. Route power and control wiring through the
utility entry. Do not run power and signal wires in the
same conduit. Connect power according to the (unit
specific) wiring diagram provided.
Protect the branch circuit in accordance with code requirements. Control wires should not be run inside the
same conduit. The unit must be electrically grounded in
accordance with the current National Electric Code,
ANSI / NFPA No. 70. In Canada use current C.S.A.
Standard C22.1 Canadian Electric Code Part 1.
Power wiring is to the unit terminal block or main
disconnect. All wiring beyond this point has been done
by the manufacturer and cannot not be modified without
effecting the unit's agency / safety certification.
AIRFLOW IS TO BE ADJUSTED AFTER
INSTALLATION TO OBTAIN AN AIR
TEMPERATURE RISE WITHIN THE RANGE
SPECIFIED ON THE RATING PLATE.
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.
Outdoor air intake adjustments should be made according building ventilation or local code requirements.
! WARNING
▲
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.
! CAUTION
▲
On three phase units the rototation must be
checked on ALL MOTORS AND COMPRESSORS.
SCROLL COMPRESSORS ARE DIRECTIONAL.
Rotation must be checked on start-up by a
qualified service technician using
suction and discharge gauges.
Scroll compressors will FAIL if run in the wrong
direction. Blower and condenser rotation
should be checked and only be altered if
necessary at the power connection.
! CAUTION
▲
START-UP TECHNICIAN MUST CHECK BLOWER
MOTOR AMPERAGE TO ENSURE THAT THE
AMPERAGE LISTED ON THE MOTOR NAMEPLATE
IS NOT EXCEEDED.
NOTE: All units are factory
wired for 208 / 230, 460 or
575 volt. If unit is to be
connected to a 208v supply,
the transformer must be
rewired for 208v service.
For 208v service interchange
the yellow and red conductor
on the low voltage control
transformer.
RED - BLK 208 volt ;
YEL - BLK 230 volt.
8
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