AAON RN-140 User Manual

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RN SERIES

Packaged Rooftop Units, Heat Pumps,

& Outdoor Air Handling Units

Installation, Operation,

Do not touch any electrical switch; do not

Immediately call your gas supplier from a phone remote from the building. Follow the

If you cannot reach your gas supplier, call

WARNING

service instructions in this manual.

WARNING

FIRE OR EXPLOSION HAZARD

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

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.

& Maintenance

o Do not store gasoline or other flammable

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

o WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.



use any phone in your building.

 Leave the building immediately.



gas supplier’s instructions.



the fire department.

o Startup and service must be performed by a

Factory Trained Service Technician.

Table of Contents

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

RN Series Feature String Nomenclature ....................................................................................... 13

General Information ...................................................................................................................... 24

Codes and Ordinances .............................................................................................................. 24

Receiving Unit .......................................................................................................................... 25

Packaged Direct Expansion (DX) Units ................................................................................... 26

Gas or Electric Heating ............................................................................................................. 27

Wiring Diagrams ....................................................................................................................... 29

Condensate Drain Pan ............................................................................................................... 29

Installation..................................................................................................................................... 30

Locating Units ........................................................................................................................... 30

Setting the Curb ........................................................................................................................ 31

Forklifting the Unit (6-25 and 30 ton) ...................................................................................... 37

Lifting the Unit ......................................................................................................................... 37

Duct Connection ....................................................................................................................... 41

Seismic Curb Installation .......................................................................................................... 42

Outside Air Rain Hood ............................................................................................................. 46

End Flashing Installation .......................................................................................................... 47

Metal Mesh Filters (6-25 and 30 ton Units) ............................................................................. 48

Electrical ................................................................................................................................... 49

Variable Speed Compressors ................................................................................................ 51

Thermostat Control Wiring ................................................................................................... 51

Gas Heating ............................................................................................................................... 52

Piping Sizing Examples ........................................................................................................ 54

Inlet and Manifold Pressures ................................................................................................ 54

Gas Pressure Regulator & Overpressure Protection Device ................................................. 54

Piping Supports ..................................................................................................................... 54

Additional Gas Piping Considerations .................................................................................. 55

Leak Testing .......................................................................................................................... 56

Refrigerant-to-Water Heat Exchanger ...................................................................................... 58

Water-Source Heat Pump Applications ................................................................................ 58

Open Loop Applications ....................................................................................................... 58

Freezing Water in the Heat Exchanger ................................................................................. 59

Water Piping ......................................................................................................................... 59

Condensate Drain Piping .......................................................................................................... 61

Heating Coils ............................................................................................................................ 62

Chilled Water Coil .................................................................................................................... 62

Electric Preheat ......................................................................................................................... 63

Energy Recovery Units ............................................................................................................. 63

Startup ........................................................................................................................................... 71

Supply Fans ............................................................................................................................... 71

Power Return Axial Flow Fans (16-25 and 30 tons) ................................................................ 72

Power Return and Exhaust Axial Flow Fans (26 and 31-140 tons) .......................................... 74

Filters ........................................................................................................................................ 75

Adjusting Refrigerant Charge ................................................................................................... 75

Checking Liquid Sub-Cooling .............................................................................................. 76

Checking Evaporator Superheat............................................................................................ 76

Adjusting Sub-cooling and Superheat Temperatures............................................................ 77

Gas Heater Instructions ............................................................................................................. 79

Condenser Fan Electronically Commutated Motor (ECM) Startup ......................................... 80

VFD Controlled Condenser Fan Startup ................................................................................... 81

Operation....................................................................................................................................... 82

Thermostat Operation ............................................................................................................... 82

Packaged DX Cooling Operation and Control ......................................................................... 82

Gas Heater Operation ................................................................................................................ 82

Electric Heating Operation ....................................................................................................... 83

Steam or Hot Water Preheating and Heating Operation ........................................................... 83

Modulating Electric Preheat ..................................................................................................... 83

Chilled Water or Non-Compressorized DX Cooling Operation ............................................... 83

Maintenance .................................................................................................................................. 84

Gas Heating ............................................................................................................................... 84

Gas Heat Exchanger Removal .................................................................................................. 85

DX Cooling ............................................................................................................................... 85

Condenser Fans (6-25 and 30 ton) ............................................................................................ 86

Condensate Drain Pans ............................................................................................................. 86

Evaporator Coil (6-25 and 30 ton) ............................................................................................ 87

Brazed Plate Heat Exchanger Cleaning .................................................................................... 87

E-Coated Coil Cleaning ............................................................................................................ 88

Microchannel Coil Cleaning ..................................................................................................... 89

Supply Fans ............................................................................................................................... 90

Phase and Brownout Protection ................................................................................................ 91

Variable Capacity Compressor Controller ................................................................................ 92

Filter Replacement .................................................................................................................... 93

Replacement Parts ................................................................................................................... 105

Appendix A - Heat Exchanger Corrosion Resistance ................................................................. 106

Appendix B - Thermistor Temperature vs. Resistance Values ................................................... 108

RN Series Startup Form .............................................................................................................. 109

Maintenance Log ........................................................................................................................ 113

Literature Change History........................................................................................................... 114

R90721 · Rev. B · 140225

Index of Tables and Figures

Tables:

Table 1 - Electric and Gas Heating Capacities ............................................................................. 28

Table 2 - A Cabinet Unit Clearances ............................................................................................ 30

Table 3 - B Cabinet Unit Clearances ............................................................................................ 30

Table 4 - C Cabinet Unit Clearances ............................................................................................ 31

Table 5 - D Cabinet Unit Clearances ............................................................................................ 31

Table 6 - E Cabinet Unit Clearances............................................................................................. 31

Table 7 - Variable Speed Compressor VFD Frequency Range .................................................... 51

Table 8 - Control Wiring............................................................................................................... 51

Table 9 - 6-8 and 10 ton Gas Connections .................................................................................... 52

Table 10 - 9 and 11-15 ton Gas Connections ................................................................................ 52

Table 11 - 16-25 and 30 ton .......................................................................................................... 52

Table 12 - 26 and 31-70 ton .......................................................................................................... 52

Table 13 - 55, 65 and 75-140 ton Gas Connections ...................................................................... 53

Table 14 - Natural Gas (ft3/hr) Maximum Piping Capacities ....................................................... 53

Table 15 - Propane (kBtu/hr) Maximum Piping Capacities ......................................................... 53

Table 16 - Gas Piping Supports .................................................................................................... 55

Table 17 - Glycol Freezing Points ................................................................................................ 59

Table 18 - Standard Brazed Plate Heat Exchanger Water Connections ....................................... 60

Table 19 - SMO 254 Brazed Plate Heat Exchanger Water Connections ...................................... 60

Table 20 - Steam Coil Connection Sizes ...................................................................................... 62

Table 21 - Hot Water Coil Connection Sizes................................................................................ 62

Table 22 - Chilled Water Coil Connection Sizes .......................................................................... 62

Table 23 - Pin Location................................................................................................................. 74

Table 24 - Pin Groove Location .................................................................................................... 74

Table 25 - Acceptable Refrigeration ............................................................................................. 77

Table 26 - R-410A and R-22 Refrigerant Temperature-Pressure Chart ....................................... 78

Table 27 - ECM Condenser Fan Cycling Options ........................................................................ 80

Table 28 - Demand Signal vs. Compressor Capacity Modulation ................................................ 93

Table 29 - 6-8 and 10 ton Pre Filters ............................................................................................ 94

Table 30 - 9 and 11-15 ton Pre Filters .......................................................................................... 94

Table 31 - 16-25 and 30 ton Pre Filters ........................................................................................ 94

Table 32 - 26, 31, and 40 ton Pre Filters ....................................................................................... 94

Table 33 - 50, 60, and 70 ton Pre Filters ....................................................................................... 95

Table 34 - 55, 65, and 75 ton Pre Filters ....................................................................................... 95

Table 35 - 90-140 ton Pre Filters .................................................................................................. 95

Table 36 - 6-8 and 10 ton Unit Filters ........................................................................................... 96

Table 37 - 9 and 11 ton Unit Filters .............................................................................................. 96

Table 38 - 13 and 15 ton Unit Filters ............................................................................................ 97

Table 39 - 16-25 and 30 ton Unit Filters ....................................................................................... 97

Table 40 - 26, 31, and 40 ton Unit Filters ..................................................................................... 98

Table 41 - 50, 60, and 70 ton Unit Filters ..................................................................................... 98

Table 42 - 55, 65, and 75 ton Unit Filters ..................................................................................... 98

Table 43 - 90-140 ton Unit Filters ................................................................................................ 99

Table 44 - 6-8 and 10 ton Energy Recovery Wheel Filters .......................................................... 99

Table 45 - 9 and 11-15 ton Energy Recovery Wheel Filters ........................................................ 99

Table 46 - 16-25 and 30 ton Energy Recovery Wheel Filters ...................................................... 99

Table 47 - 26, 31-50, 60, and 70 ton Energy Recovery Wheel Filters ....................................... 100

Table 48 - 55, 65, and 75-140 ton Energy Recovery Wheel Filters ........................................... 100

Table 49 - 26, 31-50, 60, and 70 ton Energy Recovery Wheel Filters ....................................... 100

Figures:

Figure 1 - Lockable Handle .......................................................................................................... 26

Figure 2 - RN Series A, B and C Cabinet, .................................................................................... 31

Figure 3 - RN Series D Cabinet, ................................................................................................... 31

Figure 4 - RN Series E Cabinet,.................................................................................................... 31

Figure 5 - RN Series 6-8 and 10 ton Unit Gasket Locations ........................................................ 33

Figure 6 - RN Series 9 and 11-15 ton Unit Gasket Locations ...................................................... 34

Figure 7 - RN Series 16-25 and 30 ton Unit Gasket Locations .................................................... 35

Figure 8 - RN Series 26, 31-50, 60, and 70 ton Unit Gasket Locations ....................................... 36

Figure 9 - Forklifting an RN Series A, B and C Cabinet, 6-25 and 30 tons ................................. 37

Figure 10 - Lifting Details of a 6-25 and 30 ton Standard or Power Exhaust Unit ...................... 38

Figure 11 - Lifting Details of a 6-25 and 30 ton Energy Recovery Wheel or Power Return Unit 39

Figure 12 - Lifting Details of a 26, 31-50, 60 and 70 ton Unit ..................................................... 39

Figure 13 - Lifting Details of a 55, 65 and 75-140 ton Unit ......................................................... 40

Figure 14 - Duct Connection......................................................................................................... 41

Figure 15 - Solid Bottom Seismic Curb with Filters .................................................................... 42

Figure 16 - Seismic Solid Bottom Curb without Filters Cross Section ........................................ 43

Figure 17 - Seismic Solid Bottom Curb without Filters Detail A................................................. 43

Figure 18 - Seismic Solid Bottom Curb without Filters Detail B ................................................. 43

Figure 19 - Seismic Rigid Mount Curb......................................................................................... 44

Figure 20 - 90-140 ton Condenser Coil Guard Installation Instructions 1 ................................... 45

Figure 21 - 90-140 ton Condenser Coil Guard Installation Instructions 2 ................................... 46

Figure 22 - 6-25 and 30 ton........................................................................................................... 47

Figure 23 - 6-25 and 30 ton........................................................................................................... 47

Figure 24 - 26 and 31-140 ton....................................................................................................... 47

Figure 25 - Factory Supplied End Flashings................................................................................. 48

Figure 26 - Rain Hood with Metal Mesh Filter Rack Installation ................................................ 48

Figure 27 - Unit Utility Entry ....................................................................................................... 49

Figure 28 - Back View of Power Switch from Compressor and Control Compartment (6-50, 60,

and 70 ton Units) ........................................................................................................................... 49

Figure 29 - Front View of Utility Entry and Power Switch from Control Compartment (55, 65

and 75-140 ton Units) ................................................................................................................... 50

Figure 30 - RN Series Gas Heat Exchanger .................................................................................. 53

Figure 31 - Example 6-25 and 30 ton through the Base Gas Piping ............................................. 56

Figure 32 - Supply Fan Banding ................................................................................................... 72

Figure 33 - Fan with the HUB on the Top and RET on the Bottom ............................................. 73

Figure 34 - Bushing Mount Location............................................................................................ 73

Figure 35 - RET with Pin in Groove 4 .......................................................................................... 73

Figure 36 - Fan HUB and RET Castings ...................................................................................... 73

Figure 37 - Assembled Fan ........................................................................................................... 74

Figure 38 - Back of the Fan .......................................................................................................... 74

Figure 39 - Pin Groove Location .................................................................................................. 75

Figure 40 - Pitch Pin Location ...................................................................................................... 75

Figure 41 - Example Pitch Pin ...................................................................................................... 75

Figure 42 - Gas Heater Instructions .............................................................................................. 79

Figure 43 - Gas Heat Exchanger ................................................................................................... 85

Figure 44 - Removal of a Condenser Fan Assembly .................................................................... 86

Figure 45 - Evaporator Coil Access .............................................................................................. 87

Figure 46 - 9-25 and 30 ton Supply Fan ....................................................................................... 90

Figure 47 - Bolts which Connect Motor Mount to Blower Fan .................................................... 90

Figure 48 - Voltage Monitor ......................................................................................................... 91

Figure 49 - Variable Capacity Compressor Controller ................................................................. 92

Figure 50 - Compressor Controller Flash Code Details................................................................ 93

Figure 51 - RN Series 6-8 and 10 ton Standard Filter Layout .................................................... 101

Figure 52 - RN Series 9 and 11-15 ton Standard Filter Layout .................................................. 101

Figure 53 - RN Series 16-25 and 30 ton Standard Filter Layout ................................................ 102

Figure 54 - RN Series 26, 31, and 40 ton Standard Filter Layout .............................................. 102

Figure 55 - RN Series 50-, 60, and 70 ton Standard Filter Layout ............................................. 103

Figure 56 - RN Series 55, 65, and 75 ton Standard Filter Layout, 2” Filters ............................. 103

Figure 57 - RN Series 55, 65, and 75 ton Standard Filter Layout, 4” Filters ............................. 104

Figure 58 - RN Series 90-140 ton Standard Filter Layout, 2” filters .......................................... 104

Figure 59 - RN Series 90-140 ton Standard Filter Layout, 4” Filters and 2” Pre-Filters with 4”

High Efficiency Filters ................................................................................................................ 105

Safety

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

electrical power to the furnace. More than one disconnect may be provided.

 When servicing controls, label all

wires prior to disconnecting. Reconnect wires correctly.

 Verify proper operation after

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

building.

 Never test for gas leaks with an

open flame.

 Use a gas detection soap solution

and check all gas connections and shut off valves.

CAUTION

Electric shock hazard. Before servicing, shut off all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures.

WARNING

Attention should be paid to the following statements:

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.

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.

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.

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

ROTATING COMPONENTS

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 stopped rotating.

WARNING

GROUNDING REQUIRED

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.

WARNING

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 motor’s FLA rating as shown on the motor nameplate.

CAUTION

UNIT HANDLING

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

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

CAUTION

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

CAUTION

WATER PRESSURE

WARNING

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

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.

WARNING

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.

CAUTION

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 damage, injury or death.

WARNING

WATER FREEZING

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.

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.

CAUTION

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.

CAUTION

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.

CAUTION

OPEN LOOP APPLICATIONS

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.

WARNING

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes.

5 MINUTE MINIMUM ON TIME 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.

WARNING

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.

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 must 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.

BASE MODEL

SERIES AND GENERATION

UNIT SIZE

006 = 6 ton Capacity 007 = 7 ton Capacity 008 = 8 ton Capacity 009 = 9 ton Capacity 010 = 10 ton Capacity 011 = 11 ton Capacity 013 = 13 ton Capacity 015 = 15 ton Capacity 016 = 16 ton Capacity 018 = 18 ton Capacity 020 = 20 ton Capacity 025 = 25 ton Capacity 026 = 26 ton Capacity 030 = 30 ton Capacity 031 = 31 ton Capacity 040 = 40 ton Capacity 050 = 50 ton Capacity 055 = 55 ton Capacity 060 = 60 ton Capacity 065 = 65 ton Capacity 070 = 70 ton Capacity 075 = 75 ton Capacity 090 = 90 ton Capacity 105 = 105 ton Capacity 120 = 120 ton Capacity 130 = 130 ton Capacity 140 = 140 ton Capacity

VOLTAGE

1 = 230V/1Φ/60Hz 2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 8 = 208V/3Φ/60Hz 9 = 208V/1Φ/60Hz

RN Series Feature String Nomenclature

INTERIOR PROTECTION

0 = Standard - Vertical Discharge and Return A = Interior Corrosion Protection - Vertical Discharge and Return

Model Option A: COOLING/HEAT PUMP

A1: REFRIGERANT STYLE

0 = Air Handling Unit B = R-410A - High Efficiency C = R-410A - Standard Efficiency E = R-410A Variable Capacity Scroll Compressor High Efficiency F = R-410A Variable Capacity Scroll Compressor Standard Efficiency J = R-410A VFD Compatible Scroll Compressor K = R-410A VFD Compatible Scroll Compressor + Microchannel Condenser

A2: UNIT CONFIGURATION

0 = No Cooling A = Air-Cooled Cond. + Std Evap. Coil B = Air-Cooled Cond. + 6 Row Evap. Coil J = Water-Cooled Cond. + Std Evap. Coil K = Water-Cooled Cond. + 6 Row Evap. Coil P = Air-Cooled Cond. + 6 Row Evap. Coil + Mixed Air Bypass Q = Air-Cooled Cond. + 6 Row Evap. Coil + Return Air Bypass R = Water-Cooled Cond. + 6 Row Evap. Coil + Return Air Bypass T = Water-Cooled Cond. + 6 Row Evap. Coil + Mixed Air Bypass U = Chilled Water Coil - 4 Row W = Chilled Water Coil - 6 Row 2 = Non-Compressorized + Std Evap. Coil 4 = Non-Compressorized + 6 Row Evap. Coil 6 = Air-Source Heat Pump 7 = Water-Source/Geothermal Heat Pump

RN Series Feature String Nomenclature

Model Option A: COOLING/HEAT PUMP

A3: COIL COATING

0 = Standard 1 = Polymer E-Coated Evap. and Cond. 2 = Stainless Steel Casing Evap and Cond 8 = Polymer E-Coated Cond. 9 = Polymer E-Coated Cooling Coil A = Stainless Steel Evap. Coil Casing + Polymer ECoated Cond. Coil B = Stainless Steel Casing Cond & Polymer ECoated Cooling Coil C = Stainless Steel Casing Cond. Only D = Stainless Steel Cooling Coil Casing

A4: COOLING/HEAT PUMP STAGING

0 = No Cooling 1 = 1 Stage 2 = 2 Stage 4 = 4 Stage 9 = Modulating - Lead VCC A = Modulating - All VCC B = 1 Stage + 1 Stage Auxiliary Heat C = 2 Stage + 1 Stage Auxiliary Heat D = 4 Stage + 1 Stage Auxiliary Heat E = Modulating - Lead VCC + 1 Stage Aux. Heat F = Modulating - All VCC + 1 Stage Aux. Heat H = Single Serpentine 8 fpi J = Half Serpentine 8 fpi K = Single Serpentine 10 fpi L = Half Serpentine 10 fpi M = Single Serpentine 12 fpi N = Half Serpentine 12 fpi P = 1 Stage + 2 Stage Auxiliary Heat Q = 2 Stage + 2 Stage Auxiliary Heat R = 4 Stage + 2 Stage Auxiliary Heat S = Modulating - Lead VCC + 2 Stage Aux. Heat T = Modulating - All VCC + 2 Stage Aux. Heat U = 1 Stage + 4 Stage Auxiliary Heat V = 2 Stage + 4 Stage Auxiliary Heat W = 4 Stage + 4 Stage Auxiliary Heat Y = Modulating - Lead VCC + 4 Stage Aux. Heat Z = Modulating - All VCC + 4 Stage Aux. Heat

Model Option B: HEATING

B1: HEATING TYPE

0 = No Heating 1 = Electric Heat 2 = Natural Gas Aluminized 3 = Natural Gas Stainless Steel 4 = High Altitude Natural Gas Aluminized 5 = High Altitude Natural Gas Stainless Steel 6 = LP Gas Aluminized 7 = LP Gas Stainless Steel 8 = High Altitude LP Gas Aluminized 9 = High Altitude LP Gas Stainless Steel C = Steam Distributing Standard D = Steam Distributing Polymer E-Coated E = Hot Water Standard F = Hot Water Polymer E-Coated

RN Series Feature String Nomenclature

B2: HEATING DESIGNATION

0 = No Heating 1 = Heat 1 2 = Heat 2 3 = Heat 3 4 = Heat 4 6 = Heat 6 7 = Heat 7 8 = Heat 8 9 = Heat 9 A = Heat A B = Heat B C = Heat C D = Heat D E = Heat E F = Heat F G = Heat G H = 1 Row Coil J = 2 Row Coil K = Heat K L = Heat L M = Heat M N = Heat N P = Heat P

Model Option B: HEATING

B3: HEATING STAGING

0 = No Heating 1 = 1 Stage 2 = 2 Stage 3 = 3 Stage 4 = 4 Stage 5 = 5 Stage 6 = 6 Stage 7 = 7 Stage 8 = 8 Stage 9 = Modulating Gas/SCR Electric A = Modulating/SCR Electric, 0-10V Control Signal H = Single Serpentine 8 fpi J = Half Serpentine 8 fpi K = Single Serpentine 10 fpi L = Half Serpentine 10 fpi M = Single Serpentine 12 fpi N = Half Serpentine 12 fpi

Feature 1: RETURN/OUTSIDE AIR

1A: RETURN/OUTSIDE AIR SECTION

0 = Manually Adjustable OA Opening + RA Opening A = Economizer B = Econ + Power Exhaust C = Econ + Power Return D = Econ + PE - Discharge Damper Volume Control E = Econ + PE - Discharge Damper Volume Control + 0-10V External Control F = Low cfm Total Energy Recovery Wheel G = Low cfm Total ERW + Bypass H = Low cfm Sensible ERW J = Low cfm Sensible ERW + Bypass K = 100% Outside Air - No Return Air L = Motorized Outside Air Damper + RA Opening M = Motorized Outside Air Damper - No Return Air N = Empty ERW Option Box - No Power Exhaust P = Empty ERW Option Box + Power Exhaust Q = 1% Purge Low cfm Total ERW R = 1% Purge Low cfm Total ERW + Bypass S = 1% Purge Low cfm Sensible ERW T = 1% Purge Low cfm Sensible ERW + Bypass U = High cfm Total ERW V = High cfm Total ERW + Bypass W = High cfm Sensible ERW Y = High cfm Sensible ERW + Bypass Z = 1% Purge High cfm Total ERW 1 = 1% Purge High cfm Total ERW + Bypass 2 = 1% Purge High cfm Sensible ERW 3 = 1% Purge High cfm Sensible ERW + Bypass 4 = Single Total Energy Recovery Wheel + Bypass 5 = 100% Return Air

RN Series Feature String Nomenclature

Feature 1: RETURN/OUTSIDE AIR

1B: RETURN/EXHAUST AIR BLOWER CONFIGURATION

0 = Standard – None A = 1 Blower + Standard Eff. Motor C = 1 Blower + Premium Eff. Motor D = 2 Blowers + Premium Eff. Motors E = 1 Blower + Premium Eff. + 1 VFD F = 2 Blowers + Premium Eff. + 1 VFD G = 2 Blowers + Premium Eff. + 2 VFDs

1C: RETURN/EXHAUST AIR BLOWER

0 = Standard - None

A = 12”x9” Forward Curved B = 15” Backward Curved Plenum C = 18.5” Backward Curved Plenum D = 22” Backward Curved Plenum F = 27” Backward Curved Plenum G = 22” Direct Drive Axial Flow H = 35.5” Direct Drive Axial Flow J = 15” BC Plenum - 50% Width with Banding K = 18.5” BC Plenum - 70% Width with Banding L = 22” BC Plenum - 70% Width with Banding M = 27” BC Plenum - 70% Width with Banding N = 30” Backward Curved Plenum P = 42” 9 Blade Direct Drive Axial Flow Q = 42” 12 Blade Direct Drive Axial Flow R = 24” Backward Curved Plenum S = 33” Backward Curved Plenum

1D: RETURN/EXHAUST AIR BLOWER MOTOR

0 = Standard - None C = 1 hp - 1760 rpm D = 2 hp - 1760 rpm E = 3 hp - 1760 rpm F = 5 hp - 1760 rpm G = 7.5 hp - 1760 rpm H = 10 hp - 1760 rpm L = 15 hp - 1760 rpm M = 20 hp - 1760 rpm N = 1 hp - 1170 rpm P = 2 hp - 1170 rpm Q = 3 hp - 1170 rpm R = 5 hp - 1170 rpm S = 7.5 hp - 1170 rpm T = 10 hp - 1170 rpm U = 15 hp - 1170 rpm V = 20 hp - 1170 rpm W = 25 hp - 1170 rpm Y = 30 hp - 1170 rpm 3 = 25 hp - 1760 rpm 4 = 30 hp - 1760 rpm 5 = 40 hp - 1760 rpm 6 = 50 hp - 1760 rpm

RN Series Feature String Nomenclature

Feature 2: OUTSIDE AIR CONTROL

0 = Standard - None A = 3 Position Actuator - Sensible Limit B = 3 Position Actuator - Enthalpy Limit C = Fully Modulating Actuator - Sensible Limit D = Fully Modulating Actuator - Enthalpy Limit E = DDC Actuator F = Constant Volume Outside Air G = Options A + F H = Options B + F J = Options C + F K = Options D + F L = Options E + F M = 3 Pos. Act. - Sensible Limit + CO2 Override N = 3 Pos. Act. - Enthalpy Limit + CO2 Override P = Fully Mod. Act. - Sensible + CO2 Override Q = Fully Mod. Act. - Enthalpy + CO2 Override R = DDC Actuator + CO2 Override S = Dual Minimum Position Potentiometers + Fully Mod. Act. - Sensible Limit T = Dual Minimum Position Potentiometers + Fully Mod. Act. - Enthalpy Limit U = 2 Position Actuator

Feature 3: HEAT OPTIONS

0 = Standard - None A = Regulator (2psi) with vent limiting device B = Regulator (5psi) with vent limiting device C = Regulator (2psi) vented D = Regulator (5psi) vented E = Discharge Air Override F = Options A + E G = Options B + E H = Options C + E J = Options D + E K = Auxiliary Heat K L = Auxiliary Heat L M = Auxiliary Heat M N = Auxiliary Heat N P = Auxiliary Heat P Q = Auxiliary Heat Q R = Auxiliary Heat R S = Auxiliary Heat S T = Auxiliary Heat T U = Auxiliary Heat U V = Auxiliary Heat V W = Auxiliary Heat W

Feature 4: MAINTENANCE OPTIONS

0 = Standard - None A = Field Wired 115V Outlet B = Factory Wired 115V Outlet C = Blower Aux. Contact D = Remote Start/Stop Terminals E = Options A + C F = Options A + D G = Options B + C H = Options B + D J = Options A + C + D K = Options B + C + D L = Options C + D

RN Series Feature String Nomenclature

Feature 5: SUPPLY AIR OPTIONS

5A: SUPPLY AIR BLOWER CONFIGURATION

0 = 1 Blower + Standard Eff. Motor A = 2 Blowers + Standard Eff. Motors B = 1 Blower + Premium Eff. Motor C = 2 Blowers + Premium Eff. Motors D = 1 Blower + Premium Eff. + 1 VFD F = 2 Blowers + Premium Eff. + 1 VFD G = 2 Blowers + Premium Eff. + 2 VFDs

5B: SUPPLY AIR BLOWER

B = 15” Backward Curved Plenum C = 18.5” Backward Curved Plenum D = 24” Backward Curved Plenum E = 27” Backward Curved Plenum F = 30” BC Plenum - 90% Width + 1750 rpm Max -

Aluminum Wheel

G = 15” BC Plenum - 70% Width H = 18.5” BC Plenum - 70% Width

J = 18.5” Backward Curved Plenum K = 18.5” BC Plenum - 60% Width L = 30” BC Plenum - 1600 rpm Max - Aluminum Wheel

M = 13.5” Backward Curved Plenum N = 13.5” BC Plenum - 70% Width P = 24” BC Plenum - 60% Width Q = 27” BC Plenum - 60% Width R = 22” Backward Curved Plenum S = 22” BC Plenum - 70% Width T = 17” Backward Curved Plenum U = 17” BC Plenum - 70% Width V = 33” Backward Curved Plenum W = 36.5” Backward Curved Plenum Y = 42.5” Backward Curved Plenum

5C: SUPPLY AIR BLOWER MOTOR

C = 1 hp - 1760 rpm D = 2 hp - 1760 rpm E = 3 hp - 1760 rpm F = 5 hp - 1760 rpm G = 7.5 hp - 1760 rpm H = 10 hp - 1760 rpm L = 15 hp - 1760 rpm M = 20 hp - 1760 rpm N = 1 hp - 1170 rpm P = 2 hp - 1170 rpm Q = 3 hp - 1170 rpm R = 5 hp - 1170 rpm S = 7.5 hp - 1170 rpm T = 10 hp - 1170 rpm U = 15 hp - 1170 rpm V = 20 hp - 1170 rpm W = 25 hp - 1170 rpm Y = 30 hp - 1170 rpm 3 = 25 hp - 1760 rpm 4 = 30 hp - 1760 rpm 5 = 40 hp - 1760 rpm 6 = 50 hp - 1760 rpm

Feature 6: FILTERS

6A: PRE FILTER

0 = Standard - None A = 2” Pleated - 30% Eff. - MERV 8 B = Metal Mesh Outside Air Filter C = Lint Screen Filter D = Exhaust Air ERW Filter F = Options A + D G = Options B + D H = Options A + B + D

6B: UNIT FILTER

0 = 2” Throwaway or 2” Pleated - 30% Eff. - MERV 8 A = 2” Pleated - 30% Eff. - MERV 8 B = 4” Pleated - 30% Eff. - MERV 8 C = 2” Permanent Filter + Replaceable Media F = 4” Pleated - 65% Eff. - MERV 11 G = 4” Pleated - 85% Eff. - MERV 13 H = 4” Pleated - 95% Eff. - MERV 14

RN Series Feature String Nomenclature

6C: FILTER OPTIONS

0 = Standard A = Clogged Filter Switch B = Magnehelic Gauge C = Options A + B

Feature 7: REFRIGERATION CONTROL

0 = Standard A = 5 Min. Time Delay Relay - Comp. Off B = 20 Sec. Time Delay Relay - Comp. Staging C = Fan Cycling D = Adjustable Lockouts - Each Circuit E = Freeze Stats - Each Circuit F = Options A + B G = Options A + C H = Options A + D J = Options A + E K = Options B + C L = Options B + D M = Options B + E N = Options C + D P = Options C + E Q = Options D + E R = Options A + B + C S = Options A + B + D T = Options A + B + E U = Options A + C + D V = Options A + C + E W = Options A + D + E Y = Options B + C + D Z = Options B + C + E 1 = Options B + D + E 2 = Options C + D + E 3 = Options A + B + C + D 4 = Options A + B + C + E 5 = Options A + B + D + E 6 = Options A + C + D + E 7 = Options B + C + D + E 8 = Options A + B + C + D + E

Feature 8: REFRIGERATION OPTIONS

0 = Standard A = Hot Gas Bypass Lead Stage or Hot Gas Bypass Lag Stage with Lead Variable Capacity Compressor B = Hot Gas Bypass Lead and Lag Stages C = Hot Gas Reheat D = Modulating Hot Gas Reheat E = 0°F Low Ambient Lead Stage F = Options A + C G = Options B + C H = Options A + D J = Options B + D K = Options A + E L = Options B + E

Feature 9: REFRIGERATION ACCESSORIES

0 = Standard A = Sight Glass B = Compressor Isolation Valves C = Options A + B D = ECM Condenser Fan - Multiple Speed E = ECM Condenser Fan - Head Pressure Control F = VFD Controlled Condenser Fans - Variable Speed G = Options A + D H = Options B + D J = Options A + B + D K = Options A + E L = Options B + E M = Options A + B + E N = Options A + F P = Options B + F Q = Options C + F

Feature 10: POWER OPTIONS

0 = Standard Power Block A = 100 Amp Power Switch B = 150 Amp Power Switch C = 225 Amp Power Switch D = 400 Amp Power Switch E = 600 Amp Power Switch F = 60 Amp Power Switch 5 = 800 Amp Power Switch 6 = 1200 Amp Power Switch

Feature 11: SAFETY OPTIONS

0 = Standard A = Return and Supply Air Firestat B = Return Air Smoke Detector C = Supply Air Smoke Detector D = Options B + C E = Options A + B F = Options A + C G = Options A + B + C H = Remote Smoke Detector Terminals J = Options A + H K = Options B + H L = Options C + H M = Options D + H N = Options A + B + H P = Options A + C + H Q = Options A + B + C + H

RN Series Feature String Nomenclature

Feature 12: CONTROLS

0 = Standard A = Low Limit Controls B = Phase and Brown Out Protection C = Energy Recovery Wheel Defrost D = Energy Recovery Wheel Rotation Detection E = Compressor Power Factor Correction F = Options A + B G = Options A + C H = Options A + D J = Options A + E K = Options B + C L = Options B + D M = Options B + E N = Options C + D P = Options C + E Q = Options D + E R = Options A + B + C S = Options A + B + D T = Options A + B + E U = Options A + C + D V = Options A + C + E W = Options A + D + E Y = Options B + C + D Z = Options B + C + E 1 = Options B + D + E 2 = Options C + D + E 3 = Options A + B + C + D 4 = Options A + B + C + E 5 = Options A + B + D + E 6 = Options A + C + D + E 7 = Options B + C + D + E 8 = Options A + B + C + D + E

RN Series Feature String Nomenclature

Feature 13: SPECIAL CONTROLS

0 = Terminal Block for Thermostat Control D = VAV Unit Controller - VAV Cool + CV Heat E = Constant Volume Unit Controller - CV Cool + CV Heat F = Makeup Air Unit Controller - CV Cool + CV Heat H = Field Installed DDC Controls by Others J = Factory Installed DDC Controls Furnished by Others K = Factory Installed DDC Controls Furnished by Others w/ Isolation relays L = Terminal Block for Thermostat Control with Isolation Relays U = Digital Precise Air Controller, D-PAC V = Precise Air Controller, PAC W = Terminal Block for Variable Capacity Compressor Thermostat Y = VAV Single Zone Heat Pump Unit Controller VAV Cool + VAV Heat Z = Constant Volume Heat Pump Unit Controller CV Cool + CV Heat 1 = Makeup Air Heat Pump Unit Controller - CV Cool + CV Heat 2 = VAV Single Zone Unit Controller VAV Cool + CV Heat 3 = VAV Single Zone Unit Controller VAV Cool + VAV Heat 4 = Field Installed DDC Controls by Others 5 = Field Installed DDC Controls Furnished by Others with Isolation Relays 6 = Factory Installed DDC Controls Furnished by Others with Isolation Relays (SPA)

Feature 14: PREHEAT

14A: PREHEAT CONFIGURATION

0 = Standard - None A = Steam Distributing Preheat Coil - 1 Row B = Steam Distributing Preheat Coil - 2 Row C = Hot Water Preheat Coil - 1 Row D = Hot Water Preheat Coil - 2 Row E = Modulating Electric Preheat

14B: PREHEAT SIZING

0 = Standard - None A = Single Serpentine 8 fpi B = Half Serpentine 8 fpi C = Single Serpentine 10 fpi D = Half Serpentine 10 fpi E = Single Serpentine 12 fpi F = Half Serpentine 12 fpi G = 10 kW (7.5 kW @ 208V) H = 15 kW (11.3 kW @ 208V) J = 20kW (15 kW @ 208V) K = 30kW (22.5 kW @ 208V) L = 40kW (30 kW @ 208V) M = 50kW (37.6 kW @ 208V) N = 60kW (45.1 kW @ 208V) P = 70kW (52.6 kW @ 208V) Q = 80kW (60.1 kW @ 208V) R = 90kW (67.6 kW @ 208V) S = 100kW (75.1 kW @ 208V) T = 110kW (82.6 kW @ 208V) U = 120kW (90.1 kW @ 208V)

Feature 15: Glycol Percentage

0 = Standard A = 20% Propylene Glycol B = 40% Propylene Glycol C = Field Adjustable for Glycol %

Feature 16: INTERIOR CABINET OPTIONS

0 = Standard B = Service Lights

Feature 17: EXTERIOR CABINET OPTIONS

0 = Standard A = Base Insulation B = Burglar Bars C = Condenser Coil Guards D = Options A + B E = Options A + C F = Options B + C G = Options A + B + C

RN Series Feature String Nomenclature

Feature 18: CUSTOMER CODE

0 = Standard

Feature 19: CODE OPTIONS

0 = Standard - ETL U.S.A. Listing B = Chicago - Cool + Gas C = Chicago - Cool + Electric Heat D = Chicago - Cool Only E = Chicago - Gas Only F = Chicago - Electric Heat Only G = Chicago - No Cool + No Heat H = ETL U.S.A. + Canada Listing K = California OSHPD Certification L = Shake Table Cert. (ASCE 7-05/ICC-ES AC 156) M = Seismic Construction (Non-Certified) N = California OSHPD Certification + Chicago P = Shake Table Cert. (ASCE 7-05/ICC-ES AC 156) + Chicago Q = Seismic Construction (Non-Certified) + Chicago

Feature 20: CRATING

0 = Standard A = Export Crating B = Export Crating - No Condenser Section

Feature 21: WATER-COOLED CONDENSER

0 = Standard - None A = Balancing Valves B = Water Flow Switch C = Motorized Shut-off Valve D = Head Pressure Control E = Options A + B F = Options A + C G = Options A + D H = Options B + C J = Options B + D L = Options A + B + C M = Options A + B + D R = SMO 254 Brazed Plate Heat Exchanger S = Options A + R T = Options B + R U = Options C + R V = Options D + R W = Options A + B + R Y = Options A + C + R Z = Options A + D + R 1 = Options B + C + R 2 = Options B + D + R 3 = Options C + D + R 4 = Options A + B + C + R 5 = Options A + B + D + R

Feature 22: CONTROL VENDORS

0 = None A = WattMaster Orion Controls System B = JENEsys Control System with Web UI C = WattMaster Orion Controls System with Specials E = Remote Mounted AAON Mini Controller F = JENEsys Control System with Web UI + Fox G = JENEsys Control System with Web UI + Lon H = JENEsys Control w/ Web UI + BACnet MSTP J = JENEsys Control w/ Web UI + BACnet IP K = JENEsys Control w/ Web UI + Modbus RTU L = JENEsys Control w/ Web UI + Modbus TCP

RN Series Feature String Nomenclature

Feature 23: TYPE

B = Standard - AAON Gray Paint U = Special Pricing Authorization + Special Paint X = Special Pricing Authorization + AAON Gray Paint 1 = Standard Paint + 2 Year Parts Only Warranty 4 = Standard Paint + 5 Year Parts Only Warranty 9 = Standard Paint + 10 Year Parts Only Warranty

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. A copy of this IOM should be kept with the unit.

WARNING

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.

CAUTION

General Information

RN Series packaged rooftop units, heat pumps and outdoor air handling units have been designed for outdoor installation only. Units are assembled, wired, charged and run tested at the factory.

Startup and service must be performed by a Factory Trained Service Technician.

Certification of Gas Heat Models

a. AAON gas heat exchangers have

successfully completed 10,000 burner operation cycles and corrosion resistance as specified per test standard ANSI

21.47. All gas heat exchangers used in AAON appliances are certified for use downstream of evaporator or cooling coils.

b. Certified as a Category III forced air

furnace with or without cooling.

c. Certified for outdoor installation only. d. Certified for installation on a

combustible roof with a minimum of 12”

high curb.

Certification of Steam or Hot Water Heat Models

a. Certified as a forced air heating system

with or without cooling.

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

combustible 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.

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

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 a

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

RN Series units have been tested and certified, by ETL, in accordance with UL Safety Standard 1995/CSA C22.2 No. 236, ANSI Safety Standard Z21.47b-2008/CSA

2.3b-2008, and ANSI Safety Standard Z83.8-2006/CSA 2.6-2006.

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

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.

CAUTION

Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment.

WARNING

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

WARNING

Installation of RN Series units must conform to the 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 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, and Mechanical Refrigeration Code CSA B52. All appliances 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.

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.

If repairs must be made to damaged goods, then the factory should be notified before any repair action is taken in order to protect the warranty. Certain equipment alteration, repair, and manipulation of equipment

without the manufacturer’s consent may

void the product warranty. Contact the AAON Warranty Department for assistance with handling damaged goods, repairs, and freight claims: (918) 583-2266.

Note: Upon receipt check shipment for items that ship loose such as filters and remote sensors. Consult order and shipment documentation to identify potential looseshipped items. Loose-shipped items may have been placed inside unit cabinet for security. Installers and owners should secure all doors with locks or nuts and bolts to prevent unauthorized access.

CRANKCASE HEATER

OPERATION

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.

CAUTION

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes.

5 MINUTE MINIMUM ON TIME 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.

WARNING

Figure 1 - Lockable Handle

The warranty card must be completed in full and returned to AAON not more than 3 months after unit is delivered.

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 an evaporator, condenser, liquid line filter driers, thermal expansion valves (TXV) and scroll compressors. Compressors are equipped with a positive pressure forced lubrication system.

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.

Never cut 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 will 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 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 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 servicing, emergency or complete shutdown of the unit.

During the cooling season, if the air flow 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.

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

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 amount of air while operating. If this amount of air is greatly reduced, approximately 1/3 during the heating season, the gas heat exchanger or electric heating coil may overheat, and may cut 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 fan 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.

Model Option B2

Gas Heat

Electric Heat

Input Capacity

Output Capacity

Capacity

MBH

kW (208V)

kW (230V,

460V, 575V)

1 = Heat 1

60.0

48.0

7.5

2 = Heat 2

90.0

72.0

15.0

3 = Heat 3

100.0

80.0

22.5

4 = Heat 4

270.0

218.7

30.0

5 = Heat 5

140.0

112.0

37.5

6 = Heat 6

390.0

315.9

45.1

7 = Heat 7

160.0

128.0

60.1

8 = Heat 8

405.0

328.1

75.1

100

9 = Heat 9

90.1

120

A = Heat A

120.1

160

B = Heat B

150.2

200

C = Heat C

540.0

432.0

180.2

240

D = Heat D

810.0

648.0

210.3

280

E = Heat E

1080.0

864.0

240.3

320

F = Heat F

195.0

156.0

G = Heat G

292.5

234.0

K = Heat K

150.0

120.0

L = Heat L

210.0

168.0

M = Heat M

800.0

640.0

N = Heat N

1600.0

1280.0

P = Heat P

2400.0

1920.0

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.

If unit has not been selected as a 100% outside air unit (makeup air unit) the return air duct must be sealed to the unit and the return air temperature must be maintained between 55F and 80F.

Table 1 - Electric and Gas Heating Capacities

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

CAUTION

Wiring Diagrams

Unit specific wiring diagrams 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. The 625 and 30 ton units include one drain pan connection and the 26 and 31-140 ton units include two drain pan connections. Condensate drain pipes or p-traps for each connection are factory supplied and shipped loose in the controls compartment for field installation.

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 break should be used with long runs of condensate lines.

Location

Unit Size

6-8 and 10 tons

Front -

(Controls Side)

48”

Back - (Outside Air)

36”

*Left Side

*6”

Right Side

48”

Top

Unobstructed

*Units with a water-cooled condenser or

chilled water coil require 48” of clearance

on the left side for service access. DX and no cooling air handling units with an energy

recovery wheel require 24” of clearance on

the left side for service access.

Location

Unit Size

9 and 11-15 tons

Front -

(Controls Side)

48”

Back - (Outside Air)

48”

*Left Side

*6”

Right Side

48”

Top

Unobstructed

*Units with a water-cooled condenser or

chilled water coil require 48” of clearance

on the left side for service access. DX and no cooling air handling units with an energy

recovery wheel require 24” of clearance on

the left side for service access.

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.

WARNING

Distances from adjacent public walkways, adjacent buildings, operable windows and building openings, shall conform to local codes and/or the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or the National Gas & Propane Code, CSA B149.1

WARNING

Installation

AAON equipment has been designed for quick and easy installation.

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.

Verify rooftop or foundation can support the total unit weight, including accessory weights.

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.

Vent opening must not be blocked by snow. A minimum 12” curb must be used or the

vent outlet shall be greater than 12” off the

ground/roof.

Flue gas is dangerously hot and contains containments. The user is responsible for determining if vent gases may degrade building materials.

The National Gas and Propane Installation Code, B149.1 specifies a 6 ft. horizontal vent terminal clearance to gas and electric meters and relief devices.

Local codes may supersede or further place restrictions on vent termination locations.

Table 2 - A Cabinet Unit Clearances

Table 3 - B Cabinet Unit Clearances

Location

Unit Size

16-25 and 30 tons

Front -

(Controls Side)

48”

Back - (Outside Air)

48”

*Left Side

*21”

Right Side

60”

Top

Unobstructed

*Units with a water-cooled condenser or

chilled water coil require 48” of clearance

on the left side for service access.

Location

Unit Size

26 and 31-70 tons

Front -

(Controls Side)

48”

Back - (Outside Air)

48”

*Left Side

*48”

*Right Side

*70”

Top

Unobstructed

*Right and left side unit clearances are interchangeable on units that do not have hydronic heating. Units with hydronic

heating require 70” right side access for

service.

Location

Unit Size

55, 65 and 75-140

tons

Front -

(Controls Side)

60”

Back - (Outside Air)

48”

Left Side

72”

Right Side

72”

Top

Unobstructed

Back

Right Side

Front

Right Side Back

Back

Front

Right Side

Table 4 - C Cabinet Unit Clearances

Figure 3 - RN Series D Cabinet,

26, 31-50, 60 and 70 tons

Table 6 - E Cabinet Unit Clearances

Figure 2 - RN Series A, B and C Cabinet,

6-25 and 30 tons

Table 5 - D Cabinet Unit Clearances

Figure 4 - RN Series E Cabinet,

55, 65 and 75-140 tons

Setting the Curb

Make openings in roof decking large enough to allow for duct penetration and workspace only. Do not make openings larger than necessary. Set the curb to coincide with the openings. Make sure the curb is level. Unit must be level in both horizontal axes to support the unit and reduce noise and vibration.

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

CAUTION

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.

CAUTION

Be careful to install the provided neoprene gasket according to the following figure prior to setting the unit on the curb.

Figure 5 - RN Series 6-8 and 10 ton Unit Gasket Locations

Figure 6 - RN Series 9 and 11-15 ton Unit Gasket Locations

Figure 7 - RN Series 16-25 and 30 ton Unit Gasket Locations

Figure 8 - RN Series 26, 31-50, 60, and 70 ton Unit Gasket Locations

Incorrect lifting can cause damage to the unit.

CAUTION

Forks

FORKLIFTING

9, 11-25 AND 30 TON UNITS

Forks or Fork Extensions must be 72”

in length.

CAUTION

FORKLIFTING

6-8 AND 10 TON UNITS

Forks or Fork Extensions must be at least 48” in length.

CAUTION

Forklifting the Unit (6-25 and 30 ton)

6-25 and 30 ton units can be lifted using a forklift. 9, 11-25 and 30 ton units must have forks 72” in length or the forks must have 72” fork extensions. 6-8 and 10 ton units must have forks at least 48” in length. Standard units can be lifted from all sides except the condenser side. Units with power exhaust can be lifted from the controls side or the access (right) side. Units with energy recovery wheels or power return can only be fork lifted from the access (right) side.

Forks must be perpendicular to the unit and they must be in far enough that the back of the forks are no more than 6” away from the edge of the unit.

Figure 9 - Forklifting an RN Series A, B and C Cabinet, 6-25 and 30 tons

Lifting the Unit

If cables or chains are used to hoist the unit they must be the same length. Minimum

cable length is 99” for 6-25 and 30 ton units and 180” for 26 and 31-50, 60 and 70 ton

units. Spreader bars are required for 55, 65 and 75-140 ton units. Care should be taken

to prevent damage to the cabinet, coils, and condenser fans.

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

with the outside air hood in the open position.

Before lifting unit, be sure that all shipping material has been removed from unit. Secure hooks and cables at all lifting points / lugs provided on the unit.

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

Carefully lower and align the unit with utility and duct openings. Lower the unit until the unit skirt fits around the curb. Some units are designed to overhang the curb. Take care that any recessed base rails fit around the curb. Make sure the unit is properly seated on the curb and is level.

Figure 10 - Lifting Details of a 6-25 and 30 ton Standard or Power Exhaust Unit

Figure 11 - Lifting Details of a 6-25 and 30 ton Energy Recovery Wheel or Power Return Unit

Figure 12 - Lifting Details of a 26, 31-50, 60 and 70 ton Unit

Figure 13 - Lifting Details of a 55, 65 and 75-140 ton Unit

Do not drill or punch holes in the base of the unit, from inside the unit or from below the unit to attach ductwork. Leaking may occur if unit base is punctured.

CAUTION

Duct Connection Note: If outside air will be in contact with

the air tunnel base of an A, B or C cabinet unit (6-25 and 30 tons), the unit should include the base insulation option or the base must be field insulated. D and E cabinet (26 and 31-140 tons) units include base insulation standard.

Figure 14 - Duct Connection

Seismic Curb Installation

Using a standard curb with a seismic unit will void the certification of the unit. All mounting details listed must be followed to achieve seismic certification. The AAON unit must be certified to ICC-ES AC156 when using a seismic curb for seismic certifications to apply. Any deviations or

modifications to the unit or curb will void all seismic certification.

Structural engineer of record must approve field provided building anchorage to unit or curb in compliance with OSP-0180-10. Use provided self tapping screws to attach base of unit to seismic curb bracket.

Figure 15 - Solid Bottom Seismic Curb with Filters

Figure 16 - Seismic Solid Bottom Curb without Filters Cross Section

Figure 17 - Seismic Solid Bottom Curb without Filters Detail A

Figure 18 - Seismic Solid Bottom Curb without Filters Detail B

Figure 19 - Seismic Rigid Mount Curb

Condenser Hail Guards

90-140 ton Units

Condenser hail guards fold down and become a condenser coil shipping cover on 90-140 ton RN Series units with copper tube and aluminum fin condenser coils. Condenser hail guards must be opened before startup of the unit.

Figure 20 - 90-140 ton Condenser Coil Guard Installation Instructions 1

Figure 21 - 90-140 ton Condenser Coil Guard Installation Instructions 2

Outside Air Rain Hood

Rain hood must be opened before startup of the unit. Fresh air intake adjustments should be made according to building ventilation of local code requirements.

6-25 and 30 ton Units

Remove the two screws at the bottom of the rain hood that secure it in the shipping

position. Remove the screws that attach the side pieces of the hood to the top of the hood.

Rotate the side pieces so that the holes along one edge line up with the holes on the top piece and the flange is on the inside of the rain hood.

Attach the side pieces to the top of the hood using the provided screws and attached the side pieces to the end of the unit through the flange.

Apply silicon 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.

26 and 31-140 ton Units

Remove the shipping screws from each side of the closed hood.

Lift hood outward and attach the sides of the hood to the side of the unit.

Apply silicon 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.

Figure 22 - 6-25 and 30 ton

Closed Rain Hood

Figure 23 - 6-25 and 30 ton

Open Rain Hood

Figure 24 - 26 and 31-140 ton

End Flashing Installation

On RN Series E cabinet units that are 142” wide (RN-55, 65, 75, 90, 105, 120, 130,

140) the cabinet width will overhang the shipping 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.

Open Rain Hood

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.

CAUTION

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

Figure 25 - Factory Supplied End Flashings

Metal Mesh Filters (6-25 and 30 ton Units)

Metal mesh outside air filters require installation of the filter rack on the intake of the rain hood.

Clips which hold the metal mesh filters in the filter rack should face outward.

Figure 26 - Rain Hood with Metal Mesh Filter Rack Installation

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.

WARNING

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.

CAUTION

Electrical

Verify the unit nameplate agrees with power supply. Connect power and control wiring to the unit as shown in Figure I12 and in the unit specific wiring diagram, which shows factory and field wiring and is attached to the inside of the door of the controls compartment.

Route power and control wiring, separately, through the utility entry in the base of the unit. Do not run power and control signal wires in the same conduit. The utility entry on 9-25 and 30 ton units is located in the unit base in the front right hand corner of the unit (compressor compartment). The utility entry on 26 and 31-70 ton units is located in the unit base in the front left hand corner in the unit (controls compartment). The utility entry on 55, 65 and 75-140 ton units is located in the center front of the unit. See unit drawing for specific location.

Figure 27 - Unit Utility Entry

Figure 28 - Back View of Power Switch

from Compressor and Control Compartment

(6-50, 60, and 70 ton Units)

Three phase voltage imbalance will cause motor overheating and premature failure.

CAUTION

Figure 29 - Front View of Utility Entry and

Power Switch from Control Compartment

(55, 65 and 75-140 ton Units)

Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 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.

Note: All units are factory wired for 208V, 230V, 460V, or 575V. The transformer configuration must be checked by a qualified technician prior to service, especially if unit is to be connected to a 208V or 230V supply. For 208V service interchange the yellow and red conductor on the low voltage control transformer.

Red-Black for 208V Yellow-Black for 230V

Wire power leads to the unit’s terminal block or main disconnect. All wiring beyond this point has been completed by the manufacturer and cannot be modified

without effecting the unit’s agency/safety

certification.

Supply voltage must be within the min/max range shown on the unit nameplate. Available short circuit current should not exceed the short circuit current rating (SCCR) shown on the unit nameplate.

Three phase voltage imbalance will cause motor overheating and premature failure. The maximum allowable imbalance is 2.0%.

Voltage imbalance is defined as 100 times the maximum deviation from the average voltage divided by the average voltage.

Example: (221V+230V+227V)/3 = 226V, then 100*(226V-221V)/226V = 2.2%, which exceeds the allowable imbalance.

Check voltage imbalance at the unit disconnect switch and at the compressor terminal. Contact your local power company for line voltage corrections.

Installing contractor 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.

Model (RN-)

Compressor VFD

Range (Hz)

208V and 230 V Units

055, 065 & 075-140

35-60 Hz

460V and 575V Units

055, 065, 075, 090,

120, 130

35-75 Hz

105, 140

35-60 Hz

Wire Size (Stranded)

- Copper Conductors Only

Total Wire Distance Allowable 20 AWG

200 ft

18 AWG

350 ft

16 AWG

500 ft

14 AWG

750 ft

12 AWG

1250 ft

Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Supply fan, exhaust fan, return fan, 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.

CAUTION

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.

CAUTION

No variable speed compressor shall operate below 35 Hz. Operating variable speed compressors outside the frequency range specified in this manual voids all warranties and may result in compressor failure.

CAUTION

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 105°C type AWM insulated conductors.

Variable Speed Compressors

Variable speed compressors with VFD speed control are available on 55, 65 and 75140 ton units. Variable speed compressors should not be operated outside the factory determined frequency range. The factory determined compressor VFD frequency range is given below in Table 7.

Table 7 - Variable Speed Compressor VFD

Frequency Range

Thermostat Control Wiring

If a thermostat is used for unit control, thermostat should be located on an inside wall 4-5 feet above the floor where it will not be subjected to drafts, sun exposure, or heat from electrical fixtures of appliances. Control wiring must deliver adequate voltage to components to assure proper operation. Control voltage returning from controller circuit must be a minimum of 21 VAC. To assure proper wiring use the following chart to determine the allowable wiring distances.

Table 8 - Control Wiring

Model

Option

Input

MBH

Connections

Quantity

Size

90.0

1/2” NPT

150.0

210.0

3/4” NPT

Model

Option

Input

MBH

Connections

Quantity

Size

195.0

3/4” NPT

292.5

390.0

Model

Option

Input

MBH

Connections

Quantity

Size

270

3/4” NPT

405

1” NPT

540

Model

Option

Input

MBH

Connections

Quantity

Size

540

3/4” NPT

780

540

1-1/2”

NPT

810

1080

FOR YOUR SAFETY 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

Total Wire Distance Allowable = (Quantity of Control Wires) x (Control Wire Distance)

Take the total wire distance allowable and divide by the quantity of wires to be connected. This indicates the distance allowable for that size wire. The wiring to the unit must not exceed the total wire distance allowable. If the voltage at the connectors is less than 21 VAC, isolation relays must be installed. If under external control 21 VAC must be field verified.

All external devices must be powered via a separate external power supply.

Example: A total of 8 wires must be pulled 75ft to a control the unit. What size wire should be used?

According to the Table 8, 16 AWG allows for 63ft (500 ft/8 wires) and 14 AWG allows for 94ft (750 ft/8 wires). Thus, 14 AWG should be used.

Gas Heating

Verify the unit nameplate agrees with the proper gas supply type and amount.

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 9 - 6-8 and 10 ton Gas Connections

Table 10 - 9 and 11-15 ton Gas Connections

Table 11 - 16-25 and 30 ton

Gas Connections

Table 12 - 26 and 31-70 ton

Gas Connections

*Obsolete

Model

Option

Input

MBH

Connections

Quantity

Size

800

1” NPT

1600

1-1/2”

NPT

2400

Pipe Size

Length of Pipe

20 ft

50 ft.

100 ft.

150 ft.

200 ft.

1/2”

120

3/4”

250

151

103

1”

465

285

195

160

135

1-1/4”

950

580

400

325

280

1-1/2”

1460

900

620

500

430

2”

2750

1680

1150

950

800

2-1/2”

4350

2650

1850

1500

1280

Pipe Size

Length of Pipe

20 ft

50 ft.

100 ft.

150 ft.

200 ft.

1/2”

189

114

3/4”

393

237

162

132

112

1”

732

448

307

252

213

1-1/4”

1496

913

630

511

440

1-1/2”

2299

1417

976

787

675

2”

4331

2646

1811

1496

1260

Table 13 - 55, 65 and 75-140 ton Gas

Connections

After verifying gas inlet pressure and manifold pressure the service technician must time the gas flow rate through the gas meter with a stopwatch to verify the gas input rate.

Unit nameplate input rate value has been calculated at the altitude where the unit was shipped. Above 2,000 ft the input rate is adjusted 4% for every 1,000 ft.

Table 14 - Natural Gas (ft3/hr) Maximum Piping Capacities

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

Figure 30 - RN Series Gas Heat Exchanger

Table 15 - Propane (kBtu/hr) Maximum Piping Capacities

Specific Gravity = 1.52, Supply Pressure = 11” w.c., Pressure Drop, 0.5” w.c.



BTU

MBH

1000

1080

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.

CAUTION

Do not use gas piping smaller than unit gas connections. Natural gas pipe runs longer than 20 feet and propane gas pipe runs longer than 50 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.

Piping Sizing Examples

A 100 ft pipe run is needed for a 1080 MBH natural gas heater. The natural gas has a rating of 1000 Btu/ft3 and a specific gravity of 0.6 (Obtain these values from the local gas supplier.)

From the natural gas maximum capacities table, at 100 ft and 1080 ft3/hr the required minimum pipe size is 2”.

A 100 ft pipe run is needed for a 270 MBH propane gas heater. 270 MBH = 270 kBtu/hr

From the propane gas maximum capacities table, at 100 ft and 270 kBtu/hr the required minimum pipe size is 1”.

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

A factory installed pressure tap on the outlet end of the gas valve can be used to verify a

1080 ft3/hr

manifold pressure of 3.5” w.c. for natural gas, or 10.5” w.c. for propane.

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 less than 2 psi (55.4” w.c.) and if propane gas supply

pressure is greater than 13” w.c. and less

than 2 psi (55.4” 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.

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

Table 16 - Gas Piping Supports

Additional Gas Piping Considerations

Local codes will usually require a field provided and installed manual main shutoff valve and union external to the unit. Main shutoff valve should be labeled. 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. If flexible gas piping to the unit, or in the unit, must be replaced connectors cannot be reused, only new connectors may be used.

Heat exchanger comes equipped with a condensate drain which should be plumbed to the appropriate drain according to the (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, the International Building Code, and any applicable local and regional codes and regulations.

The condensate drain connection is located next to the gas entry location. For 6-50, 60 and 70 ton units, the heat exchanger condensate drain connection from the unit is a 5/8” barbed nylon elbow connection. For 55, 65 and 75-140 ton units, the heat exchanger condensate drain connection from the unit is a 1/2” PVC connection. For 55, 65 and 75-140 ton units, the heat exchanger condensate drain can be tied into the evaporator condensate drain, if code allows.

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

LEAK CHECK GAS PIPE 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

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

CAUTION

Figure 31 - Example 6-25 and 30 ton through the Base Gas Piping

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.

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

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, which 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.

OPEN LOOP APPLICATIONS

SMO 254 brazed plated refrigerantto-water heat exchangers are recommended with all open loop applications. Failure to use a SMO 254 heat exchanger may result in premature failure of your system and possible voiding of the warranty.

WARNING

OPEN LOOP APPLICATIONS

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.

WARNING

WATER-SOURCE HEAT

PUMP APPLICATIONS

Water-source heat pump units using 100% outside air must have electric preheat if the application has a potential for heat pump heating operation with air entering the indoor coil below 43°F with an entering water loop temperature of 70°F.

CAUTION

Refrigerant-to-Water Heat Exchanger

Condenser water pump, condenser water piping, cooling tower or geothermal loop, pressure gauges, strainers, piping insulation and all components of the waterside piping must be field installed.

Water-Source Heat Pump Applications

Water-source heat pump units using 100% outside air must have electric preheat if the application has a potential for operation with air entering the indoor coil below 43°F with a water loop temperature of 70°F.

Open Loop Applications

This product contains one or more refrigerant-to-water heat exchangers made of 316 Stainless Steel. 316 Stainless Steel is subject to severe corrosion and failure when exposed to chlorides.

Do not allow water containing any form of chlorides to enter this heat exchanger.

Common forms of chlorides include:

1. Sea water mist entering an open cooling tower system.

2. Contaminated makeup water containing salt water.

3. Disinfecting the water loop with solutions containing sodium hypochlorite.

Chlorides will result in a premature failure of the condenser.

Failure of the condenser as a result of chemical corrosion is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.

Failure of the condenser 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 condenser failure from chemical corrosion due to the fluid in the condenser is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.

% Glycol

Ethylene

Glycol

Propylene

Glycol

18°F

19°F

7°F

9°F

-7°F

-6°F

-28°F

-27°F

CAUTION

WATER FREEZING

WARNING

Freezing Water in the Heat Exchanger

This product contains one or more refrigerant-to-water heat exchangers. A refrigerant-to-water heat exchanger contains refrigerant in one passage and water in another passage. Water is subject to freezing at 32°F. When water freezes in a heat exchanger significant forces are exerted on the components of the heat exchanger where the water is confined.

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.

Unit is capable of operating with Entering Water Temperatures (EWT) as low as 57°F, during the cooling mode, without the need for head pressure control. If the EWT is expected to be lower than 57°F or a more stable operation is desired, a factory provided head pressure control water valve option is available.

Glycol solution should be used if ambient temperatures are expected to fall below freezing or if the loop entering water temperature to the unit is below 50°F while operating in the heating mode (heat pump units only). Adding glycol to condenser water

causes an increase in pressure drop and also results in a decrease in unit performance. A

minimum concentration of 20% glycol solution is recommended.

Table 17 - Glycol Freezing Points

Water loop piping runs through unheated areas or outside the building should be insulated.

Water Piping

Installing contractor must ensure a differential pressure switch or water flow switch is installed between the condenser water supply and return connections. This sensor provides a signal to the unit controller that water flow is present in the refrigerant-to-water heat exchanger and the

Model (RN-)

Supply and Return

Connection Size

006, 007

1” NPT

008, 010, 009, 011, 013, 015, 016, 018,

020

1 1/2” NPT

025, 030

2” NPT

026, 031, 040

2 1/2” Grooved Pipe

050, 055, 060, 070

3” Grooved Pipe

065, 075, 090, 105

4” Grooved Pipe

120, 130, 140

5” Grooved Pipe

Model (RN-)

Supply and Return

Connection Size

016, 018, 020, 025,

030

1 1/2” NPT

WATER PRESSURE

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 water piping. Supply water connection may require a backflow preventer to prevent supply makeup water from backing up into the public water system.

WARNING

WATER PIPING

Follow national and local codes when installing water piping. Connections to the unit should incorporate vibration eliminators to reduce noise and vibration and shutoff valves to facilitate servicing. Supply and return water piping must be at least as large as the unit connections and larger depending on length of runs, rise and bends.

CAUTION

unit can operate without damaging unit components.

Table 18 - Standard Brazed Plate Heat

Exchanger Water Connections

Table 19 - SMO 254 Brazed Plate Heat

Exchanger Water Connections

Only use approved water pipe material. Avoid using galvanized material for water lines/fittings as the material is corrosive and may cause fouling of the water system.

Condenser water pump must be field sized and installed between the cooling tower/geothermal loop and self-contained unit. System should be sized in accordance with the ASHRAE Handbook. Use engineering guidelines to maintain equal distances for supply and return piping and limit bend radiuses to maintain balance in the system. Balancing valves, permanent thermometers and gauges may be required.

Before connection to the unit the condenser water system should be flushed to remove foreign material that could cause condenser fouling. Install a screen strainer with a minimum of 20 Mesh ahead of the condenser inlet to prevent condenser fouling and internal tube damage. Mineral content of the condenser water must be controlled. All makeup water has minerals in it and as the water is evaporated in the cooling tower, these minerals remain. As the mineral content of the water increases, the conductivity of the water increases.

Field provided and installed water treatment program must be compatible with stainless steel, copper, aluminum, ABS plastic, and PVC. Batch feed processes should never be

Each heat exchanger is equipped with a refrigerant pressure relief device to relieve pressure should excessive condensing pressures (>675 psig) occur. Codes may require installing contractor to connect and route relief piping outdoors. The relief valve has a 5/8” male flare outlet connection.

CAUTION

Installing contractor is responsible for properly sizing and installing water system components. Improper fluid flow due to valves, piping, or improper pump operation may result in unacceptable unit operation and void warranty.

CAUTION

PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils used with R-410A and other refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings and complete piping system failure.

CAUTION

used as concentrated chemicals can cause corrosion. Never use hydrochloric acid (muriatic acid) or chlorine as it will corrode stainless steel.

NOTE: Ball valves should be installed in the condenser water supply and return lines for unit isolation and water flow balancing. All manual flow valves should be of the ball valve design. Globe or gate valves should not be used due to high pressure drops and poor throttling characteristics.

Pressure and temperature ports are recommended in condenser water supply and return lines for system balancing. These openings should be 5 to 10 pipe diameters from the unit water connections. To allow

for mixing and temperature stabilization, wells in the water piping should extend at least ½ pipe diameter into the pipe.

Piping systems should not exceed 10 ft/sec fluid velocity to ensure tube wall integrity and reduce noise.

Condensate Drain Piping

6-25 and 30 ton units are equipped with one condensate drain pan connection, on the right side of the unit, and are furnished with a p-trap for field installation. 26 and 31-140 ton units are equipped with two condensate drain connections, one on the left side of the unit and one on the right side of the unit, and are furnished with two p-traps for field installation.

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.

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 small drip pad should be placed below the drain to protect the roof from possible damage.

If condensate is piped into the building drainage system, the drain pipe should

Model (RN-)

Steam Coil

Connection Size

006-140

2 1/8”

Model (RN-)

Hot Water Coil

Connection Size

006, 007, 008, 009, 010,

011, 013, 015

1 3/8”

016, 018, 020, 025, 030

1 5/8”

026, 031, 040, 050, 060,

070

2 1/8”

(standard)/

1 3/8” (preheat

coil)

055, 065, 075, 090, 105,

120, 130, 140

2 1/8”

Model (RN-)

Chilled Water

Coil Connection

Size

006, 007, 008, 009, 010,

011, 013, 015

1 5/8”

016, 018, 020, 025, 030

2 1/8”

026, 031, 040

2 5/8”

050, 055, 060, 065, 070,

075, 090, 105, 120, 130,

140

2 1/8”

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.

CAUTION

Piping shall be in accordance with national and local codes. Pressure limiting devices, backflow preventers and all other safety requirements are the sole responsibility of the installing contractor.

WARNING

penetrate the roof external to the unit itself. The drain line should be pitched away from the unit at least 1/8 inch per foot. On longer runs an air break should be used to ensure proper drainage.

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.

Condensate drain trapping and piping should conform to all applicable governing codes.

Heating Coils

One or two row hot water and steam heating and preheating coils can be factory installed. All valve controls for heating operation are field supplied and field installed. Hot water and steam coil connections are spun copper tube.

Water coils should not be subjected to entering air temperatures below 38°F to prevent coil freeze-up. If air temperature across the coil is going to be below this value, use a glycol solution to match the coldest air expected.

Table 20 - Steam Coil Connection Sizes

Table 21 - Hot Water Coil Connection Sizes

Chilled Water Coil

Four or six row chilled water cooling coils can be factory installed. All valve controls for cooling operation are field supplied and field installed. Chilled water coil connections are spun copper tube.

Table 22 - Chilled Water Coil Connection

Sizes

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.

CAUTION

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.

WARNING

Electric Preheat

The modulating electric preheat option is designed to temper the incoming outside air to the unit based on an enable control signal and the outside air conditions.

A 24VAC enable signal must be provided to the [PHE] terminal to enable the operation of the electric preheat. Once the preheat controller is enabled it will monitor the outside air temperature to determine if any capacity of preheat is needed. If the outside air temperature falls below the outside air temperature setpoint the electric preheat will be started up and maintain the leaving air temperature setpoint with both SCR controlled and staged electric preheat. Both setpoints are set with push button LCD interface on the preheat controller. Outside air temperature sensors and preheat discharge supply air temperature sensors are factory installed and wired to the preheat controller. Electric preheat has maximum operating outside air temperature of 60°F and a maximum preheat discharge air temperature of 80°F.

[COM], [PHO] & [PHC] feedback terminals are provided to communicate if the electric preheat is in operation. PHO is a normally open contact, PHC is a normally closed contact, and COM is the common. These terminals are not required to be connected.

[PHE] is the electric preheat operation enable. [PH+] and [PH-] are the preheat set point reset terminals.

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.

Energy Recovery Wheel

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

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”.

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; first disconnect power to the unit, in some units the energy recovery wheel assembly can be pulled out from the cabinet to view the air seals. On larger units, the energy recovery wheel may be 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.

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 discrepancies.

WARNING

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.

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.

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 “self- cleaning” 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

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

CAUTION

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.

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 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

Bearing beams shown racked

Frame Wheel

Bearing beams

Flat surface

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

CAUTION

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.

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). 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

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).

Avoid Racking of Cassette Frame

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.

CAUTION

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.

Diameter Seal Adjustment

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.

Hub Seal Adjustment

Service

Segment Installation

3. Holding segment by the two outer corners, press the segment towards the

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

CAUTION

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 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.

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

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

WARNING

Startup

(See back of the manual for startup form.)

During startup, it is necessary to perform routine checks on the performance of the unit. This includes checking the air flow, air filters, condenser water flow, dampers, heaters, and refrigerant charge.

Supply Fans

RN Series units are equipped with direct drive backward curved plenum 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 variable frequency drives. 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. Wheels come standard with a 10% air volume band, as a safety factor, in case additional air volume is required from the unit.

Air Flow 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 AAON ECat 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 blower 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.

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 32 - Supply Fan Banding

Power Return Axial Flow Fans (16-25 and 30 tons)

Blade Pitch Angle Setting Instructions

Step 1: Determine the new required pitch for the fan blades Use the fan program in AAON ECat.

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.

Bushing Mount

Bushing

Mount

Bushing

Figure 33 - 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.

Figure 34 - Bushing Mount Location

Step 5: Determine the pin location groove

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

Figure 35 - RET with Pin in Groove 4

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

Figure 36 - Fan HUB and RET Castings

Type

Bushing

Mount

Blade Pitch Angle

20°

25°

28°

30°

33°

35°

38°

40°

45°

50°

RET

HUB

HUB B -

HUB

RET

Type

Rot.

Blade Pitch Angle

20°

25°

28°

30°

33°

35°

38°

40°

45°

50°

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

Bushing Mount

Fan

Blade

Hub

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

Table 23 - Pin Location

Table 24 - Pin Groove Location

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 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.

Power Return and Exhaust Axial Flow Fans (26 and 31-140 tons)

Blade Pitch Angle Setting Instructions

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

Use the fan program in AAON ECat. Contact the AAON parts department to acquire the new pitch pins for the fan blades.

Step 2: Maintain the balance of fan

Mark the hub plate 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.

Figure 37 - Assembled Fan

Step 3: Remove the mounting nuts and bolts and separate hub plate castings

Figure 38 - Back of the Fan

Pin Groove

Pitch Pin

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

CAUTION

Step 4: Remove the fan blades and replace the pitch pins

Figure 39 - Pin Groove Location

Figure 40 - Pitch Pin Location

Figure 41 - Example Pitch Pin

Step 5: Replace the fan blades with the pitch pin of the blade in the same groove and reassemble the fan.

Replace the blades and assemble the fan making sure to place the blades in their previous blade sockets, to match up the previous orientation of hub plate casings and to replace any balancing weights in their previous locations. Tighten bolts in a cross pattern to 6.7 ft-lbs. of torque.

Step 6: Install the fan in the unit.

After placing the fan on the shaft, place the key in the shaft, make sure the screw on the bushing is aligned over the key and then tighten the screw to 9 ft-lbs torque.

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 a clogged evaporator coil.

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 may be levied for non-compliance.

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 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.

Units equipped with heat pump options should be charged in heating mode to get the proper charge. After charging, unit should be operated in cooling mode to check for correct charge. Charge may need to be adjusted for cooling mode. If adjustments are made in the cooling mode heating mode must be rerun to verify proper 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.

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

Air-Cooled Cond./Air-Air Heat Pump

Sub-Cooling

12-18°F

Sub-Cooling with

Hot Gas Reheat

15-22°F

Superheat

8-15°F

Water-Cooled Cond./Water Source Heat

Pump

Sub-Cooling

4-8°F

Superheat

8-15°F

DO NOT OVERCHARGE!

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

CAUTION

Thermal expansion valve must be adjusted to approximately 8-15°F of suction superheat. Failure to have sufficient superheat will damage the compressor and void the warranty.

CAUTION

Table 25 - Acceptable Refrigeration

Circuit Values

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.

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.

PSIG

(F)

R-410A

R-22

(F)

R-410A

R-22

(F)

R-410A

R-22

(F)

R-410A

R-22

(F)

R-410A

R-22

78.3

43.1

142.2

84.1

234.9

143.6

110

364.1

226.4

140

540.1

337.4

80.0

44.2

144.8

85.7

238.6

146.0

111

369.1

229.6

141

547.0

341.6

81.8

45.3

147.4

87.4

242.3

148.4

112

374.2

232.8

142

553.9

345.9

83.6

46.5

150.1

89.1

246.0

150.8

113

379.4

236.1

143

560.9

350.3

85.4

47.6

152.8

90.8

249.8

153.2

114

384.6

239.4

144

567.9

354.6

87.2

48.8

155.5

92.6

253.7

155.7

115

389.9

242.8

145

575.1

359.0

89.1

50.0

158.2

94.4

257.5

158.2

116

395.2

246.1

146

582.3

363.5

91.0

51.2

161.0

96.1

261.4

160.7

117

400.5

249.5

147

589.6

368.0

92.9

52.4

163.8

98.0

265.4

163.2

118

405.9

253.0

148

596.9

372.5

94.9

53.7

166.7

99.8

269.4

165.8

119

411.4

256.5

149

604.4

377.1

96.8

55.0

169.6

101.6

273.5

168.4

120

416.9

260.0

150

611.9

381.7

98.8

56.2

172.5

103.5

277.6

171.0

121

422.5

263.5

100.9

57.5

175.4

105.4

281.7

173.7

122

428.2

267.1

102.9

58.8

178.4

107.3

285.9

176.4

123

433.9

270.7

105.0

60.2

181.5

109.3

290.1

179.1

124

439.6

274.3

107.1

61.5

184.5

111.2

294.4

181.8

125

445.4

278.0

109.2

62.9

187.6

113.2

298.7

184.6

126

451.3

281.7

111.4

64.3

190.7

115.3

303.0

187.4

127

457.3

285.4

113.6

65.7

193.9

117.3

307.5

190.2

128

463.2

289.2

115.8

67.1

197.1

119.4

311.9

193.0

129

469.3

293.0

118.1

68.6

200.4

121.4

100

316.4

195.9

130

475.4

296.9

120.3

70.0

203.6

123.5

101

321.0

198.8

131

481.6

300.8

122.7

71.5

207.0

125.7

102

325.6

201.8

132

487.8

304.7

125.0

73.0

210.3

127.8

103

330.2

204.7

133

494.1

308.7

127.4

74.5

213.7

130.0

104

334.9

207.7

134

500.5

312.6

129.8

76.1

217.1

132.2

105

339.6

210.8

135

506.9

316.7

132.2

77.6

220.6

134.5

106

344.4

213.8

136

513.4

320.7

134.7

79.2

224.1

136.7

107

349.3

216.9

137

520.0

324.8

137.2

80.8

227.7

139.0

108

354.2

220.0

138

526.6

329.0

139.7

82.4

231.3

141.3

109

359.1

223.2

139

533.3

333.2

Table 26 - R-410A and R-22 Refrigerant Temperature-Pressure Chart

Gas Heater Instructions

Figure 42 - Gas Heater Instructions

Color

Terminal

Customer

Connection

Option 1

Option 2

Option 3

Option 4

Option 5

Black

0.50

BWS

208-230

VAC

208-230

VAC

208-230

VAC

208-230

VAC

208-230

VAC

Brown

0.50

BWS

208-230

VAC

208-230

VAC

208-230

VAC

208-230

VAC

208-230

VAC

Green

#10

EYELET

Ground

GND

Blue

0.50

BWS

Common

24 VAC

Yellow

0.50

BWS

Signal

PWM

24 VAC

White

0.50

BWS

Signal

24 VAC

Orange

0.50

BWS

Signal

24 VAC

RPM

300-1100

300

500

850

1100

Rotation

CCW

ECM Toolbox ID

Variable

Speed 4

Speed 3

Speed 2

Speed 1

20% PWM RPM

300

100% PWM RPM

1100

Condenser Fan Electronically Commutated Motor (ECM) Startup

The fan cycling option uses a fan cycle switch to switch between one of the discrete speed inputs (see Table 27) on the motor thus cycling between two preset speeds based upon discharge pressure of the unit. By connecting 24VAC to a single or combination of the yellow, white, or orange wires, the motor will run at the discrete speeds in Table 27.

With Customer Provided Unit Controls or WattMaster Unit Controls the WattMaster Condenser Head Pressure Module is used for variable speed control of the motor to maintain a head pressure. The motor should be factory wired to the PWM outputs of the

Table 27 - ECM Condenser Fan Cycling Options

WattMaster Condenser Head Pressure Module. See WattMaster literature for further information. (http://www.orioncontrols.com)

With JENEsys Unit Controls the controller modulates the ECM to maintain head pressure.

Note

High voltage wires out of the motor: Black & Brown - 1 Phase Line Voltage Green - Ground

Low control voltage wires out of the motor: Blue - Common Yellow - Variable Speed Control

VFD Controlled Condenser Fan Startup

With Customer Provided Unit Controls the

VFD’s are factory provided and factory programmed. VFD’s receives input from

pressure transducers on each refrigerant circuit and vary the fan speed based on the pressure inputs to maintain a discharge (head) pressure. Standard pressure setpoint is 340 psi for standard air-cooled systems and 400 psi for modulating hot gas reheat air-cooled systems.

With WattMaster Unit Controls the WattMaster Condenser Head Pressure Module is used to maintain a discharge pressure. The VFD should be factory wired to the outputs of the WattMaster Condenser Head Pressure Module. See WattMaster literature for additional information. (http://www.orioncontrols.com).

With JENEsys Unit Controls the controller directly modulates the VFD to maintain a discharge pressure.

COMPRESSOR CYCLING

5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes.

5 MINUTE MINIMUM ON TIME 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.

WARNING

Operation

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

Thermostat Operation

Heating Thermostat system switch - "Heat" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point.

Cooling Thermostat system switch - "Cool" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point.

Air Circulation Thermostat system switch - "Off" Thermostat fan switch - "Auto" or "On" No change of the thermostat temperature. With these settings, the supply blower will run continuously but the supply air will not be heated, cooled, or dehumidified.

System Off Thermostat system switch - "Off" Thermostat fan switch - "Auto" No change of the thermostat temperature. With these settings the system is shut down, with the exception of control system power.

Night and Weekend Unoccupied Operation To reduce the operating time of the unit when the space is unoccupied, such as nights and weekends, it is recommended that the temperature setting be raised about 5°F while unoccupied during the cooling season and lowered about 10°F during the heating season.

Packaged DX Cooling Operation and Control

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

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 main 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 blower 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 the supply blower 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.

Modulating Electric Preheat

Electric preheat is used to temper the incoming outside air to the unit based on an enable control signal and outside air conditions. Electric preheat has a maximum operation outside air temperature of 60°F and a maximum preheat discharge air temperature of 80°F.

Chilled Water or Non-Compressorized DX Cooling Operation

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

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.

WARNING

DANGER

Maintenance

(See back of the manual for maintenance log)

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

Gas Heating

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 energy to the igniter and the gas valve after the heating call is made.

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.

Remove the call for heating. The main gas valves should be extinguished.

The supply fans are controlled by the

ignition system. In the fan “Auto” mode the

fan comes on 45 seconds after the flame is proved and goes off 120 seconds after the heating 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.

This appliance contains a wire screen at the vent outlet. Each heating season, prior to placing the appliance in heat mode maintenance check that no debris or foreign matter has accumulated in the vent outlet. A good practice is to check for debris each time the air filters are changed.

In the event the vent outlet becomes blocked do not attempt to start the appliance in heat mode until the entire vent opening is cleared.

In the event the unit shut down because the vent was blocked a qualified technician or service agency should monitor the unit prior to re-starting.

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.

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

WARNING

DANGER

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.

Gas Heat Exchanger Removal

Removal

Disconnect all wiring on the heat exchanger.

Disconnect flex gas lines and pull out of the way.

Remove screws around the perimeter of the heat exchanger face plate that connect it to the unit. Only the outermost screws should be removed. Pull the heat exchanger straight back and out of the unit. It may be necessary to remove some of the control door jambs.

Reinstallation

Ensure that the neoprene gasket is installed around the perimeter of the heat exchanger.

Insert heat exchanger into opening so that the back of the main plate is against the unit bulkhead.

Figure 43 - Gas Heat Exchanger

Attach the heat exchanger to the bulkhead using the holes around the perimeter.

Connect flex gas lines to the piping on the heat exchanger. If flexible gas piping in the unit must be replaced connectors cannot be reused, only new connectors must be used.

Connect wiring per the wiring diagram on the controls compartment door. Purge gas lines to the gas valves at the unit.

DX Cooling

Set unit controls to cooling mode of operation with supply fans on. Check the fan 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).

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

WARNING

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.

WARNING

Condenser Fans (6-25 and 30 ton)

Condenser fans and motors can be removed and reinstalled as individual assemblies.

Removal

Take off the fan grill by removing the screws that attach it to the orifice.

The condenser fan motor wires can then be accessed and disconnected.

Remove the screws that attach the orifice to the condenser assembly. The screws are located on the top of the orifice around the perimeter, and in some cases, through the side of the condenser assembly into the orifice.

With the wires disconnected and the screws removed, the fan, motor and orifice assembly can be lifted off the unit.

Figure 44 - Removal of a Condenser Fan

Assembly

Reinstallation

Set the condenser fan, motor and orifice assembly back into the condenser assembly with the motor wires on the side closest to the control panel.

Attach the orifice to the condenser assembly using all of the points where screws were removed.

Reconnect the fan motor wires.

Attach the fan grill at all of the points where screws were removed.

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 service technician.

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

WARNING

Evaporator Coil (6-25 and 30 ton)

Removal Evacuate refrigerant from the systems.

Remove the TXV bulbs from the suction lines. Disconnect the suction and liquid line copper connections to the evaporator coil.

Figure 45 - Evaporator Coil Access

Remove the screws attaching the filter rack to the evaporator coil blank-off panels at the door opening and along the top of the coil.

Remove the screws attaching the filter rack to the back wall. Angle filter rack away from coil so it fits through the door opening. It may be necessary to remove economizer damper assembly.

Remove screws attaching access side, back, and top blank-off panels to the evaporator coil and the unit.

Angle the coil so that it fits through the door opening.

Remove the evaporator coil.

Reinstallation

Install the coil in the unit drain pan. There

should be about a 1/4” gap between the

upstream side of the coil and the back of the drain pan.

Secure the coil to the back wall of the unit with the blank-off panel. Attach the top and access side blank-off panels to the coil.

Attach the filter rack to the back, top, and access side coil blank-off panels upstream of the coil. Reinstall economizer damper assembly if necessary.

Connect the suction and liquid copper connections to the evaporator coil. Reinstall the TXV bulbs on the suction lines.

Evacuate the refrigerant systems. Weigh in the nameplate refrigerant charge.

See Adjusting Refrigerant Charge section to check for proper sub-cooling and superheat of the refrigerant systems.

Brazed Plate Heat Exchanger Cleaning

Because of a normally high degree of turbulence in brazed plate heat exchangers, for many applications the heat exchanger channels are self cleaning. For applications that are not self cleaning (i.e. hard water at high temperatures, etc.) or applications where additional cleaning is desired, it is possible to clean the brazed plate heat exchanger by circulating a cleaning liquid.

Use a tank with weak acid, 5% phosphoric acid (H3PO4) or, if the exchanger is frequently cleaned, 5% oxalic acid (H2C2O4). Pump the cleaning liquid through the exchanger. For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5 times the

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

WARNING

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.

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.

CAUTION

normal flow rate, preferably in a back-flush mode. After cleaning, the heat exchanger must be rinsed with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO) before the last rinse ensures that all acid is neutralized.

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.

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 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.

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 e-coated coil will void the warranty and may result in reduced efficiency and durability.

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

Detergents or coil cleaners are not recommended with microchannel condenser coils. Use pressurized clean water, with pressure not to exceed 140 psi. Nozzle should be 6” and 80° to 90° from coil face. Failure to do so could result in coil damage.

CAUTION

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

Microchannel Coil Cleaning Documented routine cleaning of microchannel coils with factory provided ecoating is required to maintain coating warranty coverage. See E-Coated Coil Cleaning section.

Air-cooled heat exchangers may include microchannel coils. Only clean water is recommended for cleaning microchannel coils. The water pressure used to clean should not exceed 140 psi, from no closer than 3 inches from the coils, and with the water aimed perpendicular to the coils.

Only clean water is recommended for cleaning microchannel coils. However, if solutions are mandatory to clean the unit, a cleaning solution with a pH between 5 and 9 that does not contain chlorides, sulfates, copper, iron, nickel, or titanium is required.

Field applied coil coatings are not recommended with microchannels.

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.

CAUTION

Supply Fans

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 OVERLUBRICATE.

Recommended greases are: SHELL OIL - DOLIUM R CHEVRON OIL - SRI No. 2 TEXACO INC. - PREMIUM RB

Removal (6-25 and 30 tons)

Remove fan access panel. Panel is attached with eight 3/8” bolts.

Remove the wire connections from Auxiliary Limit Switch (if applicable) which is mounted in the brace at the fan opening.

Remove the brace located at the fan opening.

Remove the six bolts that connect the motor mount to the blower frame. Two bolts are on the angle on the back of the motor mount box, two are on the bottom inside the motor mount box and two are on the inside front of the motor mount box.

Figure 46 - 9-25 and 30 ton Supply Fan

Figure 47 - Bolts which Connect Motor

Mount to Blower Fan

Slide the motor mount back away from the air inlet, so that the blower wheel is clear of

Phase Loss/Rev. LED

On/Off LED

the inlet. A screw driver or crowbar can be used to help accomplish this. Use the pry slots on the back side of the motor mount.

Pull the motor mount to the edge of the blower frame at the opening.

Remove the motor mount with the motor and blower wheel attached. Large motors will require more than one person.

Care must be taken not to damage the compressors or refrigerant lines when removing the motor and fan assembly.

Phase and Brownout Protection

Voltage monitor should be wired according to unit specific wiring diagram include in the control compartment.

Before applying power to the unit the voltage monitor should be set up. The three knobs on the front of the monitor should be adjusted.

Figure 48 - Voltage Monitor

Adjust the top knob labeled LINE VOLT to the operating voltage. This should be the operating voltage for the equipment and the measured voltage on the single or three phase lines.

Adjust the knob labeled %± to either SINGLE PHASE on the left side of the dial

or 3 PHASE on the right side of the dial. After selecting single or three phase set the knob to the percentage of Over or Under voltage desired. A typical over and under voltage percentage is 10%.

Adjust the bottom knob labeled RESTART DELAY. For automatic restart after recovery of voltage select from 2 seconds up to 5 minutes. After recovery of line voltage this is how long the monitor will wait before energizing the output relay. For manual reset adjust the knob fully clockwise to MR. After recovery of line voltage the MANUAL RESET button located between the 2 LEDs must be pressed.

Now that the settings have been made, you can apply the supply and line voltages to the monitor. The monitor will only operate when the supply voltage is available.

On power up, with the line voltage and the supply voltage applied, the monitor takes 3 to 10 seconds to evaluate the line voltage, compare that voltage to the knob settings and then energize if all parameters are satisfied or will remain off if any operating parameter is incorrect.

All of the knob adjustments are adjustable after power up, except the voltage range will not change and going from single or three phase to the other will not change (i.e. within 440 to 480 VAC, but not to 208 or 230 VAC).

LED Codes

Powering up with voltage present which matches knob settings:

1. On/Off LED = Alternating Green/Red Phase Loss LED = Out

2. On/Off LED = Out Phase Loss LED = Alt. G/R

3. On/Off LED = Alt. G/R Phase Loss LED = Out

24COM

Module Common

24VAC

Module Power

C1 & C2

Demand Input – & +

Pressure Common

Pressure Input

Pressure Power 5VDC

Pressure Shield

P5 & P6

Pressure Output – & +

T1 & T2

Discharge Temperature Sensor

A1 & A2

Alarm Relay Out

M1 & M2

Contractor

Control Voltage N

Control Voltage L

U1 & U2

Digital Unloader Solenoid

V1 & V2

Vapor Injection Solenoid

To avoid damaging the Compressor Controller do not connect wires to terminals C3, C4, T3, T4, T5, or T6.

WARNING

4. On/Off LED = Alt. G/R Flashing Phase Loss LED = Green

5. On/Off LED = Green Phase Loss LED = Green

Powering up with no voltage present:

1. On/Off LED = Alternating Green/Red Phase Loss LED = Out

Going into trip condition after operating conditions were good:

1. On/Off LED = Green Phase Loss LED = Green

2. On/Off LED = Green Flashing Phase Loss LED = Red

3. On/Off LED = Red Phase Loss LED = Red

Going to good condition from trip condition

- automatic reset:

1. On/Off LED = Red Phase Loss LED = Red

2. On/Off LED = Alt. G/R Flashing Phase Loss LED = Green

3. On/Off LED = Green Phase Loss LED = Green

Going to good condition from trip condition

- manual reset:

1. On/Off LED = Red Phase Loss LED = Red

2. On/Off LED = Alt. G/R Flashing Phase Loss LED = Green

3. Manual Reset button is pressed

4. On/Off LED = Green Phase Loss LED = Green

Variable Capacity Compressor Controller

Units with variable capacity scroll compressors may include the following compressor controller. The following is an explanation of the terminals and troubleshooting alert flash codes of the

controller. For more information on the compressor controller, see Emerson Climate Bulletin AE8-1328.

Figure 49 - Variable Capacity Compressor

Controller

Low Voltage Terminals

High Voltage Terminals

The compressor controller modulates the compressor unloader solenoid in an on/off

Demand

Signal (VDC)

Loaded %

Unloaded %

Time Loaded

Time

Unloaded

% Compressor

Capacity

1.00

Off

1.44

10%

90%

1.5 sec

13.5 sec

10%

3.00

50%

7.5 sec

50%

4.20

80%

20%

12 sec

3 sec

80%

5.00

100%

15 sec

0 sec

100%

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

WARNING

pattern according to the capacity demand signal of the system. The following table shows the linear relationship between the demand signal and compressor capacity modulation. The compressor controller protects the compressor against high discharge temperature. Refer to Appendix B

Table 28 - Demand Signal vs. Compressor Capacity Modulation

for the relationship between thermistor temperature readings and resistance values.

Figure 50 - Compressor Controller Flash Code Details

Filter Replacement

Monthly air filter inspection is required to maintain optimum unit efficiency.

It is strongly recommended that filter media be replaced monthly. Filters are located upstream of the evaporator coil in the filter and economizer section. Open access door and pull filters straight out to inspect all of the filters. Replace filters with the size indicated on each filter or as shown in the tables below. Arrow on the replacement

Feature 6A

Quantity / Size

Type

No Pre Filters

4 / 16” x 20” x 2”

Pleated, 30% Eff, MERV 8

2 / 16” x 20” x 1”

Metal Mesh, Outside Air

2 / 40” x 16” x 5/16”

Lint Screen

with RAB, Feature A2 = Q, R

2 / 40” x 16” x 5/16”

Feature 6A

Quantity / Size

Type

No Pre Filters

4 / 20” x 25” x 2”

Pleated, 30% Eff, MERV 8

2 / 20” x 25” x 1”

Metal Mesh, Outside Air

2 / 49” x 20” x 5/16”

Lint Screen

with RAB, Feature A2 = Q, R

3 / 47” x 12” x 5/16”

Feature 6A

Quantity / Size

Type

No Pre Filters

6 / 20” x 25” x 2”

Pleated, 30% Eff, MERV 8

3 / 20” x 25” x 1”

Metal Mesh, Outside Air

2 / 55” x 25” x 5/16”

Lint Screen

with RAB, Feature A2 = Q, R

3 / 55” x 16” x 5/16”

Feature 6A

Quantity / Size

Type

No Pre Filters

A 8 / 24” x 24” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 2”

B 6 / 16” x 25” x 1”

Metal Mesh, Outside Air

with PE or PR, Feature 1A = B, C

4 / 16” x 25” x 1”

8 / 24” x 24” x 5/16”

Lint Screen

filters must point towards the blower. (RAB = Return Air Bypass, PE = Power Exhaust and PR = Power Return)

Table 29 - 6-8 and 10 ton Pre Filters

Table 30 - 9 and 11-15 ton Pre Filters

Table 31 - 16-25 and 30 ton Pre Filters

Table 32 - 26, 31, and 40 ton Pre Filters

Feature 6A

Quantity / Size

Type

No Pre Filters

24 / 12” x 24” x 2”

Pleated, 30% Eff, MERV 8

B 6 / 16” x 25” x 1”

Metal Mesh, Outside Air

with PE or PR, Feature 1A = B, C

4 / 16” x 25” x 1”

12 / 47” x 12” x 5/16”

Lint Screen

Feature

Quantity / Size

Type

A,B,C,F,G,H

No Pre Filters

A,B,C,F,G,H

15 / 20” x 24” x 2” &

5 / 16” x 20” x 2”

Pleated, 30% Eff, MERV 8

A,B,C,F,G,H

56 / 20” x 20” x 1”

Metal Mesh, Outside Air

A,C

8 / 40” x 18” &

8 / 20” x 18”

Lint Screen

B,F,G,H

1 / 60” x 16” & 3 / 60” x 24” & 1 / 40” x 16” &

3 / 40” x 24”

Feature

Quantity / Size

Type

A,B,C,F,G,H

No Pre Filters

A,B,C,F,G,H

21 / 20” x 24” x 2” &

7 / 16” x 20” x 2”

Pleated, 30% Eff, MERV 8

A,B,C,F,G,H

56 / 20” x 20” x 1”

Metal Mesh, Outside Air

A,C

11 / 20” x 18” &

12 / 40” x 18”

Lint Screen

B,F,G,H

2 / 40” x 16” & 6 / 40” x 24” & 1 / 60” x 16” &

3 / 60” x 24”

Table 33 - 50, 60, and 70 ton Pre Filters

Table 34 - 55, 65, and 75 ton Pre Filters

Table 35 - 90-140 ton Pre Filters

Feature 6B

Quantity / Size

Type

4 / 16” x 20” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

2 / 20” x 20” x 2” and

1/12” x 24” x 2”

B 4 / 16” x 20” x 4”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

2 / 20” x 20” x 4” and

1/12” x 24” x 4”

C 4 / 16” x 20” x 2”

Permanent Filter Frame -

Replaceable Media

with RAB, Feature A2 = Q, R

2 / 20” x 20” x 2” and

1/12” x 24” x 2”

4 / 16” x 20” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Feature 6B

Quantity / Size

Type

4 / 20” x 25” x 2”

Fiberglass Throwaway,

25% Eff, MERV 4

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 2”

A 4 / 20” x 25” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 2”

B 4 / 20” x 25” x 4”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 4”

C 4 / 20” x 25” x 2”

Permanent Filter Frame -

Replaceable Media

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 2”

4 / 20” x 25” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Table 36 - 6-8 and 10 ton Unit Filters

Table 37 - 9 and 11 ton Unit Filters

Feature 6B

Quantity / Size

Type

4 / 20” x 25” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 2”

B 4 / 20” x 25” x 4”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 4”

C 4 / 20” x 25” x 2”

Permanent Filter Frame -

Replaceable Media

with RAB, Feature A2 = Q, R

6 / 12” x 24” x 2”

4 / 20” x 25” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Feature 6B

Quantity / Size

Type

6 / 20” x 25” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

9 / 16” x 20” x 2”

B 6 / 20” x 25” x 4”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

9 / 16” x 20” x 4”

C 6 / 20” x 25” x 2”

Permanent Filter Frame -

Replaceable Media

with RAB, Feature A2 = Q, R

9 / 16” x 20” x 2”

6 / 20” x 25” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Table 38 - 13 and 15 ton Unit Filters

Table 39 - 16-25 and 30 ton Unit Filters

Feature 6B

Quantity / Size

Type

8 / 24” x 24” x 2”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 2”

B 8 / 24” x 24” x 4”

Pleated, 30% Eff, MERV 8

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 4”

C 8 / 24” x 24” x 2”

Permanent Filter Frame -

Replaceable Media

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 2”

8 / 24” x 24” x 4”

Pleated, 65% Eff, MERV 11

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 4”

G 8 / 24” x 24” x 4”

Pleated, 85% Eff, MERV 13

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 4”

H 8 / 24” x 24” x 4”

Pleated, 95% Eff, MERV 14

with RAB, Feature A2 = Q, R

16 / 12” x 24” x 4”

Feature 6B

Quantity / Size

Type

24 / 12” x 24” x 2”

Pleated, 30% Eff, MERV 8

24 / 12” x 24” x 4”

Pleated, 30% Eff, MERV 8

24 / 12” x 24” x 2”

Permanent Filter Frame -

Replaceable Media

24 / 12” x 24” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Feature 6B

Quantity / Size

Type

25 / 18” x 20” x 2”

Pleated, 30% Eff, MERV 8

15 / 20” x 24” x 4” &

5 / 16” x 20” x 4”

Pleated, 30% Eff, MERV 8

25 / 18” x 20” x 2”

Permanent Filter Frame -

Replaceable Media

15 / 20” x 24” x 4” &

5 / 16” x 20” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Table 40 - 26, 31, and 40 ton Unit Filters

Table 41 - 50, 60, and 70 ton Unit Filters

Table 42 - 55, 65, and 75 ton Unit Filters

Feature 6B

Quantity / Size

Type

35 / 18” x 20” x 2”

Pleated, 30% Eff, MERV 8

21 / 20” x 24” x 4” &

7 / 16” x 20” x 4”

Pleated, 30% Eff, MERV 8

35 / 18” x 20” x 2”

Permanent Filter Frame -

Replaceable Media

21 / 20” x 24” x 4” &

7 / 16” x 20” x 4”

Pleated, 65% Eff, MERV 11

Pleated, 85% Eff, MERV 13

Pleated, 95% Eff, MERV 14

Feature 1A

Quantity / Size

Type

F, G, H, J, Q, R, S, T

1 / 25” x 16” x 4”

Pleated, 30% Eff, MERV 8

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, F, G

OA - 1 / 25” x 16” x 2”

EA - 1 / 25” x 16” x 2”

Feature 1A

Quantity / Size

Type

F, G, H, J, Q, R, S, T

2 / 16” x 20” x 4”

Pleated, 30% Eff, MERV 8

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, F, G

OA - 2 / 16” x 20” x 2”

EA - 2 / 16” x 20” x 2”

Feature 1A

Quantity / Size

Type

F, G, H, J, Q, R, S, T, U, V, W, Y, Z, 1, 2, 3

3 / 20” x 25” x 4”

Pleated, 30% Eff, MERV 8

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, F, G

OA - 3 / 20” x 25” x 2”

EA - 6 / 14” x 20” x 2”

Table 43 - 90-140 ton Unit Filters

Table 44 - 6-8 and 10 ton Energy Recovery Wheel Filters

Table 45 - 9 and 11-15 ton Energy Recovery Wheel Filters

Table 46 - 16-25 and 30 ton Energy Recovery Wheel Filters

Feature 1A

Quantity / Size

Type

F, G, H, J, Q, R, S, T, U, V, W, Y, Z, 1, 2, 3

4 / 24” x 24” x 4”

Pleated, 30% Eff, MERV 8

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, F, G

OA - 4 / 24” x 24” x 2”

EA - 8 / 16” x 20” x 2”

3 / 24” x 24” x 4”

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, F, G

OA - 3 / 24” x 24” x 2”

EA - 6 / 16” x 20” x 2”

Feature 1A

Quantity / Size

Type

F, G, H, J, Q, R, S, T

10 / 24” x 24” x 2”

Pleated, 30% Eff, MERV 8

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, G

OA - 10 / 24” x 24” x 2”

EA - 14 / 25” x 16” x 2”

U, V, W, Y, Z, 1, 2, 3

10 / 24” x 20” x 2”

With Energy Recovery Wheel Exhaust

Air Filters, Feature 6A - D, G

OA - 14 / 20” x 24” x 2”

EA - 14 / 25” x 16” x 2”

Feature

Quantity / Size

Type

14A

14B

A, B, C,

D, E, F

6 / 16” x 25” x 1”

Metal Mesh, Outside Air

with PE or PR, Feature 1A = B, C

4 / 16” x 25” x 1”

Table 47 - 26, 31-50, 60, and 70 ton Energy Recovery Wheel Filters

Table 48 - 55, 65, and 75-140 ton Energy Recovery Wheel Filters

Table 49 - 26, 31-50, 60, and 70 ton Energy Recovery Wheel Filters

100

AAON RN-140 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

RN Series Feature String Nomenclature

General Information

Codes and Ordinances

Receiving Unit

Packaged Direct Expansion (DX) Units

Gas or Electric Heating

Wiring Diagrams

Condensate Drain Pan

Installation

Locating Units

Setting the Curb

Forklifting the Unit (6-25 and 30 ton)

Lifting the Unit

Seismic Curb Installation

Outside Air Rain Hood

End Flashing Installation

Metal Mesh Filters (6-25 and 30 ton Units)

Electrical

Variable Speed Compressors

Thermostat Control Wiring

Gas Heating

Piping Sizing Examples

Inlet and Manifold Pressures

Gas Pressure Regulator & Overpressure Protection Device

Piping Supports

Additional Gas Piping Considerations

Leak Testing

OPEN LOOP APPLICATIONS

Refrigerant-to-Water Heat Exchanger

Water-Source Heat Pump Applications

Freezing Water in the Heat Exchanger

Water Piping

Condensate Drain Piping

Heating Coils

Chilled Water Coil

Electric Preheat

Energy Recovery Units

Startup

Supply Fans

Power Return Axial Flow Fans (16-25 and 30 tons)

Power Return and Exhaust Axial Flow Fans (26 and 31-140 tons)

Filters

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.

Checking Liquid Sub-Cooling

Checking Evaporator Superheat

Adjusting Sub-cooling and Superheat Temperatures

Gas Heater Instructions

Condenser Fan Electronically Commutated Motor (ECM) Startup

VFD Controlled Condenser Fan Startup

Operation

Thermostat Operation

Packaged DX Cooling Operation and Control

Gas Heater Operation

Electric Heating Operation

Steam or Hot Water Preheating and Heating Operation

Modulating Electric Preheat

Chilled Water or Non-Compressorized DX Cooling Operation

Maintenance

Gas Heating

Gas Heat Exchanger Removal

DX Cooling

Condenser Fans (6-25 and 30 ton)

Condensate Drain Pans

Evaporator Coil (6-25 and 30 ton)

Brazed Plate Heat Exchanger Cleaning

E-Coated Coil Cleaning

Microchannel Coil Cleaning Documented routine cleaning of microchannel coils with factory provided e­coating is required to maintain coating warranty coverage. See E-Coated Coil Cleaning section.

Supply Fans

Phase and Brownout Protection

Variable Capacity Compressor Controller

Filter Replacement

Microchannel Coil Cleaning Documented routine cleaning of microchannel coils with factory provided ecoating is required to maintain coating warranty coverage. See E-Coated Coil Cleaning section.